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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Method for Selective Cleaning of Mold Release from Composite Honeycomb Surfaces

Honeycomb structures are commonly employed as load- and force-bearing structures as they are structurally strong and lightweight. Manufacturing processes for heat-molded composite honeycomb structures commence with the placement of pre-impregnated composite layups over metal mandrels. To prevent permanent bonding between the composite layup and the metal mandrels, an agent, known as a mold release agent, is used. Mold release agents allow the molded composite material to be removed from mandrels after a heat-forming process. Without a specific removal process, mold release agents may continue to adhere to the surface of the composite material, thereby affecting the bonding of other materials that may come into contact with the composite surface in later stages of processing A constituent common to commercially available household cleaning agents is employed for the removal of mold release agents common to the manufacturing of heat-formed composite materials. The reliability of the solvent has been proven by the longevity and reliability of commercial household cleaners. At the time of this reporting, no one has attempted using constituent for this purpose. The material to be cleaned is immersed in the solution, vertically removed so that the solution is allowed to drain along cell walls and into a solvent bath, and then placed on a compressed airflow table for drying.

Pugel, Diane↗
DOE OSTI2020

Glass or metal forming mold of adjustable shape

A system for shaping glass or metal sheets or panels for use in solar collectors or microwave antennae may include an oven and an adjustable mold. The adjustable mold may comprise a molding surface located within the oven. The molding surface may be coupled to position actuators located outside of the oven via coupling elements. A sheet or panel may be placed in the oven and heated until the sheet or panel softens and takes the shape of the molding surface. The molding surface may be adjusted to achieve different shapes for glass or metal sheets or panels.

42 ENGINEERING↗
DOE OSTI2018

The Temperature and Structure Dependence of Surface Tension of CaO-SiO{sub 2}-Na{sub 2}O-CaF{sub 2} Mold Fluxes

The surface tension of mold flux is one of the most important properties and varies with the temperature from the top to the bottom of the mold, which influences the adhesion and lubrication between the liquid mold flux and the solidified shell, further influencing the quality of the continuous billet. In the present paper, the effect of temperature on the surface tension of CaO-SiO{sub 2}-Na{sub 2}O-CaF{sub 2} mold-flux melts with different CaO/SiO{sub 2} mass ratios was investigated using the maximum-pull method. Furthermore, the microstructure of mold fluxes was analyzed using FT-IR and Raman spectra to discuss the change mechanism of surface tension. The results indicated that the temperature dependence of surface tension was different with different CaO/SiO{sub 2} mass ratios, and agreed with the modification of melt structure. When the CaO/SiO{sub 2} mass ratio was 0.67 and 0.85, the change of surface tension with temperature was relatively stable, and the influence of temperature on the structure was small. When the CaO/SiO{sub 2} mass ratio was 1.03 and 1.16, with an increase of temperature, the surface tension decreased linearly and the changing amplitude was large; the degree of polymerization of melts and average radii of silicon-oxygen anions also decreased, which intensified the molecular thermal motion and weakened the intermolecular interaction, resulting in a decrease of surface tension of melts.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of B{sub 2}O{sub 3} on Crystallization, Structure, and Heat Transfer of CaO-Al{sub 2}O{sub 3}-Based Mold Fluxes

