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At least 109 records · Page 6

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NASA NTRS1991

A simulation study of turbofan engine deterioration estimation using Kalman filtering techniques

Deterioration of engine components may cause off-normal engine operation. The result is an unecessary loss of performance, because the fixed schedules are designed to accommodate a wide range of engine health. These fixed control schedules may not be optimal for a deteriorated engine. This problem may be solved by including a measure of deterioration in determining the control variables. These engine deterioration parameters usually cannot be measured directly but can be estimated. A Kalman filter design is presented for estimating two performance parameters that account for engine deterioration: high and low pressure turbine delta efficiencies. The delta efficiency parameters model variations of the high and low pressure turbine efficiencies from nominal values. The filter has a design condition of Mach 0.90, 30,000 ft altitude, and 47 deg power level angle (PLA). It was evaluated using a nonlinear simulation of the F100 engine model derivative (EMD) engine, at the design Mach number and altitude over a PLA range of 43 to 55 deg. It was found that known high pressure turbine delta efficiencies of -2.5 percent and low pressure turbine delta efficiencies of -1.0 percent can be estimated with an accuracy of + or - 0.25 percent efficiency with a Kalman filter. If both the high and low pressure turbine are deteriorated, the delta efficiencies of -2.5 percent to both turbines can be estimated with the same accuracy.

Lambert, Heather H.↗

NASA NTRS1991

A special purpose silicon compiler for designing supercomputing VLSI systems

Design of general/special purpose supercomputing VLSI systems for numeric algorithm execution involves tackling two important aspects, namely their computational and communication complexities. Development of software tools for designing such systems itself becomes complex. Hence a novel design methodology has to be developed. For designing such complex systems a special purpose silicon compiler is needed in which: the computational and communicational structures of different numeric algorithms should be taken into account to simplify the silicon compiler design, the approach is macrocell based, and the software tools at different levels (algorithm down to the VLSI circuit layout) should get integrated. In this paper a special purpose silicon (SPS) compiler based on PACUBE macrocell VLSI arrays for designing supercomputing VLSI systems is presented. It is shown that turn-around time and silicon real estate get reduced over the silicon compilers based on PLA's, SLA's, and gate arrays. The first two silicon compiler characteristics mentioned above enable the SPS compiler to perform systolic mapping (at the macrocell level) of algorithms whose computational structures are of GIPOP (generalized inner product outer product) form. Direct systolic mapping on PLA's, SLA's, and gate arrays is very difficult as they are micro-cell based. A novel GIPOP processor is under development using this special purpose silicon compiler.

Venkateswaran, N.↗

NASA NTRS2000

Electrospraying and Electrospinning of Polymers for Biomedical Applications. Poly(Lactic-Co-Glycolic Acid) and Poly(Ethylene-Co-Vinylacetate)

Significant opportunities exist for the processing of polymers (homopolymers and blends) using electric fields. Specific attention is given here to electrospinning, but we note that electroaerosol formation and field-modulated film casting represent additional processing options. Of particular interest is the ability to generate polymer fibers of sub-micron dimensions using electrospinning, down to about 0.05 microns (50 nm), a size range that has been traditionally difficult to access. In our work, poly(lactic-co-glycolic acid), PLA/PGA, poly(lactic acid) PLA, and poly(ethylene-co-vinylacetate) (PEVA) have been deposited from solutions in methylene chloride or chloroform by electrospraying or electrospinning to afford morphologically tailored materials for tissue engineering and related applications. Low solution concentrations tend to favor electrostatic spraying ('electro-aerosolization') while higher concentrations lead to spinning on fibrous mats. Preliminary observations of muscle cell growth on PLA electrospun mats are reported.

