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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

Study of advanced composite structural design concepts for an arrow wing supersonic cruise configuration

Based on estimated graphite and boron fiber properties, allowable stresses and strains were established for advanced composite materials. Stiffened panel and conventional sandwich panel concepts were designed and analyzed, using graphite/polyimide and boron/polyimide materials. The conventional sandwich panel was elected as the structural concept for the modified wing structure. Upper and lower surface panels of the arrow wing structure were then redesigned, using high strength graphite/polyimide sandwich panels, retaining the titanium spars and ribs from the prior study. The ATLAS integrated analysis and design system was used for stress analysis and automated resizing of surface panels. Flutter analysis of the hybrid structure showed a significant decrease in flutter speed relative to the titanium wing design. The flutter speed was increased to that of the titanium design by selective increase in laminate thickness and by using graphite fibers with properties intermediate between high strength and high modulus values.

Turner, M. J.↗
NASA NTRS1978

Study of advanced composite structural design concepts for an arrow wing supersonic cruise configuration, task 3

A structural design study was conducted to assess the relative merits of structural concepts using advanced composite materials for an advanced supersonic aircraft cruising at Mach 2.7. The configuration and structural arrangement developed during Task I and II of the study, was used as the baseline configuration. Allowable stresses and strains were established for boron and advanced graphite fibers based on projected fiber properties available in the next decade. Structural concepts were designed and analyzed using graphite polyimide and boron polyimide, applied to stiffened panels and conventional sandwich panels. The conventional sandwich panels were selected as the structural concept to be used on the wing structure. The upper and lower surface panels of the Task I arrow wing were redesigned using high-strength graphite polyimide sandwich panels over the titanium spars and ribs. The ATLAS computer system was used as the basis for stress analysis and resizing the surface panels using the loads from the Task II study, without adjustment for change in aeroelastic deformation. The flutter analysis indicated a decrease in the flutter speed compared to the baseline titanium wing design. The flutter analysis indicated a decrease in the flutter speed compared to the baseline titanium wing design. The flutter speed was increased to that of the titanium wing, with a weight penalty less than that of the metallic airplane.

Source record↗
DOE OSTI2020

Ultra-Light Hybrid Composite Door Design, Manufacturing and Demonstration

New Corporate Average Fuel Economy regulations require improved fuel efficiency of the future vehicle fleet. Weight reduction is key to achieving these targets. Replacing metallic body and chassis components with carbon fiber-reinforced composites offers the most weight reduction potential at up to 70%. Introduction of the BMW i3 and i8 in 2014 required mass production processes to meet 20,000+ units per year. Preforming with High Pressure Resin Transfer Molding has been implemented and meets rate, cost, and performance requirements. We will advance these technologies to develop an ultra-light driver’s side door for the vehicle with production rates of 40,000 units annually per plant in Detroit, Michigan. This project sought to employ a comprehensive systems approach for designing, manufacturing, and demonstrating an ultra-light hybrid composite automotive door. Composite structural components are integrated with other functional systems to reduce part count and full-system weight by a minimum of 42.5%. The approach will be demonstrated on a driver’s- side front door and will consider all fit, functional, safety, and cost requirements. These concepts will be evaluated using structural and crash simulations and linked to a manufacturing feasibility study, resulting in producible designs of an integrated door system. A cost model will evaluate part of the cost for the various designs and will ensure the cost target of less than $5 per pound of weight saved is met. Hybrid composites consisting of carbon, glass, and metal components will be included in our trade-off studies to satisfy these cost and performance goals.

02 PETROLEUM↗
DOE OSTI2020

Biodiesel production from engineered sugarcane lipids under uncertain feedstock compositions: Process design and techno-economic analysis

