Search NASA⌕ Search

SEARCH · Search NASA

Results for “composite tooling”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Mitigating Scatter in Mechanical Properties in AISI 410 Fabricated via Arc-Based Additive Manufacturing Process

Wire-based metal additive manufacturing utilizes the ability of additive manufacturing to fabricate complex geometries with high deposition rates (above 7 kg/h), thus finding applications in the fabrication of large-scale components, such as stamping dies. Traditionally, the workhorse materials for stamping dies have been martensitic steels. However, the complex thermal gyrations induced during additive manufacturing can cause the evolution of an inhomogeneous microstructure, which leads to a significant scatter in the mechanical properties, especially the toughness. Therefore, to understand these phenomena, arc-based additive AISI 410 samples were fabricated using robotic gas metal arc welding (GMAW) and were subjected to a detailed characterization campaign. The results show significant scatter in the tensile properties as well as Charpy V-notch impact toughness data, which was then correlated to the microstructural heterogeneity and delta (δ) ferrite formation. Post-processing (austenitizing and tempering) treatments were developed and an ~70% reduction in the scatter of tensile data and a four-times improvement in the toughness were obtained. The changes in mechanical properties were rationalized based on the microstructure evolution during additive manufacturing. Based on these, an outline to tailor the composition of “printable” steels for tooling with isotropic and uniform mechanical properties is presented and discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Unsupervised Machine Learning for Exploratory Data Analysis of Exoplanet Transmission Spectra

Abstract Transit spectroscopy is a powerful tool for decoding the chemical compositions of the atmospheres of extrasolar planets. In this paper, we focus on unsupervised techniques for analyzing spectral data from transiting exoplanets. After cleaning and validating the data, we demonstrate methods for: (i) initial exploratory data analysis, based on summary statistics (estimates of location and variability); (ii) exploring and quantifying the existing correlations in the data; (iii) preprocessing and linearly transforming the data to its principal components; (iv) dimensionality reduction and manifold learning; (v) clustering and anomaly detection; and (vi) visualization and interpretation of the data. To illustrate the proposed unsupervised methodology, we use a well-known public benchmark data set of synthetic transit spectra. We show that there is a high degree of correlation in the spectral data, which calls for appropriate low-dimensional representations. We explore a number of different techniques for such dimensionality reduction and identify several suitable options in terms of summary statistics, principal components, etc. We uncover interesting structures in the principal component basis, namely well-defined branches corresponding to different chemical regimes of the underlying atmospheres. We demonstrate that those branches can be successfully recovered with a K-means clustering algorithm in a fully unsupervised fashion. We advocate for lower-dimensional representations of the spectroscopic data in terms of the main principal components, in order to reveal the existing structure in the data and quickly characterize the chemical class of a planet.

Matchev, Konstantin T. (ORCID:0000000341829096)↗
DOE OSTI2020

Open-Source High-Fidelity Aggregate Composite Load Models of Emerging Load Behaviors for Large-Sale Analysis

The goal of this project is to accurately model the dynamic loads for power system planning and operation and to address the challenges inherent in such modeling. Existing load models are inadequate to handle the increasing proliferation of residential air conditioner loads and distributed energy resources, the emerging trends of price-responsive demand, and the growing importance of protective devices in equipment and buildings. A need has emerged to develop a fundamentally new class of load models and next-generation data tools. This work proposes to develop a set of regional–level, scalable open source load models and tools, including large-scale aggregate load protection, concept of price responsive demand, advanced load composition data, next-generation load model data tools, and advanced composite load model calibration and validation frameworks to address new challenges in the representation of next-generation load models.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Development and Integration of Predictive Models for Manufacturing and Structural Performance of Carbon Fiber Composites in Automotive Applications (Final Report)

