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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
DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats: Integration of Additive Manufacturing and Reinforced Polymer Composite

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS1978

Friction of thick laminates

Technique which improves fiber alignment and reduces void content of thick laminated structures is readily applicable to structures that contain sections such as ribs, channels, or bosses joined to thin stems of same material.

Dickerson, G. E.↗
NASA NTRS1978

Shear rupture of a directionally solidified eutectic gamma/gamma prime - alpha (Mo) alloy

Directionally solidified Mo alloys are evaluated to determine the shear rupture strength and to possibly improve it by microstructural and heat treatment variations. Bars of the alloy containing nominally 5.7% Al and 33.5% Mo by weight with balance Ni were directionally solidified at rates between 10 and 100 mm per hour in furnaces with thermal gradients at the liquid-solid interface of 250 or 100 C per cm. A limited number of longitudinal shear rupture tests were conducted at 760 C and 207 MPa in the as - solidified and in several heat treated conditions. It is shown that shear rupture failures are partly transgranular and that resistance to failure is prompted by good fiber alignment and a matrix structure consisting mainly of gamma prime. Well aligned as - solidified specimens sustained the shear stress for an average of 81 hours. A simulated coating heat treatment appeared to increase the transformation of gamma to gamma prime and raised the average shear life of aligned specimens to 111 hours. However, heat treatments at 1245 C and especially at 1190 C appeared to be detrimental by causing partial solutioning of the gamma prime, and reducing lives to 47 and 10 hours, respectively.

Harf, F. H.↗
NASA NTRS1988

Innovative design of composite structures: Further studies in the use of a curvilinear fiber format to improve structural efficiency

Further studies to determine the potential for using a curvilinear fiber format in the design of composite laminates are reported. The curvilinear format is in contrast to the current practice of having the fibers aligned parallel to each other and in a straight line. The problem of a plate with a central circular hole is used as a candidate problem for this study. The study concludes that for inplane tensile loading the curvilinear format is superior. The limited results to date on compression buckling loads indicate that the curvilinear designs are poorer in resistant buckling. However, for the curvilinear design of interest, the reduction in buckling load is minimal and so overall there is a gain in considering the curvilinear design.

Hyer, Michael W.↗
NASA NTRS1988

Fatigue damage development of various CFRP-laminates

The chronic strength and fatigue behavior of a woven carbon-fiber reinforced laminate in a balanced eight-shaft satin weave style was compared to nonwoven laminates with an equivalent cross-ply layup. Half the fibers were arranged in the direction of the load and the other half perpendicular to it. Two types of nonwoven laminates consisting of continuous fibers and aligned discontinuous fibers, both produced from carbon fiber prepregs, were studied. The cross-ply laminate with continuous fiber showed the best characteristics with regard to both static strength and fatigue. The similarities and differences in damage mechanisms in the laminates are described.

Schulte, K.↗
NASA NTRS1992

The role of biaxial stresses in discriminating between meaningful and illusory composite failure theories

The irrelevance of most composite failure criteria to conventional fiber-polymer composites is claimed to have remained undetected primarily because the experiments that can either validate or disprove them are difficult to perform. Uniaxial tests are considered inherently incapable of validating or refuting any composite failure theory because so much of the total load is carried by the fibers aligned in the direction of the load. The Ten-Percent Rule, a simple rule-of-mixtures analysis method, is said to work well only because of this phenomenon. It is stated that failure criteria can be verified for fibrous composites only by biaxial tests, with orthogonal in-plane stresses of the same as well as different signs, because these particular states of combined stress reveal substantial differences between the predictions of laminate strength made by various theories. Three scientifically plausible failure models for fibrous composites are compared, and it is shown that only the in-plane shear test (orthogonal tension and compression) is capable of distinguishing between them. This is because most theories are 'calibrated' against the measured uniaxial tension and compression tests and any cross-plied laminate tests dominated by those same states of stress must inevitably 'confirm' the theory.

Hart-Smith, L. J.↗
NASA NTRS2006

NASA Tech Briefs, December 2006

Topic include: Inferring Gear Damage from Oil-Debris and Vibration Data; Forecasting of Storm-Surge Floods Using ADCIRC and Optimized DEMs; User Interactive Software for Analysis of Human Physiological Data; Representation of Serendipitous Scientific Data; Automatic Locking of Laser Frequency to an Absorption Peak; Self-Passivating Lithium/Solid Electrolyte/Iodine Cells; Four-Quadrant Analog Multipliers Using G4-FETs; Noise Source for Calibrating a Microwave Polarimeter; Hybrid Deployable Foam Antennas and Reflectors; Coating MCPs with AlN and GaN; Domed, 40-cm-Diameter Ion Optics for an Ion Thruster; Gesture-Controlled Interfaces for Self-Service Machines; Dynamically Alterable Arrays of Polymorphic Data Types; Identifying Trends in Deep Space Network Monitor Data; Predicting Lifetime of a Thermomechanically Loaded Component; Partial Automation of Requirements Tracing; Automated Synthesis of Architecture of Avionic Systems; SSRL Emergency Response Shore Tool; Wholly Aromatic Ether-Imides as n-Type Semiconductors; Carbon-Nanotube-Carpet Heat-Transfer Pads; Pulse-Flow Microencapsulation System; Automated Low-Gravitation Facility Would Make Optical Fibers; Alignment Cube with One Diffractive Face; Graphite Composite Booms with Integral Hinges; Tool for Sampling Permafrost on a Remote Planet; and Special Semaphore Scheme for UHF Spacecraft Communications.

