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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Effect of 3D printing conditions on the micro- and macrostructure and properties of high-performance thermoplastic composites

Within the scope of extrusion based additive manufacturing, this chapter provides a review of the research in understanding the physical relationships between microstructure variables and macrostructure properties of high-performance thermoplastic polymers. The development of interlayer strength has been discussed based on the theory of inter-diffusion and re-entanglement of polymer chains at interface. The observations from the study in joining and direct-bonding of polymer surfaces provide insights into the mechanisms of the formation of interface between adjacent layers. Quantitative prediction of interfacial strength as a function of processing temperature and contact time is presented. The mechanisms that lead to reduced mechanical strength at the interface are discussed. The second half of the chapter outlined a set of printing conditions and their influence on structural properties.

Liu, Peng↗
DOE OSTI2017

Radiation instability of equal channel angular extruded T91 at ultra-high damage levels

Although several studies have shown that nano-grained alloys have higher radiation resistance than coarse-grained variants, with dense grain boundary structures acting as defect sinks to remove damage, the present study shows the failure of severe deformation to suppress void swelling in T91 alloy at ultra-high damage levels. Fe self-ion irradiation up to 1000 peak dpa produced significantly more swelling in extruded T91 than conventional T91 at 475 °C. Dramatic radiation-enhanced grain growth was observed in the extruded T91, manifested in two rapid grain growth stages. One stage occurs at a relatively low damage level, and the other at a higher damage level beyond 750 peak dpa. The second rapid growth stage is correlated with void swelling and starts at the end of the swelling incubation period. The study suggests that the defect sink properties of the growing grain boundaries under a coarsening process are different from that of stable boundary configurations. When void swelling becomes significant and voids act as a biased sink for vacancies, the growing grain boundaries act as a biased sink for interstitials, leading to rapid growth at higher damage levels.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Optimization of Hot Deformation Parameters and Constitutive Analysis for As-Cast Mg-5Li-3Zn-0.3Y Alloy Using Processing Maps

Hot deformation behavior of as-cast Mg-5Li-3Zn-0.3Y (wt.%) alloy has been studied by establishing processing maps covering the range of 200-450 °C in temperature and 0.001-10 s{sup −1} in strain rate. The map corresponding to the strain of 0.7 reveals that a domain of dynamic recrystallization occurred at 340-400 °C/0.01-0.158 s{sup −1} with its peak efficiency of approximately 31%. Analysis of the flow behaviors and microstructural observations indicated that dynamic recrystallization occurred in the domain, in which fine microstructure can be achieved. The above conditions represent the optimum processing parameters, and the flow instability regimes are also recognized from the maps. The average deformation in the deformed range was 136.414 kJ/mol which is close to that for lattice self-diffusion in magnesium and far smaller than that for as-cast Mg-5.75Zn-0.73Y-0.36Zr (wt.%) alloy. It is believed that a lower activation energy for Mg-5Li-3Zn-0.3Y alloy can partly result from both the weak particle pinning effects and adding Li into the Mg-Zn-Y-Zr alloy. Results of extrusion experiments conducted at 350 °C show that the alloy can be easily extruded with good mechanical properties of the yield strength of 132 MPa, the fracture strength of 215 MPa and the elongation of 20.9%, and the grains can be well refined.

