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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Anti-adhesive characteristics of CHF{sub 3}/O{sub 2} and C{sub 4}F{sub 8}/O{sub 2} plasma-modified silicon molds for nanoimprint lithography

The anti-adhesive characteristics of a plasma-modified silicon mold surface for nanoimprint lithography are presented. Both CHF{sub 3}/O{sub 2} and C{sub 4}F{sub 8}/O{sub 2} plasma were used to form an anti-adhesive layer on silicon mold surfaces. The gas mixing ratios of CHF{sub 3}/O{sub 2} and C{sub 4}F{sub 8}/O{sub 2} were experimentally changed between 0% and 80% to optimize the plasma conditions to obtain a low surface energy of the silicon mold. The plasma characteristics were examined by optical emission spectroscopy (OES). In order to investigate the changes in surface energy and surface chemistry of the anti-adhesive layer during repeated demolding cycles, contact angle measurements and X-ray photoelectron spectroscopy (XPS) were performed on the plasma-modified silicon mold surface. Simultaneously, the surface morphology of the demolded resists was evaluated by field-emission scanning electron microscope (FE-SEM) in order to examine the effect of the anti-adhesive layers on the duplicated patterns of the resists. It was observed that the anti-adhesive layer formed by CHF{sub 3}/O{sub 2} plasma treatment was worn out more easily during repeated demolding cycles than the film formed by C{sub 4}F{sub 8}/O{sub 2} plasma treatment, because CHF{sub 3}/O{sub 2} gas plasma formed a thinner plasma-polymerized film over the same plasma treatment time.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Additive Manufacturing of Wind Turbine Molds

The objective of this project was to explore the utility of Big Area Additive Manufacturing (BAAM) for low cost manufacturing of wind turbine molds. Engineers at Oak Ridge National Laboratory (ORNL) and TPI Composites (TPI) collaborated to design and manufacture a printed mold that can be used for resin infusion of wind turbine components. Specific focus was on required material properties (operating temperatures and pressures, coefficient of thermal expansion (CTE), thermal conductivity), surface finish (accuracy and coatings) and system integration (integrated vacuum ports, and heating element). The project began with a simple proof of principle components, targeting surface coatings and material properties for printing a small section (approximately 4’ x 4’ x 2’) of a mold. Next, the second phase scaled up and integrated with the objective of capturing all of the necessary components (integrated heating to accelerate cure time, and vacuum, sealing) for resin infusion on a mold of significant size (8’ x 20’ x 6’).

17 WIND ENERGY↗
NASA NTRS1973

Molding process for imidazopyrrolone polymers

A process is described for producing shaped articles of imidazopyrrolone polymers comprising molding imidazopyrrolone polymer molding power under pressure and at a temperature greater than 475 C. Moderate pressures may be employed. Preferably, prior to molding, a preform is prepared by isostatic compression. The preform may be molded at a relatively low initial pressure and temperature; as the temperature is increased to a value greater than 475 C., the pressure is also increased.

Johnson, C. L.↗
NASA NTRS1974

Effect of volatile removal during molding on the properties of two phenolic-fiber composites

A comparison has been made of the effect of three volatile-removing techniques during molding on the properties of phenolic-fiber composites. The first technique involved heating the molding compound from one side, initiating the volatile-producing reactions, and driving these volatiles through the compound toward the cooler side. The second technique involved the application of a vacuum to the molding cavity before and during the cure cycle. The third technique was a combination of the first two. These techniques were used in the compression molding of phenolic-asbestos and phenolic-glass composites. The effects of both the individual and combined techniques on the mechanical, thermal, and sorption properties of the composites are reported.

Price, H. L.↗
NASA NTRS1978

Molded composite pyrogen igniter for rocket motors

A lightweight pyrogen igniter assembly including an elongated molded plastic tube adapted to contain a pyrogen charge was designed for insertion into a rocket motor casing for ignition of the rocket motor charge. A molded plastic closure cap provided for the elongated tube includes an ignition charge for igniting the pyrogen charge and an electrically actuated ignition squib for igniting the ignition charge. The ignition charge is contained within a portion of the closure cap, and it is retained therein by a noncorrosive ignition pellet retainer or screen which is adapted to rest on a shoulder of the elongated tube when the closure cap and tube are assembled together. A circumferentially disposed metal ring is provided along the external circumference of the closure cap and is molded or captured within the plastic cap in the molding process to provide, along with O-ring seals, a leakproof rotary joint.

