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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 OSTI2026

Carbon fiber design improvements based on economic models

Circular fiber geometries are predominant in commercial carbon fiber material systems, but the use of this fiber shape has numerous limitations. Circular geometries have continuous symmetry, which is helpful for various processing considerations, but also have the largest possible maximum diffusion thickness for a given fiber area. This characteristic means that circular carbon fibers always have the highest material processing cost and lowest production throughput compared to any other fiber shape with the same area and tow count. To quantify material cost and other benefits for non-circular carbon fiber geometries, process models for polyacrylonitrile based carbon fiber production are developed in relationship to the carbon fiber shape, size, and tow count. For a given fiber shape, precursor production costs are shown to favor maximizing fiber size while conversion costs are minimized by the smallest fiber size. These competing cost trends result in a numerically optimal fiber size for a given shape and tow count, while both cost components are decreased by increasing tow count. Cost–performance tradeoffs for three lobe fiber geometries are studied by supplementing the cost trends with a numerical failure model to predict compressive strength for discrete shape variants. The shape selection is shown to be more sensitive to variations in cost than compressive strength while suboptimal shape designs can improve manufacturing robustness and achievable fiber volume fractions. Finally, an optimal three lobe carbon fiber is identified that balances the set of considerations while reducing costs and embodied energy and increasing production throughput compared to a commercial carbon fiber.

Carbon fiber↗
DOE OSTI2025

Interpretation of wide-angle x-ray diffraction patterns from mesophase pitch-based carbon fibers – a simulation and experimental study

Carbon fiber is a critical material in a wide range of industries, where it is highly valued for its high specific strength/stiffness, excellent wear resistance, efficient electrical and thermal transport properties, chemical resistance, and low coefficient of thermal expansion. The properties of a specific carbon fiber are closely tied to its structural characteristics at all length scales. Here, in this work, we applied wide-angle x-ray diffraction to a set of heat-treated mesophase pitch-based carbon fibers, with the goal of elucidating the crystalline structures as a function of fiber orientation. To assist with analysis and interpretation of the experimental data, we employed diffraction pattern simulations using the scalar and vector forms of the Debye scattering equation to determine the influence of basal plane orientation, crystalline ordering (turbostratic-graphitic), and basal plane asymmetry on the diffraction patterns. The results presented here suggest that growth of the transverse crystallites in mesophase pitch-based carbon fiber is fixed until graphitization temperatures are reached. The work completed here provides a framework for the analysis of carbon fiber and other oriented carbon-based materials via diffraction.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Carbon fiber production at low temperatures from polyacrylonitrile

Recent safety considerations have sought to lower the electrical conductivity of carbon fibers. Carbon fibers produced from polyacrylonitrile at low carbonization temperatures (600-900 C) possess low electrical conductivity but do not possess adequate strength. Low-temperature processes are described which improve fiber strength but do not increase electrical conductivity substantially. The processes result in a carbon fiber with nearly twice the tensile strength compared to the old process. Process development and its effect on fiber properties are reported.

Cagliostro, D. E.↗
DOE OSTI2024

Evaluating consumer 3D printing nozzles as a low cost alternative for mesophase pitch-derived carbon fiber production

Synthetic fibers, such as Kevlar fibers, SiC fibers, and carbon fibers, are essential components for constructing high performance structures. Whether for engineering, sports, energy storage (batteries and supercapacitors), or aerospace applications, fiber microstructure plays a critical role in fiber properties and functionalities. However, studying fiber nozzle configurations and spinning parameters to achieve the desired microstructure remains challenging, costly, and time consuming. Here, mesophase pitch-derived fibers were used as an example to demonstrate that low cost, commercially available 3D printer nozzles can “print” fibers. Four different nozzles were used to “print” fibers and the effects of their features on fiber properties were observed and compared to other lab spun and commercial pitch- derived CF. A longer orifice length resulted in higher modulus fiber whereas a larger draw-down ratio yielded a stronger fiber. Furthermore, the findings provide a new opportunity for 3D printer hardware application and open up opportunities for developing low-cost fibers.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Enhanced Interfacial Strength in Carbon Fiber Composites via Mussel‐Inspired Sizing Polymers

Composite materials possess a high strength-to-weight ratio. A key determinant of their mechanical performance is the interfacial strength between the fibers and the matrix. Sizing agents are commonly used to improve this interface by promoting better adhesion, though optimizing this interaction remains a significant challenge. Here, this study evaluates the use of poly(catechol-styrene) (PCS), a mussel-inspired sizing agent, to enhance fiber–matrix bonding in carbon fiber composites. Woven carbon fiber laminates were dip-coated with varying concentrations of PCS (0.05 and 0.1 wt%) and subsequently fabricated using vacuum-assisted resin transfer molding followed by compression molding. Interlaminar shear strength (ILSS) tests showed improvements of 4% and 8% for the 0.05% and 0.1% PCS treatments, respectively. These results indicate that PCS is effective in reinforcing interfacial adhesion, thereby improving the mechanical integrity of carbon fiber-reinforced composites.