Stitzel, Joel D.↗

NASA NTRS2005

Processing and Synthesis of Pre-Biotic Chemicals in Hypervelocity Impacts

Hypervelocity impacts (HVIs) may have played a significant role in establishing the initial organic inventory for pre-biotic chemistry on the Earth and other planetary bodies. In addition to the delivery of organic compounds intact to planetary surfaces, generally at velocities below approx.20 km/s, HVIs also enable synthesis of new molecules. The cooling post-impact plasma plumes of HVIs in the interstellar medium (ISM), the protosolar nebula (PSN), and the early solar system comprise pervasive conditions for organic synthesis. Such plasma synthesis (PS) can operate over many length scales (from nm-scale dust to planets) and energy scales (from molecular rearrangement to atomization and recondensation). HVI experiments with the flexibility to probe the highest velocities and distinguish synthetic routes are a high priority to understand the relevance of PS to exobiology. We describe here recent studies of PS at small spatial scales and extremely high velocities with pulsed laser ablation (PLA). PLA can simulate the extreme plasma conditions generated in impacts of dust particles at speeds of up to 100 km/s or more. When applied to carbonaceous solids, new and pre-biotically relevant molecular species are formed with high efficiency [1,2].

Brickerhoff, W. B.↗

NASA NTRSDate not supplied

Space Launch System (SLS) Human Factors Engineering Modeling & Analysis

The Human Systems Integration & Engineering (HSI&E) team at NASA’s Marshall Space Flight Center (MSFC) strives to advocate for the humans in the loop of Space Launch System’s (SLS) ground operations. Using assessment methods like human simulation, virtual reality, and physical mockups, both flight hardware and ground support equipment (GSE) are evaluated for human integration. Those ranging from 5th percentile female (approximately 5’2” tall) to 95th percentile male (approximately 6’2” tall) should be able to perform all SLS stacking operations. Operations include element physical mates, element electrical mates, and testing activities. The primary human simulation software used is Process Simulate Human (PSH) made by Siemens. This software supplies highly accurate human manikins that can interact with CAD models. PSH was used to evaluate the Transportation and Integration Platform’s (TIP) side opening that was designed for access to the Payload Adapter (PLA) cables. Technicians will need to access these cables for testing purposes before element stacking at Kennedy Space Center (KSC). After performing an analysis in PSH using the TIP side opening, it was found that neither a 5th percentile female or a 95th percentile male could perform the task as the designers had intended. There is a C-beam that blocks access to the cables (both physically and visually). An alternative analysis was performed using PSH to look at another access point to the PLA cables. Although this method would disrupt already established procedures and produce more work, the designers confirmed it was an option. Instead of technicians accessing the cables through the side opening in the TIP, a human simulation was performed for going through a panel opening in the bottom of the TIP. This method requires removal of a TIP panel and a stepladder of at least 36 inches for a 5th percentile female to access the cables.

human factors↗

DOE OSTI2022

ELASTOMERIC MICROVASCULAR SELF-HEALING MATERIALS

Damaged elastomeric diaphragms within pneumatic controllers used in the oil and gas industry lead to an unintended release of methane. Self-healing microvascular materials capable of healing various types of damage have been fabricated. These microvascular materials are designed to replace currently available commercial diaphragms found in pneumatic controllers and provide a solution to reduce unintended methane leaks. Poly(dimethylsiloxane) (PDMS) was used as the main matrix material, with additional testing conducted on polyurethane and flexibilised epoxy materials. Microvascular networks were implemented into the elastomeric membranes to act as ves- sels to deliver healing agents to the damaged areas. The complex, interdigitated channel networks were created using a 3D printed custom compounded filament composed of polylactic acid (PLA) and tin(II) oxalate. Two-part liquid casting polymers were poured around the channels into a mould to create samples with the scaffolding of the microvascular channels intact. Hollow microvascular networks were created by placing the samples within a vacuum oven at 250◦C which causes the thermal depolymerisation of PLA into its gaseous monomers. The manufactured materials were placed in test stands and pressurized using nitrogen gas to determine their healing and mechanical behaviour. Self-healing behaviour was demonstrated using PDMS matrix materials and healing chemistries within a pressure test cell. This test cell was designed to detect any damage to a sample by record- ing an outlet pressure. Damages including puncture holes, diagonal cuts and star-shaped central iv cuts were applied to the samples and a reduction in the outlet pressure was recorded for all sam- ples. A variation in channel spacing and diameter was studied to determine the optimal design of the microvascular network for self-healing performance. The mechanical performance of elastomeric membrane materials within a diaphragmatic pressurised stand was observed. Deformations and strains around the channels and channel inter- sections at the midplane of the materials were recorded using digital image correlation. Normal stresses were calculated using Hooke’s law and the material properties of the PDMS matrix. A reduction in leak rate, implying the success of self-healing, was recorded within manu- factured diaphragm samples tested within a commercial valve. PDMS is the favourable material when compared to polyurethane and flexibilised epoxy for creating

