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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Mechanical properties of the fiberglass prepreg system used for the National Transonic Facility replacement blade set

The results are presented of mechanical and physical properties characterization testing for the fiber glass prepreg system used to fabricate 15 of the replacement set of 25 fan blades for the National Transonic Facility. The fan blades were fabricated to be identical to the original blade set with the exception that the 7576 style E glass cloth used for the replacement set has a different surface finish than the original 7576 cloth. The 7781 E glass cloth and resin system were unchanged. The data are presented for elevated, room, and cryogenic temperatures. The results are compared with data from the original blade set and evaluated against selected structural design criteria. Test experience is described along with recommendations for future testing of these materials if required.

Young, Clarence P., Jr.↗
NASA NTRS2007

Hypervelocity Impact (HVI): WLE Small-Scale Fiberglass Panel Flat Multi-Layer Targets A-1, A-2, and B-1 - Volume 2

During 2003 and 2004, the Johnson Space Center's White Sands Testing Facility in Las Cruces, New Mexico conducted hypervelocity impact tests on the space shuttle wing leading edge. Hypervelocity impact tests were conducted to determine if Micro-Meteoroid/Orbital Debris impacts could be reliably detected and located using simple passive ultrasonic methods. The objective of Targets A-1, A-2, and B-2 was to study hypervelocity impacts through multi-layered panels simulating Whipple shields on spacecraft. Impact damage was detected using lightweight, low power instrumentation capable of being used in flight.

Gorman, Michael R.↗
NASA NTRS1991

Tiltrotor research aircraft composite blade repairs: Lessons learned

The XV-15, N703NA Tiltrotor Research Aircraft located at the NASA Ames Research Center, Moffett Field, California, currently uses a set of composite rotor blades of complex shape known as the advanced technology blades (ATBs). The main structural element of the blades is a D-spar constructed of unidirectional, angled fiberglass/graphite, with the aft fairing portion of the blades constructed of a fiberglass cross-ply skin bonded to a Nomex honeycomb core. The blade tip is a removable laminate shell that fits over the outboard section of the spar structure, which contains a cavity to retain balance weights. Two types of tip shells are used for research. One is highly twisted (more than a conventional helicopter blade) and has a hollow core constructed of a thin Nomex-honeycomb-and-fiberglass-skin sandwich; the other is untwisted with a solid Nomex honeycomb core and a fiberglass cross-ply skin. During initial flight testing of the blades, a number of problems in the composite structure were encountered. These problems included debonding between the fiberglass skin and the honeycomb core, failure of the honeycomb core, failures in fiberglass splices, cracks in fiberglass blocks, misalignment of mated composite parts, and failures of retention of metal fasteners. Substantial time was spent in identifying and repairing these problems. Discussed here are the types of problems encountered, the inspection procedures used to identify each problem, the repairs performed on the damaged or flawed areas, the level of criticality of the problems, and the monitoring of repaired areas. It is hoped that this discussion will help designers, analysts, and experimenters in the future as the use of composites becomes more prevalent.

Espinosa, Paul S.↗
NASA NTRS1992

Tiltrotor Research Aircraft composite blade repairs - Lessons learned

The XV-15, N703NA Tiltrotor Research Aircraft located at the NASA Ames Research Center, Moffett Field, California, currently uses a set of composite rotor blades of complex shape known as the advanced technology blades (ATBs). The main structural element of the blades is a D-spar constructed of unidirectional, angled fiberglass/graphite, with the aft fairing portion of the blades constructed of a fiberglass cross-ply skin bonded to a Nomex honeycomb core. The blade tip is a removable laminate shell that fits over the outboard section of the spar structure, which contains a cavity to retain balance weights. Two types of tip shells are used for research. One is highly twisted (more than a conventional helicopter blade) and has a hollow core constructed of a thin Nomex-honeycomb-and-fiberglass-skin sandwich; the other is untwisted with a solid Nomex honeycomb core and a fiberglass cross-ply skin. During initial flight testing of the blades, a number of problems in the composite structure were encountered. These problems included debonding between the fiberglass skin and the honeycomb core, failure of the honeycomb core, failures in fiberglass splices, cracks in fiberglass blocks, misalignment of mated composite parts, and failures of retention of metal fasteners. Substantial time was spent in identifying and repairing these problems. Discussed here are the types of problems encountered, the inspection procedures used to identify each problem, the repairs performed on the damaged or flawed areas, the level of criticality of the problems, and the monitoring of repaired areas. It is hoped that this discussion will help designers, analysts, and experimenters in the future as the use of composites becomes more prevalent.