In this study, different process schemes were designed and evaluated for biodiesel production from engineered cane lipids with uncertain fatty acid compositions. Four different process schemes were compared under (i) thermal glycerolysis and (ii) enzymatic glycerolysis approaches. These schemes were based on the biodiesel yield and economic indicators such as the net present value (NPV) and the minimum selling price (MSP) of biodiesel. A scheme with polar lipid separation under thermal glycerolysis resulted in the maximum NPV ($\$96.5$ million) and minimum MSP ($\$1107$ /ton biodiesel), respectively. Through local sensitivity analysis, it was concluded that the cane lipid percentage is the most significant factor influencing process economics. A conjoint analysis of the lipid procurement price and cane lipid percent suggested that 15% cane lipids with a low lipid procurement price ($\$0.536$ /kg) results in a positive NPV. When the cane lipid price is higher (> $\$0.80$ /kg), a 20% lipid content should be considered to achieve a positive NPV. At 20% cane lipids, the worst-case and best-case scenarios were evaluated by analyzing the interplay of the three most important parameters, Here, the best-case scenario revealed that the minimum NPV under any process scheme could yield more than $\$100$ million (or MSP: $\$0.80$ /L), and the worst-case analysis showed that losses incurred by the plant could be as high as 80 million (MSP: $\$1.36$ /L). A Monte Carlo simulation indicated that there is a 70% chance of the plant being profitable (NPV > 0).

09 BIOMASS FUELS↗
DOE OSTI2020

Data from Biodiesel Production from Engineered Sugarcane Lipids under Uncertain Feedstock Compositions: Process Design and Techno-Economic Analysis

In this study, different process schemes were designed and evaluated for biodiesel production from engineered cane lipids with uncertain fatty acid compositions. Four different process schemes were compared under (i) thermal glycerolysis and (ii) enzymatic glycerolysis approaches. These schemes were based on the biodiesel yield and economic indicators such as the net present value (NPV) and the minimum selling price (MSP) of biodiesel. A scheme with polar lipid separation under thermal glycerolysis resulted in the maximum NPV ($96.5 million) and minimum MSP ($1107/ton biodiesel), respectively. Through local sensitivity analysis, it was concluded that the cane lipid percentage is the most significant factor influencing process economics. A conjoint analysis of the lipid procurement price and cane lipid percent suggested that 15% cane lipids with a low lipid procurement price ($0.536/kg) results in a positive NPV. When the cane lipid price is higher (>$0.80/kg), a 20% lipid content should be considered to achieve a positive NPV. At 20% cane lipids, the worst-case and best-case scenarios were evaluated by analyzing the interplay of the three most important parameters, The best-case scenario revealed that the minimum NPV under any process scheme could yield more than $100 million (or MSP: $0.80/L), and the worst-case analysis showed that losses incurred by the plant could be as high as $80 million (MSP: $1.36/L). A Monte Carlo simulation indicated that there is a 70% chance of the plant being profitable (NPV > 0).

Conversion↗
DOE OSTI2024

Chemical Framework to Design Linear-like Relaxors toward Capacitive Energy Storage

ABO 3 -type perovskite relaxor ferroelectrics (RFEs) have emerged as the preferred option for dielectric capacitive energy storage. However, the compositional design of RFEs with high energy density and efficiency poses significant challenges owing to the vast compositional space and the absence of general rules. Here, we present an atomic-level chemical framework that captures inherent characteristics in terms of radius and ferroelectric activity of ions. By categorizing A/B-site ions as host framework, rattling, ferroelectrically active, and blocking ions and assembling these four types of ions with specific criteria, linear-like relaxors with weak locally correlated and highly extendable unit-cell polarization vectors can be constructed. As example, we demonstrate two new compositions of Bi 0.5 K 0.5 TiO 3- based and BaTiO 3- based relaxors, showing extremely high recoverable energy densities of 17.3 and 12.1 J cm –3 , respectively, both with a high efficiency of about 90%. Further, the role of different types of ions in forming heterogeneous polar structures is identified through element-specific local structure analysis using neutron total scattering combined with reverse Monte Carlo modeling. Further, our work not only opens up new avenues toward rational compositional design of high energy storage performance lead-free RFEs but also sheds light on atomic-level manipulation of functional properties in compositionally complex ferroelectrics.

25 ENERGY STORAGE↗
NASA NTRS1992

Microstructural design of fiber composites

The optimum performance design of composite microstructures is discussed. The forces driving progress in fiber composites are examined, and recent developments in the mechanics of laminated composites are surveyed, emphasizing thick laminates, hygrothermal effects, and thermal transient effects. The strength of continuous-fiber composites is discussed, presenting analyses of local load redistribution due to fiber breakages and treatments of statistical tensile strength theories. Modes of failure of laminated composites are examined. Elastic, physical, and viscoelastic properties as well as the strength and fracture behavior of short-fiber composites are studied, and it is shown how the performance of composites can be controlled by selecting material systems and their geometric distributions. 2D textile structural composites based on woven, knitted, and braided preforms are considered, and techniques for analyzing and modeling the thermomechanical behavior of 2D textile composites are presented. Recent developments in the processing of 3D textile preforms are introduced and the processing-microstructure relationship is demonstrated. Finite elastic deformation of flexible composites is addressed.