03 NATURAL GAS↗

DOE OSTI2024

Improving the Recyclability of Polymer Composites With Cellulose Nanofibrils

Cellulose nanofibers (CNFs) have been widely studied for their reinforcing potential in high-performance composites. While there are numerous publications on CNF-reinforced composites in a variety of polymer matrices, few have considered the recyclability of such thermoplastic composites and whether the incorporation of CNFs deteriorates or improves their performance upon reprocessing. In this study, two thermoplastic resins, poly(lactic acid) (PLA), and glycol-modified polyethylene terephthalate (PETg), were prepared with CNF reinforcement and thermomechanically recycled to investigate the effect of CNF inclusion on the composite properties after reprocessing as well as their effect on the composites’ number of useful life cycles. Additionally, changes in mechanical, thermal, rheological, molecular, and microstructural properties of the composites and/or base resins were monitored as a function of cycle numbers. As is typical, the polymers’ molecular weight and mechanical performance deteriorated with continued processing. However, the addition of spray dried CNF was found to better maintain the mechanical performance of both polymers throughout multiple recycling steps as compared to neat samples. For example, the tensile strength of PETg with 20 wt% CNF after 6 processing cycles was found to exceed that of virgin neat PETg, and higher loadings of CNF were found to preserve a higher yield strength during multiple rounds of reprocessing compared to PETg composites with lower CNF loadings. Ultimately this study indicates that the addition of CNF to some thermoplastic materials can increase both their sustainability by offsetting the use of high-embodied energy resins and their circularity by enabling performance retention over more use cycles.

42 ENGINEERING↗

DOE OSTI2025

Influence of build direction on the fracture mechanism of 3D printed octet lattices

Here, we investigate the effects of 3D printing build directions on the fracture properties of octet lattice metamaterials made of polylactic acid (PLA) and how these effects vary with the relative density of the lattices. Single-edge notch bend samples are 3D printed in two orthogonal build directions at various relative densities. Our results show that the work of fracture for octet lattices with build directions parallel to the crack plane is significantly higher than those with build directions perpendicular to the crack plane. We also observed that the ratio of specific work of fracture between the two build directions remains nearly constant across different relative densities. In contrast, the ratio of peak load between the two build directions decreases as relative density increases. Furthermore, the build direction dictates the fracture mechanism. While the perpendicular build direction predominantly results in a brittle (mode I) fracture, the parallel build direction leads to a complex, delamination-dominated (mode II type) fracture. This phenomenon is largely governed by the weak interfaces formed between the printed layers and their interaction with the lattice geometry. These results reveal that the build direction governs the fracture mechanism and work of fracture of these lattice metamaterials and is therefore an important design consideration.

3D printed PLA↗

DOE OSTI2022

Impact of biomass ash content on biocomposite properties

Owing to its low cost and sustainable nature, lignocellulosic biomass has been utilized for reinforcing polymers, but it is crucial to understand the impact of high-ash concentrations in biomass on composite strength and processing. Biomass is not only desirable for biofuel production but could also have a strong market, if high-ash biomass is acceptable, for biocomposites. In this work, natural fibers (switchgrass and corn stover) were used to reinforce polylactic acid (PLA) to produce biocomposites. Natural fibers were pretreated to obtain fibers that contain different percentages of ash. The mechanical properties (such as Young's modulus, tensile strength, failure strain, storage modulus) of corn stover/PLA composites remained largely unaffected by the ash concentration of the biomass fibers, despite the large range of ash contents (2.2–11.9 wt%). Furthermore, the tensile strengths of switchgrass/PLA composites were slightly negatively affected by the ash concentration of the switchgrass fibers (0.7–2.1 wt%). Both the switchgrass/PLA and the corn stover/PLA composites exhibited a high-enough tensile strength (49–57 MPa) and suitable complex viscosity (2.0–7.0 kPa·s at the frequency of 3.2 rad/s). They are expected to be 3D-printable through an extrusion-based additive manufacturing process.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Effects of PLA/PHB Blend Ratio and Wood Flour Loading on the Melt Rheology and Thermomechanical Properties of Biobased Polymer Composites

