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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
NASA NTRS1999

Effect of High Temperature on the Tensile Behavior of CFRP and Cementitious Composites

Concrete and other composite manufacturing processes are continuing to evolve and become more and more suited for use in non-Earth settings such as the Moon and Mars. The fact that structures built in lunar environments would experience a range of effects from temperature extremes to bombardment by micrometeorites and that all the materials for concrete production exist on the Moon means that concrete appears to be the most feasible building material. it can provide adequate shelter from the harshness of the lunar environment and at the same time be a cost effective building material. With a return to the Moon planned by NASA to occur after the turn of the century, it will be necessary to include concrete manufacturing as one of the experiments to be conducted in one of the coming missions. Concrete's many possible uses and possibilities for manufacturing make it ideal for lunar construction. The objectives of this research are summarized as follows: i) study the possibility of concrete production on the Moon or other planets, ii) study the effect of high temperature on the tensile behavior of concrete, and iii) study the effect of high temperature on the tensile behavior of carbon fiber reinforced with inorganic polymer composites. Literature review indicates that production of concrete on the Moon or other planets is feasible using the indigenous materials. Results of this study has shown that both the tensile strength and static elastic modulus of concrete decreased with a rise in temperature from 200 to 500 C. The addition of silica fume to concrete showed higher resistance to high temperatures. Carbon fiber reinforced inorganic polymer (CFRIP) composites seemed to perform well up to 300 C. However, a significant reduction in strength was observed of about 40% at 400 C and up to 80% when the specimens were exposed to 700 C.

Toutanji, Houssam A.↗
NASA NTRS1985

Monodisperse Latex Reactor (MLR): A materials processing space shuttle mid-deck payload

The monodisperse latex reactor experiment has flown five times on the space shuttle, with three more flights currently planned. The objectives of this project is to manufacture, in the microgravity environment of space, large particle-size monodisperse polystyrene latexes in particle sizes larger and more uniform than can be manufactured on Earth. Historically it has been extremely difficult, if not impossible to manufacture in quantity very high quality monodisperse latexes on Earth in particle sizes much above several micrometers in diameter due to buoyancy and sedimentation problems during the polymerization reaction. However the MLR project has succeeded in manufacturing in microgravity monodisperse latex particles as large as 30 micrometers in diameter with a standard deviation of 1.4 percent. It is expected that 100 micrometer particles will have been produced by the completion of the the three remaining flights. These tiny, highly uniform latex microspheres have become the first material to be commercially marketed that was manufactured in space.

Kornfeld, D. M.↗
DOE OSTI2025

Final report on assessment of molten salt corrosion testing of unirradiated and ion irradiated advanced manufactured high entropy alloys

Generation IV reactors and future fusion reactor designs have led to more demanding materials performance requirements due to their increased operating temperatures, corrosive coolants, and increased radiation doses compared to the current light-water reactor fleet. Among the innovative nuclear technologies under development, molten salt reactors stand out for their potential to offer superior fuel utilization, intrinsic safety characteristics, and economic viability. Of the proposed Generation IV designs, the gas fast reactor operates at 450 to 850°C and the molten salt reactor operates at 565 to 850°C, with the molten salt reactor design needing molten salt corrosion resistant materials [1, 2]. These increased temperatures and more extreme corrosion environments necessitate higher material performance, such as creep strength, radiation-tolerant microstructures, corrosion resistance, and high-temperature tensile properties. Hastelloy-N, a nickel-based alloy with additions of molybdenum and chromium, has been successfully employed to contain molten fluoride salt at temperatures up to 705°C. However, Hastelloy-N becomes embrittled upon neutron irradiation, primarily due to the accumulation of helium produced by (n,a) transmutation reactions. Furthermore, the corrosive nature of molten fluoride and chloride salts presents a formidable challenge, as these salts can react with and dissolve alloying elements such as Cr, Mo, and Fe, leading to selective leaching, loss of protective oxide layers, and accelerated degradation. High entropy alloys (HEAs) and refractory high entropy alloys (RHEAs) have emerged as a prominent area of interest, due to their ability to achieve tailored chemical compositions for specific applications. Unlike conventional alloys, HEAs are characterized by having multiple principal elements in equimolar or near equimolar ratios, leading to an unconventional alloying strategy [3]. This alloying strategy is believed to promote unique properties, such as single-phase stabilization of chemically compatible elements, lattice distortion effects due to atomic radius differences, and proposed sluggish diffusion effects. For extreme-environment applications, RHEAs have garnered much research interest because of the possibility of creating relatively ductile materials that can operate in extremely high-temperature environments, beyond the operating temperatures where other Ni-based superalloys begin to lose strength [4-6]. Idaho National Laboratory (INL) initiated a joint international effort with the Czech Republic to explore the feasibility of manufacturing HEAs for high-temperature nuclear applications using advanced manufacturing. This effort was funded at INL by the United States Department of Energy's Office of Nuclear Energy under the Advanced Reactor Technologies and Advanced Materials and Manufacturing Technologies (AMMT) Program. The HEAs were specifically designed for the corrosive and irradiation environments experienced in gas-cooled fast reactors, molten salt reactors, and fusion power. These alloys have been manufactured by multiple processes to determine the impact of manufacturing processes on the performance of the alloys in corrosive and irradiation environments. Preliminary molten salt corrosion testing showed that equimolar MoNbTiV and MoNbTi alloys exhibit exceptional performance, with arc-melted variants demonstrating only minimal degradation after 1000 hours of exposure to molten chloride salt at 700°C. Conversely, Nb2TiVZr2 showed significant molten salt corrosion susceptibility and microstructural instability during high-temperature molten salt exposures, and was, therefore deemed unfit for molten salt reactor applications. The MoNbTiV, MoNbTi, and Nb2TiVZr2 alloys were further evaluated through ion irradiation experiments conducted at the Michigan Ion Beam Laboratory at the University of Michigan. The microstructural stability and the evolution of irradiation-induced defects were characterized to assess the irradiation resistance of each of these alloys.