Chou, Tsu-Wei↗
NASA NTRS1980

Preliminary design of composite wing-box structures for global damage tolerance

A procedure is presented that incorporates the influence of potential global damage conditions into the design process for minimum-mass wing-box structures. The procedure is based on mathematical-programming optimization techniques. Material-strength, minimum-gage, and panel-buckling constraints are introduced by penalty functions, and Newton's method with approximate second derivatives of the penalty terms is used as the search algorithm to obtain minimum-mass designs. A potential global damage condition is represented by a structural model with the damaged components removed. Example minimum-mass designs are obtained that simultaneously satisfy the constraints of the damaged and undamaged configurations of both graphite-epoxy and aluminum wing-box structural models. These examples are designed with and without the influence of potential damage conditions, and results indicate that for equal mass cases the residual strength of a damaged structure is higher when the influence of potential damage is properly included in the design from the outset. Results of these examples also identify the minimum structural mass increase required to increase residual strength levels.

Starnes, J. H., Jr.↗
NASA NTRS1999

A Method for Calculating Strain Energy Release Rates in Preliminary Design of Composite Skin/Stringer Debonding Under Multi-Axial Loading

Three simple procedures were developed to determine strain energy release rates, G, in composite skin/stringer specimens for various combinations of unaxial and biaxial (in-plane/out-of-plane) loading conditions. These procedures may be used for parametric design studies in such a way that only a few finite element computations will be necessary for a study of many load combinations. The results were compared with mixed mode strain energy release rates calculated directly from nonlinear two-dimensional plane-strain finite element analyses using the virtual crack closure technique. The first procedure involved solving three unknown parameters needed to determine the energy release rates. Good agreement was obtained when the external loads were used in the expression derived. This superposition technique was only applicable if the structure exhibits a linear load/deflection behavior. Consequently, a second technique was derived which was applicable in the case of nonlinear load/deformation behavior. The technique involved calculating six unknown parameters from a set of six simultaneous linear equations with data from six nonlinear analyses to determine the energy release rates. This procedure was not time efficient, and hence, less appealing. A third procedure was developed to calculate mixed mode energy release rates as a function of delamination lengths. This procedure required only one nonlinear finite element analysis of the specimen with a single delamination length to obtain a reference solution for the energy release rates and the scale factors. The delamination was extended in three separate linear models of the local area in the vicinity of the delamination subjected to unit loads to obtain the distribution of G with delamination lengths. This set of sub-problems was Although additional modeling effort is required to create the sub- models, this local technique is efficient for parametric studies.

Krueger, Ronald↗
DOE OSTI2023

Compositionally complex perovskite oxides: Discovering a new class of solid electrolytes with interface-enabled conductivity improvements

Compositionally complex ceramics (CCCs), including high-entropy ceramics, offer a vast, unexplored compositional space for materials discovery. Herein, we propose and demonstrate strategies for tailoring CCCs via a combination of non-equimolar compositional designs and control of grain boundaries (GBs) and microstructures. Using oxide solid electrolytes for all-solid-state batteries as an example, we have discovered a class of compositionally complex perovskite oxides (CCPOs) with improved lithium ionic conductivities beyond the limit of conventional doping. For example, we demonstrate that the ionic conductivity can be improved by >60% in (Li 0.375 Sr 0.4375 )(Ta 0.375 Nb 0.375 Zr 0.125 Hf 0.125 )O 3-δ compared with the (Li 0.375 Sr 0.4375 )(Ta 0.75 Zr 0.25 )O 3-δ (LSTZ) baseline. Furthermore, the ionic conductivity can be improved by another >70% via quenching, achieving >270% of the LSTZ. Notably, we demonstrate GB-enabled conductivity improvements via both promoting grain growth and altering GB structures through compositional designs and processing. In a broader perspective, this work suggests new routes for discovering and tailoring CCCs for energy storage and many other applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Physically constrained 3D diffusion for inverse design of fiber-reinforced polymer composite materials

