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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 NTRS2012

High-Thermal-Conductivity Fabrics

Heat management with common textiles such as nylon and spandex is hindered by the poor thermal conductivity from the skin surface to cooling surfaces. This innovation showed marked improvement in thermal conductivity of the individual fibers and tubing, as well as components assembled from them. The problem is centered on improving the heat removal of the liquid-cooled ventilation garments (LCVGs) used by astronauts. The current design uses an extensive network of water-cooling tubes that introduces bulkiness and discomfort, and increases fatigue. Range of motion and ease of movement are affected as well. The current technology is the same as developed during the Apollo program of the 1960s. Tubing material is hand-threaded through a spandex/nylon mesh layer, in a series of loops throughout the torso and limbs such that there is close, form-fitting contact with the user. Usually, there is a nylon liner layer to improve comfort. Circulating water is chilled by an external heat exchanger (sublimator). The purpose of this innovation is to produce new LCVG components with improved thermal conductivity. This was addressed using nanocomposite engineering incorporating high-thermalconductivity nanoscale fillers in the fabric and tubing components. Specifically, carbon nanotubes were added using normal processing methods such as thermoplastic melt mixing (compounding twin screw extruder) and downstream processing (fiber spinning, tubing extrusion). Fibers were produced as yarns and woven into fabric cloths. The application of isotropic nanofillers can be modeled using a modified Nielsen Model for conductive fillers in a matrix based on Einstein s viscosity model. This is a drop-in technology with no additional equipment needed. The loading is limited by the ability to maintain adequate dispersion. Undispersed materials will plug filtering screens in processing equipment. Generally, the viscosity increases were acceptable, and allowed the filled polymers to still be processed.The novel feature is that fabrics do not inherently possess good thermal conductivity. In fact, fabrics are used for thermal insulation, not heat removal. The technology represents the first material that is a wearable fabric, based on company textiles and materials that will significantly conduct heat.

Chibante, L. P. Felipe↗
NASA NTRS2006

Thermal Conductivity of Ultem(TradeMark)/Carbon Nanofiller Blends

In an effort to improve polymer thermal conductivity (TC), Ultem(TradeMark) 1000 was compounded with nano-fillers of carbon allotropes. Ultem(TradeMark) 1000 was selected since it is both solution and melt processable. As-received and modified multiwalled carbon nanotubes (MWCNTs), vapor grown carbon nanofibers (CNF) and expanded graphite (EG) were investigated. MWCNTs were modified by functionalizing the surface through oxidization with concentrated acids, mixing with an alkyl bromide, and addition of alkyl and phosphorus compounds after initial treatment with n-butyl lithium. Functionalization was performed to improve the TC compatibility between the resin and MWCNTs. It was postulated that this may provide an improved interface between the MWCNT and the polymer which would result in enhanced TC. The nano-fillers were mixed with Ultem(TradeMark) 1000 in the melt and in solution at concentrations ranging from 5 to 40 wt%. Ribbons were extruded from the blends to form samples where the nano-fillers were aligned to some degree in the extrusion direction. Samples were also fabricated by compression molding resulting in random orientation of the nano-fillers. Thermal properties of the samples were evaluated by Differential Scanning Calorimetry (DSC) and Thermal Gravimetric Analyzer (TGA). Tensile properties of aligned samples were determined at room temperature. The specimens were cut from the ribbons in the extrusion direction; hence the nano-fillers are somewhat aligned in the direction of stress. Typically it was observed that melt mixed samples exhibited superior mechanical properties compared to solution mixed samples. As expected, increased filler loading led to increased modulus and decreased elongation with respect to the neat polymer. The degree of dispersion and alignment of the nano-fillers was determined by high-resolution scanning electron microscopy (HRSEM). HRSEM of the ribbons revealed that the MWCNTs and CNFs were predominantly aligned in the flow direction. The TC of the samples was measured using a Nanoflash(TradeMark) instrument. Since the MWCNTs and CNF are anisotropic, the TC was expected to be different in the longitudinal (parallel to the nanotube and fiber axis) and transverse (perpendicular to the nanotube and fiber axis) directions. The extruded ribbons provided samples for transverse TC measurements. However, to determine the TC in the longitudinal direction, the ribbons needed to be stacked and molded under 1.7 MPa and 270 C. Samples were then obtained by cutting the molded block with a diamond saw. The largest TC improvement was achieved for aligned samples when the measurement was performed in the direction of MWCNT and CNF alignment (i.e. longitudinal axis). Unaligned samples also showed a significant improvement in TC and may be potentially useful in applications when it is not possible to align the nano-filler. The results of this study will be presented.