Source record↗
NASA NTRSDate not supplied

Simulating High Energy Dynamic Impact of IM7/PEKK Continuous Fiber Laminated Thermoplastic Composite using Open Hole Coupon Experiments

The use of advanced thermoplastic composites (TPC) for structural applications in the aerospace and automotive industries has grown increasingly popular due to their high performance, high manufactured part output, and sustainability. Enhancing verification simulations of the progressive failure in TPCs at the coupon scale is needed to better validate advanced composite material models at larger length scales, such as element level panels. MAT_213, a tabulated composite material model, has been applied to simulate high velocity dynamic impact (HEDI) and is integrated in the LS-DYNA explicit finite element (FE) software. Previous efforts using MAT_213 have calibrated HEDI simulated failures with experimental data. Traditionally simulations have relied on a structured mesh to represent quasi-isotropic panels. For this study, a continuous fiber unidirectional tape, IM7/PEKK, was analyzed through a series of verification studies of notched laminate coupons, then validation analyses of quasi-isotropic panels under HEDI were compared with experimental data. Experiments using unidirectional TPC were performed to obtain tabulated stress vs strain curves using Digital Image Correlation (DIC) for input into MAT_213. Next, notched coupon experiments were used as an intermediate step to calibrate the damage and failure behavior in MAT_213. Lastly, investigations into differences between HEDI simulations using a fiber aligned mesh were compared with experimental failure patterns and damage sizes. The use of experimentally generated material behavior along with selective mesh layout improved HEDI predictions with minimal material parameter calibration.

Polymer matrix composites↗
NASA NTRS2024

Filament Wound Composite Analysis Using the NASA Multiscale Analysis Tool (NASMAT) and Finite Element Analysis

Fiber reinforced composite materials, owing to their tailorable thermomechanical and functional properties, allow one to produce a structure that is stronger, stiffer, and lighter than its metal counterpart while performing the same function, yielding a more efficient structure. This not only allows for the improvement of current technologies like aircraft structures, but also enables new technologies like gaseous hydrogen storage for mobility applications, which are otherwise impractical when manufactured using traditional metals due to weight and space restrictions or material embrittlement. However, the use of composites imposes greater design and manufacturing challenges on an engineer, since they are heterogenous, having a distinct structure across multiple length scale, behave generally anisotropically at the structural level and require complex manufacturing and processing methods. Capturing this complex behavior requires detailed numerical simulations, including the modeling of microstructural features like undulations, voids, and fiber alignment. In this paper, multiple repeating unit cells (RUCs), representing filament wound composites, are developed (via a script provided in the Appendix) and analyzed. The refinement of these RUCs is varied, and the analyses are performed using both the Abaqus finite element software and the NASA Multiscale Analysis Tool (NASMAT). A study is undertaken to compare the predicted effective elastic properties of the wound RUC to a laminate representation of the wound RUC, which neglects the undulations. Additionally, two different sets of periodic boundary conditions (PBCs) have been examined. One approximates the real boundary conditions using a standard approach and the other represents the PBCs exactly through the use of an offset. Lastly, a comparison of the local elastic stress fields is made among the models and approaches. Since wound structures are often approximated as laminated structures, it is important to understand the degree to which this assumption is valid, namely by first comparing the elastic constants and local elastic fields. This will provide, on the one hand, information concerning the bulk mechanical behavior and, on the other hand, insights concerning local load distributions and likely damage initiation sites.

