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At least 73 records · Page 4

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NASA NTRSDate not supplied

Thermal Modelling of the In-Situ Consolidation of Automated Fiber Placement Of Thermoplastic Composites

NASA is developing carbon fiber reinforced thermoplastic composites processing methods under the Hi-rate Composites Aircraft Manufacturing (HiCAM) project. The in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process has high potential to increase manufacturing throughput and lower costs as it combines the repeatability and fast lay down rates of AFP with the thermoformability of thermoplastic materials to achieve part consolidation out of the autoclave. Physics-based process models are employed in the ICAT process development to understand, fundamentally, the thermal response of the carbon fiber (CF)/polyaryletherketone (PAEK) material during the rapid heating and cooling associated with laser-assisted AFP. A one-dimensional (1-D) closed-form model was developed capable of predicting the temperature profile through-the-thickness of the tape material. In addition, a two-dimensional (2-D) model was developed to predict the heat transfer through-the-thickness and in the laydown x-direction of the AFP head motion. The solution of the Fourier heat-transfer equations in the 2-D model is approximated using the explicit finite difference numerical method. The temperature profile during placement of PAEK slit-tape materials at various laser target temperatures and placement speeds were measured during ICAT process development trials at Electroimpact®, Inc. †† and the resulting experimental data is compared with the predictions of the 1-D and 2-D models.

Christopher J. Stelter↗

DOE OSTI2024

Low-velocity impact resistance and failure characteristics of all thermoplastic woven polymer-fiber-reinforced plastic composites

This study addresses the impact performances of recyclable composites made of all thermoplastic polymer-fiber-reinforced plastics (PFRPs), where the reinforcing fibers and matrix are made of thermoplastic polymers. Three woven PFRPs systems were evaluated, including polypropylene fibers, polypropylene matrix, and high-density polyethylene matrix. In low-velocity impact scenario with an impactor speed of less than 6 m/s, our results demonstrate the energy absorption capabilities of the flat laminate PFRPs compared to woven carbon fiber-reinforced plastics (CFRPs) and aluminum alloy 5052. For the systems studied, the PFRPs can reach the specific energy absorption 89% to 115% of the CFRPs. Even compared with the aluminum alloy 5052, the PFRPs can reach up to 97%. We investigate the failure morphologies of the PFRPs using X-ray µCT scans. They reveal the PFRPs’ unique ductile failure morphologies compared to common CFRPs. In addition, we heal the perforated region in the PFRPs by applying the manufacturing process identical to the initial curing process. The healed panels are perforated again, and they recovered 30% to 38% of their original specific energy absorption, a recovery not achievable with CFRPs. This study provides valuable experimental results, and concrete insights into the potential applications of recyclable PFRPs in various engineering fields. It emphasizes their excellent energy-absorbing capability and repairability.

CFRPs↗

NASA NTRSDate not supplied

Thermal Response of Thermoplastic Composite Tape During In-situ Consolidation Automated Fiber Placement Using a Laser Heat Source

Composite materials have tremendous potential in the design and manufacture of commercial aircraft due to their high strength-to-weight and stiffness-to-weight properties. However, the use of composite materials is currently limited by high cost and long manufacturing time. The National Aeronautics and Space Administration (NASA) initiated the Hi-rate Composite Aircraft Manufacturing (HiCAM) project to investigate promising composite processing technologies with a goal of vastly improving composite commercial aircraft manufacturing rate (4-6x faster than current production rates). Laser assisted automated fiber placement (AFP) of thermoplastics is a key technology that could increase speed of composite manufacturing, but the technology has not been fully developed. In-situ consolidation AFP of thermoplastics (ICAT) could reduce time and cost even further by eliminating the time and equipment required for post-consolidation. In this work, the thermal response of laser heated ICAT was investigated using forward looking infrared (FLIR) and embedded thermocouples (TCs) to better understand fusion between layers (autohesion). Detailed explanation of the algorithm to combine FLIR and TC data will be presented. In addition, the effect of robot speed on time above melting temperature was quantified.