Carbon fiber composites↗
DOE OSTI2022

Carbon fibers derived from commodity polymers: A review

Carbon fiber composites are prohibitively expensive for a wide array of applications that would greatly benefit from their superior specific strength and specific stiffness. Replacing the market-dominant carbon fiber precursor material, polyacrylonitrile, with a low-cost alternative would significantly reduce the cost of carbon fiber production. Commodity polymers may provide such an alternative thanks to their abundance and ease of production into fibers. Furthermore, this review presents state-of-the-art carbon fiber production from polyacrylonitrile, an overview of melt-spinnable alternative precursors broadly, and an in-depth review of the latest advances in the synthesis of carbon fibers from low-cost, commodity thermoplastics such as polyethylene, polyamide, polystyrene, polyester, and poly(vinyl chloride).

36 MATERIALS SCIENCE↗
DOE OSTI2023

Performance of hybrid Innegra-carbon fiber composites

Abstract In this work material synergy with high stiffness carbon fiber with ductile high strength polypropylene fiber (Innegra S), (referred to as Innegra, herein) have been evaluated in a range of laminate designs. Both woven and discontinuous carbon fiber have been considered. The discontinuous fibers are based on three-dimensional deposition (3DEP) (referred to as 3DEP, herein) carbon fiber preform process. Eleven (11) variants of Innegra-carbon fiber hybrid laminates were investigated for tensile, flexure, compression, in-plane shear and low velocity impact response. The effect of position of Innegra within the laminate was studied and found to influence strength and stiffness properties. In terms of overall trends, Innegra provides upward of 18% improvement in strain (ductility) to the composite and eliminates brittle fracture of carbon fiber. The moduli trends follow the proportionality of Innegra fiber to carbon fiber plies. However, the strength is controlled by the interface between Innegra and carbon fiber. The primary failure mode in tension and compression is via onset of debonding between Innegra and carbon fiber. The 3DEP carbon fiber constituents provided highest values of in-plane shear indicating that three-dimensional (3D) network of carbon fiber provides higher shear resistance. The Innegra intensive variants exhibited superior energy absorption under low velocity impact, at energy levels 15–60 J. This work provides insight for designers to incorporate Innegra and carbon fiber hybrids in composite structures.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Enhancing functionalities in carbon fiber composites by titanium dioxide nanoparticles

Carbon fiber composite's high specific strength makes it incredibly useful for structural applications. However, their low strain-to-failure can be problematic in structural applications that can potentially see high strain conditions or high fatigue cycles resulting in sudden, catastrophic failure. This is further complicated by damage manifesting within the composite thus not showing damage indicators on the surface. Therefore, monitoring the structural integrity and strain history of the composite in application by itself—while maintaining positive composite performance—is vital to ensure safe operation. In this study, a homogeneous dispersion of TiO 2 nanoparticles on carbon fiber is demonstrated to generate a piezoresistive carbon fiber polymer matrix composite with enhanced self-sensing capabilities. The nanoparticle-embedded composites also exhibited superior strength and damping potential compared to the nanoparticle-free composites. The apparent interlaminar shear strength increased by up to 15% and the damping loss factor increased by an average of 150% while the piezoresistive sensitivity increased by up to 180% with the addition of a small weight fraction of nanoparticles to the fiber surface. These results demonstrate an approach to simultaneously improve the sensing capabilities, damping behavior and mechanical strength of carbon fiber composites by simply adding nanoparticles in the fiber sizing using a commercially scalable deposition method.