Composites↗
DOE OSTI2023

Aligned carbon fibers-carbon nanotube-polymer-based composite as lithium-ion battery current collector

High energy density demand is pushing the development of high-voltage cathode materials, which necessitates improved electrochemical stability of other battery components such as binders, electrolytes, and current collectors. Current collectors are considered to be an inactive component but still play an essential role. In this study, a metal-free composite film containing directionally aligned carbon fiber (CF), carbon nanotube (CNT), and polymer (P) was developed to replace aluminum foil as a cathode current collector, which relies on forming an Al 2 O 3 layer to ensure electrochemical stability at high voltage. Here, each component in the new cathode current collector played a functional role. The CNTs provided uniform current densities, and CFs improved the electronic conductivity and mechanical strength of the composite material. The polymer enhanced the adhesion of the cathode coating with the current collector and provided an impervious support to the cathode materials. The CF-CNT-P composite demonstrated excellent electrochemical and thermal stability. Cathodes coated on the CF-CNT-P composite exhibited lower charge transfer resistance, improved rate capability, and improved cyclic stability compared with the cathodes deposited on conventional aluminum foil. Additionally, the composite current collector was lighter (1.81 mg/cm 2 and 15 µm thick) than the commonly used aluminum foil (4.35 mg/cm2 and 15 µm thick), which can increase the cell energy density. Additionally, the CF-CNT-P did not need to be separated from the cathode coating during recycling and can be burnt out with binder, simplifying the recycling process.

25 ENERGY STORAGE↗
DOE OSTI2023

Enhanced through-thickness electrical conductivity and lightning strike damage response of interleaved vertically aligned short carbon fiber composites

Through-thickness electrical conductivity of carbon fiber reinforced polymers (CFRPs) is a key characteristic that determines the severity of lighting strike-induced damage. Carbon Fibers (CFs) are inherently electrically conductive and therefore provide high conductivity in the direction of the fiber orientation. However, electrical conductivities through the thickness and orthogonal to the CF orientation in CFRPs are governed by the insulating polymer matrix present between CFs. Here, in this work, through the thickness alignment of short CFs in between layers of CFRP laminates is demonstrated to improve the through-thickness electrical conductivity. Composites with interleaved vertically aligned short CF fibers (<150 μm) will be referred as V-fiber composites hereafter. The effect of the V-fiber on the lightning strike damage is evaluated against an artificial lightning strike of 100 kA (modified waveform A of SAE ARP-5412B standard). The improved through-thickness electrical conductivity of CFRP laminates (1.15 S/cm) through vertical alignment of short CFs was compared to reference CFRP laminates (0.13 S/cm) and was found to dissipate the artificial lightning strike current more efficiently. The surface damage after the artificial lightning strike in the V-fiber composites was reduced to 12.69 cm 2 compared to the reference CFRP surface damage of 57.67 cm 2 , a 78% reduction. It was also demonstrated that Joule heat generated due to lightning strike on the composites was significantly less than the reference sample using infrared (IR) thermography. A high retention (up to 78%) of flexural properties (modulus and strength) was observed in V-fiber composites post lightning strike impact as compared to only 47% retention in the reference panel.

42 ENGINEERING↗
NASA NTRS1987

Effects of fiber motion on the acoustic behavior of an anisotropic, flexible fibrous material

The acoustic behavior of a flexible fibrous material was studied experimentally. The material consisted of cylindrically shaped fibers arranged in a batting with the fibers primarily aligned parallel to the face of the batting. This type of material was considered anisotropic, with the acoustic propagation constant depending on whether the dirction of sound propagation was parallel or normal to the fiber arrangement. Normal incidence sound absorption measurements were taken for both fiber orientations over the frequency range 140 to 1500 Hz and with bulk densities ranging from 4.6 to 67 kg/cu m. When the sound propagated in a direction normal to the fiber alignment, the measured sound absorption showed the occurrence of a strong resonance, which increased absorption above that attributed to viscous and thermal effects. When the sound propagated in a direction parallel to the fiber alignment, indications of strong resonances in the data were not present. The resonance in the data for fibers normal to the direction of sound propagation is attributed to fiber motion. An analytical model was developed for the acoustic behavior of the material displaying the same fiber motion characteristics shown in the measurements.

Dahl, Milo D.↗
NASA NTRS1990

Effects of fiber motion on the acoustic behavior of an anisotropic, flexible fibrous material

The acoustic behavior of a flexible fibrous material was studied experimentally. The material consisted of cylindrically shaped fibers arranged in a batting with the fibers primarily aligned parallel to the face of the batting. This type of material was considered anisotropic, with the acoustic propagation constant depending on whether the direction of sound propagation was parallel or normal to the fiber arrangement. Normal incidence sound absorption measurements were taken for both fiber orientations over the frequency range 140 to 1500 Hz and with bulk densities ranging from 4.6 to 67 kg/cu m. When the sound propagated in a direction normal to the fiber alignment, the measured sound absorption showed the occurrence of a strong resonance, which increased absorption above that attributed to viscous and thermal effects. When the sound propagated in a direction parallel to the fiber alignment, indications of strong resonances in the data were not present. The resonance in the data for fibers normal to the direction of sound propagation is attributed to fiber motion. An analytical model was developed for the acoustic behavior of the material displaying the same fiber motion characteristics shown in the measurements.