36 MATERIALS SCIENCE↗
DOE OSTI2016

User Manual for the PROTEUS Mesh Tools

PROTEUS is built around a finite element representation of the geometry for visualization. In addition, the PROTEUS-SN solver was built to solve the even-parity transport equation on a finite element mesh provided as input. Similarly, PROTEUS-MOC and PROTEUS-NEMO were built to apply the method of characteristics on unstructured finite element meshes. Given the complexity of real world problems, experience has shown that using commercial mesh generator to create rather simple input geometries is overly complex and slow. As a consequence, significant effort has been put into place to create multiple codes that help assist in the mesh generation and manipulation. There are three input means to create a mesh in PROTEUS: UFMESH, GRID, and NEMESH. At present, the UFMESH is a simple way to generate two-dimensional Cartesian and hexagonal fuel assembly geometries. The UFmesh input allows for simple assembly mesh generation while the GRID input allows the generation of Cartesian, hexagonal, and regular triangular structured grid geometry options. The NEMESH is a way for the user to create their own mesh or convert another mesh file format into a PROTEUS input format. Given that one has an input mesh format acceptable for PROTEUS, we have constructed several tools which allow further mesh and geometry construction (i.e. mesh extrusion and merging). This report describes the various mesh tools that are provided with the PROTEUS code giving both descriptions of the input and output. In many cases the examples are provided with a regression test of the mesh tools. The most important mesh tools for any user to consider using are the MT_MeshToMesh.x and the MT_RadialLattice.x codes. The former allows the conversion between most mesh types handled by PROTEUS while the second allows the merging of multiple (assembly) meshes into a radial structured grid. Note that the mesh generation process is recursive in nature and that each input specific for a given mesh tool (such as .axial or .merge) can be used as “mesh” input for any of the mesh tools discussed in this manual.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

Reducing mechanical anisotropy in extrusion-based printed parts

The mechanical performance of 3D printed components is highly dependent upon the orientation of the part relative to the build plane. Specifically for extrusion-based printing systems, the bond between successive layers (z-direction) can be 10-25% weaker than in the printed plane (x-y plane). As advanced applications call for fiber reinforced materials and larger print systems (such as the Big Area Additive Manufacturing system) extend the layer time, mechanical performance in the z-direction can decrease by 75-90%. This paper presents a patent-pending approach for improving mechanical performance in the z-direction by depositing material vertically across multiple layers during the build. The “z-pinning” process involves aligning voids across multiple (n) layers, which are then back-filled in a continuous fashion during the deposition of layer (n+1). The “z-pinning” approach has been demonstrated to be an effective approach for increasing the strength (20% increase) and toughness (200% increase) of printed parts in the zdirection.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Additive manufacturing of nanotube-loaded thermosets via direct ink writing and radio-frequency heating and curing

Direct Ink Writing (DIW) is an extrusion-based additive manufacturing method where the print medium is a liquid-phase ‘ink’ dispensed out of nozzles and deposited along digitally defined paths. Conventional DIW of thermosetting resins relies on viscosity modifying agents, novel crosslinking chemistries, and/or long curing schedules in an oven. Here we demonstrate the use of a co-planar radio frequency applicator to generate an electric field, which can be used to rapidly heat and cure nano-filled composite resins as they are printed. This method avoids the need for an oven or post- curing step. This process consists of a sequential print-and-cure cycle which allows for printing of high-resolution, multi-layered structures. Every extruded layer is partially cured using RF before depositing the next layer; this allows the printed part to maintain structural integrity. The process enables both increased throughput and decreased touch time relative to traditional manufacturing. Commercial epoxy resin with varied nano-filler loadings were examined as DIW candidates. After printing, the thermo-mechanical properties, surface finish, and shape retention of RF-cured samples were comparable to conventionally cured samples. Furthermore, this method of manufacturing establishes RF heating as a suitable alternative to conventional methods, facilitating rapid, free-form processing of thermosetting resins without a mold.

