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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 OSTI2023

Controlled In Situ Foaming for Mechanical Responsiveness of Architected Foams

Addition of chemical blowing agents to polysiloxane resins produces foams with closed–cell morphology. Combining this chemistry with the 3D–printing technique direct ink writing (DIW) permits the creation of architected foams with controllable, hierarchical tiers of porosity. Here, using a two–component foaming ink, the extent of foaming can be controlled by incorporating an active mixing printhead as part of the fabrication process. Changes in the mixing speed allows for in situ control of the foaming reaction where the mixing speed is directly correlated with the resulting foaming that occurs upon extrusion. These architected foams display tunable mechanical responses, porosities, and open–to–closed cell ratios. While chemically blown polysiloxane foam is a well–established material, utilizing DIW as fabrication technique presents a novel approach for creating tailored, architected foams that require minimal post–processing.

36 MATERIALS SCIENCE↗
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

Examining astrophysical gas cloud collapse using an optical depth-scaled, x-ray-irradiated, carbon-foam sphere

When stellar radiation interacts with a molecular cloud, the cloud's fate depends on the strength of the incident radiation and the radiation's mean-free-path within the cloud [F. Bertoldi, Astrophys. J. 346, 735–755 (1989)]. Under the right conditions, the radiation compresses the cloud and a star formation may occur. Where and when the stellar formation occurs in the cloud's collapse are open questions. Direct observation of the complete star–cloud lifecycle is nearly impossible due to the immense timescales and distances over which the interaction occurs. Laboratory astrophysics offers a way to investigate such a system by scaling the important astrophysical parameters to the laboratory. This work describes laboratory experiments to study the radiation-driven implosion of clouds, using x rays from a laser-irradiated, thin, gold foil as a surrogate star and a carbon-foam sphere as a surrogate cloud. An optically thick system, theoretically corresponding to a star-forming regime, was selected by choice of the foam density. Gold foil and sphere motions were imaged by x-ray radiography. Radiographic images show the formation of an interface between rarefied gold and carbon plasmas, a shock moving into the sphere, and a blunting of the initial sphere's shape. Measurements show that the shock moved linearly around 64 μm/ns into the sphere, and the gold–carbon interface formed by 2 ns at the sphere edge remained stationary. The deformation of the sphere was driven by the incident radiation and not by mechanical pressures applied by gold plasma. The blunting of the sphere was likely due to the geometric reduction of flux near the sphere's poles. Higher x-ray flux near the sphere's equator caused high compression and a faster shock, which flattened the sphere. We will discuss the results and implications of our observations.

VanDervort, R. W. [University of Michigan 1 , Ann ↗
DOE OSTI2023

Stability study of aqueous foams under high-temperature and high-pressure conditions relevant to Enhanced Geothermal Systems (EGS)