The goal of this project is to develop integrated, state-of-the-art, computational modeling tools based on an integrated computational materials engineering (ICME) methodology that are critically needed to enable structural carbon fiber (CF) applications in automobiles. These tools are designed to predict the manufacturing and structural performance of CF composites, including stochastic effects. During the first phase of the project, the manufacturing and structural performance tools, including a stochastic driver, were developed, calibrated, and validated against coupon and component level test results. For this project, from the manufacturing side, the development efforts were focused on high-pressure resin transfer molding (HP-RTM), a potentially game-changing manufacturing technology that is capable of reaching the 3-5-minute cycle time that is necessary for volume manufacturing of composites. On the structural performance side, the crashworthiness of CF structures was studied. Accordingly, computational tools were developed and validated. The resulting differences between the numerical predictions and the experimental results in the first phase of the project were required to be less than 15%. During the second phase of the project, the manufacturing and performance tools were integrated by mapping the manufacturing outcomes (e.g., fiber angles, residual stresses, degree of cure, and defects) into the structural models. Also, using the tools developed in this project, an automotive assembly currently manufactured in steel (2016 GM Malibu) was redesigned to be manufactured using advanced CF composites with the objective of comparing the performance of the CF assembly with the developed ICME model predictions. The weight, performance and cost of the CF assembly were compared with the baseline steel assembly as well. The CF underbody design was shown to be 30% lighter than the corresponding steel design. The CF underbody assembly withstood the side pole impact with less than half the intrusion for the steel assembly. Excellent correlations within 10% for both peak impact load and intrusion were observed between the numerical predictions and experimental results. Based on the cost models developed in the project, the cost increase per Kg saved was determined to be $22. The project team has prepared a total of 28 publications in various journals and conferences and broadly communicated the project results for the benefit of the composite industry. The project team has also prepared a total of 10 patent applications that were submitted to the US Patent and Trademark office.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Validation of Fast Reactor Depletion Tools Using EBR-II Measured Data

The validation of simulation tools for calculating fuel depletion and evolution in fast reactors is vital for design, licensing, deployment, operations, and material accountancy. The Physics Analysis Database (PADB) and Analytical Laboratory (AL) database contain measured data collected from Experimental Breeder Reactor II (EBR-II) and were used to validate the most recent versions of the Argonne Reactor Computation (ARC) tool suite and ORIGEN-S for calculating isotopic compositions in irradiated fast reactor fuel. The PADB contains important modeling and operational information about the EBR-II core design, fuel cycle, and analytical results from the legacy versions of the ARC tool suite. The AL database contains the measured isotopic compositions of irradiated samples taken from core subassemblies. A new procedure was developed for the ARC tool suite to perform the EBR-II depletion simulation, as well as to perform more detailed isotopic calculations using ORIGEN-S calculations by coupling it with the ARC suite. Both the ARC and ARC-ORIGEN results were compared with the AL measured data for all relevant samples and showed good agreement for the major actinides. Good agreement with measured data was also achieved using the ARC-ORIGEN approach for several fission products.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Deep learning of experimental electrochemistry for battery cathodes across diverse compositions

Artificial intelligence (AI) has emerged as a tool for discovering and optimizing novel battery materials. However, the adoption of AI in battery cathode representation and discovery is still limited due to the complexity of optimizing multiple performance properties and the scarcity of high-fidelity data. Here, we present a machine learning model (DRXNet) for battery informatics and demonstrate the application in the discovery and optimization of disordered rocksalt (DRX) cathode materials. We have compiled the electrochemistry data of DRX cathodes over the past 5 years, resulting in a dataset of more than 19,000 discharge voltage profiles on diverse chemistries spanning 14 different metal species. Learning from this extensive dataset, our DRXNet model can capture critical features in the cycling curves of DRX cathodes under various conditions. Our approach offers a data-driven solution to facilitate the rapid identification of novel cathode materials, accelerating the development of next-generation batteries for carbon neutralization.

25 ENERGY STORAGE↗
DOE OSTI2025

Framework and Tool for Artificial Intelligence & Machine Learning (AI/ML) Enabled Automated Non-Destructive Inspection of Composites Aerostructures Manufacturing

Vehicles and systems in the field of aerospace have two major requirements: a high demand for a large quantity and an expectation to perform for their lifetime with little to no failures. Thus, there is a need for a fast production rate of aerospace products with high quality. Improvements to production rate have many benefits, including a reduction in energy consumption per unit manufactured. This would be from factory energy usage, which is required to build and verify a product. Manufacturing process specifications require inspection of parts to determine if any flaws are present. Depending on factory planning and product quality, especially at higher rates, the evaluation process can pose a production rate bottleneck. This project was comprised of using artificial intelligence and machine learning (AI/ML) methods on inspection evaluations with the objective of reducing the required time to produce an aerospace structure or product and without reducing the final quality.

