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NASA NTRSDate not supplied

Finite Element Modeling for Compression Strength Prediction of Honeycomb Cores with Geometric Imperfections Measured using X-ray CT Imaging

Aluminum honeycomb cores have been used extensively in composite sandwich panels due to having high bending rigidity while maintaining low density. During manufacturing of the aluminum honeycomb, the thin metal walls are susceptible to imperfections that deviate from an ideal honeycomb shape. Computational tools to quantify imperfections and investigate their effects on quasi-static compression and impact response can inform design criteria to construct safer and lighter launch vehicle structures. This paper presents the results of a study on finite element modeling of metallic honeycomb cores (HCC) with geometric imperfections measured using X-ray Computer Tomography (CT), to predict the compression response. Finite element (FE) models are constructed with measured imperfections with appropriate boundary conditions. It is shown that the average behavior of larger 10x11 cell models can be predicted by sampling single cell models from the larger domain. Amplification of imperfections for cells at the center of sampled specimens are mode switched from the larger out-of-plane imperfection to the mode shape of the adjacent cells resulting in strengthening of the center specimens.

aluminum honeycomb↗

DOE OSTI2023

Overexpression of a gibberellin 20-oxidase gene in poplar xylem led to an increase in the size of nanocellulose fibrils and improved paper properties

Cellulose, the major component of secondary cell walls, is the most abundant renewable long-chain polymer on earth. Nanocellulose has become a prominent nano-reinforcement agent for polymer matrices in various industries. We report the generation of transgenic hybrid poplar overexpressing the Arabidopsis gibberellin 20-oxidase1 gene driven by a xylem-specific promoter to increase gibberellin (GA) biosynthesis in wood. X-ray diffraction (XRD) and sum frequency generation spectroscopic (SFG) analyses showed that cellulose in transgenic trees was less crystalline, but the crystal size was larger. The nanocellulose fibrils prepared from transgenic wood had an increased size compared to those from wild type. When such fibrils were used as a reinforcing agent in sheet paper preparation, the mechanical strength of the paper was significantly enhanced. Engineering the GA pathway can therefore affect nanocellulose properties, providing a new strategy for expanding nanocellulose applications.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

The F-box protein gene exo-1 is a target for reverse engineering enzyme hypersecretion in filamentous fungi

Carbohydrate active enzymes (CAZymes) are vital for the lignocellulose-based biorefinery. The development of hypersecreting fungal protein production hosts is therefore a major aim for both academia and industry. However, despite advances in our understanding of their regulation, the number of promising candidate genes for targeted strain engineering remains limited. Here, we resequenced the genome of the classical hypersecreting Neurospora crassa mutant exo-1 and identified the causative point of mutation to reside in the F-box protein–encoding gene, NCU09899. The corresponding deletion strain displayed amylase and invertase activities exceeding those of the carbon catabolite derepressed strain ?cre-1, while glucose repression was still mostly functional in ?exo-1. Surprisingly, RNA sequencing revealed that while plant cell wall degradation genes are broadly misexpressed in ?exo-1, only a small fraction of CAZyme genes and sugar transporters are up-regulated, indicating that EXO-1 affects specific regulatory factors. Aiming to elucidate the underlying mechanism of enzyme hypersecretion, we found the high secretion of amylases and invertase in ?exo-1 to be completely dependent on the transcriptional regulator COL-26. Furthermore, misregulation of COL-26, CRE-1, and cellular carbon and nitrogen metabolism was confirmed by proteomics. Finally, we successfully transferred the hypersecretion trait of the exo-1 disruption by reverse engineering into the industrially deployed fungus Myceliophthora thermophila using CRISPR-Cas9. Our identification of an important F-box protein demonstrates the strength of classical mutants combined with next-generation sequencing to uncover unanticipated candidates for engineering. These data contribute to a more complete understanding of CAZyme regulation and will facilitate targeted engineering of hypersecretion in further organisms of interest.

