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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Developing Microalgae-Based Non-Isocyanate Polyurethane Foam Materials

Polyurethane is a versatile material with a wide range of applications in the production of foam products such as car seats, mattresses, footwear, insulation foam, and more. The traditional process for producing polyurethane foam involves the fast reaction of isocyanate with water, which generates CO2 as a blowing agent. However, the use of isocyanate has raised concerns due to its potential for causing allergic reactions and aspiration symptoms. This has led to increased regulation of isocyanate, leading to a growing interest in developing alternatives. Non-isocyanate polyurethane (NIPU) has emerged as a promising alternative to traditional toxic PU production. The most promising approach for producing NIPU is the aminolysis of cyclic carbonate with diamine. The NIPU produced through this process has a polyhydroxyurethane structure, which is similar to traditional PU chemistry. We have demonstrated that microalgal oil is a favored feedstock, as it can provide high reactivity for industrial applications. However, the NIPU production process does not generate gas, and a blowing agent is required to achieve the desired foam structure. One of the challenges in producing NIPU foam is to match the bubble formation and curing rates. We have developed a novel approach to producing NIPU foam that utilizes carbamate as a bifunctional blowing and crosslinking agent. We have used vegetable oil and microalgal oil as feedstocks to produce various NIPU for characterization. The development of microalgal NIPU provides an exciting opportunity for reducing the environmental impact of foam production and improving the safety of the materials used in the production process. The production of value-added NIPU foam can also drive down the cost of microalgal biorefinery, advancing the commercialization of microalgal biofuel.

algae↗
DOE OSTI2026

Develop Renewable/Sustainable Material to Displace Petroleum-Derived Polymer Foams (CRADA Final Report)

NLR and EDEN will partner together to develop renewable, biodegradable alternatives to polyfoam (polyurethane) polymer foams. The initial focus will be on developing cellulose-based foam with tunable mechanical properties. NLR will produce and test the cellulose-based foam materials and characterize its microstructure and mechanical properties. Relationships between mechanical performance formulation and fabrication methods will be developed.

09 BIOMASS FUELS↗
DOE OSTI2025

FY25 Cellular Silicone Foam Friction Testing Summary Report

This effort was a collaboration between LANL groups MPA-CINT, E-13, and V-14 to characterize various properties of foam materials for programmatic work. Specifically, MPA-CINT staff members’ contribution to this effort was to perform friction testing of cellular silicone foams of two different porosities with respect to two engineering materials with predefined surface roughnesses. The selected foams (henceforth serving as the sled material interface exposed to motion) had porosities of 67% and 70% with respect to fabricated values. The other materials used in the friction testing measurement couple (static track material) were 304 Stainless Steel (304 SS) and Very High-Temperature Glass-Mica Ceramic, known as Macor®.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Absolute Hugoniot measurements in low-density plastic foams on the NIKE shock compression platform

The propagation of Mbar-range shock waves in low-density foam materials is of interest to target design in all approaches to inertial confinement fusion, high energy density physics, and laboratory astrophysics. We report absolute Hugoniot measurements for CH 1.72 N 0.086 O 0.37 plastic foams with 73 and 94 mg/cm 3 densities in the 32–107 km/s shock velocity range. The experiments were performed on the shock compression platform developed on the NIKE KrF laser facility at the U.S. Naval Research Laboratory. NIKE's 4 or 8-ns long flat-top laser pulses drive steady shock waves into foam targets at the ablative pressures of 1–7 Mbar. The propagation of the ablation and shock fronts is tracked continuously in time using streaked side-on monochromatic x-ray imaging radiography. The straight x−t trajectories of the shock and ablation fronts in the recorded streak images confirmed their steadiness. The SESAME tabulated equation of state predictions generally agrees with our Hugoniot data within a 95% confidence band. The experimental uncertainty of the evaluated shock density compression ratios remains large, indicating the need for more experiments and improved theoretical understanding of the strong shock propagation mechanisms in dry foams.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Foam and Unreacted Material Reduction in Magnesium Oxysulfate for SRPPF Waste Solidification