Ghose, S.↗
DOE OSTI2026

Ultrasonic-Assisted Extrusion Processing for Enhancing Physical Properties of High-Density Polyethylene by Flow-Induced Crystallization

The evolution of crystallinity resulting from stress imposed on a melt, known as flow-induced crystallinity, can strongly influence the mechanical and physical properties of semicrystalline polymers. This study investigates shear-induced crystallization by applying an ultrasonic field to the melt flow as it passes through dies with various geometries. A custom-built sonication die is employed for controlling the dynamic temperature and shear environment, resulting in molecular alignment and potential for flow-induced crystallization. Application of both conventional and ultrasonic shear rates at the equilibrium melt temperature of high-density polyethylene (HDPE) was investigated to accelerate crystallinity and manipulate the crystal morphology across the film in pursuit of improved mechanical and gas barrier properties without the need for additives or other polymer layers. The relationships among ultrasonic-assisted extrusion processing, polymer structure, and performance were analyzed using wide- and small-angle X-ray scattering (WAXS and SAXS), tensile testing, and oxygen transmission rate (OTR) analysis. Multiple linear regression models were implemented to predict the correlation among HDPE structure, process, and properties. Structural analysis revealed that both conventional and ultrasonic shear rates had the most significant influence on lamellar spacing and redistribution of rigid and soft amorphous fractions within the crystalline domains, ultimately dictating the mechanical and physical properties of the films. The goal is to explore the potential of the ultrasonic-assisted high crystallinity monolayer that can replace some of the functionality of complex, heterogeneous multilayer packaging with a single-material film having enhanced oxygen barrier properties.

crystallinity↗
NASA NTRS1981

The evolution of the lunar Nectaris multiring basin

The paper begins by discussing the pre-Nectaris crust, the formation of the basin, its age and its geophysics. The pre-mare basalt deposits are categorized into smooth plains deposits, cratered and patterned plains, knobby terrain, and massifs, and the structure, chemical composition, and probable origin of these are discussed. Alternative scenarios for the formation of the plains are that they consist of impact melt ejecta, ejecta overlying smoothed-out preexisting topographic material, or ejecta overlying extrusive deposits. The mare deposits are assessed in terms of their composition, basalt ages and thickness, and eruption styles. A probable age of 3.6 billion years for the basalts is given. The tectonics of mare ridges and fractures and floor-fractured craters are gone into. Post-mare cratering is also discussed. It is concluded that the morphology of multiring basins is strongly dependent on lithosphere thickness.

Whitford-Stark, J. L.↗
NASA NTRS1990

The microstructure and properties of rapidly solidified, dispersion-strengthened NiAl

An advanced rapid solidification technology for processing reactive and refractory alloys, utilized to produce large quantities of melt-spun filaments of NiAl, is presented. The melt-spun filaments are pulverized to fine particle sizes, and subsequently consolidated by hot extrusion or hot isostatic pressing. Rapid solidification process gives rise to very fine-grained microstructures. However, exposure to elevated temperature during hot consolidation leads to grain growth. Alloying agents such as borides, carbides, and tungsten can pin the grain boundaries and retard the grain growth. Various alloy compositions are investigated. The eventual goal is to utilize the hot-extruded and forged stock to grow single-crystal NiAl blades for advanced gas-turbine engine applications. Single-crystal NiAl, containing a uniform dispersion of carbide strengthening precipitates, is expected to lead to highly creep-resistant turbine blades, and is of considerable interest to the aerospace propulsion industry.

Jha, S. C.↗
DOE OSTI2026

BOTTLE: Hybrid Chemical-Mechanical Separation and Upcycling of Mixed Plastic Waste

The main objective of this project is to develop a hybrid mechanical-chemical recycling technology for multilayered and laminated plastics. We aimed to separate and upcycle up to more than 80% of the two main constituents of such structures, polyolefins and polyesters, for a significantly lower cost and at higher energetic efficiency and much larger throughputs than chemical recycling. At the end of the project, the team was able to: a) Develop an extrusion-based separation technology that resorts to polyester depolymerizaton and extraction and allows for more than 90% of the polyester to be separated in the melt from the main polyolefin stream. b) Depolymerize the separated PET to more than 90%, which facilitates its posterior repolymerization and guarantees its retention in the polymer value-chain. c) Develop a zeolite-induced extrusion-based technology able to conduct continuous catalytic cracking of polyolefins, including highly contaminated PCR streams, at temperatures as low as 350 OC. d) Show, using LCA/TEA analysis that the two technologies are much more advantageous techno-economically and over the material’s life cycle than existing recycling technologies.

