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At least 127 records · Page 7

Low cost carbon fiber as potential lightning strike protection for wind turbine blades

Until recently, glass fiber composites (GFRP) were the preferred choice to prepare wind turbine blades due to their low cost compared to their counterpart carbon fiber composites (CFRP). However, to harvest the maximum wind energy, ever larger wind turbine blades are being manufactured. To support such a large structure carbon fiber composites CFRP have become the integral part of load bearing structures in the blade. In this work, we are proposing to utilize the low cost carbon fiber (LCCF), manufactured at Carbon Fiber Technology Facility (CFTF) of Oak Ridge National Laboratory (ORNL) as not only the cost effective alternative to the currently used carbon fiber (CF) but also as the lightning strike protection of the wind turbine blades. Wind turbines often get hit by lightning strikes due to their operating locations. LCCF can provide structural integrity to these gigantic structures and mitigate the effect of lightning strike on them by effectively dissipating the current. Two composite panels made of LCCF were tested against artificial lightning strikes of 100 kA and 200 kA (component A of lightning waveform SAE ARP 5412-B). The results showed very high resilience of LCCF composite due to their high electrical conductivity both in-plane and in through-thickness directions. There was no significant damage (fiber breakage, resin evaporation or delamination) in both the cases.

Kumar, Vipin↗

Micromechanical Design of Carbon Nanotube Ribbon Reinforced Polymer Composite Materials

Lightweight materials are an important component of the design of aerospace structures. Carbon nanotube materials have been considered for this purpose due to the strength and stiffness of individual nanotubes, and the commercial availability of bulk formats such as fibers. These fibers can have a ribbon cross section which results in a different design space for their composites relative to traditional reinforcements which have a round cross section. This work applies brick-and-mortar micromechanical models and classical lamination theory with an inverse approach to investigate the design space of these composites. Using this approach, the influences of fiber geometry and axial and transverse mechanical properties are mapped. Finally, a sensitivity study is performed and the relative impacts of ±10% variations in the constituent material and geometric properties are ranked. Lamina axial moduli were found to range from a maximum of 3x to 1x minimum relative to a target quasi-isotropic laminate modulus depending on the anisotropy and shear modulus of the lamina. The fiber targets depended strongly on the fiber volume fraction in the lamina and the fiber axial modulus target was found to range from 4.8x to 3.2x the quasi-isotropic laminate target. The sensitivity analysis found that the largest driver of performance was the volume fraction, followed by the fiber axial modulus. While bio-based brick-and-mortar composites, such as nacre, can benefit from reinforcement aspect ratios above 10, for carbon nanotube ribbon (or carbon fiber)/polymer composites the sensitivity study indicated that the optimal cross-sectional aspect ratio was relatively smaller, potentially less than three.

Micromechanics↗

Lightweight carbon-carbon thermal protection system for STARPROBE

This paper describes the preliminary design, development, and initial testing of prototype carbon-carbon components of the thermal protection system of the NASA STARPROBE spacecraft. The thermal protection system is designed to limit the spacecraft scientific instrument package to a maximum temperature of 55 C during the time of closest approach to the earth's sun when the peak radiative heating rate reaches 393 w/sq cm. The thermal protection system is comprised of a carbon-carbon thin shell primary shield and two carbon-carbon sandwich construction secondary shields which block reradiation from the primary shield to the spacecraft. These shields are joined and stiffened by carbon-carbon structural members and attached to the spacecraft with eight thin-walled carbon-carbon struts. Prototype parts of the principal components have been fabricated and will be tested in a solar radiative flux environment simulating peak mission values in late 1984.

Dirling, R. B., Jr.↗

Multifunctional Carbon Foams for Aerospace Applications

Carbon foams produced by the controlled thermal decomposition of inexpensive coal extracts exhibit a combination of structural and thermal properties that make them attractive for aerospace applications. Their thermal conductivity can be tailored between 0.5 and 100 W/mK through precursor selection/modification and heat treatment conditions; thus, they can serve in either thermal protection or heat transfer systems such as heat exchangers. Because their structure is essentially a 3D random network of graphite-like members, they also can be considered low-cost, easily fabricated replacements for multi-directional structural carbon fiber preforms. Strengths of over 4000 psi in compression are common. Their density can be designed between 0.1 and 0.8 g/cc, and they can be impregnated with a variety of matrices or used, unfilled, in sandwich structures. These foams also exhibit intriguing electrochemical properties that offer potential in high-efficiency fuel cell and battery applications, mandrels and tooling for composite manufacture, ablative performance, and fire resistance. This paper presents the results of research conducted under NASA SBIR Topic 99.04.01, General Aviation Technology, supported from Langley Research Center. The potential of foam design through precursor selection, cell size and density control, density grading, and heat treatment is demonstrated.