The development of sustainable, biobased polymer composites is crucial for reducing supply chain dependence on fossil fuels. A major challenge lies in understanding and predicting the processability of these sustainable material alternatives, which directly impacts large-scale manufacturing. Here, this study systematically investigates the effect of poly(lactic acid) (PLA)/polyhydroxybutyrate (PHB) blend ratios and wood flour (WF) loadings on the thermal, rheological, and mechanical properties of the composites. Composites were prepared via melt compounding and characterized by using differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), oscillatory shear melt rheology, tensile testing, and scanning electron microscopy. Results showed that increasing the PHB content lowered the glass transition temperature, while higher PHB and WF loadings decreased thermal stability. Complex viscosity decreased with increasing PHB in 0 and 10% WF, whereas it increased in 20% and 30% WF for PHB-rich blends (80/20 and 70/30 PLA/PHB) due to stronger filler interactions with flexible PHB chains. At 30% WF, PHB-containing composites also showed elastic dominance with G′ higher than G″. This behavior was confirmed by van Gurp–Palmen plots, where the phase angle decreased with increasing PHB and WF loadings. WF addition also shifted Cole–Cole plots away from semicircular terminal relaxation, while time–temperature superposition validity was maintained, confirming that polymer chain dynamics continue to dominate melt behavior. Young’s modulus increased with WF loading, while tensile strength and toughness decreased due to weaker interfacial adhesion between the matrix and the filler. Interestingly, 10% WF systems containing PHB exhibited the highest toughness among all of the filled systems, indicating synergistic reinforcement from WF fillers and PHB-induced ductility. Overall, melt rheology effectively captured the internal structure and stiffness of the composites as the formulation changed, reinforcing the concept that the PLA/PHB ratio and WF content can be tuned to adjust melt elasticity and balance mechanical property trade-offs for targeted applications.

melt rheology↗

DOE OSTI2025

Self-assembly of wood-based shape memory composites triggered by solar-thermal energy

Transporting and assembling large, complex structures poses significant challenges due to their size, geometry, and cost. Additionally, the installation sites are often inaccessible or hazardous for humans, necessitating self-assembling capabilities in these structures. To mitigate these challenges, we propose using 3D printing materials with shape memory effect (SME) for both transport and construction. This approach involves developing 3D modular components into flat sheets for easier transportation, and then self-assembling into 3D structures on-site using solar energy. To gain a deeper understanding of the factors influencing material memory performance, we have chosen a composite PLA/WF, which is polylactic acid (PLA) with 20 wt% wood flour (WF) for this purpose, leveraging its high tensile modulus at 0.966 GPa, low cost, and sustainability. Printed shapes with this material can maintain a recovery ratio over 90% after 3 cycles. While traditional composites fillers (e.g. glass or carbon fiber) are added to enhance mechanical and thermal properties, the addition of bio-based fillers like WF accomplish similar goals without compromising sustainability. We conducted multiple experiments to demonstrate how environmental conditions (i.e. temperature) maximize the material’s SME. Although still at an early stage, this study provides initial insights into bridging the gap between the small-scale nature of shape memory polymers (SMPs) and their potential for large-scale additive manufacturing, addressing a critical need for efficient and sustainable construction. In the long term, we hope our study contributes to the design vision of utilizing SMPs for transportation, assembly, and deployment of complex structures, providing a new pathway for sustainable construction and transportation of large-scale structures to hard-to-access locations such as disaster-affected areas and remote deserts, etc.