Laser Heating↗

NASA NTRS2024

Joining, Disassembly, and Reconfiguration of Thermoplastic Composites for Space Applications

Thermoplastic composites are increasingly being investigated for aerospace applications because of their relatively short processing time, good chemical and radiation resistance, and potential for reforming and reuse via melting. The manufacturing, reforming, and reuse of thermoplastic composites can be leveraged to advance joining, disassembly, and reassembly of structures for space exploration activities. Potential applications include, but are not limited to, habitats and on-orbit assembly and/or reassembly of large-scale truss structures.

Reassembly↗

NASA NTRS2026

Thermoplastic Matrix Composite Design for Cryotanks Using Multiscale Modeling and Bayesian Optimization

Designing lightweight, robust cryogenic storage tanks is critical for future launch vehicles, in-space propellant storage, and hydrogen powered aircraft. This work presents a multiscale modeling and Bayesian optimization framework for the design of thermoplastic matrix composite cryotanks. Molecular dynamics simulations are first used to determine temperature-dependent constituent properties for candidate thermoplastic matrices, which are homogenized to the lamina scale using NASA’s Multiscale Analysis Tool (NASMAT). These lamina properties, in combination with laminate family generation rules, are evaluated in HyperX structural optimization software to identify stacking sequences that meet all cryogenic load requirements. A Bayesian optimization framework is applied, with HyperX in the loop (via the HyperX API) to efficiently search across material and laminate design variables, yielding an optimized cryotank configuration with significant reductions in design cycle time compared to exhaustive search approaches.

thermoplastics↗

DOE OSTI2024

Thermoplastic Elastomers and Their Physical Gels Electrospun into Tunable Microfibrous Nonwoven Mats: Structure Formation and Property Enhancement

Abstract Thermoplastic elastomers (TPEs) based on styrenic block copolymers constitute excellent examples of self‐networking macromolecules that are employed in a wide range of contemporary technologies as molded parts. In such applications, these TPEs exist as dense (nonporous) films or other shapes. Here, it is first demonstrated that a series of commercial TPEs possessing comparable compositions can be electrospun from solution to form microfibers that are arranged into nonwoven mats that are breathable. An important consideration for microfiber formation is the copolymer molecular weight, which regulates i) the viscosity of the parent solution prior to electrospinning, ii) the ability of these copolymers to self‐assemble during electrospinning, iii) the microfiber morphology, and iv) the mechanical properties of the resultant microfibers. The addition of a midblock‐selective aliphatic oil to these TPEs yields thermoplastic elastomer gels (TPEGs), wherein the copolymer morphology and mechanical properties become highly composition‐tunable. Electrospinning TPEGs from a binary oil+solvent solution introduces a micelle inversion mechanism that begins with an oil‐rich micellar core and ends with a styrene‐rich micellar core, required for network stabilization, as the solvent dries during microfiber solidification. This work has implications for the production of controllably low‐modulus microfibrous materials possessing modestly improved toughness but exceptional extensibility and enhanced optical transparency.

Shamsi, Mohammad↗

DOE OSTI2025

Scalable fabrication of a tough and recyclable spore-bearing biocomposite thermoplastic polyurethane