Heier, W. C.↗
NASA NTRS1983

Process for Molding Nonreinforced (Neat) Resins

Void free moldings obtained for neat, condensation, thermosetting resins. Thermally and mechanically treat resin prior to molding to reduce amount of volatiles. With volatiles reduced molding temperature and pressure are applied in way to drive out remaining volatiles during molding.

Dickerson, G. E.↗
NASA NTRS1983

Technique for removing resin from a molded object

Resin is removed from a molded object in such a way that no cracks or expansion occurs in the casting. The resin is first mixed with a ceramics powder or metal powder. This mixture is then molded and the resin is removed by heat. The molded object is then placed into a container which is sealed and large enough to allow the gas from the resin to be controlled by heat from the resin. The gas pressure at the surface of the object is increased by the gas pressure generated from the resin and the resin removed. The increase in gas pressure from the surface of the molded object is 1.5 atm to 3 atm at 350 C to 400 C.

Hemmi, I.↗
NASA NTRS1985

Transfer molding of PMR-15 polyimide resin

Transfer molding is an economically viable method of producing small shapes of PMR-15 polyimide. It is shown that with regard to flexural, compressive, and tribological properties transfer-molded PMR-15 polyimide is essentially equivalent to PMR-15 polyimide produced by the more common method of compression molding. Minor variations in anisotropy are predictable effects of molding design and secondary finishing operations.

Reardon, J. P.↗
NASA NTRS1989

Making Internal Molds Of Long, Curved Tubes

Mold material carried to internal weld joint and removed after impression taken. Remotely operated device makes impression mold of interior surface of tube at weld joint. Mold provides indication of extent of mismatch between members at joint. Maneuvered to weld inspected through curved tube 3 in. in diameter by 50 in. long. Readily adapted to making molds to measure depth of corrosion in boiler tubes or other pipes.

Burley, Richard K.↗
NASA NTRS1993

Verification of a two-dimensional infiltration model for the resin transfer molding process

A two-dimensional finite element model for the infiltration of a dry textile preform by an injected resin was verified. The model, which is based on the finite element/control volume technique, determines the total infiltration time and the pressure increase at the mold inlet associated with the RTM process. Important input data for the model are the compaction and permeability behavior of the preform along with the kinetic and rheological behavior of the resin. The compaction behavior for several textile preforms was determined by experimental methods. A power law regression model was used to relate fiber volume fraction to the applied compaction pressure. Results showed a large increase in fiber volume fraction with the initial application of pressure. However, as the maximum fiber volume fraction was approached, the amount of compaction pressure required to decrease the porosity of the preform rapidly increased. Similarly, a power law regression model was used to relate permeability to the fiber volume fraction of the preform. Two methods were used to measure the permeability of the textile preform. The first, known as the steady state method, measures the permeability of a saturated preform under constant flow rate conditions. The second, denoted the advancing front method, determines the permeability of a dry preform to an infiltrating fluid. Water, corn oil, and an epoxy resin, Epon 815, were used to determine the effect of fluid type and viscosity on the steady state permeability behavior of the preform. Permeability values measured with the different fluids showed that fluid viscosity had no influence on the permeability behavior of 162 E-glass and TTI IM7/8HS preforms. Permeabilities measured from steady state and advancing front experiments for the warp direction of 162 E-glass fabric were similar. This behavior was noticed for tests conducted with corn oil and Epon 815. Comparable behavior was observed for the warp direction of the TTI IM7/8HS preform and corn oil. Mold filling and flow visualization experiments were performed to verify the analytical computer model. Frequency dependent electromagnetic sensors were used to monitor the resin flow front as a function of time. For the flow visualization tests, a video camera and high resolution tape recorder were used to record the experimental flow fronts. Comparisons between experimental and model predicted flow fronts agreed well for all tests. For the mold filling tests conducted at constant flow rate injection, the model was able to accurately predict the pressure increase at the mold inlet during the infiltration process. A kinetics model developed to predict the degree of cure as a function of time for the injected resin accurately calculated the increase in the degree of cure during the subsequent cure cycle.