A magnesium oxysulfate (MOS) grout formulation has been proposed to solidify the liquid effluent from the Savannah River Plutonium Processing Facility (SRPPF) Aqueous Recovery System (ARS). This formulation uses a combination of light-burnt MgO, anhydrous MgSO 4 , and dead-burnt MgO resulting in a grout with good mixability and acceptable density. The setting time for the grout is within the operational limits of the SRPPF facility and the leachate pH is ~9.4, which is within the assumed pH range of the brine from the Waste Isolation Pilot Plant (WIPP). When first tested at the 1-gallon small-scale and 55-gallon full-scale, there was a significant foam layer that raised concerns of a nonhomogeneous final form. A nonhomogeneous mixture could have variable density throughout the waste form and therefore allow for unequal shielding. To reduce the potential for unequal shielding in the final form, a series of foam reduction tests were carried out and a final formulation of 28 wt% light burnt MgO, 10 wt% MgSO 4 , and 62 wt% dead burnt MgO was used to remove the foam in under two hours while still maintaining a mix that has an acceptable density, mix time, peak temperature, and set time.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Minimized aging of isocyanurate-based rigid cellular foams for buildings through tailored barrier facers and optimized formulation

The thermal resistivity (h·ft 2 ·°F/Btu/in.) of closed-cell rigid foam insulation materials significantly decreases over time. Diffusion-tight facers are designed to significantly enhance initial thermal resistivity and long-term thermal performance by preventing gas diffusion into the foam cells and inhibiting the escape of low thermal conductivity blowing agents. In addition to the gas diffusion property of the facer film, adhesion between the foam and the facer is crucial for achieving diffusion-tight bonding. Here, this study addresses the challenge of thermal aging by investigating how facer film properties and foam formulation influence the durability of thermal performance. A systematic evaluation was conducted to understand the effects of polymeric barrier films, surface treatments, facer coverage, and foam matrix rigidity on thermal resistivity over time. Key findings reveal that diffusion-tight facers, particularly those with metallized layers and compatible heat seal layers, significantly reduce gas exchange and improve foam-facer adhesion. The optimized system, incorporating barrier facers and a tailored polyisocyanurate foam formulation, achieved initial and aged thermal resistivity values after 200 days of approximately 8.3 and 7.4 h ft 2 ·°F/Btu/in., respectively representing only a 10 % reduction compared to a 17 % reduction observed in control samples without facers. Notably, polyurethane spray foams with facers exhibited only a 4 % reduction in thermal resistivity, compared to a 23 % decrease in control samples, demonstrating nearly six times better retention of thermal performance. This innovative facer technology presents a promising solution for reducing energy costs and represents a significant advancement in optimizing energy management for building envelopes in future technologies. This technology can also be adapted for other applications that necessitate the preservation of long-term thermal performance.

Wanasinghe, Shiwanka Vidarshi [Oak Ridge National ↗
DOE OSTI2025

Bioinspired Dry‐Steam Superinsulation Straw Foam

Abstract Cellulosic materials offer sustainable advantages for building energy conservation. However, their development has been hindered by reduced thermal performance, often caused by structural collapse during the transition from solution to solid. Inspired by natural goose down, a bio‐based, lightweight insulation foam derived from agricultural waste straw is presented. Through in situ synthesis, bio‐silica fibers with branched structures capable of supporting hollow silica microspheres are fabricated. After steam‐mediated processing, the resulting foam exhibit low density (95 mg cm − 3 ), high porosity (95.5%), low thermal conductivity (0.03 ± 0.003 W mK −1 ), and a cyclic compressive strength of 90 kPa at 50% strain. Owing to the synergistic microstructure formed by branched bio‐fibers and hollow silica spheres, the bio‐silica foam exhibit outstanding thermal insulation performance relative to other bio‐based foams prepared by ambient drying. A passivated insulation panel is further developed by incorporating this material as the core component, achieving a thermal conductivity of 0.0275 W mk −1 and flexural strength of 6.85 MPa. The panel demonstrated durability with stable thermal performance throughout a 60‐day outdoor test. Moreover, the bio‐silica foam shows a carbon footprint of 7.50 kgCO₂ kg −1 at 70.2 wt.% silica, highlighting its promise as a sustainable insulation solution for green buildings.

Chemistry↗
DOE OSTI2024

A novel digital lifecycle for Material‐Process‐Microstructure‐Performance relationships of thermoplastic olefins foams manufactured via supercritical fluid assisted foam injection molding