In Enhanced Geothermal System (EGS) hydraulic fracturing is carried out by injecting cold water into deep Hot Dry Rocks (HDR) under carefully controlled conditions to create new or reopen existing fractures. Water-based fracturing fluids demonstrate some challenges including immense quantity of water usage, water sensitivity of the formations, water blocking, and lack of proppant carrying capacity and transportation. Thus, an alternative is to use foam-based fracturing fluid which offers potential advantage over conventional water-based fracturing fluid such as minimum water usage, reduced wellbore damage, high proppant carrying capacity, and less environmental damage. However, foams are complex mixture of gaseous phase and liquid phase which are thermodynamically unstable at downhole conditions, and their stability can decrease over time due to liquid drainage, bubble coarsening, and coalescence. This paper shows laboratory experiments executed to study foam stability at high temperature (200°C) and high pressure (6.9MPa) conditions which simulates the geothermal environment. Foam stability was characterized by half-life of foam, which is defined as the time taken by the foam to decreases by 50% of its original height due to drainage. In this paper, two types of gaseous phases, nitrogen (N 2 ) and carbon dioxide (CO 2 ) were investigated. Also, based on successful practice of foam-based fracturing fluid in oil and gas industries, four surfactants, including Alpha olefin sulfonate (AOS), Sodium dodecyl sulfonate (SDS), Tergitol™ (NP – 40), and Cetyltrimethylammonium chloride (CTAC) at optimum concentration of 1wt.% were tested for best stability performance. In addition, different stabilizing agents including guar gum, bentonite clay, crosslinker, silicon dioxide nanoparticles (SiO 2 ), graphene oxide (GO) were also studied. Experimental results showed that N 2 foams were more stable than CO 2 foams. It was observed that foam half-life decreased with the increase in temperature. Among all the surfactants, AOS foams showed the most promising thermal stability at high temperatures. Moreover, with the addition of stabilizing agents, foam's half-life was enhanced. Stabilizing agents such as crosslinker and GO dispersion showed the most stable foams with half-life recorded at 20min and 17min, respectively, at 200°C and 6.9MPa. Finally, pressure also showed a positive effect on foam stability; with increased pressure, foam half-life was increased. Based on the experimental data, analytical models for the effect of temperature and pressure were developed, considering foam degradation is a first-order kinetic reaction that linearly depends on the foam drainage mechanism. The effect of temperature on foam half-life was studied as an exponential decay model. In this model, foam half-life is a function of drainage rate constant (D A ) and activation energy (E a ) of the foam system. The effect of pressure on foam half-life was found to obey a power-law model where an increase in pressure showed an increase in foam half-life. Furthermore, a linear relation was studied for the effect of pressure on foam activation energy and drainage rate. Then the combined effects of temperature and pressure were studied, which yielded an analytical model to predict the foam stabilities in terms of half-life for different foam compositions. In conclusion, this research indicates that with an appropriate selection of surfactants and stabilizing agents, it is possible to obtain stable foams, which could replace conventional water fracturing fluid under EGS conditions.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

CHIPFoam Modification to Allow for Modelling SWIFT Foams

SWIFT (Silicon-water in Familiar Template) foams are silicone foams that have a continuous porosity without having any obvious spherical or ellipsoidal pore shapes. Like other foamed rubber, SWIFT foams can experience large reversible deformations. Because of their microstructure, SWIFT foams have a stiffering behavior in compression that is very abrupt compared to most other foamed rubbers. Work by Benedikt reported by Miller showed that fitting compressive test data with the CHIPFoam model in its current form is impractical and inaccurate. This report describes an extension made to CHIPFoam to allow the modeling of SWIFT foams. While the extension allows the modeling of SWIFT foams, it also extends the range of porosity of foams that can be modelled with CHIPFoam to include very high porosity (>99%) foamed rubber. The previous model was unstable for porosities greater than 70%. The changes made to CHIPFoam include the introduction of a critical porosity at which the compressible Danielsson strain energy function that couples volumetric and deviatoric mechanical behavior begins to increase with compression. This new feature also required the introduction of a third term in the multiplicative decomposition of the relative volume, J . The organization of this report is described here. The first section, SWIFT Foam Structure and Mechanical Behavior, describes the structure of SWIFT foams as contrasted to other foamed rubbers. It also contrasts the mechanical behavior of SWIFT foams to other more traditional foamed rubbers. The second section, CHIPFoam Modifications, describes the specific modifications done to be able to modify the delayed rapid compressive stiffening seen in SWIFT foams. The third section, Results, demonstrates the use of the modified model to fit compressive loading response data from a SWIFT foam sample. The fourth section, Conclusions and Further Work, puts the work in perspective and presents likely further work.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Assessment of Bulk Oxygen Capacity and Transient Redox Behavior of Foamed Lanthanum Strontium Manganese Perovskites