36 MATERIALS SCIENCE↗
NASA NTRS1985

Crustal development in the terrestrial planets

The development of planetary crusts may be divided into primary, resulting from melting during accretion, and secondary crusts developed by partial melting from planetary mantles. The Mercurian crust is probably primary with no compelling evidence of later basaltic extrusions. Reflectance spectral evidence for the existence Fe2(+) is equivocal. The Viking Lander XRF data on Mars indicate basaltic material at both sites 4,000 km apart. Surface aeolian processes would be expected to provide a homogeneous average of the crust, but no evidence of more siliceous material is present. This conclusion is weakly supported by the Russian gamma ray data. No evidence for granite appears from the Russian Venera XRF data which indicates MORB-type and alkali basalt (4% K2O) surface compositions. The highlands of Ishtar Terra and Aphrodite probably owe their elevation to tectonic processes rather than compositional effects. Venus may thus resemble the early Archean Earth. The terrestrial granitic continental crust is a product of episodic multiple partial melting events, probably a consequence of the presence of surface water.

Taylor, S. R.↗
NASA NTRS1995

The 1200 K compressive properties of N-containing NiAl

As part of a series of experiments to understand the role of N on the strength of NiAl, a heat of NiAl was enriched with N by melting and atomization to powder in a nitrogen atmosphere. Following consolidation of the powder by hot extrusion, 1200 K compressive properties were measured in air. Within the range of strain rates examined, 10(exp -3) to 10(exp -9) s(exp -1), the strength of the N-enriched NiAl was greater than that of a simple 15 micron grain size polycrystalline, binary NiAl alloy. For the most part the overall improvement in strength is ascribed to the fine grain size of the N-doped NiAl rather than the alloy chemistry; however, the alloy displayed a complex behavior exhibiting both weakening effects as well as strengthening ones.

Whittenberger, J. Daniel↗
NASA NTRS1995

1200 K Compressive Properties of N-Containing Nial

As part of a series of experiments to understand the role of N on the strength of NiAl, a heat of NiAl was enriched with N by melting and atomization to powder in a nitrogen atmosphere. Following consolidation of the powder by hot extrusion, 1200 K compressive properties were measured in air. Within the range of strain rates examined, 10 exp -3 to 10 exp -9/s, the strength of the N-enriched NiAl was greater than that of a simple 15 micron grain size polycrystalline, binary NiAl alloy. For the most part the overall improvement in strength is ascribed to the fine grain size of the N-doped NiAl rather than the alloy chemistry; however, the alloy displayed a complex behavior exhibiting both weakening effects as well as strengthening ones.

Whittenberger, J. D.↗
DOE OSTI2025

Processing behavior evolution of recycled polypropylene: An integrated experimental and Computer-Aided engineering simulation study

Polypropylene (PP) comprises 21% of global plastics production and 18% of plastics waste, yet less than 1% of solid-waste PP is recycled in the United States (U.S.), representing significant environmental and economic challenges. Mechanical recycling, the most prevalent recycling method, subject's materials to thermomechanical stresses, which typically degrade polymer properties, affecting the quality of polymer products. This study replicates the impact of mechanical recycling through multiple extrusion cycles to examine the effects on PP's processing behavior. Dynamic scanning calorimetry (DSC) measurements showed stable melting behavior across all processing conditions, while crystallization analysis exhibited consistent shifts in kinetic parameters. Rheological characterization demonstrated progressive viscosity reductions through successive cycles, particularly pronounced at elevated reprocessing temperatures. Here, the integration of this experimental data into injection molding simulations showed that recycled PP maintains viable processing characteristics. Our findings establish quantitative correlations between processing history and material behavior, enabling optimization of processing parameters directly rather than relying on trial-and-error approaches. While these results reflect idealized recycling conditions with minimal contamination, they provide a framework for understanding fundamental property evolution during mechanical recycling.