36 MATERIALS SCIENCE↗
NASA NTRS1995

Evidence of seasonally dependent stratosphere-troposphere exchange and purging of lower stratospheric aerosol from a multiyear lidar data set

Tropospheric and lower stratospheric aerosol backscatter data obtained from a calibrated backscatter lidar at Pasadena, California (34 deg N latitude) over the 1984-1993 period clearly indicate tightly coupled aerosol optical properties in the upper troposphere and lower stratosphere in the winter and early spring, due to the active midlatitude stratospheric-tropospheric (ST) exchange processes occurring at this time of year. Lidar data indicate that during pre-Pinaturbo background conditions, the subsequent purging of the aerosol in the upper troposphere caused a significant reduction in the aerosol content throughout the 8 - 18 km altitude region in the early spring period. The post-Pinatubo evidence of intense exchange in the winter and early spring is a significant increase in the upper tropospheric aerosol content, such that the backscatter levels reach values nearly equivalent to the enhanced backscatter levels existing in the lower stratosphere. The calculated stratospheric mass extrusion rate is consistent with a 45-day lifetime of lower stratospheric aerosol during this part of the year, which implies that midlatitude ST exchange is a significant sink for stratospheric aerosol.

Menzies, Robert T.↗
DOE OSTI2016

Coalescence in PLA-PBAT blends under shear flow: Effects of blend preparation and PLA molecular weight

Blends containing 75 wt. % of an amorphous polylactide (PLA) with two different molecular weights and 25 wt. % of a poly[(butylene adipate)-co-terephthalate] (PBAT) were prepared using either a Brabender batch mixer or a twin-screw extruder. These compounds were selected because blending PLA with PBAT can overcome various drawbacks of PLA such as its brittleness and processability limitations. In this study, we investigated the effects of varying the molecular weight of the PLA matrix and of two different mixing processes on the blend morphology and, further, on droplet coalescence during shearing. The rheological properties of these blends were investigated and the interfacial properties were analyzed using the Palierne emulsion model. Droplet coalescence was investigated by applying shear flows of 0.05 and 0.20 s{sup −1} at a fixed strain of 60. Subsequently, small amplitude oscillatory shear tests were conducted to investigate changes in the viscoelastic properties. The morphology of the blends was also examined using scanning electron microscope (SEM) micrographs. It was observed that the PBAT droplets were much smaller when twin-screw extrusion was used for the blend preparation. Shearing at 0.05 s{sup −1} induced significant droplet coalescence in all blends, but coalescence and changes in the viscoelastic properties were much more pronounced for the PLA-PBAT blend based on a lower molecular weight PLA. The viscoelastic responses were also somehow affected by the thermal degradation of the PLA matrix during the experiments.

36 MATERIALS SCIENCE↗
NASA NTRS1976

An oxide dispersion strengthened Ni-W-Al alloy with superior high temperature strength

Oxide dispersion strengthened alloys based on the WAZ-20 nickel-base alloy were prepared by the mechanical alloying process described by Benjamin (1973), and evaluated. The results of microstructural examinations and mechanical property determinations are discussed. It is shown that WAZ-20, a high gamma-prime fraction alloy having a high gamma-prime solvus temperature, can be effectively dispersion strengthened. The strengths obtained were outstanding, especially at 1150 and 1205 C. The strength is attributed to a combination of highly alloyed matrix, elongated grain structure, and hard phase dispersion. Tensile ductility can be improved by post-recrystallization heat treatment. The new alloy shows some potential for low stress post-extrusion forming.

Glasgow, T. K.↗
DOE OSTI2019

Development of Green Composites Based on Polypropylene and Corncob Agricultural Residue

Green composites of polypropylene (PP) and corncob (CCB) agricultural residue with CCB content ranging from 5 to 30 wt% were compounded by melt extrusion and their properties investigated by density measurements, thermogravimetric analyses, differential scanning calorimetry, scanning electron microscopy (SEM) and tension, flexural and impact properties. Properties were dependent on CCB content. SEM micrographs showed that PP/CCB composites are composed of all layers of the corncob, but with a higher content of woody ring and pith. Composites with CCB up to 20 wt% presented particles evenly dispersed into PP matrix and density values ranging from 0.929 to 1.026 g/cm{sup 3}. Thermal analyses showed that CCB is thermally stable up to 200 °C, ensuring that no degradation took place during processing, and PP/CCB composites are more crystalline than neat PP. Tensile strength and elongation at break of the composites decreased respectively from 30 to 20 MPa, and 22.7 to 3.7%, and the elastic modulus increased while the impact strength remained practically constant at 14 J/m for the filling contents tested. Elastic and flexural moduli increased respectively from 906 MPa to 1.1 GPa and from to 1.26 to 1.81 GPa with corncob addition.