Abstract This research significantly enhances the applicability of thermoplastic olefins (TPOs) in the automotive industry using supercritical N 2 as a physical foaming agent, effectively addressing the limitations of traditional chemical agents. It merges experimental results with simulations to establish detailed material‐process‐microstructure‐performance (MP2) relationships, targeting 5–20% weight reductions. This innovative approach labeled digital lifecycle (DLC) helps accurately predict tensile, flexural, and impact properties based on the foam microstructure, along with experimentally demonstrating improved paintability. The study combines process simulations with finite element models to develop a comprehensive digital model for accurately predicting mechanical properties. Our findings demonstrate a strong correlation between simulated and experimental data, with about a 5% error across various weight reduction targets, marking significant improvements over existing analytical models. This research highlights the efficacy of physical foaming agents in TPO enhancement and emphasizes the importance of integrating experimental and simulation methods to capture the underlying foaming mechanism to establish material‐process‐microstructure‐performance (MP2) relationships. Highlights Establishes a material‐process‐microstructure‐performance (MP2) for TPO foams Sustainably produces TPO foams using supercritical (ScF) N 2 with 20% lightweighting Shows enhanced paintability for TPO foam improved surface aesthetics Digital lifecycle (DLC) that predicts both foam microstructure and properties DLC maps process effects & microstructure onto FEA mesh for precise prediction

Engineering↗
DOE OSTI2025

Shape‐Stabilization of Phase Change Materials with Carbon‐Conscious Poly(hydroxy)Urethane Foams

Thermal energy regulation is a significant challenge, contributing to over 30% of annual greenhouse gas emission (GHG) emissions. Phase change materials (PCMs) offer a promising solution by storing thermal energy, which can enable the reuse of waste heat for heating and cooling; however, developing materials for shape-stabilized PCMs remains crucial. This work investigates a self-foaming poly(hydroxy)urethane (PHU), derived from a non-isocyanate polyurethane (NIPU), as a porous support for shape-stabilizing paraffinic and salt hydrate PCMs. PHU-encapsulated paraffinic PCMs exhibited excellent thermal stability over repeated cycles. Thermal stability with salt hydrate PCMs, specifically calcium chloride hexahydrate (CaCl 2 •6H 2 O), is achieved by the incorporation of 5 wt.% barium carbonate (BaCO 3 ) into the PHU foam. This enabled stable cycling for over 48 cycles with desirable thermal properties, i.e., a melting point ≈30 °C, high enthalpy (ca. 138 J g −1 per cycle), and a consistent freezing point ≈20 °C, making it suitable for applications in buildings and electric vehicle battery insulation. Also, incorporating graphite (1.5–10 wt.%) into the foam enhanced the thermal conductivity of shape-stabilized CaCl 2 •6H 2 O during heating and cooling cycles. Overall, the approach detailed here offers a carbon-conscious and chemically tunable material for thermal energy storage.

25 ENERGY STORAGE↗
DOE OSTI2025

Foaming prediction in pure liquids from dimensionless numbers inspired by the theory of fluid behavior for drops

Foaming prediction is critical for selecting materials and designing processes in industries such as bioprocessing and gas processing. Existing models lack the generality needed for a wide range of materials and overlook the foaming behavior in pure liquids. Here, this work presents a novel method for predicting foaming in pure liquids based on their density, surface tension, and viscosity, using Reynolds ( Re ) and Ohnesorge ( Oh ) numbers. A foaming prediction map, leveraging the theory of fluid drop behavior, was developed by plotting these numbers. This map delineates distinct non-foaming and foaming regions, functioning as a binary classifier for foaming predictions. The map was fitted and validated through shake test experiments on 46 liquids, demonstrating reliable predictions, except for a specific region characterized by small Oh and large Re numbers. This region corresponded to relatively low foam stability and high turbulence, making foaming predictions challenging for liquids in this category.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

ThermoPI—an Online Tool to Calculate Heat Transfer Through Foam Insulation

Thermal insulation materials with ultra-low effective thermal conductivity are crucial for a multitude of applications. Over the years, a significant amount of experimental work has been dedicated to creating new insulation materials with low thermal conductivity. Similarly, substantial efforts have been made to enhance the theoretical understanding of thermal transport mechanisms in thermal insulation materials and to push the boundaries of lower thermal conductivity. However, ample room remains for enhancing the thermal resistivity of closed-cell foam insulations. To aid in the development of ultra-low effective thermal conductivity foam insulations, Oak Ridge National Laboratory has introduced a unique online tool, ThermoPI. This tool calculates not only the effective thermal conductivity but also the thermal conductivity components for porous materials, including gases, solids, and radiative, based on the materials’ structural information (e.g., porosity, pore size, gas species, pressure, solid species, pore geometry, and temperature).This tool collected and improved the existing theoretical models for thermal insulation materials’ gas, solid, and radiative thermal conductivity. These improved models have been validated with experimental data. Effective medium theory and sound velocity softening effects are considered for solid thermal conductivity. The built-in solid materials include polystyrene, polyurethane, polyethylene, and silica. Users are allowed to input new solid materials that are not built inside the tool. For gas thermal conductivity, the subcontinuum Knudsen effect is considered. In addition to several built-in gases, users can input new gases. For solid and radiative thermal conductivity calculations, several models are available to select, and the tool can determine the best model to choose based on the materials that users input. Users are also allowed to change selections manually. In addition, the tool can also calculate the effect of interfacial resistance on the overall thermal conductivity of layered materials. This work will elaborate on the tool and discuss how it can guide the development of new insulation products.