Hammond, Vincent H.↗
NASA NTRS1994

Design and technical support for development of a molded fabric space suit joint

NASA Ames Research Center has under design a new joint or element for use in a space suit. The design concept involves molding a fabric to a geometry developed at Ames. Unusual characteristics of this design include the need to produce a fabric molding draw ratio on the order of thirty percent circumferentially on the surface. Previous work done at NASA on molded fabric joints has shown that standard, NASA qualified polyester fabrics as are currently available in the textile industry for use in suits have a maximum of about fifteen percent draw ratio. NASA has done the fundamental design for a prototype joint and of a mold which would impart the correct shape to the fabric support layer of the joint. NASA also has the capability to test a finished product for suitability and reliability. Responsibilities resting with Georgia Tech in the design effort for this project are textile related, namely fiber selection, fabric design to achieve the properties of the objective design, and determining production means and sources for the fabrics. The project goals are to produce a prototype joint using the NASA design for evaluation of effectiveness by NASA, and to establish the sources and specifications which would allow reliable and repeatable production of the joint.

Olson, L. Howard↗
NASA NTRS1997

Fabrication and Evaluation of Graphite Fiber-Reinforced Polyimide Composite Tube Forms Using Modified Resin Transfer Molding

The techniques necessary for the fabrication of a complex three-dimensional tubular form using a PMR-type resin have been developed to allow for the construction of several tubes with good physical and mechanical properties. Employing established resin transfer molding practices, the relatively non-hazardous AMB-21 in acetone formulation was used to successfully impregnate four layers of AS4 braided graphite fiber preform previously loaded around an aluminum cylindrical core in an enclosed mold cavity. Using heat and vacuum, the solvent was evaporated to form a prepreg followed by a partial imidization and removal of condensation products. The aluminum core was replaced by a silicone rubber bladder and the cure cycle continued to the final stage of 550 F with a bladder internal pressure of 200 lbs/sq in while simultaneously applying a strong vacuum to the prepreg for removal of any additional imidization products. A combination of several modifications to the standard resin transfer molding methodology enabled the mold to 'breathe', allowing the imidization products a pathway for escape. AMB-21 resin was chosen because of the carcinogenic nature of the primary commercial polyimide PMR-15. The AMB-21 resin was formulated using commercially available monomers or monomer precursors and dissolved in a mixture of methyl alcohol and acetone. The viscosity of the resulting monomer solution was checked by use of a Brookfield rheometer and adjusted by adding acetone to an easily pumpable viscosity of about 600 cP. In addition, several types of chromatographic and thermal analyses were of the braids, and excess handling of the preforms broke some of the microscopic fibers, needlessly decreasing the strength of the finished part. In addition, three dimensional braided preforms with fibers along the length of the tube will be significantly stronger in tension than the braided preforms used in this study.

Exum, Daniel B.↗
DOE OSTI2014

Method and mold for casting thin metal objects

Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Porous media heat transfer for injection molding

The cooling of injection molded plastic is targeted. Coolant flows into a porous medium disposed within an injection molding component via a porous medium inlet. The porous medium is thermally coupled to a mold cavity configured to receive injected liquid plastic. The porous medium beneficially allows for an increased rate of heat transfer from the injected liquid plastic to the coolant and provides additional structural support over a hollow cooling well. When the temperature of the injected liquid plastic falls below a solidifying temperature threshold, the molded component is ejected and collected.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Investigation of pressure-controlled injection molding on the mechanical properties and embodied energy of recycled high-density polyethylene

