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NASA NTRSDate not supplied

Advanced Composite Solar Sail System (ACS3) Mission Update

The Advanced Composite Solar Sail System (ACS3) will be the first practical solar sail for the National Aeronautics and Space Administration. [1] ACS3 will also be the first spaceflight demonstration of NASA compact deployable composite boom technology.[2] The primary mission objective of ACS3 will be to deploy and characterize an 80-m2 composite boom structure solar sail technology in low Earth orbit. Extended mission goals will be to demonstrate controlled solar sailing flight via a series of orbit raising and lowering maneuvers. Target mission orbit is a 1000 km x 1000 km midnight-noon sun-synchronous orbit. Launch of ACS3 is scheduled for July 2023 with sail deployment in September 2023. Mission duration is expected to be six to nine months. The ACS3 solar sail vehicle is a 12U Cubesat consisting of a bus module, containing flight and solar sail control avionics, and a solar sail module, containing the composite booms and metallized polymer solar sail membranes of the solar sail structure stowed within a boom deployer mechanism. A four-camera instrument suite for 360-degree imaging of the ACS3 solar sail during and after deployment is also housed within the bus module. The ACS3 80-m2 solar sail design is a sub-scale version of an intermediate-size 500-m2 solar sail using NASA deployable composite boom technology. The sail consists of four metallized 2-m thick polyethylene naphthalate (PEN) 20-m2 triangular quadrants supported by four 7-m long lenticular cross-section composite booms. Booms are flattened and co-coiled for stowage within a tape-spool driven deployer mechanism. Total mass of the ACS3 space vehicle including solar sail is 16 kg. An overview of the ACS3 mission and mission systems will be provided in this presentation. This overview will include descriptions of the solar sail structures and materials technology used with ACS3, and discussion of the scalability and extensibility of the ACS3 solar sail to future larger-scale solar sailing mission requirements. An update on progress towards the launch of ACS3 in July 2023 will also be provided. References [1] https://www.nasa.gov/directorates/spacetech/small_spacecraft/ACS3 [2] https://www.nasa.gov/directorates/spacetech/game_changing_development/projects/dcb

Solar sail↗
NASA NTRS2002

The Stress-strain Behavior of Polymer-Nanotube Composites from Molecular Dynamics Simulations

Stress-strain curves of polymer-carbon nanotube composites are derived from molecular dynamics simulations of a single-walled carbon nanotube embedded in polyethylene. A comparison is made between the response to mechanical loading of a composite with a long, continuous nanotube (replicated via periodic boundary conditions) and the response of a composite with a short, discontinuous nanotube. Both composites are mechanically loaded in the direction of and transverse to the NT axis. The long-nanotube composite shows an increase in the stiffness relative to the polymer and behaves anisotropically under the different loading conditions. The short-nanotube composite shows no enhancement relative to the polymer, most probably because of its low aspect ratio. The stress-strain curves are compared with rule-of-mixtures predictions.

Frankland, S. J. V.↗
NASA NTRS2011

Detection of Carbon Monoxide Using Polymer-Carbon Composite Films

A carbon monoxide (CO) sensor was developed that can be incorporated into an existing sensing array architecture. The CO sensor is a low-power chemiresistor that operates at room temperature, and the sensor fabrication techniques are compatible with ceramic substrates. Sensors made from four different polymers were tested: poly (4-vinylpryridine), ethylene-propylene-diene-terpolymer, polyepichlorohydrin, and polyethylene oxide (PEO). The carbon black used for the composite films was Black Pearls 2000, a furnace black made by the Cabot Corporation. Polymers and carbon black were used as received. In fact, only two of these sensors showed a good response to CO. The poly (4-vinylpryridine) sensor is noisy, but it does respond to the CO above 200 ppm. The polyepichlorohydrin sensor is less noisy and shows good response down to 100 ppm.