Gabriel, Raphael↗

NASA NTRS2015

Fracture of Carbon Nanotube - Amorphous Carbon Composites: Molecular Modeling

Carbon nanotubes (CNTs) are promising candidates for use as reinforcements in next generation structural composite materials because of their extremely high specific stiffness and strength. They cannot, however, be viewed as simple replacements for carbon fibers because there are key differences between these materials in areas such as handling, processing, and matrix design. It is impossible to know for certain that CNT composites will represent a significant advance over carbon fiber composites before these various factors have been optimized, which is an extremely costly and time intensive process. This work attempts to place an upper bound on CNT composite mechanical properties by performing molecular dynamics simulations on idealized model systems with a reactive forcefield that permits modeling of both elastic deformations and fracture. Amorphous carbon (AC) was chosen for the matrix material in this work because of its structural simplicity and physical compatibility with the CNT fillers. It is also much stiffer and stronger than typical engineering polymer matrices. Three different arrangements of CNTs in the simulation cell have been investigated: a single-wall nanotube (SWNT) array, a multi-wall nanotube (MWNT) array, and a SWNT bundle system. The SWNT and MWNT array systems are clearly idealizations, but the SWNT bundle system is a step closer to real systems in which individual tubes aggregate into large assemblies. The effect of chemical crosslinking on composite properties is modeled by adding bonds between the CNTs and AC. The balance between weakening the CNTs and improving fiber-matrix load transfer is explored by systematically varying the extent of crosslinking. It is, of course, impossible to capture the full range of deformation and fracture processes that occur in real materials with even the largest atomistic molecular dynamics simulations. With this limitation in mind, the simulation results reported here provide a plausible upper limit on achievable CNT composite properties and yield some insight on the influence of processing conditions on the mechanical properties of CNT composites.

Jensen, Benjamin D.↗

NASA NTRSDate not supplied

CFD Modeling & Validation of Single Bubble Growth During Cavitation in Zero Gravity

Cryogenic Fluid Management (CFM) in zero gravity represents a vital area of research as NASA pursues future long-duration space missions. Success of these missions relies heavily on the ability to store and transfer the cryogenic liquid fuels efficiently and safely. In the Zero Boil-Off Tank (ZBOT-1) Experiment in 2018, unexpected and intense phase change occurred at the screened Liquid Acquisition Device (LAD) during tank pressure control that was later attributed to cavitation. The cavitation ultimately resulted in pump failure. Since cryogen cavitation during storage and transfer of propellants in microgravity has been a source of serious concern for the aerospace community, a series of drop tower experiments with liquid methane were also performed at the University of Bremen to carefully study cavitation from a single bubble nucleus in an engineered micron-sized wall cavity. As the test cell is depressurized during the 10-second drop, cavitation causes bubble growth from the nucleus. Here, in a collaboration between the Case Western Reserve University and University of Bremen, we present a two-phase Computational Fluid Dynamics (CFD) model of bubble growth from a single wall cavity during depressurization in microgravity. Both 2D axisymmetric and 3D parametric simulation case studies are performed to show the evolution of the bubble growth. The model uses a Volume of Fluid (VOF) approach with and without adaptive mesh refinement and adaptive time stepping to capture the growth dynamics using an explicit formulation with algebraic reconstruction of the interface. CFD results show good agreement with corresponding experiment. Based on the velocity, temperature, and volume fraction fields generated by the validation case studies, detailed discussion and analysis of fluid flow and heat transfer during bubble growth process are presented to delineate the intricacies of the cavitation process. Strengths and shortcomings of the present numerical approach in capturing this phenomenon are also highlighted.

Two Phase Flow↗

NASA NTRS2003

Home Insulation With the Stroke of a Brush

Hy-Tech Thermal Solutions, LLC, of Melbourne, Florida, is producing a very complex blend of ceramic vacuum-filled refractory products designed to minimize the path of hot air transfer through ceilings, walls, and roofs. The insulating ceramic technology blocks the transfer of heat outward when applied to paint on interior walls and ceilings, and prevents the transfer of heat inward when used to paint exterior walls and roofs, effectively providing year-round comfort in the home. As a manufacturer and marketer of thermal solutions for residential, commercial, and industrial applications, Hy-Tech Thermal Solutions attributes its success to the high performance insulating ceramic microsphere originally developed from NASA thermal research at Ames Research Center. Shaped like a hollow ball so small that it looks as if it is a single grain of flour to the naked eye (slightly thicker than a human hair), the microsphere is noncombustible and fairly chemical-resistant, and has a wall thickness about 1/10 of the sphere diameter, a compressive strength of about 4,000 pounds per square inch, and a softening point of about 1,800 C. Hy-Tech Thermal Solutions improved upon these properties by removing all of the gas inside and creating a vacuum. In effect, a 'mini thermos bottle' is produced, acting as a barrier to heat by reflecting it away from the protected surface. When these microspheres are combined with other materials, they enhance the thermal resistance of those materials. In bulk, the tiny ceramic 'beads' have the appearance of a fine talcum powder. Their inert, nontoxic properties allow them to mix easily into any type of paint, coating, adhesive, masonry, or drywall finish. Additionally, their roundness causes them to behave like ball bearings, rolling upon each other, and letting the coatings flow smoothly. When applied like paint to a wall or roof, the microsphere coating shrinks down tight and creates a dense film of the vacuum cells. The resulting ceramic layer improves fire resistance, protects from ultraviolet rays, repels insects such as termites, and shields from the destructive forces of nature.