Rogers, D. K.↗

Heteroatom-Modified and Compacted Zeolite-Templated Carbons for Gas Storage

Methane, the primary component of natural gas, is an energy-rich fuel by weight but exhibits lower energy density by volume than diesel and gasoline; efforts to increase its “volumetric” energy density have been focused on the design and synthesis of a porous scaffold that can bind the methane favorably. Novel approaches typically invoke the highly designable class of materials known as metal-organic frameworks (MOFs) owing to the relative difficulty of controlling carbon structure and composition precisely, without the use of a metal-based node. In this project, we instead explore the concept of carbon templating to achieve a porous scaffold with atomistically thin walls separated at a distance of ~1.2 nm, ideal for the formation of precisely two layers of methane per pore. This bottom-up templating approach permits the use of any small molecular precursor to build up the carbon scaffold, begging the question: which other elements (besides carbon) can be used to tune the surface for optimal methane binding without compromising the structure of the overall material? Boron and nitrogen were both explored and nitrogen was identified as the ideal agent for increasing methane binding to the optimal strength for use at near room temperature. Densification of the resulting materials by mechanical compaction was then explored to produce free-standing pellets with the highest methane “delivery” capacities of any known material. Here we define the amount “delivered” as the amount stored minus the amount remaining in the tank at 73 psi, the lowest useful pressure for vehicular transportation applications. The key features of the resulting methane storage system are rapid discharging and refueling speeds, extremely long cycle life (infinite cycle life for high-purity methane), a near-constant heat of refueling (making the heat generated upon refueling easier to manage), and a low maximum pressure of operation (<1500 psi), enabling the use of all-metal Type I cylinders and significantly reducing the costs of conversion of existing vehicles to cleaner burning, abundantly available natural gas). The technical effectiveness of this approach was further improved by exploring several cost-reduction strategies and investigating the reliability of such storage systems in the presence of “real” natural gas mixtures which contain a mixture of gaseous species.

03 NATURAL GAS↗

Self-Organization and Nitrogen Incorporation in Diamond-Like Carbon Microstructures Synthesized by Nonthermal Plasma

Nonthermal plasma activation of light alkanes is an encouraging decarbonization strategy to produce chemicals or fuels from abundant and/or flared carbon sources. However, prolific carbon growth on both the catalyst and electrode has limited its practicality, requiring additional knowledge of the carbon structure and growth mechanism before breakthroughs are realized. Furthermore, visual evidence is provided for nonuniform diamond-like carbon (DLC) microstructures that materialize in a coaxial dielectric barrier discharge (DBD) reactor flowing ethane and He at 278 K. Through a connection to known behaviors of DBD microdischarge patterns, the microstructure spacing was controlled by altering the applied voltage (ΔV) of the plasma or the burning voltage (U b ). Additionally, carbon valorization through nitrogen incorporation from N 2 was explored as an orthogonal solution to carbon mitigation, with N/C values >0.25 achieved and both sp 2 and sp 3 C–N bonding observed in the microstructures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Advanced Technology Composite Fuselage - Manufacturing

The goal of Boeing's Advanced Technology Composite Aircraft Structures (ATCAS) program is to develop the technology required for cost-and weight-efficient use of composite materials in transport fuselage structure. Carbon fiber reinforced epoxy was chosen for fuselage skins and stiffening elements, and for passenger and cargo floor structures. The automated fiber placement (AFP) process was selected for fabrication of stringer-stiffened and sandwich skin panels. Circumferential and window frames were braided and resin transfer molded (RTM'd). Pultrusion was selected for fabrication of floor beams and constant-section stiffening elements. Drape forming was chosen for stringers and other stiffening elements cocured to skin structures. Significant process development efforts included AFP, braiding, RTM, autoclave cure, and core blanket fabrication for both sandwich and stiffened-skin structure. Outer-mold-line and inner-mold-line tooling was developed for sandwich structures and stiffened-skin structure. The effect of design details, process control and tool design on repeatable, dimensionally stable, structure for low cost barrel assembly was assessed. Subcomponent panels representative of crown, keel, and side quadrant panels were fabricated to assess scale-up effects and manufacturing anomalies for full-scale structures. Manufacturing database including time studies, part quality, and manufacturing plans were generated to support the development of designs and analytical models to access cost, structural performance, and dimensional tolerance.