42 ENGINEERING↗
NASA NTRS1997

High Temperature Structural Foam

The Aerospace Industry is experiencing growing demand for high performance polymer foam. The X-33 program needs structural foam insulation capable of retaining its strength over a wide range of environmental conditions. The High Speed Research Program has a need for low density core splice and potting materials. This paper reviews the state of the art in foam materials and describes experimental work to fabricate low density, high shear strength foam which can withstand temperatures from -220 C to 220 C. Commercially available polymer foams exhibit a wide range of physical properties. Some with densities as low as 0.066 g/cc are capable of co-curing at temperatures as high as 182 C. Rohacell foams can be resin transfer molded at temperatures up to 180 C. They have moduli of elasticity of 0.19 MPa, tensile strengths of 3.7 Mpa and compressive strengths of 3.6 MPa. The Rohacell foams cannot withstand liquid hydrogen temperatures, however Imi-Tech markets Solimide (trademark) foams which withstand temperatures from -250 C to 200 C, but they do not have the required structural integrity. The research activity at NASA Langley Research Center focuses on using chemical blowing agents to produce polyimide thermoplastic foams capable of meeting the above performance requirements. The combination of blowing agents that decompose at the minimum melt viscosity temperature together with plasticizers to lower the viscosity has been used to produce foams by both extrusion and oven heating. The foams produced exhibit good environmental stability while maintaining structural properties.

Weiser, Erik S.↗
NASA NTRS1987

Advanced powder metallurgy aluminum alloys via rapid solidification technology, phase 2

Marko's rapid solidification technology was applied to processing high strength aluminum alloys. Four classes of alloys, namely, Al-Li based (class 1), 2124 type (class 2), high temperature Al-Fe-Mo (class 3), and PM X7091 type (class 4) alloy, were produced as melt-spun ribbons. The ribbons were pulverized, cold compacted, hot-degassed, and consolidated through single or double stage extrusion. The mechanical properties of all four classes of alloys were measured at room and elevated temperatures and their microstructures were investigated optically and through electron microscopy. The microstructure of class 1 Al-Li-Mg alloy was predominantly unrecrystallized due to Zr addition. Yield strengths to the order of 50 Ksi were obtained, but tensile elongation in most cases remained below 2 percent. The class 2 alloys were modified composition of 2124 aluminum alloy, through addition of 0.6 weight percent Zr and 1 weight percent Ni. Nickel addition gave rise to a fine dispersion of intermetallic particles resisting coarsening during elevated temperature exposure. The class 2 alloy showed good combination of tensile strength and ductility and retained high strength after 1000 hour exposure at 177 C. The class 3 Al-Fe-Mo alloy showed high strength and good ductility both at room and high temperatures. The yield and tensile strength of class 4 alloy exceeded those of the commercial 7075 aluminum alloy.

Ray, Ranjan↗
NASA NTRS1981

Weathering of Mars - Antarctic analog studies

Subaerial extrusion of lavas above permafrost is proposed as a possible weathering regime leading to the presence of Martian surface fines, and the characteristics of this process are examined through a study of the analogous altered terrestrial basalts from Antarctica. On the basis of mineralogical and petrological analyses of samples obtained from core cuttings recovered by the Dry Valley Drilling Program from rocks predominantly of an aklalic basalt-phonolite suite, it is found that in the absence of liquid water, weathering is geologically slow, and that zeolites predominate over clays as secondary mineral. Of the possible weathering processes proposed for Mars, it is concluded that both subaerial extrusion and subpermafrost intrusion of lavas involving liquid water would be less important volumetrically than the hydrothermal alteration of impact melt sheets if water were present during an intense phase of early bombardment, or than subsequent solid-gas alteration reactions. It is thus predicted that the present Martian fines should contain a major contribution from the ancient crust as typified by the southern cratered highlands, and a lesser contribution from the younger basaltic lavas.

Berkley, J. L.↗
NASA NTRS2004

Development of a Plastic Melt Waste Compactor for Space Missions Experiments and Prototype Design

This paper describes development at NASA Ames Research Center of a heat melt compactor that can be used on both near term and far term missions. Experiments have been performed to characterize the behavior of composite wastes that are representative of the types of wastes produced on current and previous space missions such as International Space Station, Space Shuttle, MIR and Skylab. Experiments were conducted to characterize the volume reduction, bonding, encapsulation and biological stability of the waste composite and also to investigate other key design issues such as plastic extrusion, noxious off-gassing and removal of the of the plastic waste product from the processor. The experiments provided the data needed to design a prototype plastic melt waste processor, a description of which is included in the paper.