Espinosa, Paul S.↗
DOE OSTI2023

Economic competitiveness of pultruded fiber composites for wind turbine applications

Pultrusion manufacturing of fiber reinforced polymers has been shown to yield some of the highest mechanical properties for unidirectional composites, having a high degree of fiber alignment with consistent performance. Pultrusions offer a low-cost manufacturing approach for producing unidirectional composites with a constant cross-section and are used in many applications, including spar caps of wind turbine blades. However, as an intermediate processing step for wind blades, the additional cost of manufacturing pultrusions must be accompanied by sufficient increases in mechanical performance and system benefits. Wind turbine blades are manufactured using vacuum-assisted resin transfer molding with infused unidirectional fiberglass or carbon pultrusions for the spar cap. Infused fiberglass composites are among the most cost-effective structural materials available and replacing this material in the cost-driven wind industry has proven challenging, where infused fiberglass spar caps are still the predominant material system in use. To evaluate alternative material systems in a pultruded composite form, it is necessary to understand the costs for this additional manufacturing step which are shown to add 33%–55% on top of the material costs. A pultrusion cost model has been developed and used to quantify cost sensitivities to various processing parameters. The mechanical performance for pultruded composites is improved versus resin-infusion manufacturing with a 17% increase in design strength at a constant fiber volume fraction, but also enables higher achievable fiber volume fractions. The cost-specific mechanical performance is compared as a function of processing parameters for pultruded composites to identify the opportunities for alternative material and manufacturing approaches for wind turbine spar caps. Finally, four materials are compared in a representative wind turbine blade model to assess the performance of pultruded carbon fiber systems and pultruded fiberglass relative to infused fiberglass, where the pultruded systems produce lower weight blades with various cost distinctions.

42 ENGINEERING↗
DOE OSTI2023

Optimized Carbon Fiber Composites in Wind Turbine Blade Design: Follow-On Studies