36 - MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Influence of the Space Environment on Geopolymer Lunar Concrete

NASA is set to embark on the next era of human space exploration on the Artemis program. An eventual goal of the program is to maintain a human presence on the lunar surface. With such a goal comes the challenge of providing durable infrastructure that is suitable for the Moon and utilizes in-situ resources. Bringing materials form Earth poses a financial burden and increased safety concern. The composition of the lunar soil makes it advantageous to create a geopolymer concrete material. The lunar regolith can be used in the as found condition on the lunar surface and most of the mixing solution can be extracted form the regolith. It is envisioned than any concrete infrastructure would make use of additive manufacturing techniques with a temporary controlled environment enclosure to mitigate the harsh lunar conditions. Data is needed to benchmark how the material behaves once exposed to such an extreme environment so structural failures are mitigated.

Peter J. Collins↗
NASA NTRS2023

A 3D Printable Alloy Designed for Extreme Environments

Multiprincipal-element alloys are an enabling class of materials owing to their impressive mechanical and oxidation-resistant properties, especially in extreme environments. Here we develop a new oxide-dispersion-strengthened NiCoCr-based alloy using a model-driven alloy design approach and laser-based additive manufacturing. This oxide-dispersion-strengthened alloy, called GRX-810, uses laser powder bed fusion to disperse nanoscale Y 2 O 3 particles throughout the microstructure without the use of resource-intensive processing steps such as mechanical or in situ alloying. We show the successful incorporation and dispersion of nanoscale oxides throughout the GRX-810 build volume via high-resolution characterization of its microstructure. The mechanical results of GRX-810 show a twofold improvement in strength, over 1,000-fold better creep performance and twofold improvement in oxidation resistance compared with the traditional polycrystalline wrought Ni-based alloys used extensively in additive manufacturing at 1,093 °C. The success of this alloy highlights how model-driven alloy designs can provide superior compositions using far fewer resources compared with the ‘trial-and-error’ methods of the past. These results showcase how future alloy development that leverages dispersion strengthening combined with additive manufacturing processing can accelerate the discovery of revolutionary materials.

Timothy M. Smith↗
DOE OSTI2024

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A stable atmospheric-pressure plasma for extreme-temperature synthesis

Plasmas can generate ultra-high-temperature reactive environments that can be used for the synthesis and processing of a wide range of materials. However, the limited volume, instability and non-uniformity of plasmas have made it challenging to scalably manufacture bulk, high-temperature materials. Here we present a plasma set-up consisting of a pair of carbon-fibre-tip-enhanced electrodes that enable the generation of a uniform, ultra-high temperature and stable plasma (up to 8,000 K) at atmospheric pressure using a combination of vertically oriented long and short carbon fibres. The long carbon fibres initiate the plasma by micro-spark discharge at a low breakdown voltage, whereas the short carbon fibres coalesce the discharge into a volumetric and stable ultra-high-temperature plasma. As a proof of concept, we used this process to synthesize various extreme materials in seconds, including ultra-high-temperature ceramics (for example, hafnium carbonitride) and refractory metal alloys. Moreover, the carbon-fibre electrodes are highly flexible and can be shaped for various syntheses. In conclusion, this simple and practical plasma technology may help overcome the challenges in high-temperature synthesis and enable large-scale electrified plasma manufacturing powered by renewable electricity.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Advanced Manufacturing Techniques and Compositions of High Entropy Alloys for Nuclear Applications