36 MATERIALS SCIENCE↗
NASA NTRS2007

Coating Carbon Fibers With Platinum

A process for coating carbon fibers with platinum has been developed. The process may also be adaptable to coating carbon fibers with other noble and refractory metals, including rhenium and iridium. The coated carbon fibers would be used as ingredients of matrix/fiber composite materials that would resist oxidation at high temperatures. The metal coats would contribute to oxidation resistance by keeping atmospheric oxygen away from fibers when cracks form in the matrices. Other processes that have been used to coat carbon fibers with metals have significant disadvantages: Metal-vapor deposition processes yield coats that are nonuniform along both the lengths and the circumferences of the fibers. The electrical resistivities of carbon fibers are too high to be compatible with electrolytic processes. Metal/organic vapor deposition entails the use of expensive starting materials, it may be necessary to use a furnace, and the starting materials and/or materials generated in the process may be hazardous. The present process does not have these disadvantages. It yields uniform, nonporous coats and is relatively inexpensive. The process can be summarized as one of pretreatment followed by electroless deposition. The process consists of the following steps: The surfaces of the fiber are activated by deposition of palladium crystallites from a solution. The surface-activated fibers are immersed in a solution that contains platinum. A reducing agent is used to supply electrons to effect a chemical reduction in situ. The chemical reduction displaces the platinum from the solution. The displaced platinum becomes deposited on the fibers. Each platinum atom that has been deposited acts as a catalytic site for the deposition of another platinum atom. Hence, the deposition process can also be characterized as autocatalytic. The thickness of the deposited metal can be tailored via the duration of immersion and the chemical activity of the solution.

Effinger, Michael R.↗
DOE OSTI2021

Development of a Lower Cost, High Volume, Commercially Available, Precursor for Lower Cost Carbon Fiber for Automotive and Wind Blade Applications

Essentially all carbon fibers used in structural applications are presently manufactured from solution spun polyacrylonitrile (PAN) precursor. Solution spinning is accomplished at relatively low temperatures using very large amounts of environmentally unfriendly solvents that impart major impact to line speed and costs involved with handling and reclaiming the solvents and associated “waste streams” required in spinning and extracting those solvents. Dralon and others have demonstrated the dry spinning of PAN in the production of some acrylic fibers for textile applications, but to this point it has not been demonstrated in the production of carbon fibers. In dry spinning, the PAN polymer is also dissolved into similar solvents, although typically less solvent is utilized to maintain a somewhat higher solids content of 20-50%. The use of lower overall solvent quantities and elimination of the need for solvent/water separation simplifies and reduces the cost of solvent recovery operations. Other portions of the precursor production and carbon fiber manufacturing processes are quite similar. The work described in this report demonstrated that dry spun acrylic fiber can be an attractive candidate for carbon fiber precursor of potential interest to applications looking to capture the specific stiffness (stiffness per unit mass) and specific strength (strength per unit mass) of carbon fiber when produced at a discount relative to commercial carbon fibers in the market today. Dralon has determined that the dry spinning process utilized for producing fibers used as precursors in this project requires 27% less energy versus producing comparable fibers via the industry standard wet spinning process. Identification of carbon fiber manufacturers, as well as applications development and targeted marketing, will be required to achieve significant in-roads into mission areas of interest to DOE, such as automotive applications and wind turbine blades. In support of that activity, initial data produced in this project indicate the innovative approach as described in this report can meet at least the baseline property requirements identified for these applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Method of producing carbon fibers from multipurpose commercial fibers

A method of producing carbon fibers includes the step of providing polyacrylonitrile precursor polymer fiber filaments. The polyacrylonitrile precursor filaments include from 87-97 mole % acrylonitrile, and less than 0.5 mole % of accelerant functional groups. The filaments are no more than 3 deniers per filament. The polyacrylonitrile precursor fiber filaments can be arranged into tows of at least 150,000 deniers per inch width. The arranged polyacrylonitrile precursor fiber tows are stabilized by heating the tows in at least one oxidation zone containing oxygen gas and maintained at a first temperature T1 while stretching the tows at least 10% to yield a stabilized precursor fiber tow. The stabilized precursor fiber tows are carbonized by passing the stabilized precursor fiber tows through a carbonization zone. Carbon fibers produced by the process are also disclosed.

Naskar, Amit K.↗
DOE OSTI2023

Unveiling the microstructural evolution of carbon fibers derived from polyamide-6

Polyacrylonitrile-based carbon fibers have dominated the industry for decades, but the high cost of polyacrylonitrile has prevented the widespread adoption of carbon fiber in high-volume structural applications. As such, a significant amount of research has been dedicated to finding an alternative, low-cost carbon fiber precursor. In this work, carbon fibers were produced from polyamide-6 using metal salt impregnation and a thermo-oxidative stabilization step. To gain further insight into the carbonization process and microstructural transformation, the morphologies, crystallinities, elemental compositions, and thermal stabilities of the fibers were characterized at various stages of processing. The stabilization step resulted in a significant increase in carbon yield, indicating a dramatic increase in thermal stability. This is due to the crosslinking of polyamide-6 chains, which was confirmed by functional group analysis. The crystallinity of the fibers was also significantly altered during processing, as the produced carbon fibers consisted of pseudo-amorphous carbon with two distinct regions of metal salt impregnation. Finally, the findings and microstructural evolution mechanisms provide guidelines for further research into carbon fiber produced from polyamide-6.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Radiation damage of a two-dimensional carbon fiber composite (CFC)