Manufacturing with secondary feedstock has been identified as an effective strategy to improve plastic circularity. However, product quality inconsistencies arise due to variations in molecular weight, rheology, and mechanical properties. This work evaluates the processing of recycled high-density polyethylene using pressure-controlled injection molding with a focus on processing behavior and energy consumption. Further, the effects of injection velocity, packing pressure, and transfer position are benchmarked against a conventional velocity-controlled process. The experimental results show that the novel process control strategy significantly affects the mechanical properties, in-mold rheology, and energy consumption. Parts fabricated using pressure-controlled injection molding showed higher tensile properties due to increased macromolecular orientation. Additionally, reduced energy was used due to lower melt pressures required to completely replicate the cavity geometry. The results demonstrate the potential of the technology to support increased utilization of secondary feedstock and reduced carbon footprint.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Analysis and Design for Sustainable Circularity of Barrier Films Used in Sheet Molding Composites Production

Sheet molding composites (SMC) are thermoset based molding compounds with a global market size of USD 2.1 billion in 2020. SMC is usually processed with multilayer barrier/carrier films to prevent emissions from volatile organic compounds (VOC). The plastic barriers are separated from SMC after the curing process and discarded. To illustrate the high consumption volume of SMC barrier/carrier films, Kohler Co., a company which uses SMC in their bath and showering product lines, alone generates over 1M lb/year of SMC barrier/carrier film waste. Therefore, high amount of SMC barrier/carrier film plastic waste creates a great opportunity for reusing, recycling, or valorization at its end of life. This can be achieved through transition from a linear to a circular supply chain design. However, this transition will not be feasible without overcoming the technical and economic barriers. This project aims to tackle this by making the film circular. Different end of life alternatives will be evaluated experimentally. The reusability of the film will be studied through applying different mechanical and solvent cleaning techniques. The operability concerns regarding the utilization of the cleaned film for long run operations will be addressed by thermally stitching the film. Pelletizing of the cleaned film will also be investigated as a viable technique for recycling or downcycling of the film as molded products. In addition to technical barriers, designing a sustainable circular supply chain for SMC carrier film products requires uncovering the collaboration opportunities between suppliers and users at different stages of the value chain to expand its use to other products. These opportunities will be investigated by finding companies willing to buy or treat the plastic film waste. Finally, the economic viability and environmental impacts of these circular design alternatives will be evaluated through techno-economic assessment (TEA) and life cycle analysis (LCA). Techno-economic and life cycle inventory data for various pathways will also be made available as one of the main outcomes of this project. Preliminary LCA results indicate that the current SMC film supply chain (base case) emits 5.81 tonne CO2 eq. and consumes 104 GJ energy per tonne of SMC film. It is estimated that alternative circular pathways result in 14-20% less CO2 emissions and 34-44% reduction in embodied energy. This project will develop a tool to analyze the circularity and sustainability of hundreds of combinations of alternatives in different life cycle stages. Users of this tool will be able to choose the best combination among these alternatives with respect to the selected economic, environmental and circularity objectives.

circular economy↗
DOE OSTI2018

A Physical Model to Study the Effects of Nozzle Design on Dispersed Two-Phase Flows in a Slab Mold Casting Ultra-Low-Carbon Steels

The effects of nozzle design on dispersed, two-phase flows of the steel-argon system in a slab mold are studied using a water-air model with particle image velocimetry and ultrasound probe velocimetry techniques. Three nozzle designs were tested with the same bore size and different port geometries, including square (S), special bottom design with square ports (U), and circular (C). The meniscus velocities of the liquid increase two- or threefold in two-phase flows regarding one-phase flows using low flow rates of the gas phase. This effect is due to the dragging effects on bubbles by the liquid jets forming two-way coupled flows. Liquid velocities (primary phase) along the narrow face of the mold also are higher for two-phase flows. Flows using nozzle U are less dependent on the effects of the secondary phase (air). The smallest bubble sizes are obtained using nozzle U, which confirms that bubble breakup is dependent on the strain rates of the fluid and dissipation of kinetic energy in the nozzle bottom and port edges. Through dimensionless analysis, it was found that the bubble sizes are inversely proportional to the dissipation rate of the turbulent kinetic energy, ε{sup 0.4}. A simple expression involving ε, surface tension, and density of metal is derived to scale up bubble sizes in water to bubble sizes in steel with different degrees of deoxidation. The validity of water-air models to study steel-argon flows is discussed. Prior works related with experiments to model argon bubbling in steel slab molds under nonwetting conditions are critically reviewed.

36 MATERIALS SCIENCE↗