The reaction between traditional CaO-SiO{sub 2}-based mold fluxes and high-Al steel inevitably changes flux composition, and, consequently, flux properties. This problem can be mitigated by using CaO-Al{sub 2}O{sub 3}-based mold fluxes. To maintain appropriate melting properties, CaO-Al{sub 2}O{sub 3}-based mold fluxes contain B{sub 2}O{sub 3}, which is an effective fluxing agent that decreases the liquidus temperature. In this article, the effects of B{sub 2}O{sub 3} on crystallization behavior, structure, and heat transfer of CaO-Al{sub 2}O{sub 3}-based mold fluxes were studied using single/double hot thermocouple technique, Raman spectroscopy, and infrared emitter technique. The increase of B{sub 2}O{sub 3} content from 7.6 to 13.1 mass pct suppressed the crystallization tendency of mold fluxes in continuous cooling experiments and isothermal experiments conducted over 1273 K (1000 °C). The isothermal crystallization below 1273 K (1000 °C) was also inhibited when B{sub 2}O{sub 3} content increased from 7.6 to 9.6 mass pct; but a further increase of B{sub 2}O{sub 3} content to 13.1 mass pct did not show a visible effect on the crystallization tendency. The increase of B{sub 2}O{sub 3} content from 9.6 to 13.1 mass pct improved the heat fluxes under an incident thermal radiation of 1.6 MW/m{sup 2}; however, the increase of B{sub 2}O{sub 3} content from 7.6 to 9.6 mass pct slightly decreased the heat transfer rate. Crystallization of fluxes and heat transfer were discussed in relation to flux structure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Experimental Study of the Mold Flow Induced by a Swirling Flow Nozzle and Electromagnetic Stirring for Continuous Casting of Round Blooms

This study focuses on an experimental investigation of the fluid flow in round bloom continuous casting using a 1:3 model of the industrial casting process. A swirling flow nozzle, represented by the specific design of the RHI Magnesita GYRONOZZLE, is used to produce a swirling motion in the cylindrical mold. The test section is integrated into the Mini-LIMMCAST facility at HZDR, which is operated at room temperature using the ternary alloy GaInSn. Systematic measurements of horizontal and vertical velocity profiles are performed by means of the Ultrasound Doppler Velocimetry. The second part of the study focuses on the interaction between the flow driven by the GYRONOZZLE and concurrent electromagnetic stirring in the mold (M-EMS) by applying rotating magnetic fields (RMFs) at different magnetic flux densities. The effect of the GYRONOZZLE on the flow pattern inside the mold is examined with and without superimposed RMFs and compared to those of a standard single-port nozzle. The measurements reveal that the GYRONOZZLE induces a swirling flow in the whole mold. It is further shown that the influence of a simultaneously applied RMF is mainly restricted to the lower part of the mold since the transport of angular momentum to the top is suppressed by the jets pouring out from the GYRONOZZLE.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Al{sub 2}O{sub 3}/(B{sub 2}O{sub 3 }+ Na{sub 2}O) Ratio on CaO-Al{sub 2}O{sub 3}-Based Mold Fluxes: Melting Property, Viscosity, Heat Transfer, and Structure

CaO-Al{sub 2}O{sub 3}-based mold fluxes, which are under development for the continuous casting of high-Al steel, contain fluxing compounds, such as Na{sub 2}O and B{sub 2}O{sub 3}. The reaction between [Al] and the fluxing agents in mold fluxes leads to an increase in Al{sub 2}O{sub 3} and a decrease in B{sub 2}O{sub 3} and Na{sub 2}O concentrations, changing the properties of mold fluxes. The effect of the Al{sub 2}O{sub 3}/(B{sub 2}O{sub 3 }+ Na{sub 2}O) ratio on the melting properties, viscosity, heat transfer, and structure of the CaO-Al{sub 2}O{sub 3}-based mold fluxes is presented in this work. The increase of the Al{sub 2}O{sub 3}/(B{sub 2}O{sub 3 }+ Na{sub 2}O) ratio in the fluxes raised the melting temperature and high-temperature viscosity of mold fluxes but decreased the heat transfer rate across the flux disks. It also enhanced the degree of polymerization by promoting the formation of 3-D aluminate structure, which accounted for the change of the viscous behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Overcoming geometric limitations in metallic glasses through stretch blow molding