This project has identified opportunities to bring further reductions in the mass and cost of modern wind turbine blades through the use of alternative material systems and manufacturing processes. The fiber reinforced polymer material systems currently used by the wind industry have stagnated as the technology continues to mature and as a means to reduce risk while introducing new products with continually increasing blade lengths. However, as blade lengths continue to increase, the challenge of controlling blade mass becomes even more critical to enabling the associated levelized cost of energy reductions. Stiffer and stronger reinforcement fibers can help to resolve the challenges of meeting the loading demands while limiting the increase in weight, but these materials are substantially more expensive than the traditional E-glass fiber systems. One goal of this project and associated work is to identify pathways that improve the cost-effectiveness of carbon fiber such that it is the reinforcement of choice in the primary structural elements of wind blades. The use of heavy-tow textile carbon fiber material systems has been shown to reduce the blade mass by 30-31% when used in the spar cap and by up to 7% when used in edgewise reinforcement. A pultrusion cost model was developed to enable a material cost comparison that includes an accurate estimate of the intermediate manufacturing step of pultrusion for the carbon fiber composite. Material cost reductions were revealed in most cases for the heavy-tow textile carbon fiber compared to infused fiberglass. The use of carbon fiber in the edgewise reinforcement produced the most notable material cost reduction of 33% for the heavy-tow textile carbon fiber. The mass and cost savings observed when using carbon fiber in edgewise reinforcement demonstrate a clear opportunity of this design approach. A carbon fiber conversion cost model was expanded to include a characterization of manufacturing costs when using advanced conversion processes with atmospheric plasma oxidation. This manufacturing approach was estimated to reduce the cost of carbon fiber material systems by greater than 10% and can be used with textile carbon systems or traditional carbon fiber precursors. The pultrusion cost model was also used to assess the opportunity for using pultruded fiberglass in wind blades, studying conventional E-glass fiber reinforcement. When using pultruded fiberglass as the spar cap material for two design classifications, the blade weight was reduced by 6% and 9% compared to infused fiberglass. However, due to the relatively large share of the pultrusion manufacturing cost compared to fiber cost, the spar cap material cost increased by 12% and 7%. When considering the system benefits of reduced blade mass and potentially lower blade manufacturing costs for pultruded composites, there may be opportunity for pultruded E-glass in wind blade spar caps, but further studies are needed. There is a clearer outcome for using pultruded fiberglass in the edgewise reinforcement where it resulted in a blade mass reduction of 2% and associated reinforcement material cost reduction of 1% compared to infused E-glass. The use of higher performing glass fibers, such as S-glass and H-glass systems, will produce greater mass savings but a study is needed to assess the cost implications for these more expensive systems. The most likely opportunity for these high-performance glass fibers is in the edgewise reinforcement, where the increased strength will reduce the damage accumulation of this fatigue-driven component. The blade design assessments in this project characterize the controlling material properties for the primary structural components in the flapwise and edgewise directions for modern wind blades. The observed trends with low and high wind speed turbine classifications for carbon and glass fiber reinforced polymer systems help to identify where cost reductions are needed, and where improvements in mechanical properties would help to reduce the material demands.

17 WIND ENERGY↗
DOE OSTI2016

Improved explosive collection and detection with rationally assembled surface sampling materials

Sampling and detection of trace explosives is a key analytical process in modern transportation safety. In this work we have explored some of the fundamental analytical processes for collection and detection of trace level explosive on surfaces with the most widely utilized system, thermal desorption IMS. The performance of the standard muslin swipe material was compared with chemically modified fiberglass cloth. The fiberglass surface was modified to include phenyl functional groups. When compared to standard muslin, the phenyl functionalized fiberglass sampling material showed better analyte release from the sampling material as well as improved response and repeatability from multiple uses of the same swipe. The improved sample release of the functionalized fiberglass swipes resulted in a significant increase in sensitivity. Various physical and chemical properties were systematically explored to determine optimal performance. The results herein have relevance to improving the detection of other explosive compounds and potentially to a wide range of other chemical sampling and field detection challenges.

Explosive detection↗
DOE OSTI2016

Evaluation of the U.S. Department of Energy Challenge Home Program Certification of Production Builders - Chicago, IL and Devens, MA