Thermoplastic polyurethanes (TPUs) are a class of versatile thermoplastic elastomers, but most of their products lack a proper recycling strategy or have no end-of-life solutions. To pursue a sustainable end-of-life solution for TPU-based products, self-disintegrating biocomposite TPUs have recently been developed by embedding spores of TPU-degrading bacteria into TPUs via melt extrusion. Herein, we improve upon spore-bearing biocomposites and demonstrate industrially relevant manufacturing conditions for fabricating biocomposite TPUs. To minimize the coloration of biocomposite TPUs, spore production was modified. The innate brown color of the resulting materials was diminished by reducing FeSO 4 in sporulation media, generating white spores without compromising spore productivity, viability, morphology or heat-shock tolerance. Biocomposite TPUs containing white spores displayed a 45 % increase in toughness compared to TPUs without spores, while retaining ∼ 90 % spore viability post processing. Furthermore, biocomposite TPU fabrication was demonstrated using a scalable continuous extruder followed by injection molding. Biocomposite TPUs generated by these industry-relevant processes exhibited comparable toughness improvement and spore viability to biocomposite TPU prepared using a lab scale microcompounder, while enhancing productivity by 30-fold. Finally, spore addition significantly improved the recyclability of biocomposite TPUs, enabling 80 % toughness retention after 5 rounds of iterative melt processing. Additionally, no negative effect on the lifespan of the generated TPUs was observed over 1 year of storage. Overall, this study confirms that spore-bearing biocomposite TPUs are promising for practical applications, offering an accessible method to enhance toughness and sustainability of commercial TPUs through the incorporation of spore-based living fillers.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Effects of processing temperature, pressure, and fiber volume fraction on mechanical and morphological behaviors of fully-recyclable uni-directional thermoplastic polymer-fiber-reinforced polymers

This work explores a type of composite called thermoplastic polymer-fiber-reinforced polymers (PFRPs), often referred to as self-reinforced composites (SRCs). A representative PFRP was exemplified using unidirectional (UD) ultra-high-molecular-weight polyethylene (UHMWPE) fibers embedded in a high-density polyethylene (HDPE) matrix. The effects of compression molding temperature and pressure on the mechanical and morphological behaviors of the filament-wound PFRPs with various fiber volume fractions (V f ) were experimentally investigated. The results elucidate the evolution of morphologies and tensile properties of the PFRPs due to thermal melting, fiber misalignment from pressure, and (V f )-induced structural variance, which has not been comprehensively reported yet. The highest specific tensile strength and modulus of the PFRP laminae reach 600 MPa/(g/cm 3 ) and 31 GPa/(g/cm 3 ), respectively. These properties are comparable to glass-/aramid-fiber-reinforced polymers (GFRPs, GFRTPs, AFRPs, and AFRTPs), with PFRPs exhibiting better ductility (specific strain at peak load ≈ 4%/(g/cm 3 )) than other common polymer composites. The motivation for this work was the high recyclability of PFRPs, which can be recycled by melting both the fibers and the matrix, and then reshaped them for re-manufacturing composites to maximize the efficiency in material reuse. This process simplifies the implementation of closed-loop recycling, re-manufacturing, and reuse to support sustainability in composites. This work aims to contribute to advancing thermoplastic PFRPs for their potential applications in various industries.

36 MATERIALS SCIENCE↗

DOE OSTI2026

A physically based mechanical model for Mullins effect in thermoplastic polyurethanes

Despite decades of research, connecting the chemical and physical structure of thermoplastic polyurethanes to their mechanical properties remains highly challenging. Of particular note are their large-deformation and rate-dependent behaviors, which vary greatly with molecular chemistry, including the type and relative content of soft and hard segments. In this work, we develop a physically motivated mechanical theory for predicting the behavior of thermoplastic polyurethanes. The theory incorporates a representation of microstructural evolution during mechanical deformation, which captures the signatures of stress softening over cyclic loading (commonly referred to as the Mullins effect). There are only eight physically motivated fitting parameters, including a direct dependence on the hard segment fraction. The model predicts that increasing the hard segment fraction leads to higher stiffness and greater energy dissipation, in quantitative agreement with published experimental data. Furthermore, we provide a comprehensive analysis of the model and validate its predictions across several independent datasets focused on mechanical characterization. Direct comparisons to experimental data demonstrate its predictive capability on the effect of loading rate, cyclic deformations, and applied tension or compression. Altogether, this work establishes a predictive framework that connects polymer chemistry and microstructure to emergent mechanical behaviors.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Evaluation of Common Thermoplastic Polymers in High-Pressure Cycling Hydrogen Under Ambient and Cold Environments as Applicable to the Hydrogen Infrastructure