42 ENGINEERING↗
DOE OSTI2024

In situ X-ray and IR probes relevant to Earth science at the Advanced Light Source at Lawrence Berkeley Laboratory

Access to synchrotron X-ray facilities has become an important aspect for many disciplines in experimental Earth science. This is especially important for studies that rely on probing samples in situ under natural conditions different from the ones found at the surface of the Earth. The non-ambient condition Earth science program at the Advanced Light Source (ALS), Lawrence Berkeley National Laboratory, offers a variety of tools utilizing the infra-red and hard X-ray spectrum that allow Earth scientists to probe Earth and environmental materials at variable conditions of pressure, stress, temperature, atmospheric composition, and humidity. These facilities are important tools for the user community in that they offer not only considerable capacity (non-ambient condition diffraction) but also complementary (IR spectroscopy, microtomography), and in some cases unique (Laue microdiffraction) instruments. The availability of the ALS’ in situ probes to the Earth science community grows especially critical during the ongoing dark time of the Advanced Photon Source in Chicago, which massively reduces available in situ synchrotron user time in North America.

58 GEOSCIENCES↗
DOE OSTI2021

Large-scale additive manufacturing tooling for extrusion-compression molds

Carbon fiber reinforced polymer composites (CFPC) have been used in additive manufacturing (AM) due to both the high-strength-to-weight and superior-stiffness-to-weight ratios. CF AM is being considered for tooling applications. In AM, CFPCs are usually aligned along the deposition direction; however, it results in anisotropic thermal properties which affect the heat transfer and warpage of the final part. In this study, three male molds with different infill patterns were produced via the material extrusion additive manufacturing (EDF-AM) process. These include (a) 0°: infill pattern along the printing direction; (b) 90°: infill pattern perpendicular to the printing direction; and (c) 0°/90°: alternate layers along and perpendicular directions. The effect of the infill pattern on thermal conductivity was analyzed and observed that 0° infill (surface temperature: 79.2°C) had the highest conductivity; and 90° infill (surface temperature: 66.4°C) had the least.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Demo 5: RapidClave Technology Demonstrations – Round II (Task 2)

The purpose of this project task was to make automotive composite part manufacturing more cost competitive for low volume production and thereby drive composite application innovation. The strategy was to incorporate low-cost preforming, snap cure resins, and RapidClave® processing to create an alternative to conventional automotive composite manufacturing based on SMC. The program used RapidClave® technology from Globe Machine Manufacturing, fast-curing (“snap cure”) epoxy resins from Hexion, and conformable/stretchable glass fiber reinforcement mats produced by Owens Corning for rapid preforming. O’Gara Armoring retrofits vehicles to meet special security needs, such as larger doors to facilitate easier entry into the vehicle. O’Gara has a variety of custom vehicles in need of custom doors that require affordable tooling to produce approximately 100 ship sets/year. The project focused on a composite door panel application provided by O’Gara that is currently made by manual chopped fiber spray-up processing. UDRI reverse-engineered the current composite door panel and created tooling for use in the RapidClave®. UDRI designed an improved composite door using MultiMat fiberglass reinforcement from Owens Corning. UDRI made snap cure resin films from Hexion resin. Finally, UDRI conducted molding trials to compare autoclave processing with RapidClave® processing. The technical goals of the project were to reduce tooling cost by 50% as compared to SMC compression molding and to reduce cycle time by 50% compared to current manual spray-up process. The approach to reduce tool costs is based on use of single sided tooling for use at 100 psi, as compared to matched metal SMC tooling. An added benefit realized from the program is that the Owens Corning mat provided more uniform thickness and improved performance. Tensile and flexural strengths and moduli were increased by at least 50%. This task also demonstrated a 75% decrease in cycle time. O’Gara is evaluating the technology demonstrated in this project for some of their current production. Additionally, there are new products O’Gara is pursuing which require higher production rates than their current products. O’Gara has identified these new products as good candidates for the RapidClave® technology. The cost advantages demonstrated by this project would then lead to significant economic development. In conclusion, this task successfully combined the RapidClave® technology from Globe with a snap cure epoxy resin film system from Hexion and preform material from Owens Corning. Further research is needed to better map the technical limits such as cycle time of these technologies. Additionally, the technology should be extended in terms of size and shape to include large parts outside of automotive applications, such as a small aircraft fuselage.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Deep Learning for Spectroscopic X-ray Nano-Imaging Denoising