Carbon fiber composites (CFC) are, among other applications, already in use as low-impedance collimating elements for intercepting TeV-level protons machines, like the CERN Large Hadron Collider. Towards a comprehensive understanding of these materials’ properties and behavior, a series of radiation damage campaigns have been undertaken in order to quantitively investigate the response of AC-150 K CFC to high proton fluences. The CFCs dimensional changes, stability, micro-structural evolution, and structural integrity below and above 5 × 10 20 p/cm 2 fluence threshold were studied. The irradiating particles were protons of kinetic energies in the range of 130–200 MeV. The effects of the irradiation temperature (~90–180°C and 280–500°C) combined with the proton fluence on the dimensional stability and the microstructural evolution of this anisotropic two-dimensional composite structure were studied using precision dilatometry and X-ray diffraction. Our results shed light on the fluence-based limitations for these composite materials. Furthermore, we compare these results with reference unirradiated graphite, and we discuss the similarities and differences in the dimensional changes and post-irradiation annealing properties.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Computational investigations of Dienes defect- and vacancy-induced changes in the electronic and vibrational properties of carbon fiber structural units

Carbon fiber (CF) is a promising lightweight alternative to steel and is of significant interest for energy applications. As CF continues to find new uses and is exposed to new external conditions, a noninvasive method of monitoring its structural integrity is critical. Raman spectroscopy is a commonly used method for this monitoring; however, it is highly inferential, and the interpretation of the data is not always straightforward. In this work, we perform density functional theory (DFT) calculations to investigate changes in the vibrational properties of CF structural units (i.e., graphene and graphite) caused by monovacancy and Dienes defects as a foundation for modeling more complex defects that move our model toward that of realistic CF. Using large computational supercells, we can understand how these defects change the electronic structure and vibrational properties of graphene and graphite for interdefect distances near those of the lower experimental limit. The monovacancy opens an electronic bandgap at the K point. Although no such electronic gap is opened by the Dienes defect, both defects introduce flat defect bands near the Fermi energy. The Dienes defect creates long-range deviations of the phonons, leading to substantial broadening of the highest frequency optical modes in the band structure compared to that of the pristine material. In contrast, the phonon changes caused by the monovacancy are short range, and only minor changes in the band structure or phonon density of states were observed. These findings can assist in the interpretation of experimental results by providing atomic-scale insight into key electronic and vibrational features.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1984

A New Generation of Sub Mm Telescopes, Made of Carbon Fiber Reinforced Plastic

Carbon fiber reinforced plastic (CFRP) appears to be the material most suited for the construction of submillimeter telescopes (SMT) not only for ground-based use but also for space applications. The accuracy of the CFRP reflectors needs to be improved beyond value of the 17 micron rms envisaged for the 10 m SMT.

Mezger, P.↗
NASA NTRS1990

Effects of heat treatment on carbon fibers

Commercially produced carbon fibers were heat treated to graphitization temperatures. The fibers were characterized for mechanical and physical properties, including density, D0002 spacing, strength, and modulus in both the 'as received' and heat treated conditions. Mechanical property changes were correlated with the physical property changes in the fibers.

Brown, D. Kyle↗
DOE OSTI2020

Additive manufacturing of two-phase lightweight, stiff and high damping carbon fiber reinforced polymer microlattices

Carbon fiber reinforced polymer (CFRP) composite is known for its high stiffness-to-weight ratio and hence is of great interest in several engineering fields such as aerospace, automotive, defense, etc. However, such a composite is not suitable for energy dissipation as failure occurs with very little or no plastic deformation. Herein, we present an extendable multi-material projection microstereolithography process capable of producing carbon-fiber-reinforced cellular materials that achieve simultaneously high specific stiffness and damping coefficient. Inspired by the upper bounds of stiffness-loss coefficient in a two-phase composite, we designed and additively manufactured CFRP microlattices with soft phases architected into selected stiff-phase struts. Our results, confirmed by experimental and analytical calculations, revealed that the damping performance can be significantly enhanced by the addition of only a small fraction of the soft phase. The presented design and additive manufacturing strategy allow for optimizing mutually exclusive properties. As a result, these CFRP microlattices achieved high specific stiffness comparable to commercial CFRP, technical ceramics, and composites, while being dissipative like elastomers.

36 MATERIALS SCIENCE↗