Thermoplastic polymers are required to perform unfailingly under stringent conditions of changing pressures (35 MPa to 70 MPa) and temperatures (-40°C to +85°C) in storage and fueling operations. Although diffusivity in glassy polymers appear to be an order of magnitude lower than elastomers, polymer microstructural attributes such as degree of crystallinity and presence of polar and non-polar groups on the main chain with and without branching can play a substantial role in influencing their behaviors in hydrogen environments. In the work described here, the effect of high-pressure hydrogen cycling on PEEK, PTFE, PA11, HDPE, POM (and different commercial grades of these polymers) under ambient and cold (-40°C) conditions is addressed. Ex-situ characterization for polymer changes included density measurements for impact of hydrogen retention, hardness changes using nanoindentation, storage modulus and glass transition changes using dynamic mechanical and thermal analysis (DMTA), degree of crystallization with Differential Scanning Calorimetry (DSC) and tensile testing following ASTM D412. In other evaluations, solid-state nuclear magnetic resonance (NMR), attenuated total reflectance Fourier transform infra-red spectroscopy (ATRFTIR), X-ray diffraction (XRD), and X-ray CT results are presented. The overall impact of these evaluations is to establish a technical basis for the behaviors of common thermoplastics in cycling hydrogen environments under ambient and cold temperatures while establishing the relationship between polymer structure-based properties and hydrogen transport effects.

Menon, Nalini C.↗

DOE OSTI2026

Lithographic crystallinity regulation in additive fabrication of thermoplastics (CRAFT)

For semicrystalline polyolefin thermoplastics, the balance between interconnected ordered crystalline and disordered amorphous regions is paramount to their performance and processability. However, contemporary manufacturing strategies, from injection molding to three-dimensional (3D) printing, result in monolithic objects, unable to spatially encode crystallinity. We develop a light-based approach for fabricating mechanically robust polyolefin thermoplastics with microscopic control over crystallinity in 3D space. Light dosage governs polymer stereochemistry giving access to a continuum of materials, from strong rigid plastics, such as high-density polyethylene, to more extensible materials akin to low-density polyethylene, all at the flick of a switch. Leveraging this finding in lithographic grayscale 3D printing enables rapid multimaterial fabrication with voxel-level control over optical and mechanical properties, opening avenues in information storage, soft robotics, and energy damping.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Degradable Biocomposite Thermoplastic Polyurethanes

In this project, the team developed tough and degradable biocomposite thermoplastic polyurethanes (TPUs) by incorporating bacterial spores into TPUs as a biofunctional living filler. The team screened various bacteria and selected the Bacillus subtilis ATCC 6633 strain as the final candidate, primarily due to its genomic availability, sporulation ability and TPU assimilation activity. The heat-shock tolerance of ATCC 6633 spores was further improved through evolutionary engineering via Adaptive Laboratory Evolution (ALE), demonstrating a 17.7-fold enhanced germination efficiency post heat-shock treatment compared to the wild-type strain (WT). The team fabricated biocomposite TPUs by incorporating lyophilized powder of heat-shock tolerized (HST) spores during the hot melt extrusion (HME) of TPU at 135 °C. The baseline TPU used in this project is a commercially available soft-grade TPU (BCF45) manufactured by BASF. Colony forming unit (CFU) assays quantified that WT and HST spores in the TPU matrix retained approximately 20% and 100% survivability, respectively, after HME. Tensile testing demonstrated that the spores behaved as a polymer-reinforcing filler, positively affecting the overall tensile properties of the biocomposite TPU. For example, biocomposite TPU with WT and HST spores (BC TPU WT and BC TPU HST , respectively) exhibited up to 25% and 37% improved toughness, respectively, compared to TPU without spores. BC TPU HST showed remarkably improved disintegration in autoclaved compost (92% mass loss in 5 months), which simulated a microbially poor environment for TPU degradation. When compared to TPU without spores (44% mass loss in 5 months) the acceleration of degradation is marked. Respirometry confirmed that 72% of BC TPU HST was biomineralized into CO2 within 6 months, indicating that spores in the biocomposite TPU were germinated by utilizing nutrients in the autoclaved compost, facilitating TPU degradation at the end of the material's life. The team demonstrated the scale-up of biocomposite TPU fabrication using continuous extrusion and injection molding techniques. Processing conditions optimized in a lab-scale microcompounder were successfully transferred to a continuous extruder with a 30-fold increased throughput. Biocomposite TPUs prepared using these industry-relevant processes showed comparable toughness improvements to samples prepared in the lab-scale extruder. Excitingly, following compounding in the pilot-extruder the composite material could be injection molded, while retaining high spore viability and similar toughness improvements. The team also found that spores in biocomposite TPU served as antioxidants, preventing toughness decay during the recycled extrusion of BC TPU HST . Long-term storage tests over one year showed that the addition of spores had no negative effect on the longevity of the TPU. Furthermore, the team demonstrated the fabrication of spore-bearing biocomposite polymers with other polyesters such as PBAT, PLA, and PCL. We obtained promising preliminary data that showed overall toughness improvements for all polymers with spore addition. Finally, life cycle assessment (LCA) and techno-economic analysis (TEA) were carried out, which indicated minimal additional cost of fabrication. Overall, a tough and degradable biocomposite thermoplastic was successfully developed through this project, with all tasks completed successfully, achieving >100% of the objectives.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their Gen5d 5 m turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three rotors initially deployed were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. The new rotor utilized a novel infusible thermoplastic resin system. Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermomechanical characterization, and evaluation of material performance in marine environments to understand the key differences between the fiberglass-reinforced epoxy and Elium composites used for the respective rotors. Matrix burn-off tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period; however, it was determined that the Elium laminates had higher diffusion coefficients, so they initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while periodic mass measurements were taken. The datasets were extrapolated to assume a full 20-year operational life span, and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗

NASA NTRS1969

Imprinting of confining sites for cell cultures on thermoplastic substrates

Prevention of test cell migration beyond the field of observation involves confining cells or cultures in microlagoons made in either a layer of grease or a thermoplastic substrate. Thermoplastic films or dishes are easily imprinted with specifically designed patterns of microlagoons.

Cone, C. D.↗

NASA NTRS1975

Graphite fiber reinforced thermoplastic resins

Mechanical properties of neat resin samples and graphite fiber reinforced samples of thermoplastic resins were characterized with particular emphasis directed to the effects of environmental exposure (humidity, temperature and ultraviolet radiation). Tensile, flexural, interlaminar shear, creep and impact strengths were measured for polysulfone, polyarylsulfone and a state-of-the-art epoxy resin samples. In general, the thermoplastic resins exhibited environmental degradation resistance equal to or superior to the reference epoxy resin. Demonstration of the utility and quality of a graphite/thermoplastic resin system was accomplished by successfully thermoforming a simulated compressor blade and a fan exit guide vane.

Novak, R. C.↗

NASA NTRS1981

A multi-purpose thermoplastic polyimide

A linear thermoplastic polyimide, LARC-TPI, has been characterized and developed for a variety of high-temperature applications. In its fully imidized form, this new material can be used as an adhesive for bonding metals such as titanium, aluminum, copper, brass, and stainless steel. LARC-TPI is being evaluated as a thermoplastic for bonding large pieces of polyimide film to produce flexible, 100% void-free laminates for flexible circuit applications. The further development of LARC-TPI as a potential molding powder, composite matrix resin, high-temperature film and fiber will also be discussed.

Saint Clair, A. K.↗

NASA NTRS1982

LARC-TPI: A multi-purpose thermoplastic polyimide

A linear thermoplastic polyimide, LARC-TPI, was characterized and developed for a variety of high temperature applications. In its fully imidized form, this material can be used as an adhesive for bonding metals such as titanium, aluminum, copper, brass, and stainless steel. LARC-TPI was evaluated as a thermoplastic for bonding large pieces of polyimide film to produce flexible, 100 void-free laminates for flexible circuit applications. The development of LARC-TPI as a potential molding powder, composite matrix resin, high temperature film and fiber is also discussed.

St.clair, A. K.↗

NASA NTRS1981

A multi-purpose thermoplastic polyimide

Saint Clair, A. K.↗