In line with the objectives of the Department of Energy, Office of Nuclear Energy, Advanced Materials and Manufacturing Technologies (AMMT) program, this work focuses on new materials development and qualification research and development for next-generation, high-temperature nuclear reactors. High entropy alloys (HEAs) have the potential to serve in these extreme environments of next-generation nuclear reactors because of their unique phase transformation pathways and nanoscale and mesoscale microstructures. The current work focuses on understanding such nuclear-energy-relevant HEAs through a detailed literature survey, selected experimental work, and developing a decision matrix with criteria for the identification of HEAs that may have the most impact and value for further examination.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Novel additive manufacturing for plasma facing materials ‐ creating a research pathway for minority students

This project addresses two critical and intertwined challenges in fusion energy, namely the shortage of a broadly trained scientific workforce and the lack of scalable manufacturing solutions for plasma-facing components (PFCs). Through a collaboration among Florida International University (FIU), Miami Dade College (MDC), and Purdue University, the project established structured, reproducible educational and research pathways that recruit and advance students from institutions historically outside the fusion energy enterprise, building the human capital that this field urgently needs. The project integrates the complementary research strengths of FIU and Purdue to investigate flash sintering as a transformative processing route for tungsten-based PFCs. Unlike conventional sintering approaches, flash sintering offers rapid densification at significantly reduced thermal budgets, making it a compelling candidate for fabricating complex tungsten geometries that must withstand extreme plasma-facing environments. Systematic experimental and modeling efforts will elucidate the fundamental mechanisms governing microstructure evolution, grain boundary chemistry, and thermomechanical response during flash sintering — knowledge that is presently lacking but essential for translating this technology into reliable manufacturing practice. The convergence of workforce development and cutting-edge manufacturing research positions this project to deliver measurable, durable impact: a pipeline of fusion-ready researchers cultivated through expanded institutional partnerships, and a validated materials processing framework that accelerates domestic readiness for next-generation fusion reactor construction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Alkali cation stabilization of defects in 2D MXenes at ambient and elevated temperatures

Transition metal carbides have been adopted in energy storage, conversion, and extreme environment applications. Advancements in their 2D counterparts, known as MXenes, enable the design of unique structures at the ~1 nm thickness scale. Alkali cations have been essential in MXenes manufacturing processing, storage, and applications, however, exact interactions of these cations with MXenes are not fully understood. In this study, using Ti 3 C 2 T x , Mo 2 TiC 2 T x , and Mo 2 Ti 2 C 3 T x MXenes, we present how transition metal vacancy sites are occupied by alkali cations, and their effect on MXene structure stabilization to control MXene’s phase transition. We examine this behavior using in situ high-temperature x-ray diffraction and scanning transmission electron microscopy, ex situ techniques such as atomic-layer resolution secondary ion mass spectrometry, and density functional theory simulations. In MXenes, this represents an advance in fundamentals of cation interactions on their 2D basal planes for MXenes stabilization and applications. Broadly, this study demonstrates a potential new tool for ideal phase-property relationships of ceramics at the atomic scale.

42 ENGINEERING↗
NASA NTRS2014

GCD TechPort Data Sheets Thermal Protection System Materials (TPSM) Project

The Thermal Protection System Materials (TPSM) Project consists of three distinct project elements: the 3-Dimensional Multifunctional Ablative Thermal Protection System (3D MAT) project element; the Conformal Ablative Thermal Protection System (CA-TPS) project element; and the Heatshield for Extreme Entry Environment Technology (HEEET) project element. 3D MAT seeks to design, develop and deliver a game changing material solution based on 3-dimensional weaving and resin infusion approach for manufacturing a material that can function as a robust structure as well as a thermal protection system. CA-TPS seeks to develop and deliver a conformal ablative material designed to be efficient and capable of withstanding peak heat flux up to 500 W/ sq cm, peak pressure up to 0.4 atm, and shear up to 500 Pa. HEEET is developing a new ablative TPS that takes advantage of state-of-the-art 3D weaving technologies and traditional manufacturing processes to infuse woven preforms with a resin, machine them to shape, and assemble them as a tiled solution on the entry vehicle substructure or heatshield.