Designing fiber-reinforced polymer composites (FRPCs) with a tailored nonlinear stress-strain response is crucial for applications such as energy absorption in crash structures, flexible robotics, and impact-resistant protective gear. However, the inherent complexities of composite materials and the multitude of parameters involved, render traditional design and optimization methods inadequate for achieving effective inverse design of composites. In this paper, we present an AI-based inverse design framework that effectively and efficiently generates FRPCs with targeted nonlinear stress-strain responses. We introduce a physically constrained diffusion model (PC3D_Diffusion) capable of managing the complexities of composite materials and producing detailed, high-quality designs. We propose a loss-guided, learning-free approach to generate physically feasible microstructure designs by explicitly enforcing physical constraints during the generation process. For training purposes, 1.35 million FRPC samples were created, and their corresponding stress-strain curves were computed using established physics-based computational models. The results show that PC3D_Diffusion consistently generates high-quality designs with tailored mechanical behaviors, while guaranteeing compliance with the physical constraints. PC3D_Diffusion advances FRPC inverse design and may facilitate the inverse design of other 3D materials, offering potential applications in industries reliant on materials with custom mechanical properties.

Xu, Pei [Clemson Univ., SC (United States)]↗
NASA NTRS2010

Determining Shear Stress Distribution in a Laminate

A "simplified shear solution" method approximates the through-thickness shear stress distribution within a composite laminate based on an extension of laminated beam theory. The method does not consider the solution of a particular boundary value problem; rather, it requires only knowledge of the global shear loading, geometry, and material properties of the laminate or panel. It is thus analogous to lamination theory in that ply-level stresses can be efficiently determined from global load resultants at a given location in a structure and used to evaluate the margin of safety on a ply-by-ply basis. The simplified shear solution stress distribution is zero at free surfaces, continuous at ply boundaries, and integrates to the applied shear load. The method has been incorporated within the HyperSizer commercial structural sizing software to improve its predictive capability for designing composite structures. The HyperSizer structural sizing software is used extensively by NASA to design composite structures. In the case of through-thickness shear loading on panels, HyperSizer previously included a basic, industry-standard, method for approximating the resulting shear stress distribution in sandwich panels. However, no such method was employed for solid laminate panels. The purpose of the innovation is to provide an approximation of the through-thickness shear stresses in a solid laminate given the through-thickness shear loads (Qx and Qy) on the panel. The method was needed for implementation within the HyperSizer structural sizing software so that the approximated ply-level shear stresses could be utilized in a failure theory to assess the adequacy of a panel design. The simplified shear solution method was developed based on extending and generalizing bi-material beam theory to plate-like structures. It is assumed that the through-thickness shear stresses arise due to local bending of the laminate induced by the through-thickness shear load, and by imposing equilibrium both vertically and horizontally, the through-thickness shear stress distribution can be calculated. The resulting shear stresses integrate to the applied shear load, are continuous at the ply interfaces, and are zero at the laminate-free surfaces. If both Qx and Qy shear loads are present, it is assumed that they act independently and that their effects can be superposed. The calculated shear stresses can be rotated within each ply to the principal material coordinates for use in a ply-level failure criterion. The novelty of the simplified shear solution method is its simplicity and the fact that it does not require solution of a particular boundary value problem. The advantages of the innovation are that an approximation of the though-thickness shear stress distribution can be quickly determined for any solid laminate or solid laminate region within a stiffened panel.

Bednarcyk, Brett A.↗
DOE OSTI2026

Supramolecular Assembly of Multielement Ribbon-like Structures Derived from Halide Perovskites

Halide perovskites are crucial materials with broad applications owing to their exceptional optoelectronic properties. Vacancy-ordered double perovskites, featuring highly tunable transition metal sites, enable controllable optoelectronic properties through multielement compositional design. Here, in this study, we introduced 18-crown-6 into the vacancy-ordered double perovskites system and developed two-dimensional ribbon-like single crystals (18C6@K) 2 {PtSnTeIrRe} 1 Cl 6 via an antisolvent supramolecular assembly method, demonstrating morphology modulation through multielement composition design. The crystals crystallize in the centrosymmetric space group $P\bar{1}$. The dumbbell-shaped structural units (crown ether@A)2MX6 pack along a and b axes to form a 2-dimensional (2D) monolayer, and these monolayers further stack along the c axis to generate the ribbon-like single crystals. Energy-dispersive X-ray spectroscopy (EDX) qualitatively confirmed the uniform distribution of the five transition metals throughout the crystal, while inductively coupled plasma atomic emission spectroscopy (ICP–AES) quantitatively verified their atomic ratios. We further investigated the origin of the morphology, distinct from the previously reported cube-like single crystals with the $R\bar{3}$ space group. When acetonitrile was used as the solvent, three-dimensional crystals with $R\bar{3}$ symmetry were obtained, whereas dimethylformamide (DMF) was essential for forming two-dimensional ribbon-like single crystals. The essential role of DMF could be ascribed to its capability to maintain a higher concentration of the building blocks. Moreover, Ir 4+ and Pt 4+ cations also played critical roles in inducing the two-dimensional ribbon-like morphology. The three-element (18C6@K) 2 {PtSnTe}1Cl 6 single crystals exhibited bright yellow emission under 375 nm laser excitation, demonstrating the tunability of optoelectronic properties of this class of material.