Dahl, Milo D.↗
NASA NTRS1975

Structure and thermal cycling stability of a hafnium monocarbide reinforced directionally solidified cobalt-base eutectic alloy

A nominal composition of Co-15Cr-2ONi-10.5 Hf-0.7 C (NASA-HAFCO-11) was directionally solidified at 0.8 cm/hr growth rate to produce aligned HfC in a cobalt matrix alloy. The aligned HfC fibers were present as rod and plate types. The diameter of the aligned fibers was about 1 micron, with volume fraction in the range of 11 to 15 percent. The growth direction of the fibers was parallel to the 100. The NASA-HAFCO-11 alloy was subjected to thermal cycling between 425 deg and 1100 C, using a 2.5 minute cycle. No microstructural degradation of the HfC fibers in the alloy was observed after 2500 cycles.

Kim, Y. G.↗
NASA NTRS1975

Structure and thermal cycling stability of a hafnium monocarbide reinforced directionally solidified cobalt-base eutectic alloy

A nominal composition of Co-15Cr-20Ni-10.5Hf-0.7C was directionally solidified at 0.8 cm/hr growth rate to produce aligned HfC in a cobalt matrix alloy. The aligned HfC fibers were present as rod and plate types. The diameter of the aligned fibers was about 1 micron, with volume fraction in the range of 11 to 15 per cent. The growth direction of the fibers was parallel to the 100 direction. The alloy was subjected to thermal cycling between 425 and 1100 C, using a 2.5 minute cycle. No microstructural degradation of the HfC fibers in the alloy was observed after 2500 cycles.

Kim, Y. G.↗
DOE OSTI2021

Alternative Damage Tolerant Materials for Wind Turbine Blades: An Overview

Current wind turbine blade materials may not be damage tolerant to the extent necessary to optimize the Levelized Cost of Energy (LCOE) of wind energy plants. Traditionally, wind turbine blades have been designed using a safe-life approach, but advances in inspection techniques and structural health monitoring solutions give rise to the opportunity to design wind turbine blades using a damage tolerant approach. Materials selection is a key element of da mage tolerant design, so the extent of the damage tolerance of alternative materials has been analyzed through a literature review and discussions with industry leaders. Fabrics and resin selection significantly affect the damage tolerance of composites. Changes to fabric architecture may include through-the-thickness (TTT) fibers, stretch-broken carbon fiber (SBCF) composites, and aligned discontinuous fiber reinforced composites (ADFRCs). Previous research has demonstrated that using TTT fibers in creases damage tolerance, but additional research is necessary to demonstrate the effectiveness of SBCFs and ADFRCs in mitigating damage. Several studies have demonstrated increased damage tolerance when toughened resin systems are used. In addition to toughened resin systems, thermoplastics have been shown to be tougher than thermosets. However, thermosets have been traditionally preferred in wind turbine blade manufacturing due to ease of manufacturing. Thermoplastic resin system s have been developed that can be used with conventional manufacturing methods but have yet to be studied for its damage tolerant capabilities. Furthermore, cost and stress analyses on where to effectively implement TTT fibers, SBCF composites, ADFRCs, and toughened resin systems must be executed prior to incorporating new materials into wind turbine blade manufacturing.

17 WIND ENERGY↗
NASA NTRS1986

Stresses and deformations in composite tubes due to a circumferential temperature gradient

A linear elasticity solution for determining the response of composite tubes subjected to a circumferential temperature gradient is presented. Numerical examples are used to show that, in a single layer tube, fiber orientation strongly influences response. When the fibers are aligned axially, all stress components in the tube are small. When the fibers are aligned circumferentially, the hoop stress becomes large. This difference in behavior is due to the large difference between the radial and circumferential coefficients of thermal expansion when the fibers are oriented circumferentially. In multilayer tubes, stresses are quite high and just two constants characterize the overall bending and axial deformations of the tubes.

Hyer, M. W.↗
NASA NTRS2017

Aligned and Electrospun Piezoelectric Polymer Fiber Assembly and Scaffold

A method of manufacturing and/or using a scaffold assembly for stem cell culture and tissue engineering applications is disclosed. The scaffold at least partially mimics a native biological environment by providing biochemical, topographical, mechanical and electrical cues by using an electroactive material. The assembly includes at least one layer of substantially aligned, electrospun polymer fiber having an operative connection for individual voltage application. A method of cell tissue engineering and/or stem cell differentiation that uses the assembly seeded with a sample of cells suspended in cell culture media, incubates and applies voltage to one or more layers, and thus produces cells and/or a tissue construct. In another aspect, the invention provides a method of manufacturing the assembly including the steps of providing a first pre-electroded substrate surface; electrospinning a first substantially aligned polymer fiber layer onto the first surface; providing a second pre-electroded substrate surface; electrospinning a second substantially aligned polymer fiber layer onto the second surface; and, retaining together the layered surfaces with a clamp and/or an adhesive compound.

Scott Carnell, Lisa A.↗