Wilden, K. S.↗

Scatter in Carbon/Silicon Carbide (C/SiC) Composites Quantified

Carbon-fiber-reinforced silicon carbide matrix (C/SiC) composites processed by chemical vapor infiltration are candidate materials for aerospace thermal structures. Carbon fibers can retain properties at very high temperatures, but they are known to have poor oxidation resistance in adverse, high-temperature environments. Nevertheless, the combination of CVI-SiC matrix with higher stiffness and oxidation resistance, the interfacial coating, and additional surface-seal coating provides the necessary protection to the carbon fibers, and makes the material viable for high-temperature space applications operating under harsh environments. Furthermore, C/SiC composites, like other ceramic matrix composites (CMCs), exhibit graceful non-catastrophic failure because of various inherent energy dissipating mechanisms. The material exhibits nonlinearity in deformation even at very low stress levels. This is the result of the severe matrix microcracking present in the as processed composite because of large differences between the coefficients of thermal expansion of the fiber and the matrix. Utilization of these advanced composites in next generation space vehicles will require innovative structural configurations, updated materials, and refined analyses. Structural safety issues for these vehicles are in direct competition with performance and cost. One would have to quantify the uncertainties associated with the design using formal probabilistic methods. Specifically four fundamental aspects on which analyses are based-- (1) loading conditions, (2) material behavior, (3) geometrical configurations, and (4) structural connections between the composite components and baseline structure--are stochastic in nature. A direct way to formally account for uncertainties is to develop probabilistic structural analysis methods where all participating variables are described by appropriate probability density functions. The present work, however, focuses on analyzing the stochastic material behavior of these advanced composites using formal probabilistic analysis methods. Often, some of the desirable property characteristics that allow composites to offer advantages over conventional structural materials (like tailoring of composite properties) and the complexity are in fact responsible for their greater statistical variability and the requirements for more characterization tests. Composite properties are anisotropic as well, having different properties in different directions. This means that characterization of a property such as stiffness--which will vary greatly depending on the orientation of the fiber relative to the direction of the testing--must be repeated for several different directions and loading conditions. The fabrication process for composites also introduces statistical variations in properties and geometry. A composite part is produced in a number of steps, each of which introduces statistical variability. The matrix is usually produced from a combination of raw materials; and the fiber, which has its own set of properties, is often coated or surface treated, introducing yet another source of variability.