Homer, Margie L.↗
DOE OSTI2021

Aging mechanisms of filled cross-linked polyethylene (XLPE) cable insulation material exposed to simultaneous thermal and gamma radiation

Thermal and simultaneous thermal and gamma radiation aging experiments were conducted on an industry grade cross-linked polyethylene (XLPE) cable insulation material, which is a composite material with XLPE as polymer matrix and various additives and fillers. Reverse engineering was conducted to identify and quantify the material composition given that this information was not revealed by the cable manufacture. Samples were then aged at temperatures of 60, 90, and 115 °C, exposed to gamma radiation for total doses of 0 to 324 kGy, and at dose rates of 0 to 540 Gy/h. Aging mechanisms were studied using various materials characterization techniques including pyrolysis gas chromatography mass spectrometry (Py-GCMS), differential scanning calorimetry (DSC), nuclear magnetic resonance spectroscopy (NMR), and gel-fraction tests. Results show that the flame-retardant components were decomposed into smaller molecules when the material was exposed to gamma radiation, while no changes were observed when the samples were aged thermally without gamma radiation. With exposure to gamma radiation, the crystalline phase of the XLPE were damaged by gamma radiation introducing defects in the crystals, resulting in smaller and less perfect crystals. The dominance of chain scission or chain reformation process largely depends on the chain mobility, which is decided by the aging temperature. Chain scission was seen to dominate when the material was exposed to gamma radiation at 60 °C. Chain cross-linking slightly dominated when the material was exposed to gamma radiation at 90 °C and became more dominant with exposure to gamma radiation at 115 °C. No significant change to the XLPE polymer matrix was observed when the samples were exposed to thermal aging without gamma radiation. Finally, antioxidant is more effective in protecting the XLPE polymer matrix under thermal aging, but less effective with sample exposure to gamma radiation.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2023

Two Mesoporous Domains Are Better Than One for Catalytic Deconstruction of Polyolefins

Catalytic hydrogenolysis of polyolefins into valuable liquid, oil, or wax-like hydrocarbon chains for second-life applications is typically accompanied by the hydrogen-wasting co-formation of low value volatiles, notably methane, that increase greenhouse gas emissions. Catalytic sites confined at the bottom of mesoporous wells, under conditions in which the pore exerts the greatest influence over the mechanism, are capable of producing less gases than unconfined sites. A new architecture was designed to emphasize this pore effect, with the active platinum nanoparticles embedded between linear, hexagonal mesoporous silica and gyroidal cubic MCM-48 silica (mSiO 2 /Pt/MCM-48). This catalyst deconstructs polyolefins selectively into ~C 20 –C 40 paraffins and cleaves C–C bonds at a rate (TOF = 4.2 ± 0.3 s –1 ) exceeding that of materials lacking these combined features while generating negligible volatile side products including methane. The time-independent product distribution is consistent with a processive mechanism for polymer deconstruction. In contrast to time- and polymer length-dependent products obtained from non-porous catalysts, mSiO 2 /Pt/MCM-48 yields a C 28 -centered Gaussian distribution of waxy hydrocarbons from polyolefins of varying molecular weight, composition, and physical properties, including low-density polyethylene, isotactic polypropylene, ultrahigh-molecular-weight polyethylene, and mixtures of multiple, post-industrial polyolefins. Here, coarse-grained simulation reveals that the porous-core architecture enables the paraffins to diffuse away from the active platinum site, preventing secondary reactions that produce gases.

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

Fused filament fabrication of novel phase-change material functional composites

Additively manufactured polymer heat exchangers are of recent interest in the thermal sciences due to their lightweight and intricate heat-transfer-enhancing geometrical features. The goal of the present research is to directly encapsulate phase-change material (PCM) into polymer filament for the purpose of 3D printing polymer heat exchangers capable of latent heat thermal energy storage and management. PCMs have the ability to absorb large amounts of latent heat while undergoing a solid-to-liquid phase change at a nearly constant temperature. Encapsulation or containment of PCMs is necessary to prevent leaking since the material continuously cycles between a liquid and a solid state. An organic-based PCM and high-density polyethylene (HDPE) were combined and extruded into a functional composite filament. For the first time, with the aid of a heated enclosure and HDPE build plates, it was demonstrated that these functional composite materials can be printed using fused filament fabrication (FFF). Printing HDPE is known to be difficult; however, based on what was observed in the current study, the PCM and HDPE composite was easier to print than pure HDPE. Thermal properties, such as latent heat of fusion, phase-change temperature, and thermal conductivity, of the composite filament and 3D printed samples were investigated and compared with compression-molded bulk material. Finally, the microstructures of the composite filament and 3D printed samples were visualized, and the basic structures of the HDPE and PCM within both the filament and 3D printed parts were clearly delineated.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Photo-actuators via epitaxial growth of microcrystal arrays in polymer membranes