HEEET↗
NASA NTRSDate not supplied

Implementing the 3-D woven Mid-Density Carbon Phenolic (3MDCP) Heat Shield for the Mars Sample Return (MSR) Earth Entry Vehicle (EEV)

he Mars Sample Return (MSR)Program will return Martian soil samples to Earth in the early 2030s. Since the biological content of these samples is unknown, and potentially upsetting to Earth’s biosphere, the Earth Entry Vehicle (EEV) is required to be the most reliable entry probe ever devised. Entering Earth’s atmosphere at ~12 km/s, after up to a 6-day in-space free flight phase, the EEV must tolerate the cis-lunar Micro-Meteoroid environment, the near-Earth Orbital debris environment, and then entry heating of over 3,000 W/cm2 and pressures of250 kPa before ballistically impacting Earth’s surface at nearly 45 m/s. To reliably accomplish such a mission, NASA Ames is implementing the 3-D woven Mid-Density Carbon Phenolic (3MDCP) Heat Shield, derived from the prior Heatshield for Extreme Entry Environments(HEEET) material system [1]. 3MDCP development accomplishments to date, along with the future efforts to deliver the flight hardware are presented, along with a discussion of the manufacturing risks and accompanying mitigations achieved.

J C Vander Kam↗
NASA NTRS1977

Evaluation of solar cells for potential space satellite power applications

The evaluation focused on the following subjects: (1) the relative merits of alternative solar cell materials, based on performance and availability, (2) the best manufacturing methods for various solar cell options and the effects of extremely large production volumes on their ultimate costs and operational characteristics, (3) the areas of uncertainty in achieving large solar cell production volumes, (4) the effects of concentration ratios on solar array mass and system performance, (5) the factors influencing solar cell life in the radiation environment during transport to and in geosynchronous orbit, and (6) the merits of conducting solar cell manufacturing operations in space.

Source record↗
NASA NTRS2004

A Bootstrap Approach to Martian Manufacturing

In-Situ Resource Utilization (ISRU) is an essential element of any affordable strategy for a sustained human presence on Mars. Ideally, Martian habitats would be extremely massive to allow plenty of room to comfortably live and work, as well as to protect the occupants from the environment. Moreover, transportation and power generation systems would also require significant mass if affordable. For our approach to ISRU, we use the industrialization of the U.S. as a metaphor. The 19th century started with small blacksmith shops and ended with massive steel mills primarily accomplished by blacksmiths increasing their production capacity and product size to create larger shops, which produced small mills, which produced the large steel mills that industrialized the country. Most of the mass of a steel mill is comprised of steel in simple shapes, which are produced and repaired with few pieces of equipment also mostly made of steel in basic shapes. Due to this simplicity, we expect that the 19th century manufacturing growth can be repeated on Mars in the 21st century using robots as the primary labor force. We suggest a "bootstrap" approach to manufacturing on Mars that uses a "seed" manufacturing system that uses regolith to create major structural components and spare parts. The regolith would be melted, foamed, and sintered as needed to fabricate parts using casting and solid freeform fabrication techniques. Complex components, such as electronics, would be brought from Earth and integrated as needed. These parts would be assembled to create additional manufacturing systems, which can be both more capable and higher capacity. These subsequent manufacturing systems could refine vast amounts of raw materials to create large components, as well as assemble equipment, habitats, pressure vessels, cranes, pipelines, railways, trains, power generation stations, and other facilities needed to economically maintain a sustained human presence on Mars.

Dorais, Gregory A.↗
DOE OSTI2023

Determining the Effects of Neutron Irradiation on the Structural Integrity of Additively Manufactured Heat Exchangers for Very Small Modular Reactor Applications, DOE Final Report (Project # 19-16980)