36 MATERIALS SCIENCE↗
NASA NTRS2002

Geology and Origin of Europa's Mitten Feature (Murias Chaos)

The "Mitten" (provisionally named Murias Chaos by the International Astronomical Union) is a region of elevated chaos-like terrain in the leading hemisphere of Europa. Its origin had been explained under the currently debated theories of melting through a thin lithosphere or convection within a thick one. Galileo observations reveal several characteristics that suggest that the Mitten is distinct from typical chaos terrain and point to a different formational process. Photoclinometric elevation estimates suggest that the Mitten is slightly elevated with respect to the surrounding terrain; geologic relations indicate that it must have raised significantly from the plains in its past, resembling disrupted domes on Europa's trailing hemisphere. Moreover, the Mitten material appears to have extruded onto the plains and flowed for tens of kilometers. The area subsequently subsided as a result of isostatic adjustment, viscous relaxation, and/or plains loading. Using plate flexure models, we estimated the elastic lithosphere in the area to be several kilometers thick. We propose that the Mitten originated by the ascent and extrusion of a large thermal diapir. Thermal-mechanical modeling shows that a Mitten-sized plume would remain sufficiently warm and buoyant to pierce through the crust and flow unconfined on the surface. Such a diapir probably had an initial radius between 5 and 8 km and an initial depth of 20-40 km, consistent with a thick-lithosphere model. In this scenario the Mitten appears to represent the surface expression of the rare ascent of a large diapir, in contrast to lenticulae and chaos terrain, which may form by isolated and clustered small diapirs, respectively.

Figueredo, P. H.↗
DOE OSTI2024

High Velocity Joining of Multi-material Stacks Containing 3rd Generation Advanced High-Strength Stainless Steel and Aluminum Extrusion and Casting (Abstract)

Advanced lightweight materials, including multi-phase steels, aluminum extrusions and aluminum castings, have increasingly replaced mild steel to meet original equipment manufacturer (OEM) demand for increased fuel economy and crash-safety requirements. Third Generation (Gen 3) AHSS provides a superior combination of strength and ductility for crash energy management components in the vehicle body-in-white (BIW). Aluminum extrusions are widely used for bumper, door rocker panel, cradle and battery frame applications. Aluminum castings are increasingly being used in electric vehicles to provide part consolidation, weight saving and increased driving range. Rocker panels are, for example, an important component of the battery electric vehicle (BEV) body structure. The rocker panel serves several purposes, including structural support, crash resistance, protection for the vehicle's underbody and battery tray, and contributing to the overall aesthetics. In order to reduce weight, rocker panels are usually constructed using outer panels consisting of 3rd generation advanced high strength steels (AHSS) and an inner multicell aluminum extrusion structure for energy absorption which protects the batteries in a crash event. It is well known, however, that these material combinations provide significant challenges for joining and are susceptible to liquid metal embrittlement and loss of strength. The overall goal is to find a solution that addresses these challenges in order to produce multi-material vehicle components with reduced weight and minimal galvanic and recyclability issues. The approach being proposed here is to utilize a novel high velocity (HiVe) riveting and clinching technique recently demonstrated by Pacific Northwest National Laboratory (PNNL) to join (2T/3T) sheets of aluminum alloys and steel. This process will not only address the aforementioned challenges but also help significantly reduce the joining cycle time. This work will also demonstrate use of HiVe assemblies to be retrofitted to existing body-shop robots thus having minimal impact to existing body shop operations.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Development of Large Scale Extrusion Deposition for Structural Applications