Murthy, Pappu L. N.↗

High-Pressure Lightweight Thrusters

Returning samples of Martian soil and rock to Earth is of great interest to scientists. There were numerous studies to evaluate Mars Sample Return (MSR) mission architectures, technology needs, development plans, and requirements. The largest propulsion risk element of the MSR mission is the Mars Ascent Vehicle (MAV). Along with the baseline solid-propellant vehicle, liquid propellants have been considered. Similar requirements apply to other lander ascent engines and reaction control systems. The performance of current state-ofthe- art liquid propellant engines can be significantly improved by increasing both combustion temperature and pressure. Pump-fed propulsion is suggested for a single-stage bipropellant MAV. Achieving a 90-percent stage propellant fraction is thought to be possible on a 100-kg scale, including sufficient thrust for lifting off Mars. To increase the performance of storable bipropellant rocket engines, a high-pressure, lightweight combustion chamber was designed. Iridium liner electrodeposition was investigated on complex-shaped thrust chamber mandrels. Dense, uniform iridium liners were produced on chamber and cylindrical mandrels. Carbon/carbon composite (C/C) structures were braided over iridium-lined mandrels and densified by chemical vapor infiltration. Niobium deposition was evaluated for forming a metallic attachment flange on the carbon/ carbon structure. The new thrust chamber was designed to exceed state-of-the-art performance, and was manufactured with an 83-percent weight savings. High-performance C/Cs possess a unique set of properties that make them desirable materials for high-temperature structures used in rocket propulsion components, hypersonic vehicles, and aircraft brakes. In particular, more attention is focused on 3D braided C/Cs due to their mesh-work structure. Research on the properties of C/Cs has shown that the strength of composites is strongly affected by the fiber-matrix interfacial bonding, and that weakening interface realizes pseudo-plastic behavior with significant increase in the tensile strength. The investigation of high-temperature strength of C/Cs under high-rate heating (critical for thrust chambers) shows that tensile and compression strength increases from 70 MPa at room temperature to 110 MPa at 1,773 K, and up to 125 MPa at 2,473 K. Despite these unique properties, the use of C/Cs is limited by its high oxidation rate at elevated temperatures. Lining carbon/carbon chambers with a thin layer of iridium or iridium and rhenium is an innovative way to use proven refractory metals and provide the oxidation barrier necessary to enable the use of carbon/ carbon composites. Due to the lower density of C/Cs as compared to SiC/SiC composites, an iridium liner can be added to the C/C structure and still be below the overall thruster weight. Weight calculations show that C/C, C/C with 50 microns of Ir, and C/C with 100 microns of Ir are of less weight than alternative materials for the same construction.

Holmes, Richard↗

Interactions among soil texture, pore structure, and labile carbon influence soil carbon gains

Perennial vegetation with high plant diversity, e.g., restored prairie, is known for stimulation of soil carbon (C) gains, due in part to enhanced formation of pore structure beneficial for long-term C storage. However, the prevalence of this phenomenon across soils of different types remains poorly understood. The aim of the study was to assess the associations between pore structure, soil C, and their differences in monoculture switchgrass and polyculture restored prairie vegetation across a wide range of soils dominating the Upper Midwest of the USA. Six experimental sites were sampled, representing three soil types with texture ranging from sandy to silt loams. The two vegetation systems studied at each site were (i) monoculture switchgrass (Panicum virgatum L.), and (ii) polyculture restored prairie, also containing switchgrass as one of its species. X-ray computed micro-tomography (µCT) was employed to analyze soil pore structure. Structural equation modeling and multiple path analyses were used to assess direct and indirect effects of soil texture and pore characteristics on microbial biomass C (MBC), particulate organic matter (POM), dissolved organic C (DOC), short-term respiration (CO 2 ), and, ultimately, soil organic C (SOC). Across studied sites, prairie increased fractions of medium (50–150 µm Ø) pores by 11–45 %, SOC by 3–69 %, and MBC by 18–59 % (except for one site). The greater were the prairie-induced increases in the medium pore volumes, the greater were the prairie-induced SOC gains. Greater C losses via CO 2 and DOC contributed to slower C accumulation in the prairie soil. We surmise that the interactive feedback loop relating medium pores and soil C acts across a wide range of soil textures and is an important mechanism through which perennial vegetation with high plant diversity, such as restored prairie, promotes rapid SOC gains.

54 ENVIRONMENTAL SCIENCES↗

Design fabrication, testing, and delivery of shuttle heat pipe leading edge test modules. Volume 1: Executive summary

The construction of two test modules is presented for a feasibility demonstration of a concept for reusable space shuttle wing leading edge surfaces. In this leading edge concept high temperature heat pipes were incorporated into the structure to cool the stagnation region, allowing the use of super-alloys in place of refractory metal, ablator protected, or carbon-carbon structures. The program included the analysis and design of the heat pipes, their integration into the test module structure, heat pipe development testing, construction of the test modules and a facility adapter, and formulation of recommended testing conditions. The results of the heat pipe and leading edge module thermal analyses indicate the test modules will meet the design goal; reducing the leading edge temperature at the stagnation line from 1315 C (2400 F) to less than 1010 C (1850 F). The development tests demonstrated that the module assembly could be brazed with active heat pipes, as was borne out by the subsequent successful brazing of both modules with active heat pipes loaded with sodium.