Synchrotron transmission X-ray microscopy with absorption near edge structure (TXM-XANES) is a powerful tool for investigating the structure and composition of materials at nano- to meso-scales. It is, however, often challenged by high levels of noise that obscure critical details at the single-pixel level. To address this issue, a deep learning-based algorithm is developed for suppressing the image noise, grounded in self-supervised learning principles. In contrast to traditional image denoising methods, this approach successfully enhances the visibility of fine details while significantly reducing the noise in the X-ray images. Through this advancement, the potential of the approach for improving the accuracy and interpretability of the TXM-XANES data is demonstrated, thereby enabling more precise detection of nanoscale phenomena such as inhomogeneous cation redox and metal segregation in battery cathode materials. This technique offers an effective new avenue for harnessing the full potential of synchrotron TXM-XANES imaging, paving the way for a range of exciting new studies in materials science and beyond.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Synchrotron Photoionization Study of the Diisopropyl Ether Oxidation

Abstract Scientific evidence has shown oxygenates help to reduce dangerous pollutants arising from burning fossil fuel in the automotive sector. For this reason, their use as additives has spread widely. The aim of this work consists in providing a comprehensive identification of the main primary oxidation products of diisopropyl ether (DIPE), one of the most promising among etheric oxygenates. The Cl‐initiated oxidation of DIPE is examinated by using a vacuum ultraviolet (VUV) synchrotron radiation at the Advanced Light Source (ALS) of the Lawrence Berkeley National Laboratory (LBNL). Products are identified on the basis of their mass‐to‐charge ratio, shape of photoionization spectra, adiabatic ionization energies, and chemical kinetic profiles, at three different temperatures (298, 550, and 650 K). Acetone, propanal, propene, and isopropyl acetate have been identified as major reaction products. Acetone is the main primary product. Theoretical calculations using the composite CBS‐QB3 method provided useful tools to validate the postulated reaction mechanisms leading to experimentally observed species. The formation of other species is also discussed.

Giustini, Andrea↗
DOE OSTI2020

Topological analysis of X-ray CT data for the recognition and trending of subtle changes in microstructure under material aging

X-ray computed tomography (CT) is an established non-destructive tool for 3D imaging of multiphasic composites. Numerous applications of X-ray CT in medical diagnosis and materials characterization have been reported, many involving field-specific innovations in the imaging technology itself. Yet, quantitative summarization to link image features to properties of interest has been rare. Here we address this issue by employing state-of-the-art technics in scalar field topology for the summarization of X-ray CT images of an example biphasic system. By varying processing-parameters we create different microstructures, evolve them through accelerated thermal aging, CT-image them pre- and post-aged, and demonstrate the ability of our image summarization method to systematically track process- and age-related changes, which can often be very subtle. A novel aspect of the algorithm involves recognition over multiple resolution levels, which provides deeper insight into the pattern relationship between grain-like features and their neighbors. The method is general, adaptable to diverse image reconstruction methods and materials systems, and particularly useful in applications where practical constraints on the sample-size limits the reliable use of more complex models, e.g., convolutional neural networks.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Outstanding questions on xylan biosynthesis

Xylan is the second most abundant polysaccharide in plant biomass. It is a crucial component of cell wall structure as well as a significant factor contributing to biomass recalcitrance. Xylan consists of a linear chain of β-1,4-linked xylosyl residues that are often substituted with glycosyl side chains, such as glucuronosyl/methylglucuronosyl and arabinofuranosyl residues, and acetylated at O-2 and/or O-3. Xylan from gymnosperms and dicots contains a unique reducing end tetrasaccharide sequence that is not detected in xylan from grasses, bryophytes and seedless vascular plants. Grass xylan is heavily decorated at O-3 with arabinofuranosyl residues that are frequently esterified with hydroxycinnamates. Further, genetic and biochemical studies have uncovered a number of genes involved in xylan backbone elongation and acetylation, xylan glycosyl substitutions and their modifications, and the synthesis of the unique xylan reducing end tetrasaccharide sequence, but some outstanding issues on the biosynthesis of xylan still remain unanswered. Here, we provide a brief overview of xylan structure and focus on discussion of the current understanding and open questions on xylan biosynthesis. Further elucidation of the biochemical mechanisms underlying xylan biosynthesis will not only shed new insights into cell wall biology but also provide molecular tools for genetic modification of biomass composition tailored for diverse end uses.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Size-Dependent Thermal Shifts to MOF Nanocrystal Optical Gaps Induced by Dynamic Bonding