Shrestha, Som [ORNL] (ORCID:0000000183993797)↗
DOE OSTI2026

Advanced Materials for Plasma-Exposed Robust Electrodes

The AMPERE project developed a new class of electrode materials that dramatically improve fusion device performance and longevity. By using Volumetrically Complex Materials (VCMs)—advanced porous metal foams optimized via plasma-material interaction science—the project achieved up to 85% reduction in sputtering erosion under fusion-relevant plasma conditions, far surpassing the goal of 40% reduction. This means these novel electrodes produce far fewer impurities and debris in the plasma, addressing a key challenge in fusion reactors by allowing greater plasma efficiency and power output due to the reduction of power losses due to unwanted interactions with wall-borne impurities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Nanoengineered Shape-Memory Hemostat

Uncontrolled hemorrhage is the predominant cause of preventable combat deaths. Various biomaterials serve as hemostatic agents due to their procoagulant or absorptive activity. However, these biomaterials often lack expansion capabilities, which severely limits use in noncompressible wounds. This study combines a hemostatic nanocomposite with a shape-memory polymer foam to design a composite material with both hemostatic and physical expansion properties. This composite is fabricated in two formulations: a foam externally coated in a highly concentrated nanocomposite (“coated composite”) and a foam containing a diluted nanocomposite infused throughout its pores (“infused composite”). Both formulations retain the shape-memory foam's expansion property. Further, the coated composite shows improved fluid uptake (>2-fold) versus infused composites or foam. The nanocomposite component dissociates from the foam under degradative conditions, with the foam remaining stable for 30 days. Hemostatic studies illustrate that the coated composite reduces the clotting time by ≈20%. Alternatively, the infused composite improves clotting over a larger distance (up to ≈2× distance from the composite). These results signify a modular hemostatic ability: the coated composite reduces clotting and improves fluid uptake, while the infused composite achieves diffuse clotting and maintains mechanical properties. Thus, these materials pose a strong potential for use in noncompressible wounds.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Using low cost, bio-derived and recycled materials in advanced scalable small- and medium- wind turbine manufacturing

In partnership with Bergey Windpower, this project explored the use of recyclable and recycled materials in small- to medium-wind turbine blades (WTBs). A recyclable epoxy resin and infusible thermoplastic resin were investigated using identical fiber reinforcements and manufacturing practices used as Bergey, and the substitution of continuous virgin glass fiber (GF) layers with recycled nonwoven GF (rGF, NW) mats was trialed. The alternative resins both showed very promising performance in terms of static tensile and flexural behavior as well as thermal properties and fatigue behavior in comparison with that of the incumbent materials used at Bergey. The NW rGF materials, however, were found to be a poor substitute for the continuous GF materials for two primary reasons. Firstly, the NW mats took up significantly more resin than their continuous counterparts, which would increase both the weight and the cost of the WTBs. Additionally, an unexpected reaction occurred between the rGF and epoxy materials that resulted in a highly porous, foamed structure. The foaming phenomenon was not observed with the rGF NW and infusible thermoplastic material, but the resin uptake was still prohibitively high. Based on the results of this study, recyclable infusible resins could be viable candidate materials for Bergey in the future. The foaming reaction with the rGF NW mats could prove highly useful in other applications requiring structural foams and has been used to produce demonstrative sandwich panels.

17 WIND ENERGY↗
DOE OSTI2025

Synthesis and Characterization of Soy Hull Biochar-Based Flexible Polyurethane Foam Composites

Flexible polyurethane foams are a diverse class of materials encompassing furniture, packaging, automotive, and many other industrial and domestic applications. Polyurethane foams are synthesized by the addition of polyols and isocyanates; however, the petroleum origin and toxic nature of isocyanates have driven many to look for more sustainable routes to production. Renewable fillers have emerged as a biobased resource to decrease the carbon footprint of this widely used polymeric material. In this study, soy hulls, as mass-produced, industrial by-products of soybean production, were used to create a biochar beneficial in the synthesis of flexible polyurethane foam composites. The addition of soy hull biochar was found to maintain the compression properties of foams at a decreasing isocyanate index, reducing the amount of isocyanates needed for production. In addition, the addition of biochar decreased the flammability of foams, important for many applications where consumer safety is important. The results point to the ability to create safer, more sustainable, and even more cost-effective polyurethane foams through the reduction in isocyanate use while maintaining the properties of this important class of polymers.