Photomechanical crystals composed of three-dimensionally ordered and densely packed photochromes hold promise for high-performance photochemical actuators. However, bulk crystals with high structural ordering are severely limited in their flexibility, resulting in poor processibility and a tendency to fragment upon light exposure, while previous nano- or microcrystalline composites have lacked global alignment. Here we demonstrate a photon-fuelled macroscopic actuator consisting of diarylethene microcrystals in a polyethylene terephthalate host matrix. These microcrystals survive large deformations and show a high degree of three-dimensional ordering dictated by the anisotropic polyethylene terephthalate, which critically also has a similar stiffness. Overall, these ordered and compliant composites exhibit rapid response times, sustain a performance of over at least hundreds of cycles and generate work densities exceeding those of single crystals. In conclusion, our composites represent the state-of-the-art for photochemical actuators and enable properties unattainable by single crystals, such as controllable, reversible and abrupt jumping (photosalient behaviour).

36 MATERIALS SCIENCE↗
DOE OSTI2020

Influence of plasticizers on thermal and mechanical properties of biocomposite filaments made from lignin and polylactic acid for 3D printing

Polylactic acid (PLA) and organosolv lignin were mixed at different ratios and extruded to obtain PLA-lignin composite filaments. PLA was replaced with lignin up to 20 wt%. Two plasticizers (polyethylene glycol (PEG) 2000 and struktol TR451) were added in varying concentrations to enhance the properties of PLA_L20 (20% lignin in PLA) composite filaments. Furthermore, the effect of lignin in PLA, and PEG, and struktol in PLA_L20 composites was investigated via tensile test, differential scanning calorimetry, thermogravimetric analysis, scanning electron microscopy, Fourier transform infrared spectroscopy of the filaments, and dynamic mechanical analysis of 3D printed samples. A 2 wt% PEG was able to enhance both tensile stress and elongation at maximum load of PLA_L20 composite by 19% and 35%, respectively, whereas struktol TR451 was able to improve elongation at maximum load by 24%.

3D printing↗
NASA NTRS1992

Ni-H2 cell separator matrix engineering

This project was initiated to develop alternative separator materials to the previously used asbestos matrices which were removed from the market for health and environmental reasons. The objective of the research was to find a material or combination of materials that had the following characteristics: (1) resistant to the severe conditions encountered in Ni-H2 cells; (2) satisfactory electrical, electrolyte management, and thermal management properties to function properly; (3) environmentally benign; and (4) capable of being manufactured into a separator matrix. During the course of the research it was discovered that separators prepared from wettable polyethylene fibers along and in combination with potassium titanate pigment performed satisfactory in preliminary characterization tests. Further studies lead to the optimization of the separator composition and manufacturing process. Single ply separator sheets were manufactured with 100 percent polyethylene fibers and also with a combination of polyethylene fibers and potassium titanate pigment (PKT) in the ratio of 60 percent PKT and 40 percent fibers. A pilot paper machine was used to produce the experimental separator material by a continuous, wet laid process. Both types of matrices were produced at several different area densities (grams/sq m).