TO4 Task 3.1 - K Hovnanian Chicago, IL DOE Challenge Home Program Certified Home Constructed and Verified Specifications DOE Challenge Home Building envelope Ceiling R-49 blown fiberglass, Grade I Walls 2x4 framing @ 16 o.c. with R-13 fiberglass batts, Grade I and 1"" R-5 extruded polystyrene (XPS) insulating sheathing Frame Floors R-38 blown fiberglass, Grade I Basement Walls R-19 fiberglass batts draped full height, Grade I Basement Slab uninsulated Windows Above Grade: ENERGY STAR certified, U=0.29, SHGC=0.28 Basement: Non ENERGY STAR certified, U=0.29, SHGC=0.24 Infiltration 2 ACH 50 Mechanical systems Heat 95% AFUE sealed combustion natural gas furnace in conditioned space Goodman GMH950703BXAF Cooling 13 SEER split system Goodman GSX130301BC DHW AO Smith Vertex 100 0.96 EF natural gas tank water heater in 2nd floor utility closet Hot Water Distribution Redesigned trunk and branch Compliant with EPA WaterSense Efficient Distribution Requirements Ducts Located 100% in conditioned space via floor joists leak free to outside (5% or less) Ventilation Central Fan Integrated Supply (CFIS) ventilation with 6"" insulated outside air duct Fan Controller: Air Cycler FRV, with 6"" motorized damper 50 CFM outside air flow, 33% duty cycle (10 minutes on, 20 minutes off); ASHRAE 62.2-2010 compliance via an exhaust fan - Panasonic FV-08VQ5 WhisperCeiling Rerturn Pathways Active Return at Master Bedroom Transfer Grilles in Secondary Bedrooms Appliances, Lighting, MELs Lights 80% ENERGY STAR certified CFL Appliances ENERGY STAR certified refrigerator, dishwasher, and clothes washer; Natural gas range/oven and clothes dryer" STRUCTURE - Test House Lot 145 - 2013 DOE Challenge Test House Task 3.1 Bolingbrook, IL 60490 House is constructed and is DOE Challenge Verified by Don Nelson, a local rater. The purpose of this project was to evaluate integrated packages of advanced measures in individual test homes to assess their performance with respect to Building America Program goals, specifically compliance with the DOE Challenge Home Program. To that end, Building Science Corporation (BSC) consulted on the construction of five test houses by three cold climate production builders in three separate U.S. cities. (1) K. Hovnanian Homes, Chicago, Illinois (2) David Weekley Homes, Denver, Colorado (3) Transformations, Inc., Devens, Massachusetts. Overall, the builders have concluded that the energy related upgrades (either through the prescriptive or performance path) represent reasonable upgrades. The builders commented that while not every improvement in specification was cost effective (as in a reasonable payback period), many were improvements that could improve the marketability of the homes and serve to attract more energy efficiency discerning prospective homeowners. However, the builders did express reservations about the associated checklists and added certifications. An increase in administrative time was observed with all builders. The checklists and certifications also inherently increase cost due to: (1) Adding services to the scope of work for various trades, such as HERS Rater and heating, ventilation, and air conditioning contractor. (2) Increased material costs related to the checklists, especially the U.S. Environmental Protection Agency Indoor airPLUS and WaterSense Efficient Hot Water Distribution requirement. Ceiling - 18" cellulose Walls - 12" open cell spray foam in double stud walls Foundation - R-10 under slab, 3 1/2" closed-cell spray foam at walls Windows - Harvey U=0.20, SHGC=0.22 Infiltration - 1.0 sq in per 100 sq ft Heating - Mini split heat pump, 10.6 HSPF, 23 SEER Cooling - Mini split heat pump, 10.6 HSPF, 23 SEER DHW - 0.97 EF instantaneous propane water heater Ventilation - bathroom exhaust fans as basic option, HRV upgrade option Adams Circle Devens MA 01434 Cavite Street Devens, MA 01434

Array↗
NASA NTRS1973

Flight service evaluation of PRD-49/epoxy composite panels in wide bodied commercial transport aircraft

L-1011 aircraft fairing panel configurations were selected as test parts to compare the fabrication, costs and service performance characteristics of PRD-49 and fiberglass. These parts are currently fiberglass reinforced structure and the purpose of this program is to evaluate the results of direct substitution of PRD-49 fabric for the fiberglass. Three ship sets of these panels have been fabricated for a five year flight service evaluation on three L-1011 commercial airlines operating in widely diverse route structures. The standard tools and machining techniques used for fiberglass parts are unacceptable for cutting, trimming, and drilling the tougher PRD-49 fibers. Therefore, a machining development study was undertaken to provide the necessary new tools and machining techniques. After incorporating these new developments in the fabrication and installation of the panels, a manufacturing cost study revealed that the labor hours were only increased by about 12.5 percent.