Bulk metallic glasses (BMGs) exhibit remarkable mechanical properties, such as high strength and elasticity, which is often paired with fracture toughness. Their supercooled liquid region gives rise to plastic-like processing and suggests parts and shapes that can otherwise not be obtained for crystalline metals. However, current processing techniques only allow for limited options in terms of geometry, thicknesses uniformity, and shape complexity. Here we introduce a new processing technique, “stretch blow molding,” to expand the range of possible parts and increase the available geometries that can be fabricated with BMGs. Additionally, a model is derived that allows for the quantification and prediction of stretch blow molding and provides insight into its potential use and limitations. We demonstrate that with stretch blow molding overall strains exceeding 2000% are achievable, compared to the previously reported ~150% of blow molding. With the ability to stretch blow mold shapes that were previously unachievable with any other metal fabrication technique in a fast and economical manner, and the superb properties of BMGs, we look forward to a broad commercial adaptation of this technique.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Joining technique for in-oven/autoclave molds manufactured by large scale polymer additive manufacturing

Large scale additive manufacturing (AM) of fiber-reinforced polymer composites has gained traction in the mold and die community over the last decade, largely due to reduced material cost and lead time. However, limitations in mold size remain present due to printer volume constraints and costs associated with large format machines. Here, this paper describes a method for producing additively manufactured polymer molds in segments with an O-ring joint design, which can be machined and subsequently assembled for autoclave applications. The developed joining mechanism allows for maintaining the vacuum integrity during the cure cycle while accounting for the anisotropic nature of the additively manufactured polymer molds. Over a range of tested temperatures, 20–200 °C, the multi-part mold joining design was able to achieve full vacuum of ∼73.7 cmHg (29 inchHg) and maintain a vacuum integrity with vacuum losses less than 1.5 cmHg/5min (0.6 inchHg).

Joining↗
DOE OSTI2015

Electrical and dielectric properties of foam injection-molded polypropylene/multiwalled carbon nanotube composites

A combination of high dielectric permittivity (ε′) and low dielectric loss (tan δ) is required for charge storage applications. In percolative systems such as conductive polymer composites, however, obtaining high ε′ and low tan δ is very challenging due to the sharp insulation-conduction transition near the threshold region. Due to the particular arrangement of conductive fillers induced by both foaming and injection molding processes, they may address this issue. Therefore, this work evaluates the application of foam injection molding process in fabricating polymer nanocomposites for energy storage. Polypropylene-multiwalled carbon nanotubes (PP-MWCNT) composites were prepared by melt mixing and foamed in an injection molding process. Electrical conductivity (σ), ε′ and tan δ were then characterized. Also, scanning and transmission electron microscopy (SEM and TEM) was used to investigate the carbon nanotube’s arrangement as well as cellular morphology. The results showed that foam injection-molded composites exhibited highly superior dielectric properties to those of solid counterparts. For instance, foamed samples had ε′=68.3 and tan δ =0.05 (at 1.25 vol.% MWCNT), as opposed to ε′=17.8 and tan δ=0.04 in solid samples (at 2.56 vol.% MWCNT). The results of this work reveal that high performance dielectric nanocomposites can be developed using foam injection molding technologies for charge storage applications.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2014

Light Metals Permanent Mold Casting

Current vehicles use mostly ferrous components for structural applications. It is possible to reduce the weight of the vehicle by substituting these parts with those made from light metals such as aluminum and magnesium. Many alloys and manufacturing processes can be used to produce these light metal components and casting is known to be most economical. One of the high integrity casting processes is permanent mold casting which is the focus of this research report. Many aluminum alloy castings used in automotive applications are produced by the sand casting process. Also, aluminum-silicon (Al-Si) alloys are the most widely used alloy systems for automotive applications. It is possible that by using high strength aluminum alloys based on an aluminum-copper (Al-Cu) system and permanent mold casting, the performance of these components can be enhanced significantly. This will also help to further reduce the weight. However, many technological obstacles need to be overcome before using these alloys in automotive applications in an economical way. There is very limited information in the open literature on gravity and low-pressure permanent mold casting of high strength aluminum alloys. This report summarizes the results and issues encountered during the casting trials of high strength aluminum alloy 206.0 (Al-Cu alloy) and moderate strength alloy 535.0 (Al-Mg alloy). Five engineering components were cast by gravity tilt-pour or low pressure permanent mold casting processes at CanmetMATERIALS (CMAT) and two production foundries. The results of the casting trials show that high integrity engineering components can be produced successfully from both alloys if specific processing parameters are used. It was shown that a combination of melt processing and mold temperature is necessary for the elimination of hot tears in both alloys.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2014

Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - FY 2014 Fourth Quarterly Report

During the last quarter of FY 2014, the following technical progress has been made toward project milestones: 1) Autodesk, Inc. (Autodesk) has implemented a new fiber length distribution (FLD) model based on an unbreakable length assumption with Reduced Order Modeling (ROM) by the Proper Orthogonal Decomposition (POD) approach in the mid-plane, dual-domain and 3D solvers. 2) Autodesk improved the ASMI 3D solver for fiber orientation prediction using the anisotropic rotary diffusion (ARD) – reduced strain closure (RSC) model. 3) Autodesk received consultant services from Prof. C.L. Tucker at the University of Illinois on numerical simulation of fiber orientation and fiber length. 4) PlastiComp, Inc. (PlastiComp) suggested to Purdue University a procedure for fiber separation using an inert-gas atmosphere in the burn-off furnace. 5) Purdue University (Purdue) hosted a face-to-face project review meeting at Purdue University on August 6-7, 2014. 6) Purdue conducted fiber orientation measurements for 3 PlastiComp plaques: fast-fill 30wt% LCF/PP edged-gated, slow-fill 50wt% LCF/PP edge-gated, and slow-fill 50wt% LCF/PP center-gated plaques, and delivered the orientation data for these plaques at the selected locations (named A, B, and C) to PNNL. 7) PNNL conducted ASMI mid-plane analyses for the above PlastiComp plaques and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. 8) PNNL planned the project review meeting (August 6-7, 2014) with Purdue. 9) PNNL performed ASMI analyses for the Toyota complex parts with and without ribs, having different wall thicknesses, and using the PlastiComp 50wt% LCF/PP, 50wt% LCF/PA66, 30wt% LCF/PP, and 30wt% LCF/PA66 materials to provide guidance for tool design and modifications needed for molding these parts. 10) Magna Exteriors and Interiors Corp. (Magna) molded plaques from the 50% LCF/PP and 50% LCF/PA66 materials received from Plasticomp in order to extract machine purgings (purge materials) from Magna’s 200-Ton Injection Molding machine targeted to mold the complex part. 11) Toyota and Magna discussed with PNNL tool modification for molding the complex part.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Influence of Shell Mold Composition on the As-cast Macro- and Micro-structure of Thin-Walled IN713C Superalloy Castings

In the investment casting process, the building of ceramic layers around the wax pattern is the main time-consuming stage. Increasing their number ensures sufficient mechanical properties, but also lengthens the whole process, including drying time and preheating of the mold. Four molds for casting Ni-based superalloy IN713C were strengthened by glass fibers, included in the slurry, and metal powder, of Al, Cu, Fe or Ni, in the coverage. Castings were subjected to microstructural investigations in order to find out if the new design can be promising for the manufacture of jet engine components. Bend tests revealed that the green strengths of all new molds were higher, at least 3.65 MPa, than that of the unmodified molds, 3.0 MPa. Optical microscopy revealed that the composition of a mold had a strong influence on stereological parameters of equiaxed IN713C grains. Microstructural observation and hardness measurements of castings revealed differences in the volume fraction of strengthening phases, porosity and hardness. The microstructure due to the complex chemical composition of IN713C consisted of several phases including ternary eutectics as a consequence of L → γ + Ni{sub 7}Zr{sub 2} + (Nb, Zr)C.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additive Manufacturing of Molds for Fabrication of Insulated Concrete Block

Oak Ridge National Laboratory (ORNL) worked with concrete block manufacturer, NRG Insulated Block, to demonstrate additive manufacturing of a multi-component block mold for its line of insulated blocks. Solid models of the mold parts were constructed from existing two-dimensional drawings, and the parts were fabricated on a Stratasys Fortus 900 using ULTEM™ 9085. Block mold parts were delivered to NRG and installed on one of their fabrication lines. While form and fit were acceptable, the blocks made from the molds collapsed when extruded from the printed molds during NRG’s testing. However, the project demonstrated significant time and cost reductions and achieving proper functionality through the use of different additive manufacturing techniques.