Source record↗

DOE OSTI2025

Mode transitions and spoke structures in E × B Penning discharge

Two-dimensional particle-in-cell simulations in the (radial-azimuthal) plane perpendicular to the axial direction of a cylindrical $E$ x $B$ Penning discharge are presented. The low-pressure discharge is self-consistently supported by plasma ionization from the electron beam injected axially, along the direction of the external magnetic field. It is shown that with the increasing strength of the external magnetic field, the discharge undergoes a sequence of transitions between several azimuthal modes. Azimuthal m > 1 spiral arm structures are excited at low magnetic field values as plasma confinement improves and the radial density profile becomes peaked. With a larger field, spiral arms with m > 1 are replaced by the m = 1 spoke mode, most clearly seen in plasma density. A transition from spiral arms to the spoke regime occurs when the plasma potential in the center changes from weakly positive (or zero) to negative. Further increase in the magnetic field results in a well-developed m = 1 spoke mode with additional small-scale higher-frequency m > 1 structures inside and around the spoke. It is shown that while ionization and collisions affect some characteristics of the observed fluctuations, the basic features of the spoke and m > 1 spiral structure remained similar without ionization. The role of energy conservation in small-scale high-frequency modes and spoke dynamics is discussed. It is demonstrated that in regimes with the m = 1 spoke mode, additional m = 4 harmonics of the ion and electron fluxes to the wall appear due to the square boundary. The frequency of the m = 1 mode is weakly affected by the geometry of the boundary.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Enhancing the multi-functional properties of renewable lignin carbon fibers via defining the structure–property relationship using different biomass feedstocks

Lignin has been explored extensively as a renewable precursor for carbon materials, considering its abundance as a major component of plant cell walls and its sustainability as a byproduct of both lignocellulosic biorefinery and the paper-making industry. Despite the extensive efforts to define the process–property relationship, it remains largely unknown how lignin biosynthesis and its chemistry would impact the resultant carbon fiber properties, for both mechanical and electroconductive performances. Such inadequate understanding fundamentally limits feedstock design and selection to improve carbon fiber properties toward broader commercial applications. Using lignin from a broad range of biomass feedstocks for carbon fiber manufacturing, we have fundamentally explored the structure–function relationship between lignin chemistry and carbon fiber performance. Specifically, lignin extracted from hardwood (sugar maple), softwood (loblolly pine and red cedar), and herbaceous plants (corn stover and switchgrass) was used for carbon fiber manufacturing, considering the very different lignin structures from these feedstocks. Linear regression models were established to define the relationship between carbon fiber mechanical properties and lignin structural characteristics. The results highlighted that the content of β-O-4 linkages correlates significantly with the tensile strength and elastic modulus of lignin carbon fibers, indicating that more linear β-O-4 linkages would promote the carbon fiber mechanical performance. Moreover, electroconductive properties are essential for broader energy device application of lignin-based carbon fibers, yet the mechanisms controlling their electroconductivity are largely unknown. Furthermore, we hereby demonstrated that a higher β-O-4 content also promotes the electroconductivity of lignin carbon fibers. Microstructure analysis further revealed that the crystallite size and content of the pre-graphitic turbostratic carbon structure in lignin-based carbon fibers were enhanced as the β-O-4 linkages increased. The content of β-O-4 linkages has shown a strong correlation with the crystallite content in a linear regression model. This study thus revealed the underlying mechanisms regarding how the lignin structure in planta defines the resultant carbon fiber properties. Moreover, the study also highlighted the correlation between the mechanical and electroconductive properties of lignin-based carbon fibers, both of which were defined by the lignin structure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

THE DESIGN OF RADIAL HONEYCOMB LATTICES FOR IMPACT ENERGY ABSORPTION IN RADIOACTIVE MATERIALS PACKAGES

In this research we present a variation on the corrugation technique of honeycomb lattices, for cylindrical honeycombs, making them much easier to design for impact energy absorption in radioactive materials packages. This variation, termed radial honeycomb lattices, eliminates the residual strain and saddle effect. The use of honeycomb lattices provides advantages over the typically used foams. While foams are effective at absorbing impact energy, they can burn, their material properties are difficult to control, they can degrade over time, and procurement of raw materials can be dependent on timing of manufacturer batch runs. While the weaknesses of foam are strengths for honeycomb lattices, lattices have a different set of problems. Typically, when cylindrical honeycomb lattices are manufactured, they are manufactured flat, wrapped around a mandrel of the desired radius, and then brazed. This approach introduces residual strains, resulting in the saddle effect, which limits both the radial thickness and cylinder length. The radial honeycomb lattice approach presented here makes the design of thicker and longer cylinder honeycombs possible. To address these issues, we propose a honeycomb lattice which changes in cross-section from the inner to the outer radius of the cylinder. This causes the lattice to automatically wrap into a cylinder as it exits the corrugating gears. The theoretically bounding case, of a square cross-section at the inner radius, transitioning through a hexagon, to a diamond cross-section at the outer radius, results in a maximum thickness of approximately 41% of the inner radius. Full mathematical derivations, implemented in computer code, allow for the design of an entire radial honeycomb lattice, including the corrugating gears. To accomplish this only the radial thickness, inner cross-section shape, cell size, and nominal gear radius need to be specified, making the design of these lattices very efficient. Radial honeycomb lattice prototypes have demonstrated that the honeycomb does indeed wrap into a cylinder as intended, without the saddle effect, and can therefore be used to create thick-walled cylinders of any length. These design improvements make cylindrical honeycomb lattices much more accessible as a design element for radioactive materials packages