Conventional semiconductor nanocrystals exhibit wide-ranging optical behavior, whereas the size-dependent photophysical properties of metal–organic framework (MOF) nanocrystals remain an open research frontier. Furthermore, we present size- and temperature-dependent optical absorption spectra of common MOFs with particle sizes ranging from tens of nanometers to several micrometers. All materials exhibit optical gaps that decrease at elevated temperatures, which we attribute to the dynamic nature of MOF metal–linker bonds. Accordingly, whereas the labile titanium–carboxylate bonds of MIL-125 give rise to bandgaps that red-shift by ~600 meV over 300 K, the more rigid zinc–imidazolate bonds of ZIF-8 produce a red-shift of only ~10 meV. Furthermore, smaller particles induce far larger decreases to optical gaps. Taken together, these results suggest MOF bonding becomes more flexible with smaller nanocrystal sizes, offering a powerful tool for manipulating optical behavior through composition, temperature, and dimensionality.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

X-ray fluorescence mapping: Insights into mesoscale structure impact on battery functional electrochemistry

Abstract Electron transfer and ion transport occurs over multiple-length scales ranging from the atomic to mesoscale within battery materials and electrodes. Micro-X-ray fluorescence (µ-XRF) is an important characterization tool as it can resolve structural, compositional, and redox information while providing insight into the spatial distribution of an electroactive material. In this work, µ-XRF mapping is used to probe the distribution of iron within thin planar slurry-based and thick porous carbon nanotube (CNT)-based magnetite (Fe 3 O 4 ) electrodes. Notably, the porous CNT-based electrode showed homogenous distribution of Fe within the electrode whereas the planar electrode demonstrated distinct Fe aggregates. This information was used to rationalize the electrochemistry observed by cyclic voltammetry and galvanostatic cycling. The thick porous electrode delivered 215% more capacity per gram of magnetite during the first discharge, consistent with increased electrode homogeneity enabling effective ion access and electron transfer. Graphical Abstract

Sadique, Nahian↗
DOE OSTI2023

An Overview of the Molten Salt Thermal Properties Database–Thermophysical, Version 2.1.1 (MSTDB-TP v.2.1.1)

The current status of the Molten Salt Thermodynamic Database- Thermal Physical (MSTDB-TP) is reported. Building off of MSTDB-TP and through the direction of the Roadmap for thermal property measurement of Molten Salt Reactor systems, MSTDB-TP 2.1.1 has now been released containing a total 448 salt entries (data from 140+independent studies) compared to the original commit of 62, containing thermophysical properties including density, viscosity, thermal conductivity, and heat capacity. Along with the new database release, further advancement of Saline, a C++application programming interface (API), and a graphical user interface (GUI) has facilitated increased user/developer interaction with the database. Furthermore, estimation techniques, first principles calculations (Ab-Initio) and interpolation/extrapolation methods (Redlich-Kister/Muggianu), have shown great promise in the future of thermophysical property determination for filling out compositional spaces and investigating experimentally difficult salts (hazardous/expensive). This report describes the database composition, development and advancement of database tools, and the strategy of advancing and implementing estimation data into future iterations of the database for MSTDB-TP.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

WA-IsoC_MSC1.1.0

The soil microbiome is central to the cycling of carbon and other nutrients and to the promotion of plant growth. Despite its importance, analysis of the soil microbiome is difficult due to its sheer complexity, with thousands of interacting species. Here, we reduced this complexity by developing model soil microbial consortia that are simpler and more amenable to experimental analysis but still represent important microbial functions of the native soil ecosystem. Samples were collected from an arid grassland soil and microbial communities (consisting mainly of bacterial species) were enriched on agar plates containing chitin as the main carbon source. Chitin was chosen because it is an abundant carbon and nitrogen polymer in soil that often requires the coordinated action of several microorganisms for complete metabolic degradation. Several soil consortia were derived that had tractable richness (30-50 OTUs) with diverse phyla representative of the native soil, including Actinobacteria, Bacteroidetes, Firmicutes, Proteobacteria and Verrucomicrobia. The resulting consortia can be stored as glycerol or lyophilized stocks at -80° C and revived while retaining community composition, greatly increasing their use as tools for the research community at large. One of the consortia that was particularly stable was chosen as a model soil consortium (MSC-1) for further analysis. MSC-1 species interactions were studied using both pairwise co-cultivation in liquid media and during growth in soil under several perturbations. Co-abundance analyses highlighted interspecies interactions and helped to define keystone species, including Mycobacterium, Rhodococcus, and Rhizobiales taxa. These experiments demonstrate the success of an approach based on naturally enriching a community of interacting species that can be stored, revived, and shared. The knowledge gained from querying these communities and their interactions will enable better understanding of the soil microbiome and the roles these interactions play in this environment.

54 ENVIRONMENTAL SCIENCES↗