4D printing↗

DOE OSTI2024

Epoxy Coating of Biofiber: An Effective Modifier of Biofiber Physical and Flow Properties for Improved Tensile Behavior of Biofiber-Reinforced Biocomposite

Biocomposites combine renewable, plant-based fibers with degradable polymers and are an attractive option for sustainable, lightweight, and cost-effective materials with a low carbon footprint, especially for large-scale additive manufacturing. One of the major challenges in the widespread adoption of biocomposites is that their mechanical performance is significantly inferior to that of synthetic composites. Surface treatment is a common and effective technique to improve the mechanical properties of the biofibers used in biocomposites. This study aims to investigate the physical and flow properties of surface-treated biofibers, as well as the tensile properties of their PLA-based biocomposite, to gain insights into how surface treatment changes the fiber‘s characteristics and biocomposite‘s mechanical properties. Surface treatment was created using a two-component epoxy system by reacting poly(bisphenol A-co-epichlorohydrin) glycidyl end-capped (PBG) and dicyandiamide (DICY). The treatment was tested on two different biofibers (loblolly pine and corn stover fibers) with three different PBG/DICY molar ratios (0.25, 0.5, and 2). Results showed that surface-treated fibers improved the tensile strength and Young‘s modulus of the biocomposites. Loblolly pine biocomposites from fibers treated with a PBG/DICY ratio of 0.25 exhibited the best tensile properties. The surface treatment resulted in a more loosely dispersed fiber bulk structure, as evidenced by less fiber agglomeration into smaller particle sizes, higher fiber sphericity, and lower loose bulk density. This can enhance stress distribution and the overall mechanical performance of the biocomposites. Additionally, surface-treated fibers exhibited better dynamic flow properties.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Microporous structure in silicone polymers with polylactic acid and polyethylene glycol microspheres: Synthesis and characterization

Porosity in polymer parts could improve mechanical properties while reducing weight and density. Individual pores must be small enough that bulk mechanical properties are retained but significant enough to reduce the density of the material. Filler materials can be incorporated into polymer matrices and removed to create voids. Here, this paper focuses on creating spherical pores in silicone matrices by inserting and removing core materials or fillers during post-cure. A method was developed to incorporate pore formers into an uncured polymer resin and remove the pore former materials from the matrix. Polyethylene glycol (PEG) and polylactic acid (PLA) microspheres were created and incorporated into silicone matrices as pore formers. Microspheres with controllable size distributions were formed via an emulsion formation. Microspheres are removed from the matrix by solvent extraction and calcination. Thermogravimetric Analysis (TGA), Dynamic Mechanical Analysis (DMA), and optical imaging characterize and determine the successful creation of micropores in the polymer matrices.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A custom 3D printed paddlewheel improves growth in flat panel photobioreactor

One of the main challenges with using flat panel photobioreactors for algal growth is uneven mixing and settling of cells in corners, especially when bubbling is the only method used for mixing. Here, in order to improve mixing in our flat panel reactor, we designed a custom paddlewheel. Paddlewheels are frequently used in outdoor algae raceway ponds to improve mixing and we are taking advantage of the same principle for mixing in the reactor. The paddlewheel is easily integrated into our PSI FMT150 1‐L flat panel photobioreactor and is printed on a 3D printer using high temperature poly lactic acid (HT‐PLA). With the inclusion of an annealing step, the paddlewheel is autoclavable. Addition of the paddlewheel in the reactor minimized cell settling and improved algal growth, as evidenced by a nearly 40% increase in oxygen production rates. Nutrient dispersion and utilization in the culture was also improved as evidenced by a corresponding 38% decrease in CO 2 concentration. The paddlewheel device presented here is a cost‐effective method for improving algal growth in a flat panel photobioreactor.

09 BIOMASS FUELS↗

DOE OSTI2019

A novel targeted plugging and fracture‐adaptable gel used as a diverting agent in fracturing

Abstract Diverting agents that could plug a targeted location and fill different shapes of fractures have attracted an increasing attention in the field of fracturing. In this study, a series of novel diverting agents were prepared by mixing aldehyde sodium alginate (ASA) and amino gelatin (AG) through a Schiff base reaction to form a primary network, polylactic acid (PLA) fibers were added to produce a 3D network, and Ca 2+ was mixed in as an ionic cross‐linking agent to strengthen the cross‐linking points. It was found that gelation time, swelling behavior, and mechanical performance could be controlled by varying the content of aldehyde groups and amino groups. Gelation time could be controlled in 1‐10 minutes. Plugging behavior and degradation tests demonstrated that the hydrogel could suit fractures with various shapes and plug effectively under high temperatures and pressures, and it could eventually become acidic fluid to help clean the wellbore. This novel ASA/AG/PLA hydrogel constitutes a promising environmentally friendly diverting agent in the application of diversion fracturing.