Synthesis of solar thermochemical hydrogen (STCH) production redox materials with engineered structures, for example, replica foams, can enable efficient heat and mass transport and are critical for scaled-up systems. Prior work has motivated the use of lanthanum strontium manganese (LSM)-type perovskites as foamed STCH materials, but the effect of their morphology on bulk and kinetic behavior has not been reported. In this work, replica and direct foamed samples of La 0.65 Sr 0.35 MnO 3-δ (LSM35) were fabricated and compared to synthesized powders and dense monoliths, and similarly synthesized CeO 2-δ (ceria) foams, regarding their specific reaction rates and bulk oxygen capacity/H 2 yields. Changes in oxygen capacity (Δδ) and reaction rates were measured between 1200 °C and 1400 °C by using fixed ratios of steam and hydrogen during both reduction and oxidation steps, allowing for analysis under practical high conversion conditions. Results suggest bulk behavior and reaction rates of the foamed LSM materials are comparable to their powder analogues. Differences in reaction rates were observed only when replica foamed samples were subjected to rapid laser heating (emulating conditions expected in solar furnaces), which is expected but has not been demonstrated at such a small scale. Here, foamed samples were further subjected to 50 redox cycles at 1400 °C to evaluate their stability. Results show no statistically significant decrease in hydrogen production for any of the foamed samples, but the direct foamed samples became brittle with time. Together, these results demonstrate the viability of replica foamed LSM perovskites for integration in scaled-up STCH systems.

08 HYDROGEN↗
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 OSTI2023

Heat transfer model for moving packed-bed particle-to-sCO 2 heat exchangers integrated with metal foams

Particle-to-supercritical carbon dioxide (sCO 2 ) heat exchangers (HXs) play a vital role in coupling heat transfer fluid (HTF) from high-temperature thermal receivers to power cycle working fluids (WF). Heat transfer enhancement is essential for adopting particle-based moving packed-bed heat exchangers (MPBHXs) in next-generation thermal energy storage (TES) systems, as MPBHXs usually exhibit low particle bed-to-wall heat transfer coefficients. High-porosity metal foams have shown their effectiveness in heat transfer enhancement. Here, this work presents a continuum heat transfer model to demonstrate the heat transfer enhancement in MPBHXs when the particle bed channel is filled with high porosity metal foams compared to open channel MPBHXs. The presence of metal foams increases the effective thermal conductivity in the particle channel and enhances the interstitial heat transfer coefficient between the moving particle bed and the stationary metal foams. The present model considers coupled two-dimensional (2D) heat transfer in the particle channel with metal foams and 1D heat transfer in the sCO 2 channel and the dividing wall. The temperature profiles for the particle bed, metal foam, dividing wall, and sCO 2 stream, as well as the local heat flux profiles between those, are studied in detail for various foam porosities, from which the particle bed-to-wall heat transfer coefficient, overall heat transfer coefficient, and total heat transfer rate for the MPBHX are determined. The effects of major MPBHX design and operating parameters on the particle bed-to-wall heat transfer coefficient and overall heat exchange capacity are thoroughly examined; thus, the MPBHX performance improvement with metal foams is quantified for each case. The present heat transfer model can provide valuable insights into the metal-foam MPBHX design and optimization, scale-up, and operating parameters selection.

42 ENGINEERING↗
DOE OSTI2025

Fatty acid foams for nonselective physical removal of microplastics from aqueous solutions

Microplastics (MPs) are pervasive environmental contaminants whose removal from water remains a major challenge due to their small size, chemical diversity, and dynamic surface properties arising from environmental aging/weathering. Here, we present a concept of foam-based separation method that physically traps MPs in the foam phase using microtubular assemblies of 12-hydroxystearic acid. These foams are stabilized by anisotropic fatty acid microtubules formed in the presence of ethanolamine, which jam within the foam channels and suppress fluid drainage thereby enhancing MP retention and foam stability. MPs of different sizes, polymer compositions (including polystyrene, polypropylene, polyethylene terephthalate, and polytetrafluoroethylene), and weathered states were retained in the foam phase without requiring chemical modification or relying on chemical interactions between the fatty acid and MPs. Thermally induced transition of the fatty acid microtubules into nanomicelles above the characteristic phase transition temperature (∼35 °C) enables controlled foam collapse and recovery of trapped MPs. The cumulative removal efficiency can exceed 85% through multiple foaming cycles, matching predictions from a probabilistic retention model. This work shows that foams can provide a simple platform to trap MPs, thus providing a new physical-removal strategy that does not rely on the particles’ chemistry.