Scott, W. E.↗
DOE OSTI2023

Two-step conversion of polyethylene into recombinant proteins using a microbial platform

Background: The increasing prevalence of plastic waste combined with the inefficiencies of mechanical recycling has inspired interest in processes that can convert these waste streams into value-added biomaterials. To date, the microbial conversion of plastic substrates into biomaterials has been predominantly limited to polyhydroxyalkanoates production. Expanding the capabilities of these microbial conversion platforms to include a greater diversity of products generated from plastic waste streams can serve to promote the adoption of these technologies at a larger scale and encourage a more sustainable materials economy. Results: Herein, we report the development of a new strain of Pseudomonas bacteria capable of converting depolymerized polyethylene into high value bespoke recombinant protein products. Using hexadecane, a proxy for depolymerized polyethylene, as a sole carbon nutrient source, we optimized media compositions that facilitate robust biomass growth above 1 × 10 9 cfu/ml, with results suggesting the benefits of lower hydrocarbon concentrations and the use of NH 4 Cl as a nitrogen source. We genomically integrated recombinant genes for green fluorescent protein and spider dragline-inspired silk protein, and we showed their expression in Pseudomonas aeruginosa, reaching titers of approximately 10 mg/L when hexadecane was used as the sole carbon source. Lastly, we demonstrated that chemically depolymerized polyethylene, comprised of a mixture of branched and unbranched alkanes, could be converted into silk protein by Pseudomonas aeruginosa at titers of 11.3 ± 1.1 mg/L. Conclusion: This work demonstrates a microbial platform for the conversion of a both alkanes and plastic-derived substrates to recombinant, protein-based materials. The findings in this work can serve as a basis for future endeavors seeking to upcycle recalcitrant plastic wastes into value-added recombinant proteins.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS1991

An examination of the damage tolerance enhancement of carbon/epoxy using an outer lamina of spectra (R)

Low velocity instrumented impact testing was utilized to examine the effects of an outer lamina of ultra-high molecular weight polyethylene (Spectra) on the damage tolerance of carbon epoxy composites. Four types of 16-ply quasi-isotropic panels (0, +45, 90, -45) were tested. Some panels contained no Spectra, while others had a lamina of Spectra bonded to the top (impacted side), bottom, or both sides of the composite plates. The specimens were impacted with energies up to 8.5 J. Force time plots and maximum force versus impact energy graphs were generated for comparison purposes. Specimens were also subjected to cross-sectional analysis and compression after impact tests. The results show that while the Spectra improved the maximum load that the panels could withstand before fiber breakage, the Spectra seemingly reduced the residual strength of the composites.

Lance, D. G.↗
NASA NTRS2007

Development of Multifunctional Radiation Shielding Materials for Long Duration Human Exploration Beyond the Low Earth Orbit

One of the major challenges for long duration human exploration beyond the low Earth orbit and sustained human presence on planetary surfaces would be development of materials that would help minimize the radiation exposure to crew and equipment from the interplanetary radiation environment, This radiation environment consists primarily of a continuous flux of galactic cosmic rays (GCR) and transient but intense fluxes of solar energetic particles (SEP). The potential for biological damage by the relatively low percentage of high-energy heavy-ions in the GCR spectrum far outweigh that due to lighter particles because of their ionizing-power and the quality of the resulting biological damage. Although the SEP spectrum does not contain heavy ions and their energy range is much lower than that for GCRs, they however pose serious risks to astronaut health particularly in the event of a bad solar storm The primary purpose of this paper is to discuss our recent efforts in development and evaluation of materials for minimizing the hazards from the interplanetary radiation environment. Traditionally, addition of shielding materials to spacecrafts has invariably resulted in paying a penalty in terms of additional weight. It would therefore be of great benefit if materials could be developed not only with superior shielding effectiveness but also sufficient structural integrity. Such a multifunctional material could then be considered as an integral part of spacecraft structures. Any proposed radiation shielding material for use in outer space should be composed of nuclei that maximize the likelihood of projectile fragmentation while producing the minimum number of target fragments. A modeling based approach will be presented to show that composite materials using hydrogen-rich epoxy matrices reinforced with polyethylene fibers and/or fabrics could effectively meet this requirement. This paper will discuss the fabrication of such a material for a crewed vehicle. Ln addition, the capability of synthesizing radiation shielding materials for habitat structures primarily from Lunar or Martian in-situ resources will also be presented. Such an approach would significantly _reduce the cost associated with transportation of such materials and structures from earth. Results from radiation exposure measurements will be presented demonstrating the shielding effectiveness of the developed materials. Mechanical testing data will be discussed to illustrate that the specific mechanical properties of the developed composites are comparable to structural aluminum based alloys currently used for the space shuttle and space station.