Wooley, J. H.↗
DOE OSTI2016

SU-D-BRC-04: Development of Proton Tissue Equivalent Materials for Calibration and Dosimetry Studies

Purpose: To develop new proton tissue equivalent materials (PTEM), urethane and fiberglass based, for proton therapy calibration and dosimetry studies. Existing tissue equivalent plastics are applicable only for x-rays because they focus on matching mass attenuation coefficients. This study aims to create new plastics that match mass stopping powers for proton therapy applications instead. Methods: New PTEMs were constructed using urethane and fiberglass resin materials for soft, fat, bone, and lung tissue. The stoichiometric analysis method was first used to determine the elemental composition of each unknown constituent. New initial formulae were then developed for each of the 4 PTEMs using the new elemental compositions and various additives. Samples of each plastic were then created and exposed to a well defined proton beam at the UF Health Proton Therapy Institute (UFHPTI) to validate its mass stopping power. Results: The stoichiometric analysis method revealed the elemental composition of the 3 components used in creating the PTEMs. These urethane and fiberglass based resins were combined with additives such as calcium carbonate, aluminum hydroxide, and phenolic micro spheres to achieve the desired mass stopping powers and densities. Validation at the UFHPTI revealed adjustments had to be made to the formulae, but the plastics eventually had the desired properties after a few iterations. The mass stopping power, density, and Hounsfield Unit of each of the 4 PTEMs were within acceptable tolerances. Conclusion: Four proton tissue equivalent plastics were developed: soft, fat, bone, and lung tissue. These plastics match each of the corresponding tissue’s mass stopping power, density, and Hounsfield Unit, meaning they are truly tissue equivalent for proton therapy applications. They can now be used to calibrate proton therapy treatment planning systems, improve range uncertainties, validate proton therapy Monte Carlo simulations, and assess in-field and out-of-field organ doses.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

Field Testing Unvented Roofs with Asphalt Shingles in Cold and Hot-Humid Climates

Insulating roofs with dense-pack cellulose (instead of spray foam) has moisture risks, but is a lower cost approach. If moisture risks could be addressed, buildings could benefit from retrofit options, and the ability to bring HVAC systems within the conditioned space. Test houses with unvented roof assemblies were built to measure long-term moisture performance, in the Chicago area (5A) and the Houston area (2A). The Chicago-area test bed had seven experimental rafter bays, including a control vented compact roof, and six unvented roof variants with cellulose or fiberglass insulation. The interior was run at 50% RH. All roofs except the vented cathedral assembly experienced wood moisture contents and RH levels high enough to constitute failure. Disassembly at the end of the experiment showed that the unvented fiberglass roofs had wet sheathing and mold growth. In contrast, the cellulose roofs only had slight issues, such as rusted fasteners and sheathing grain raise. The Houston-area roof was an unvented attic insulated with spray-applied fiberglass. Most ridges and hips were built with a diffusion vent detail, capped with vapor permeable roof membrane. Some ridge sections were built as a conventional unvented roof, as a control. In the control unvented roofs, roof peak RHs reached high levels in the first winter; as exterior conditions warmed, RHs quickly fell. In contrast, the diffusion vent roofs had drier conditions at the roof peak in wintertime, but during the summer, RHs and MCs were higher than the unvented roof (albeit in the safe range).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Optimized Carbon Fiber Composites in Wind Turbine Blade Design

The objective of this study is to assess the commercial viability to develop cost-competitive carbon fiber composites specifically suited for the unique loading experienced by wind turbine blades. The wind industry is a cost-driven market, while carbon fiber materials have been developed for the performance-driven aerospace industry. Carbon fiber has known benefits for reducing wind turbine blade mass due to the significantly improved stiffness, strength, and fatigue resistance per unit mass compared to fiberglass; however, the high relative cost has prohibited broad adoption within the wind industry. Novel carbon fiber materials derived from the textile industry are studied as a potentially more optimal material for the wind industry and are characterized using a validated material cost model and through mechanical testing. The novel heavy tow textile carbon fiber is compared with commercial carbon fiber and fiberglass materials in representative land-based and offshore reference wind turbine models. Some of the advantages of carbon fiber spar caps are observed in reduced blade mass and improved fatigue life. The heavy tow textile carbon fiber is found to have improved cost performance over the baseline carbon fiber and performed similarly to the commercial carbon fiber in wind turbine blade design, but at a significantly reduced cost. This novel carbon fiber was observed to even outperform fiberglass when comparing material cost estimates for spar caps optimized to satisfy the design constraints. This study reveals a route to enable broader carbon fiber usage by the wind industry to enable larger rotors that capture more energy at a lower cost.