42 ENGINEERING↗
NASA NTRS1967

Improved compression molding process

Modified compression molding process produces plastic molding compounds that are strong, homogeneous, free of residual stresses, and have improved ablative characteristics. The conventional method is modified by applying a vacuum to the mold during the molding cycle, using a volatile sink, and exercising precise control of the mold closure limits.

Heier, W. C.↗
NASA NTRS1978

Standard Molded Composite Rocket Pyrogen Igniter - A progress report

The pyrogen igniter has the function to furnish a controlled, high temperature, high pressure gas to ignite solid propellant surfaces in a rocket motor. Present pyrogens consist of numerous inert components. The Standard Molded Pyrogen Igniter (SMPI) consists of three basic parts, a cap with several integrally molded features, an ignition pellet retainer plate, and a tube with additional integrally molded features. A description is presented of an investigation which indicates that the SMPI concept is a viable approach to the design and manufacture of pyrogen igniters for solid propellant rocket motors. For some applications, combining the structural and thermal properties of molded composites can result in the manufacture of lighter assemblies at considerable cost reduction. It is demonstrated that high strength, thin walled tubes with high length to diameter ratios can be fabricated from reinforced plastic molding compound using the displacement compression process.

Lucy, M. H.↗
NASA NTRS1979

Development of processes and techniques for molding thermally stable, fire-retardant, low-smoke-emitting polymeric materials

All available newly developed nonmetallic thermally stable polymers were examined for the development of processes and techniques by compression molding, injection molding, or thermoforming cabin interior parts. Efforts were directed toward developing molding techniques of new polymers to economically produce usable nonmetallic molded parts. Data on the flame resistant characteristics of the materials were generated from pilot plant batches. Preliminary information on the molding characteristics of the various thermoplastic materials was obtained by producing actual parts.

Silverman, B.↗
NASA NTRS1983

Injection molding ceramics to high green densities

The injection molding behavior of a concentrated suspension of Si powder in wax was studied. It was found that the injection molding behavior was a function of the processing techniques used to generate the powder. Dry ball-milled powders had the best molding behavior, while air classified and impact-milled powders demonstrated poorer injection moldability. The relative viscosity of these molding batches was studied as a function of powder properties: distribution shape, surface area, packing density, and particle morphology. The experimental behavior, in all cases, followed existing theories. The relative viscosity of an injection molding composition composed of dry ball-milled powders could be expressed using Farris' relation.

Mangels, J. A.↗
NASA NTRS1984

An investigation into the injection molding of PMR-15 polyimide

The chemorheological behavior of the PRM-15 molding compounds were characterized, the range of suitable processing parameters for injection molding in a reciprocating screw injection molding machine was determined, and the effects of the injection molding processing parameters on the mechanical properties of molded PMR-15 parts were studied. The apparatus and procedures for measuring viscosity and for determining the physical response of the material during heating are described. Results show that capillary rheometry can be effectively used with thermosets if the equipment is designed to overcome some of the inherent problems of these materials. A uniform temperature was provided in the barrel by using a circulating hot oil system. Standard capillary rheometry methods can provide the dependence of thermoset apparent viscosity on shear rate, temperature, and time. Process conditions resulting in complete imidization should be carefully defined. Specification of controlled oven temperature is inadequate and can result in incomplete imidization. For completely imidized PMR-15 heat at 15 C/min melt flow without gas evolution occurs in the temperature range of 325 C to 400 C.

Colaluca, M. A.↗