Zhang, Yuyuan↗

DOE OSTI2019

N-Silylated Benzothiazolium Dye as a Coupling Agent for Polylactic Acid/Date Palm Fiber Bio-composites

This work proposes a benzothiazole derivative bearing a silane moiety as a new coupling agent for polylactic acid (PLA) reinforced by date palm fibers (DPFs). The bio-composites are prepared by solution blending followed by melt compounding. From the samples produced, a complete characterization is performed including morphological, mechanical and thermal properties as a function of fiber content. The results show that the proposed fiber treatment is an easy and effective method to improve the interfacial properties and fiber dispersion leading to better material performance. For example, the addition of only 1 wt% of the dye–IPTMS to the bleached DPF not only improved the thermal stability of the biocomposites, but also led to a significant increase of the Young’s modulus at 7 wt% and higher torsion modulus up to 5 wt% (optimum value).

36 MATERIALS SCIENCE↗

DOE OSTI2020

Functionalizing magnet additive manufacturing with in-situ magnetic field source

Additive manufacturing via 3-D printing technologies have become a frontier in materials research, including its application in the development and recycling of permanent magnets. This work addresses the opportunity to integrate magnetic field sources into 3-D printing process in order to enable printing, alignment of anisotropic permanent magnets or magnetizing of magnetic filler materials, without requiring further processing. Specifically, a nonaxisymmetric electromagnet-type field source architecture was designed, modelled, constructed, installed to a fused filament commercial 3-D printer, and tested. The testing was performed by applying magnetic field while printing composite anisotropic Nd-Fe-B + Sm-Fe-N powders bonded in Nylon12 (65 vol.%) and recycled Sm-Co powder bonded in PLA (15 vol.%). Magnetic characterization indicated that the degree-of-alignment of the magnet powders increased both with alignment field strength (controlled by the electric current applied to the magnetizing system) and the printing temperature. Both coercivity and remanence were found to be strongly dependent on the degree-of-alignment, except for printing performed below but near the Curie temperature of Nd-Fe-B (310 ° C). At applied field of 0.15 kOe, Sm-Co and hybrid Nd-Fe-B/Sm-Fe-N printed samples showed degrees-of-alignment of 83 % and 65 %, respectively. The variations in coercivity were consistent with previous observations in bonded magnet materials. This work verifies that integration of magnetic field sources into 3-D printing processes will result in magnetic alignment of particles while ensuring that other advantages of 3-D printing are retained.

3-D printing↗

DOE OSTI2021

In-situ magnetic alignment model for additive manufacturing of anisotropic bonded magnets

In this work, we report a mathematical framework which predicts the degree of alignment (DoA) in an in-situ aligned additively manufactured 3D printed bonded magnets. A multiphysics model is developed which couples the harmonious interactions of magnetic particles in a viscous flowing polymer under the presence of an external magnetic field. The hydrodynamic fluid-particle interaction is paired with the magnetophoretic force to predict the particle trajectory and distribution during extrusion through a 3D printer nozzle. Succeeding the force balance, a magnetohydrodynamic torque equilibrium analysis is performed to predict the net-orientation of the magnetic particles as a function of the applied field strength, viscous forces, and particle-to-particle interactions (P2P). Experimental validation of the DoA predictions is performed using 65 vol% Nd-Fe-B+Sm-Fe-N in Nylon12 (DoA exp = 0.620 and DoA theory = 0.686) and 15 vol% Sm-Co in PLA (DoA exp = 0.830 and DoA theory = 0.863). A parametric analysis is performed to analyze the effect of operating and design parameters like alignment field strength, magnetic loading fraction, extrusion load, and particle size. The model predicts a competing behavior between particle-fluid and particle-particle interactions under the presence of an applied field. Lastly, the model provides a framework to efficiently predict the DoA in tandem with a functionalized-magnetic 3D printer and allows the user to adjust the operating parameters according to the desired DoA.

36 MATERIALS SCIENCE↗