Johnson, William R. [Savannah River National Labor↗

DOE OSTI2020

Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring

The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.

08 HYDROGEN↗

NASA NTRS2014

Behavior of Particle Depots in Molten Silicon During Float-Zone Growth in Strong Static Magnetic Fields

In the photovoltaics industry, the largest market share is represented by solar cells made from multicrystalline silicon, which is grown by directional solidification. During the growth process, the silicon melt is in contact with the silicon nitride coated crucible walls and the furnace atmosphere which contains carbon monoxide. The dissolution of the crucible coating, the carbon bearing gas, and the carbon already present in the feedstock, lead to the precipitation of silicon carbide, and silicon nitride, at later stages of the growth process. The precipitation of Si3N4 and SiC particles of up to several hundred micrometers in diameter leads to severe problems during the wire sawing process for wafering the ingots. Furthermore the growth of the silicon grains can be negatively influenced by the presence of particles, which act as nucleation sources and lead to a grit structure of small grains and are sources for dislocations. If doped with Nitrogen from the dissolved crucible coating, SiC is a semi conductive material, and can act as a shunt, short circuiting parts of the solar cell. For these reasons, the incorporation of such particles needs to be avoided. In this contribution we performed model experiments in which the transport of intentionally added SiC particles and their interaction with the solid-liquid interface during float zone growth of silicon in strong steady magnetic fields was investigated. SiC particles of 7μm and 60μm size are placed in single crystal silicon [100] and [111] rods of 8mm diameter. This is achieved by drilling a hole of 2mm diameter, filling in the particles and closing the hole by melting the surface of the rod until a film of silicon covers the hole. The samples are processed under a vacuum of 1x10(exp -5) mbar or better, to prevent gas inclusions. An oxide layer to suppress Marangoni convection is applied by wet oxidation. Experiments without and with static magnetic field are carried out to investigate the influence of melt convection on the distribution of particles and their incorporation into the crystal. The field strengths applied by a superconducting magnet are 1T, 3T, 4.5T, and 5T. The increase in field strength dampens the melt flow, and so this study provides comparative data to the crystal growth experiment to be carried out onboard the sounding rocket mission TEXUS 51, where purely diffusive growth condition will be achieved under microgravity conditions.

Jauss, T.↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

additive manufacturing↗

NASA NTRS2002

RWPV bioreactor mass transport: earth-based and in microgravity

Mass transport and mixing of perfused scalar quantities in the NASA Rotating Wall Perfused Vessel bioreactor are studied using numerical models of the flow field and scalar concentration field. Operating conditions typical of both microgravity and ground-based cell cultures are studied to determine the expected vessel performance for both flight and ground-based control experiments. Results are presented for the transport of oxygen with cell densities and consumption rates typical of colon cancer cells cultured in the RWPV. The transport and mixing characteristics are first investigated with a step change in the perfusion inlet concentration by computing the time histories of the time to exceed 10% inlet concentration. The effects of a uniform cell utilization rate are then investigated with time histories of the outlet concentration, volume average concentration, and volume fraction starved. It is found that the operating conditions used in microgravity produce results that are quite different then those for ground-based conditions. Mixing times for microgravity conditions are significantly shorter than those for ground-based operation. Increasing the differential rotation rates (microgravity) increases the mixing and transport, while increasing the mean rotation rate (ground-based) suppresses both. Increasing perfusion rates enhances mass transport for both microgravity and ground-based cases, however, for the present range of operating conditions, above 5-10 cc/min there are diminishing returns as much of the inlet fluid is transported directly to the perfusion exit. The results show that exit concentration is not a good indicator of the concentration distributions in the vessel. In microgravity conditions, the NASA RWPV bioreactor with the viscous pump has been shown to provide an environment that is well mixed. Even when operated near the theoretical minimum perfusion rates, only a small fraction of the volume provides less than the required oxygen levels. 2002 Wiley Periodicals, Inc.

Models, Biological↗