Source record↗

Systematic Evaluation of Carbon Hosts for High-Energy Rechargeable Lithium-Metal Batteries

Rechargeable lithium batteries (RLBs) have attracted wide attention for achieving high energy and low cost, but the poor stability of the Li anode has remained as a large challenge. In the last several years, great efforts have been made to develop carbon anode structures for RLB applications. A wide range of carbon structures as well as many chemical modification strategies have been investigated to improve the Coulombic efficiency and extend the cycle life of the anodes or the cells. However, currently there is no clear conclusion on key factors that determine the performance of such the types of carbon structures due to the wide range of experimental conditions used in such studies. In this study, we systematically evaluated and compared the electrochemical properties of representative carbon anode materials as well as chemically functionalized carbon materials in different electrolytes. We have found that chemical functionalization, metallic loading, and the types of micro or nano-structures all have an effect on Li deposition/stripping process, but by far the most critical factor is the nature of the electrolytes. All carbon materials produced poor Coulombic efficiency and cycle life in conventional carbonate or ether-based electrolytes. However, when a Li metal compatible is used, the average Coulombic efficiency of Li metal deposition on all carbon structures is increased to 99% or higher. This study provides critical lessons on the directions for carbon anodes for RLBs. Based on these findings, we constructed Li metal coin cells using prelithiated hard carbon, LiNi0.6Mn0.2Co0.2O2 (NMC622) cathode, and compatible electrolyte and tested the cells under conditions of lean electrolyte, lean Li metal and high cathode loading required for more than 300 Wh kg-1 specific energy. More than 200 stable cycles were demonstrated with over 80% capacity retention. Furthermore, the existing challenges and potential approaches have been discussed to further extend the cyclability of lithium-metal batteries under practical conditions.

Liu, Yao↗

Investigation of poly(phenylacetylene) derivatives for carbon precursor with high carbon yield and good solubility

This paper investigates a family of poly(phenylacetylene) derivatives with a p-electrons conjugated polymer backbone and side groups containing only sp 2 and sp carbons. The objective is to identify the suitable carbon precursor that is processible and can be transformed to carbonaceous material with high carbon yield by a simple (one-step) thermal transformation process (without any external reagent). Poly(phenylacetylene) with para-substituted acetylene group poly(PA-A) shows an exceptionally high C-yield (~90%) in one-step heating from ambient temperature to 1000 °C under N 2 atmosphere. Unfortunately, this poly(PA-A) polymer is quite sensitive to heat and light with very limited solubility. On the other hand, poly(phenylacetylene) with para-substituted phenylacetylene group, i.e. poly(PA-PA), offers a relatively high C-yield (~80%) and also good solubility in common organic solvents, such as toluene and tetrahydrofuran (THF). Several uniform dark-red poly(PA-PA) fibers with smooth surface and fiber diameter in the range of 3–6 μm were prepared from 30 wt% poly(PA-PA)/THF solution using electrospinning technique. Furthermore, the resulting precursor fibers were converted to the corresponding carbon structure in a one-step thermal heating process under N 2 atmosphere. Both X-ray and Raman spectra show the polymorphous carbon morphology with the graphene crystalline domains.

36 MATERIALS SCIENCE↗

Experimental Validation and Continuous Testing of an On-Purpose High-Yield Pitch Synthesis Process for Producing Carbon Fiber from US Domestic Coal

This project aims to develop technology that converts domestic United States (US) raw coal to high quality, high value, and marketable carbon fiber. More specifically, the project aims to significantly improve the selectivity and yield of carbon fiber produced per ton of coal over conventional coal pitch-based production by using low-severity direct coal conversion technology to maximize the yield of pitch from coal, suitable for production of carbon fiber. To meet the stated objective of developing a technology platform, capable of producing high quality, high-value and marketable carbon fiber from domestic US coal, the proposed scope of work involves testing of a low-severity direct coal liquefaction (LS-DCL) process approach. The isotropic pitch produced from the LS-DCL process will be thermally treated using conventional processes to convert to a liquid crystal or “mesophase” pitch as a precursor for structural carbon fibers. This mesophase pitch will then be melt-spun into fiber, oxygen stabilized, and carbonized using conventional processes. The resulting carbon fiber will be evaluated for mechanical properties and suitability for structural applications such as automotive parts and spars for wind turbine blades. The overall process is expected to significantly lower the cost of fiber compared to state of the art fibers produced from polyacrylonitrile (PAN) precursors.