Sen, S.↗
NASA NTRSDate not supplied

Process Development and Testing for Lunar Habitats

Non-metallic composites are appealing for Lunar habitats due to their low specific weight and contribution to passive radiation shielding. This application of composite materials presents notable challenges, however: flammability risks are higher due to elevated oxygen levels expected in habitat structures and absorbed radiation can cause damage long-term. The Materials and Processes Laboratory at Marshall Space Flight Center awarded funding for an internal research and development study which included fabrication and testing of composite materials for Lunar habitats. Composite layups used carbon fiber or ultra-high molecular weight polyethylene reinforcement and a variety of polymer matrices. Pre-impregnated fabric was autoclave cured; however, novel coatings were incorporated during select layups. Samples from each panel were used for screening-level flammability testing (ASTM D 2863) and combined vacuum ultraviolet and electron irradiation followed by tension testing (ASTM D5766). Two of the tested composite materials exceeded a 37% limiting oxygen index. Material property degradation for a 10 year simulated radiation dose was minimal in most cases.

manufacturing↗
NASA NTRS1982

Tribological characteristics of a composite total-surface hip replacement

Continuous fiber, woven E glass composite femoral shells having the same elastic properties as bone were fabricated. The shells were then encrusted with filled epoxy wear resistant coatings and run dry against ultrahigh molecular weight polyethylene acetabular cups in 42,000 and 250,000 cycle wear tests on a total hip simulator. The tribological characteristics of these continuous fiber particulate composite femoral shells articulating with ultrahigh molecular weight polyethylene acetabular cups were comparable to those of a vitallium ball articulating with an ultrahigh molecular weight polyethylene acetabular cup.

Jones, W. R., Jr.↗
DOE OSTI2022

Rossi-alpha Analysis of Thermal/Epithermal eXperiments Optimized for Polyethylene Thermal Neutron Scattering

Accurate nuclear data is the foundation for predictive simulations and design of new experimental in the nuclear community. The criticality safety community has particular interest in benchmarking assemblies with thermal neutron data. To address such needs the Nuclear Criticality Safety Program (NCSP) funded the Thermal/Epithermal eXperiments (TEX) campaigns that were to be completed between Lawrence Livermore National Laboratory (LLNL) and Los Alamos National Laboratory (LANL). Specifically, analysis of plutonium with a thermal neutron spectrum expands on previous work to help validate thermal scattering law data, which can have larger impacts in thermal applications. The first of these experiments were successfully conducted in 2018, but this paper will focus on the 2021 measurement focused on investigating the the thermal scattering law (TSL) for polyethylene. These experiments were successfully conducted at the National Criticality Experiments Research Center (NCERC) using the Planet vertical lift critical assembly machine. Polethylene plates were layered with trays of Zero Power Physics Reactor (ZPPR) 24 plates in a 12" by 12" square. The ZPPR plates were 2" by 3" by 0.125" bearing weapons grade plutonium. The polyethylene moderator was either 2" or 1.6875" thick. This work builds on the Rossi-alpha calculations done by McKenzie et al. for the same detector-assembly system and will only focus on the Rossi-alpha neutron noise method. This work will aim to further validate the results of the experiment through a novel neutron noise python package. Following similar methodology to the previous analysis, analysis of TEX evaluated the prompt neutron decay constant at delayed critical, $α_{DC}$ using Rossi-alpha for different polyethylene moderator thicknesses. These results will help improve understanding of TSL in critical experiments. Alpha (α), is the prompt neutron decay constant of the measured system and allows for the evaluation of a systems propensity to sustain fission chains via prompt neutrons. The single value description of the assemblies allow for comparison between experiments regardless of composition, geometry, and reflectors/moderators. Rossi-alpha measurements were performed on the polyethylene moderated TEX experiments to estimate $α_{DC}$.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
NASA NTRS2003

Molecular modeling of polymer composite-analyte interactions in electronic nose sensors