Large Scale Extrusion Deposition (LSED) is an evolving additive manufacturing (AM) technology that research, such as that taking place at Oak Ridge National Laboratory (ORNL) and companies like Local Motors, are continuing to utilize and develop new applications. A major LSED application of interest has been molds and tooling as it allows for much shorter production time and lower cost. However, interest has been expanding into using LSED for more structural applications due to more frequent use of high performing polymer composites as feedstock. The use of LSED for structural applications is of particular interest to Local Motors as it is currently being used to create commercially viable, energy efficient electric vehicles. LSED offers a unique opportunity when compared to traditional manufacturing methods as it can significantly reduce the number of components necessary, while decreasing embodied energy and carbon emissions. Even with these benefits however, it is important that LSED is properly understood from a structural aspect as this field has not been as heavily researched as tooling. To ensure a high level of safety and repeatability is an essential responsibility of a manufacturer whose products are structural in nature. As such it is important to understand the materials and LSED process to make structural objects that the manufacturer can be confident in. The main goals of this project were to: develop and investigate materials that are of interest for structural LSED applications, further develop and understand the current machines used in LSED and develop simulations tools of LSED and the mechanical properties of the created structure. Material development focused on composite materials that have high mechanical properties and are stable in a variety of environments. The materials were tested to determine their as printed mechanical and thermal properties as these are necessary for simulations. Once the materials were investigated thoroughly, it allowed for simulations to be performed to compare to experimental data with simulations. Materials were also vetted to determine candidates for multi-material printing. The machine development focused around the areas of process monitoring, non-destructive evaluation, and quality control. Finally, the goal of the simulations was to develop a realistic model of printed structures, including in-process simulation and dynamic simulation. The routes to get to some of these goals and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. This project resulted in many valuable results such as the development of an nondestructive evaluation (NDE) technique for interlayer defects, proof of simulation for warpage in simple parts, the development and utilization of a profilometer to monitor a print for defects or inconsistencies, thorough investigation of a material used commercially for structural LSED applications and valuable experimental data on the applicability and advantages of multi-material crush structures versus their neat counterparts by creation and testing of samples.

36 MATERIALS SCIENCE↗
DOE OSTI2025

3D printed polymer gaskets for custom-form batteries

Additive manufacturing (AM) processes, like 3D printing, help to facilitate complex and customizable battery geometries which can provide design freedom and enhance volumetric energy density within electronic devices. AM materials must have the thermal and mechanical properties that enable printability, and when used in batteries, AM materials must also be chemically and electrochemically compatible with the battery chemistry. The compatibility between AM materials and the battery is of particular importance for the cell packaging materials which must be inert and are often overlooked. This study systematically studies AM-compatible polymeric materials for use as gaskets in lithium-ion cells. The materials investigated include three thermoplastics suitable for material extrusion printing: polylactic acid (PLA), polycarbonate, and polypropylene/polyethylene copolymer (PPPEC); and two photoresins suitable for vat photopolymerization (VPP) printing: an acrylate-based photoresin and a polyethylene glycol diacrylate photoresin. The AM gasket materials were tested in comparison to a conventional commercial polypropylene gasket. Mechanical testing (swell measurements and material stiffness) and electrochemical testing (linear sweep voltammetry and galvanostatic cycling of full cells) demonstrated that PLA and the VPP polymers were the least compatible with the lithium-ion battery chemistry, despite their prevalent use in studies of AM batteries, and that PPPEC was the most compatible.