Chemistry↗
DOE OSTI2025

Heat Transfer in Void Generating Foam Decomposition: Further Development

Continued development of the additive conductivity material model, used to simulate changes in heat transfer that occurs in void generating foam decomposition, has resulted in an improved model and new features. The previous version of the model was calibrated against the Aria Bulk Fluid Element (BFE) solution and proposed a third-order polynomial correction term best captured the increased heat transfer due to voids in the foam. An investigation of the Fuego Conjugate Heat Transfer (CHT) and Aria BFE solutions at several geometries revealed the CHT solution and BFE solution had differing behavior across length scales, especially at smaller scales. Five calibration studies, using the Fuego CHT as the calibration data, were carried out with polynomial functions of 4-th, 3-rd, 2-nd, 1-st and 0-th orders to determine the best correction function that generalized well across length scales. Each polynomial function was calibrated/trained on six different sized geometries and then tested on three uniquely sized geometries. This study revealed that the 1-st order additive conductivity model performed the best. A new feature of void formation scaling was implemented to more realistically capture the heat transfer as voids are created. A scaling term was added to the model to activate the conductivity correction as decomposition progresses.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Coal-Waste-Enhanced Filaments for Additive Manufacturing of High-Temperature Plastics and Ceramic Composites

In the United States, coal waste from over a century of mining and burning coal for heat and electricity has accumulated as mountains of coal fly ash and bottom ash and acre-size ponds, coal fines and gob. These materials can be a problem for local communities and water systems. A cost-effective process to utilize high volumes of these coal wastes in a high-value product would be beneficial to those communities by reducing the amount of waste and providing jobs, manufacturing components, and materials from the waste. Many coal-to-products technologies (e.g., carbon fibers, graphene, carbon foam) rely on carefully choosing the starting material and then altering it chemically or thermally to make the products work. Due to the wide variability of composition and coal content in typical coal waste streams, many high-volume coal waste streams are likely to be unsuitable for use in those technologies. Semplastics’ technology has been shown to utilize most types of coal waste successfully without any pre-selection or pre-processing requirements other than a nominal particle-size reduction for wastes like bottom ash. This characteristic of Semplastics’ solution may enable the use of much larger volumes of a wider range of coal wastes than other coal-to-products technologies. In this project, Semplastics leveraged its unique experience with both coal waste (fly ash or coal combustion residuals), resin materials, and 3D printing to develop 3D printer filaments using common coal wastes – bituminous coal fines and fly ash – and researched the feasibility of using other forms of coal waste as fillers. Simple 3D-printed parts were successfully produced from the coal waste enhanced filaments, which were found to have improved strength and stiffness.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

The role of moisture in MgCl 2 salt: A multiscale approach to TES performance

This study presents a comprehensive multiscale analysis to evaluate the influence of moisture on the thermal performance of thermal energy storage systems using magnesium chloride (MgCl 2 ) as the phase-changing material. The system uses graphite foam with 90% relative density to enhance thermal conductivity. The analysis includes thermal conductivity calculations and specific heat capacity for different hydrate phases of MgCl 2 : Anhydrous, Mono, Di, Tetra, and Hexa. These properties were evaluated for the first time using the phonon density of states from Density Functional Theory simulations. Results showed that thermal conductivity decreased, while specific heat capacity increased by a factor of two as the phase changed from anhydrous to hexahydrate. Meso-scale models were created to account for the anisotropy of graphite foam and property variations of the MgCl 2 hydrate phases. Asymptotic Expansion homogenization simulations determined the anisotropic thermal conductivity for all phases. This unique methodology improved simulation accuracy, which matched experimental data for anhydrous MgCl 2 . A parametric study examined various operating conditions and their effect on TES performance. It revealed that higher charging temperatures did not enhance exergy efficiency, but increased discharge mass flow rates improved it due to better heat transfer. Thermal performance evaluated by the exergy efficiency remained consistent across hydrate systems under the tested conditions. Furthermore, the study suggests that this uniformity is linked to missing key data, particularly latent heat and melting point for different hydrates. Overall, it highlights the importance of multiscale effects and accurate material properties in designing and optimizing TES systems.

Molten salt degradation↗