Zhu, Heqing [University of California, Berkeley, C↗
NASA NTRS1976

Optimum design of composite laminates with thermal effects

An analytical approach to determine an optimum laminate for a variety of thermal and mechanical loading combinations is presented. The analysis is performed for a linear elastic material under static mechanical and uniform thermal loadings. The problem is restricted to a unit width and length laminate with angle orientations resulting in an orthotropic, symmetric, and balanced configuration. An objective function defining total strain energy, is formulated and an optimum laminate design determined subject to constraints on stiffness, average coefficient of thermal expansion, and strength. The objective function is formulated in terms of the orientation angles, number of plies, and material properties. The method presented has, in varying degrees, shown that the design of a laminate can be accomplished using strain energy minimization as the primary criteria. The results of various combinations of applied constraints in the optimized design process are presented and discussed.

Markham, L. R.↗
NASA NTRS1987

Innovative design of composite structures: Use of curvilinear fiber format to improve structural efficiency

To increase the effectiveness and efficiency of fiber-reinforced materials, the use of fibers in a curvilinear rather than the traditional straightline format is explored. The capacity of a laminated square plate with a central circular hole loaded in tension is investigated. The orientation of the fibers is chosen so that the fibers in a particular layer are aligned with the principle stress directions in that layer. Finite elements and an iteration scheme are used to find the fiber orientation. A noninteracting maximum strain criterion is used to predict load capacity. The load capacities of several plates with different curvilinear fibers format are compared with the capacities of more conventional straightline format designs. It is found that the most practical curvilinear design sandwiches a group of fibers in a curvilinear format between a pair of +/-45 degree layers. This design has a 60% greater load capacity than a conventional quasi-isotropic design with the same number of layers. The +/-45 degree layers are necessary to prevent matrix cracking in the curvilinear layers due to stresses perpendicular to the fibers in those layers. Greater efficiencies are achievable with composite structures than now realized.

Hyer, M. W.↗
NASA NTRS1998

Infrastructure Retrofit Design via Composite Mechanics

Select applications are described to illustrate the concept for retrofitting reinforced concrete infrastructure with fiber reinforced plastic laminates. The concept is first illustrated by using an axially loaded reinforced concrete column. A reinforced concrete arch and a dome are then used to illustrate the versatility of the concept. Advanced methods such as finite element structural analysis and progressive structural fracture are then used to evaluate the retrofitting laminate adequacy. Results obtains show that retrofits can be designed to double and even triple the as-designed load of the select reinforced concrete infrastructures.

Chamis, Christos, C.↗
NASA NTRS1990

Innovative design of composite structures: The use of curvilinear fiber format to improve buckling resistance of composite plates with central circular holes

The gains in buckling performance are explored that can be achieved by deviating from the conventional straightline fiber format and considering the situation whereby the fiber orientation in a layer, or a group of layers, can vary from point to point. The particular situation studied is a simply supported square plate with a centrally located hole loaded in compression. By using both a sensitivity analysis and a gradient-search technique, fiber orientation in a number of regions of the plate are selected so as to increase the buckling load relative to baseline straightline designs. The sensitivity analysis is used to determine which regions of the plate have the most influence on buckling load, and the gradient search is used to find the design that is believed to represent the absolute maximum buckling load for the conditions prescribed. Convergence studies and sensitivity of the final design are discussed. By examining the stress resultant contours, it is shown how the curvilinear fibers move the load away from the unsupported hole region of the plate to the supported edges, thus increasing the buckling capacity. The tensile capacity of the improved buckling design is investigated, and it is shown that both tensile capacity and buckling capacity can be improved with the curvilinear fiber concept.

Hyer, M. W.↗