3D printing↗
DOE OSTI2018

PROTEUS-MOC User Manual

The PROTEUS-MOC code is a three-dimensional (3D) neutron transport code based on the finite element mesh and the method of characteristics (MOC) which combines a 2D MOC with the discontinuous Galerkin finite element method for the axial direction. Thus, for PROTEUS-MOC, a 3D geometry is represented with by the implicit extrusion of a single 2D planar geometry with different material assignments allowable on each plane. The code requires four input files for a steady-state calculation without the thermal feedback: a driver input, a mesh input, a cross section input, and a material assignment input. With thermal feedback, a T/H input file is needed. For kinetics, a kinetics driver input file is required. The PROTEUS-MOC software produces a text output file as well as a data file which includes integral and average quantities such on fluxes, powers, temperatures, densities, etc. The detailed output file can be converted to the VTK format using the post processing code so that the outputs can be visualized using a visualization software such as VisIt.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Increasing Interlaminar Strength in Large Scale Additive Manufacturing

Interlaminar strength of extrusion-based additively manufactured parts is known to be weaker than the strength seen in the printed directions (X and Y). With Big Area Additive Manufacturing (BAAM), large parts lead to long layer times that are prone to splitting, sometimes referred to as delamination, between the layers. Fiber filled materials, such as carbon fiber reinforced ABS, are used to counter-act the effects of thermal expansion, but the fibers stay in-plane meaning that no fibers span from layer to layer, which helps counteract the weak interlaminar strength that causes splitting. A solution to this is a patent pending approach known as “z-pinning”. The process involves strategically positioning voids across multiple layers that will be backfilled with hot extrudate. This paper will explore the benefits and results of using “z-pinning” in large scale additive manufacturing.

Roschli, Alex↗
DOE OSTI2020

The Effects of Annealing after Equal Channel Angular Extrusion (ECAE) on Mechanical and Magnetic Properties of 49Fe-49Co-2V Alloy

Equal channel angular extrusion (ECAE) of 49Fe-49Co-2V, also known as Hiperco® 50A or Permendur-2V, greatly improves the strength and ductility of this alloy, while sacrificing soft magnetic performance. In this work, ECAE Hiperco specimens were subjected to post-ECAE annealing in order to improve soft magnetic properties. The microstructure, mechanical properties, and magnetic performance are summarized in this study. Annealing begins above 650°C and a steep decline in yield strength is observed for heat treatments between 700 and 840°C due to grain growth and the Hall-Petch effect, although some strength benefit is still observed in fully annealed ECAE material compared to conventionally processed bar. Soft magnetic properties were assessed through B-H hysteresis curves from which coercivity (Hc) values were extracted. Hc decreases rapidly with annealing above 650°C as well, i.e. improved soft magnetic behavior. The observed trend is attributed to annealing and grain growth in this temperature regime, which facilitates magnetic domain wall movement. The coercivity vs. grain size results generally follow the trend predicted in the literature. The magnetic behavior of annealed ECAE material compares favorably to conventional bar, possibly due to mild crystallographic texturing which enhances properties in the post-ECAE annealed material. Overall, this study highlights a definitive tradeoff between mechanical and magnetic properties brought about by post-ECAE annealing and grain growth.

annealing↗
NASA NTRS1977

Shock compression and adiabatic release of a titaniferous mare basalt

A report is presented regarding the dynamic properties of a rock indigenous to the mare basins of the moon. The reported data were obtained in a study of sample 70215, a very titanium-rich basalt (58% pyroxene, 18% ilmenite, 15% plagioclase, 6% olivine, and 3% quartz by weight). This rock is probably representative of a class of the earliest mare-filling extrusive rocks which are exposed on the present lunar surface. Two series of experiments were performed. One set of experiments involved the measuring of Hugoniot and release adiabats to 15.7 GPa with a propellant gun apparatus. In the second set of experiments, a light-gas gun was employed to yield Hugoniot data at about 120 GPa and release states at about 90 GPa. Lunar basalt 70215 appears to be among the densest rocks in the present lunar sample collection, having a crystal density of 3.38 g/cu cm and a porosity of about 1.3%. The results of the experiments have important implications for both the degree of shock metamorphism expected for impact processes and the extent of ejecta transport on mare surfaces with high-titanium basalt composition.

Ahrens, T. J.↗