01 COAL, LIGNITE, AND PEAT↗

Highly Ordered Carbon Coating Prepared with Polyvinylidene Chloride Precursor for High‐Performance Silicon Anodes in Lithium‐Ion Batteries

Abstract A highly ordered carbon structure based on polyvinylidene chloride precursor has been developed to host silicon nanoparticles. The stoichiometric ratio of sacrificial H and Cl elements facilitated full utilization of the carbon content of the precursor that produced robust carbon coatings on silicon nanoparticles with excellent mechanic properties and electrochemical stabilities. The optimal sintering temperature and carbon content have been investigated. When evaluated as the anode of a lithium‐ion battery (LIB), the Si : C 1 : 2 composite sintered at 800 °C (SiC12‐800) provided excellent capacity retention of 85 % at 0.1 C after 50 cycles with an enhanced CE, which reached 99 % only after 10 cycles. The SiC12‐800 electrode maintained a specific capacity of 709.2 mAh/g after 300 cycles at 0.3 C, and delivered a high rate performance of 737.9 mAh/g and 485.6 mAh/g at 5 C and 10 C, respectively. The results indicate that polymer precursors with stoichiometric ratio of sacrificial elements have high potential for generating highly robust carbon coatings for silicon anodes in high energy density LIBs.

Zhou, Shuo↗

Hex-C 558 : A new porous metallic carbon allotrope for lithium-ion battery anode

Due to the limited specific capacity of graphite anodes in lithium-ion batteries (LIBs), it is imperative to find alternatives with better performance. Here in this work, we propose, for the first time, a three dimensional (3D) porous metallic 5-5-8 carbon monolith with hexagonal lattice as a potential candidate. With 5-5-8 carbon nanoribbon as the building block, this material, named Hex-C558, goes beyond graphene-nanoribbon-based 3D porous carbon structures. Using first-principles calculations, we show that Hex-C 558 is not only dynamically and thermally stable, but also is energetically more favorable than many other theoretically predicted carbon allotropes. More importantly, Hex-C 558 is metallic with ordered ionic conducting channels and possesses a low mass density of 1.05 gcm -3 , exhibiting great potential for ion-battery applications. As an anode for LIBs, Hex-C558 possesses a large specific capacity of 591 mAhg -1 , low diffusion energy barrier of 0.27 eV (at low Li concentration) and 0.52 eV (at high Li concentration), a low open-circuit voltage of 0.51 V, and a small volume change of 2.4%. This work provides a new route for the design and synthesis of novel carbon materials for battery applications by using pentagon-based building units.

36 MATERIALS SCIENCE↗

Valorizing the carbon byproduct of methane pyrolysis in batteries

While low-cost natural gas remains abundant, the energy content of this fuel can be utilized without greenhouse gas emissions through the production of molecular hydrogen and solid carbon via methane pyrolysis. In the absence of a carbon tax, methane pyrolysis is not economically competitive with current hydrogen production methods unless the carbon byproducts can be valorized. In this work, we assess the viability of the carbon byproduct produced from methane pyrolysis in molten salts as high-value-added anode or conductive additive for secondary Li-ion and Na-ion batteries. Raman characterization and electrochemical differential capacity analysis demonstrate that the use of molten salt mixtures with catalytically-active FeCl 3 - or MnCl 2 result in more graphitic carbon co-products. These graphitic carbons exhibit the best electrochemical performance (up to 272 mAh/g of reversible capacity) when used as Li-ion anodes. For all carbon samples studied here, disordered carbon domains and retained salt species trapped and/or intercalated into the carbon structure were identified by X-ray photoelectron and multinuclear solid-state nuclear magnetic resonance spectroscopy. The latter lead to reduced electrochemical activity and reversibility, and poorer rate performance compared to commercial carbon anodes. The electronic conductivity of the pyrolyzed carbons is found to be highly dependent on their purity, with the purest carbon exhibiting an electronic conductivity nearly on par with that of commercial carbon additives. These findings suggest that more effective removal of the salt catalyst could enable applications of these carbons in secondary batteries, providing a financial incentive for the large-scale implementation of methane pyrolysis for “low-carbon” hydrogen production.

08 HYDROGEN↗