17 WIND ENERGY↗
NASA NTRS1974

Reinforced polyquinoxaline gasket and method of preparing the same

A gasket or seal resistant to ionizing radiation and liquid hydrogen temperatures is made up of a laminated polyquinoxaline resin-fiberglass cloth body portion and a molded polyquinoxaline encapsulating film. The laminated body is prepared by stacking thin sheets of the resin alternately with fiberglass cloth and heating the assembly under pressure with the temperature, pressure and resin film thickness being controlled so that only partial impregnation of the fiberglass cloth is produced. The encapsulating resin film is preheated at about 300 f and applied to the laminate body by molding at a temperature of about 625 F. The molded gasket is then deflashed and post-cured by heating at 675 to 700 F.

Vanauken, R.↗
NASA NTRS1974

Flight service evaluation of PRD-49/epoxy composite panels in wide-bodied commercial transport aircraft

Fairing panels were fabricated to evaluate the fabrication characteristics and flight service performance of PRD-49 (Kevlar-49) a composite reinforcing material and to compare it with the fiberglass which is currently in use. Panel configurations were selected to evaluate the PRD-49 with two resin matrix materials in sandwich and solid laminate construction. Left and right hand versions of these configurations were installed on L-1011's which will accumulate approximately 3000 flight hours per year per aircraft. The direct substitution of PRD-49 for fiberglass produced a twenty-six percent weight reduction on the panel configurations. Examination of these panels revealed that there was no visible difference between the PRD-49 and adjacent fiberglass panels.

Wooley, J. H.↗
NASA NTRS1981

Laboratory study of efficient add-on treatments for interior noise control in light aircraft

Experimental and theoretical studies of the transmission loss (TL) of 1.15 x 1.46 m flat stiffened-skin aluminum panels are described. Panel configurations included panels with no treatment and eight combinations of treatments consisting of a fiberglass-septum layer, a foam-foil damping material, and a plywood double wall trim panel. Measured TL of the untreated panel and the panel with a damping layer showed characteristics of the double mass law: at low frequencies the TL followed a mass law trend associated with the average mass of both skin and stiffness, while at higher frequencies the TL followed a mass law trend associated with skin mass only. A comparison of TL for panels treated with a damping layer, a fiberglass layer, or a trim panel showed that the effects of damping are frequency dependent with some performing better below 500 Hz and others performing better above 500 Hz. Treatment combinations showed that two treatments with the same mass could have TL values different by about 10 dB, while other combinations having weights different by a factor of two could have TL values within a few dB over most of the frequency range. The highest TL values (50 dB at 1000 Hz) were obtained with a treatment consisting of a fiberglass layer, a trim panel, and damping layers on both the stiffened panel and the trim panel.

Mixson, J. S.↗
NASA NTRS1983

Passive Orbital Disconnect Strut (PODS 3), structural and thermal test program

A test program is undertaken to verify that the lifetime of a shuttle launchable dewar can be increased by using passive orbital disconnect struts (PODS). A detailed design is performed on the cold end (PODS-III) portion of the strut. Structural analysis of the thin-wall fiberglass tube allows selection of the optimum winding angle and tube dimensions. Structural tests on the thin-wall fiberglass tube measure both the tension and compression modulus at ambient and LN2 temperatures, the radial deflection versus side load, and the ultimate compression strength of the tube at LN2 temperature. The thermal expansion of the fiberglass tube plus Invar is also measured down to 78 K. The axial gap at the wedge portion of the stem is set based on these data. The PODS-III test article parts are fabricated and assembled using a detailed assembly procedure. The thermal conductants in the orbital configuration was measured for body temperatures between 5 and 40 K. This temperature range covers the predicted ground hold and orbit temperatures for vapor-cooled supports. The test results are then compared with heat leak values predicted before the test began. Side load, axial compression load, and tension load tests conclude the test program.

Parmley, R. T.↗