Auburn University (AU) teamed with the University of Missouri Research Reactor (MURR) and Kansas State University (KSU) to determine how to best use laser-powder bed fusion (L-PBF) additive manufacturing (AM) methods for generating radiation resistant nickel-based superalloys, Inconel alloy 625 and 718, for special purpose reactor (SPR) or very small modular reactor (vSMR) heat-exchangers (HeXs). Compact, conformal, and durable HeXs that are tolerant of extreme environments are needed for supporting the technical maturity of next-generation, portable compact reactors. AM is an enabler for realizing this new wave of HeXs – providing a means to make customizable hot and cold stream architectures with novel flow path geometries (e.g., tortuous channels with non-uniform, asymmetric cross-sections) and reduced layer-to-layer contact resistance (i.e., no separate bonding procedure required). AM further enables a more time/cost efficient means for fabricating SPRs by reducing the number of suppliers required for HeX assembly and allowing for on-site HeX fabrication. The project aim has been to better understand how neutron irradiation affects the microstructure and properties of additively manufactured nickel-based superalloys, to accelerate their safe, reliable use in the modular reactor industry. The major objective was to qualify/quantify the microstructure and microhardness of nickel-based superalloys (including Inconel 718 and 625) additively manufactured via the L-PBF process in the neutron-dosed (irradiated) and non-irradiated states over a course of 3 years. Effects of build orientation during L-PBF and post-AM heat treatments on neutron resistance, microstructure and mechanical properties were also investigated. Neutron damage mechanisms via hardening were characterized. This project combined subject-matter experts in AM, mechanical/microstructure metallic part characterization, and neutron irradiation, as well as unique assets and capabilities at AU and MURR at MU, to ensure project results translated to effectively addressing known gaps in nuclear science and engineering. Parts were fabricated using L-PBF systems readily available at AU. Specimens were then irradiated using MURR facilities; a manipulator equipped hot cell was also used to measure material hardness after dosing. MURR, a 10 MW, light-water nuclear reactor, is the largest, highest powered, highest-flux university owned research reactor in the U.S. The major findings in this project provide evidence that AM can serve as an alternative way to build structural components for future advanced small modular reactors using advanced materials like Inconel 625 (IN625) or Inconel 718 (IN718). After full spectrum neutron irradiation, vertically as-built AM IN625 samples were observed to display better resistance towards radiation-induced-hardening defects relative to traditionally machined metals. A Vickers microhardness tester, using settings of 1 kgf and dwell time of 15 seconds per indentation, was used to measure hardness in this study. The as-built, vertically printed samples experienced 1.2% of radiation hardening vs. 5.25% radiation hardening observed in wrought IN625. Another set of IN625 and IN718 samples were exposed to fast neutron irradiation. It was observed that IN718 showed more resistance towards radiation hardening compared to IN625 samples indicating IN718 had a better performance. Results showed that the IN718 samples experienced less change (-2.5 to 3.24 %) in microhardness. On the other hand, IN625 samples underwent more (0.9 to 7.21%) change in microhardness after fast neutron irradiation. AM IN625 samples were irradiated using an ion (proton) beam in cyclotron. The mechanical properties of AM samples post irradiation were compared with wrought samples. The irradiated region on the samples were tested using nano-hardness indention. It was observed that the beam current and time used in this study generated an annealing effect and thus reduced the hardness of the samples. The sum of the project results provide precious insight into how one may minimize radiation hardening in AM materials while maintaining material property constraints. Results should assist engineers in selecting an appropriate heat treatment for AM nickel-based superalloys for increased radiation resistance. Results should increase confidence levels for adopting AM for building nuclear reactor components which perform the same or better than conventionally manufactured components. Fast neutron irradiation testing provided an accelerated means of obtaining radiation effects without making materials radioactive and difficult to handle.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Aerogel with Unparalleled Performance and Cost-Effectiveness for All Insulation Needs (CRADA Final Report)

Westwood Aerogel investigated the reproducible production of an ambiently or electromagnetic spectrum assisted drying of extremely porous aerogel materials. Traditional aerogel processing is limited by low throughput and scalability due to supercritical drying. Westwood Aerogel’s advanced manufacturing process enables commercialization and deployment at scale, making aerogel materials more accessible to a range of industries and applications. We focused on shifting from the lab scale environment to manufacturing prototypes. The initial manufacturing model is based on the float glass process, which is the industry standard for glass window production, and the paper drying process. By incorporating an ambient drying process a continuous line model can be used from start to finish. The project team worked to develop a continuous manufacturing system to scale-up and reduce costs while maintaining the lightweight and insulative properties of aerospace-grade aerogel. While aerogels are extremely insulative, lightweight, and thin materials (making them ideal insulators across application spaces), high costs and stagnant innovation have hampered their wider adoption. Traditional manufacturing of aerogel requires supercritical extraction of pore fluid to obtain highly insulating materials, which is an energy intensive batch process and limits aerogel production output. Westwood Aerogel’s proprietary ambient drying process enables the continuous production of highly insulative aerogel materials without the use of supercritical extraction.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Materials in Extremes [Slides]

Goals: Realization of advanced predictive models that capture aspects of processing structure-properties-performance (PSPP) in ways that build on scale bridging, data science, and transformational physics insights from experiments; Based on a robust and seamless integration of sample manufacturing, characterization (pre- and post-mortem), theory and simulation, and novel experiments; Ultimately we want to be able to reliably predict performance, and control the functionality of materials in extreme environments.

36 MATERIALS SCIENCE↗