We report a molecular modeling study to investigate the polymer-carbon black (CB) composite-analyte interactions in resistive sensors. These sensors comprise the JPL electronic nose (ENose) sensing array developed for monitoring breathing air in human habitats. The polymer in the composite is modeled based on its stereoisomerism and sequence isomerism, while the CB is modeled as uncharged naphthalene rings with no hydrogens. The Dreiding 2.21 force field is used for the polymer, solvent molecules and graphite parameters are assigned to the carbon black atoms. A combination of molecular mechanics (MM) and molecular dynamics (NPT-MD and NVT-MD) techniques are used to obtain the equilibrium composite structure by inserting naphthalene rings in the polymer matrix. Polymers considered for this work include poly(4-vinylphenol), polyethylene oxide, and ethyl cellulose. Analytes studied are representative of both inorganic and organic compounds. The results are analyzed for the composite microstructure by calculating the radial distribution profiles as well as for the sensor response by predicting the interaction energies of the analytes with the composites. c2003 Elsevier Science B.V. All rights reserved.

NASA Center JPL↗
DOE OSTI2023

Polyester-based epoxy vitrimer integrating spent coffee ground as a natural filler

Coffee is a widely consumed beverage, but approximately 80% mass of coffee cherry is discarded as waste. Here, in this study, spent coffee grounds (SCG) were recycled and used as a natural filler in a polyester-based epoxy matrix made from reactions of diglycidyl ethers of Bisphenol A and polyethylene glycol with methyl nadic anhydride. The properties of SCG/epoxy composites with various SCG contents up to 40% w/w were evaluated using various techniques such as FT-IR spectroscopy, tensile testing, optical microscopy, differential scanning calorimetry, and rheology. The SCG filled polyester-based epoxy matrix demonstrated excellent dimensional stability and retained a permanently crosslinked network, but re-shaping was possible at ~150 °C through transesterification, which occurred due to a dynamic chain exchange reaction between the ester group of the epoxy matrix and the hydroxyl group of the SCG fillers. The transesterification also improved the interfacial adhesion between the matrix and SCG fillers, resulting in tensile strength of over 20 MPa and a modulus of around 2.5 GPa, even with high SCG contents up to 40% w/w. While neat, cured epoxy shows thermoset behavior, filling the matrix with SCG enables reforming and origami-inspired spontaneous change in shape.

42 ENGINEERING↗
DOE OSTI2023

Cycling of block copolymer composites with lithium-conducting ceramic nanoparticles

Solid polymer and perovskite-type ceramic electrolytes have both shown promise in advancing solid-state lithium metal batteries. Despite their favorable interfacial stability against lithium metal, polymer electrolytes face issues due to their low ionic conductivity and poor mechanical strength. Highly conductive and mechanically robust ceramics, on the other hand, cannot physically remain in contact with redox-active particles that expand and contract during charge-discharge cycles unless excessive pressures are used. To overcome the disadvantages of each material, polymer-ceramic composites can be formed; however, depletion interactions will always lead to aggregation of the ceramic particles if a homopolymer above its melting temperature is used. In this study, we incorporate Li 0.33 La 0.56 TiO 3 (LLTO) nanoparticles into a block copolymer, polystyrene- b -poly (ethylene oxide) (SEO), to develop a polymer-composite electrolyte (SEO-LLTO). TEMs of the same nanoparticles in polyethylene oxide (PEO) show highly aggregated particles whereas a significant fraction of the nanoparticles are dispersed within the PEO-rich lamellae of the SEO-LLTO electrolyte. We use synchrotron hard x-ray microtomography to study the cell failure and interfacial stability of SEO-LLTO in cycled lithium-lithium symmetric cells. Three-dimensional tomograms reveal the formation of large globular lithium structures in the vicinity of the LLTO aggregates. Encasing the SEO-LLTO between layers of SEO to form a “sandwich” electrolyte, we prevent direct contact of LLTO with lithium metal, which allows for the passage of seven-fold higher current densities without signatures of lithium deposition around LLTO. We posit that eliminating particle clustering and direct contact of LLTO and lithium metal through dry processing techniques is crucial to enabling composite electrolytes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