Guillot, Kennedy A. [Louisiana State Univ., Baton ↗
DOE OSTI2023

Evaluation of the relative importance of preheat from hohlraum x rays and a radiative shock on a low-density foam

Indirectly driven shock-tube experiments were performed on the Omega Laser Facility to evaluate the relative importance of hohlraum x ray and radiative shock preheat sources on a low-density foam. X rays emitted from the hohlraum and a subsequent shock wave are channeled into a low-density foam sample, which contains a plastic preheat-witness disk placed downstream of the foam. Simultaneous radiographic measurements of the shock speed in the foam and the expansion rate of the witness disk due to preheat allow for the observation of effects from the hohlraum's low-energy and high-energy x-ray spectrum. Here we showed, from simulations, that low-energy x rays from the hohlraum are preferentially absorbed near the ablator surface (where the hohlraum and the shock tube meet), while higher-energy x rays largely pass through the ablator and foam and are volumetrically absorbed by the witness disk. Reproducing the experimentally measured shock speed and expansion of the witness disk simultaneously, we extracted the temperature evolution of preheated foam from the simulation and evaluated the relative importance of preheat sources on a low-density foam from hohlraum x-ray radiation and radiative shock. We found that radiation from the shock front was more effective at preheating the low-density foam than the high-energy x rays from the hohlraum. This shock-tube preheat experiment is important for understanding the results of the MARBLE experiments at the National Ignition Facility because initial conditions of foam-filled MARBLE capsules are sensitive to preheat.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
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

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 OSTI2024

Enhancement of the Physical and Mechanical Properties of Cellulose Nanofibril-Reinforced Lignocellulosic Foams for Packaging and Building Applications

Biobased foams have the potential to serve as eco-friendly alternatives to petroleum-based foams, provided they achieve comparable thermomechanical and physical properties. We propose a facile approach to fabricate eco-friendly cellulose nanofibril (CNF)-reinforced thermomechanical pulp (TMP) fiber-based foams via an oven-drying process with thermal conductivity as low as 0.036 W/(m·K) at a 34.4 kg/m3 density. Acrodur®, iron chloride (FeCl3), and cationic polyacrylamide (CPAM) were used to improve the foam properties. Acrodur® did not have any significant effect on the foamability and density of the foams. Mechanical, thermal, cushioning, and water absorption properties of the foams were dependent on the density and interactions of the additives with the fibers. Due to their high density, foams with CPAM and FeCl3 at a 1% additive dosage had significantly higher compressive properties at the expense of slightly higher thermal conductivity. There was slight increase in compressive properties with the addition of Acrodur®. All additives improved the water stability of the foams, rendering them stable even after 24 h of water absorption.

Chemistry↗
DOE OSTI2025

Use of Captured CO2 for Production of Sustainable Polyurethane Foams in Automotive Applications

Captured CO2 has been investigated as a feedstock for the production of polyurethane (PU) foams for automotive applications. Previous work has shown successful incorporation of CO2 into polyols via three distinct reaction pathways. These CO2-derived polyols, as well as several commercially available polyols with varying CO2 content, were used to produce PU foams for automotive seating and NVH (noise, vibration, and harshness) applications. Foam formulations were optimized to maximize sustainable content while maintaining manufacturability constraints and performance requirements for each end use application. PU foams were first formulated at lab scale to confirm free rise and molded foam properties, then scaled up to pilot and industrial scales to evaluate production manufacturing feasibility. Finally, CO2-derived foams were used to produce molded components for end use product validation. Life cycle assessment (LCA) was used to quantify the environmental impact of using captured CO2 and bio-renewable content into polyols and PU foams through the metrics of global warming potential and embodied energy. Tradeoffs among environmental impacts, energy usage, manufacturability, and PU foam performance from the incorporation of CO2 and bio-renewable content will be discussed.

Lee, Ellen [Ford Motor Company]↗