Pace, Gregory↗
DOE OSTI2024

Highly Efficient Vacuum Smelting of Aluminum

The goal of this SBIR project was to develop and demonstrate an innovative aluminum smelting technology that will significantly increase the range of aluminum alloys that can be manufactured from recycling of scrap aluminum. This will result in reduction of need for primary aluminum with corresponding 95% energy and CO 2 emission benefits. The proposed melting of pre-sorted aluminum alloys using UHV’s patented high throughput sorter funded by ARPA-E METALS program in an energy efficient vacuum furnace avoids the typical 5% metal loss due to oxidation of molten metal. In addition, pre-sorting scrap into different categories (cast, wrought, extrusion and aerospace) allows lower cost production of high value aluminum alloys without the need for adding alloying elements to primary aluminum. During this SBIR project, pure aluminum and several different commercial alloys were procured and melted in a laboratory furnace in vacuum, CH4 and air environments. The slag and oxidation formation were measured using weight and cross-sectional scanning electron microscope. The results otained were mixed and did not show direct correlation between furnace pressure and oxidation. We believe that the results were tainted due to small furnace size and non-uniformity of oxidation layer. A more thorough investigation is required to prove the advantages of vacuum smelting which could not be performed due to the COVID-19 lockdowns during this project. The theoretical fact remains that in the absence of oxygen in the furnace, there should be no oxide after melting, however the team could not prove it experimentally, and thus decided to dis-continue the project.

36 MATERIALS SCIENCE↗
NASA NTRS1984

Advanced powder metallurgy aluminum alloys via rapid solidification technology

Aluminum alloys containing 10 to 11.5 wt. pct. of iron and 1.5 to 3 wt. pct. of chromium using the technique of rapid solidification powder metallurgy were studied. Alloys were prepared as thin ribbons (.002 inch thick) rapidly solidified at uniform rate of 10(6) C/second by the melt spinning process. The melt spun ribbons were pulverized into powders (-60 to 400 mesh) by a rotating hammer mill. The powders were consolidated by hot extrusion at a high reduction ratio of 50:1. The powder extrusion temperature was varied to determine the range of desirable processing conditions necessary to yield useful properties. Powders and consolidated alloys were characterized by SEM and optical metallography. The consolidated alloys were evaluated for (1) thermal stability, (2) tensile properties in the range, room temperature to 450 F, and (3) notch toughness in the range, room temperature to 450 F.

Ray, R.↗
DOE OSTI2025

Chemical Recycling of Polycaprolactones via Reactive Melt Processing

Chemical recycling is a promising technology for the deconstruction of waste plastics into monomers or other chemical intermediates, which can be converted into other value-added products or repolymerized into polymers. In this work, polycaprolactone and poly(4-propylcaprolactone) were chemically recycled by exploiting ring-closing depolymerization (RCD). To demonstrate the utility of this approach, reactive distillation experiments were initially conducted in a heated round-bottom flask with a distillation head to explore the effect of temperature and catalyst loading on RCD. Inspired by industrial devolatilization equipment, analogous experiments were conducted using a twin-screw melt compounder that was modified to simultaneously heat and mix polymer in the presence of a catalyst while continuously removing the evolved monomer vapors with a vacuum system and collecting them in a cold trap. Yield and selectivity of the recovered monomer were characterized by 1 H nuclear magnetic resonance spectroscopy and gas chromatography-mass spectrometry. Importantly, the more scalable twin-screw melt compounder approach produced values of monomer selectivity (∼90%) and yield (∼80%) similar to those of the round-bottom flask experiments. The recovered monomers were also successfully repolymerized into the same neat polymer with comparable molar masses without purification steps or adding initiator. Here, the results of this study promote the use of reactive devolatilization extrusion as a scalable approach to polyester depolymerization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1986

A mid-Archaean ophiolite complex, Barberton Mountain land

New field observations and structurally restored geologic sections through the southern part of 3.5-3.6 Ga Barberton greenstone belt show that its mafic to ultramafic rocks form a pseudostratigraphy comparable to that of Phanerozoic ophiolites; this ancient ophiolite is referred to as the Jamestown ophiolite complex. It consists of an intrusive-extrusive mafic-ultramafic section, underlain by a high-temperature tectono-metamorphic residual peridotitic base, and is capped by a chert-shale sequence which it locally intrudes. Geochemical data support an ophiolitic comparison. Fraction of high temperature melting PGE's 2500 C in the residual rocks suggest a lower mantle origin for the precursors of this crust. An oceanic rather than arc-related crustal section can be inferred from the absence of contemporaneous andesites. The entire simatic section has also been chemically altered during its formation by hyrothermal interaction with the Archean hydrosphere. The most primitive parent liquids, from which the extrusive sequence evolved, may have been picritic in character. Rocks with a komatiitic chemistry may have been derived during crystal accumulation from picrite-crystal mushes (predominantly olivine-clinopyroxene) and/or by metasomatism during one or more subsequent episodes of hydration-dehydration. The Jamestown ophiolite complex provides the oldest record with evidence for the formation of oceanic lithosphere at constructive tectonic boundaries.

Dewit, M. J.↗