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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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15 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Determining Compression Characteristics of Honeycomb Material - 19674

The objective is to determine compression test characteristics of stainless steel honeycomb material to be able to represent honeycomb structures accurately in analytical models used to simulate hypothetical accident scenarios of shipping packages. Honeycomb is a material used primary in the aerospace industry due to its high strength-to-weight ratio. Because it doesn't have a shelf life and can withstand high heats, it is an excellent candidate for a structural material in package designs. Honeycomb has orthotropic material properties. The honeycomb currently being evaluated is made of metal ribbons spot welded together to form hexagon pattern between metal plates. The hexagon ribbons are brazed to the metal plates. The complexity of the honeycomb significantly lengthens the simulation time, which is further complicated when the brazing, welding, and imperfections of the material is considered. This means to affectively represent the honeycomb in simulation programs, such as Abaqus, the material needs to be approximated as a uniform orthotropic material. This requires material properties in each of the three directions, T, W, and L. The T direction is defined as the 'strong' direction, perpendicular to the honeycomb sheet. The L direction is parallel the ribbon and the W direction is perpendicular to the ribbon. Honeycomb has 3 different compression stages. Stage 1 is the initial compression where the honeycomb maintains its structural integrity and does not permanently deform from loads from normal operations. Stage 2 is when the initial buckling causes irreversible damage to the honeycomb. Stage 2 is the one we are most interested in because it absorbs the most energy from a hypothetical accident scenario. During Stage 2, the honeycomb fails layer-by-layer, indicating that the more layers, the longer material crushing is sustained, and thus the more energy that is absorbed. Stage 3 is final compression, similar to compressing solid metal. During stage 3 the stress increases with a diminishing rate of elongation and the honeycomb is completely failed where the plates between the honeycomb core sandwich the crushed honeycomb ribbon. The stress-strain graph bellow shows compression test of 3 different samples in the T direction. The red lines divide the three stages. The far left is Stage 1, the middle stage 2, and the right stage 3. The data collected is displayed in the table below. The expressions in the table represent the regression formula that represents each stage of the compression on a stress-strain graph. Stage 1 is assumed to intersect with the origin; data for stage 3 for the crush in W and L directions where unable to be gathered due to the nature of failure for those directions. Stage 1 and 2 are linear regressions while stage 3 is a degree 2, to best match the curve. Linear regression is used on stage 2 because ultimately that represents the energy absorbed. With more data, a degree n x 2 regression would be a more appropriate regression for stage 2, where n is the number of layers. The table below is the approximation of each scenario and stage. Each stage starts and ends at the intersection of the next stage. There where two main objectives for these tests: firstly to understand how honeycomb performs under extreme compression, and secondly to be able to numerically represent the honeycomb structure. Both of these where completed to varying degrees. It is important understood how the honeycomb fails. If it is crushed in the T direction it retains its integrity even after being crushed, however when crushed in the L and W crush direction, if it fails, it disintegrates, and loses all integrity. Also, the more layers the more time the material spends in stage 2. Failure is started by buckling, thus if there is any imperfection, the stress will not spike but transition straight into stage 2. The data collected and aggregated can be used for initial simulation of honeycomb used in packages. The initial testing has set the ground work for more data to be collected in order to verify results and to allow more confidence in the simulation results. This is only the initial data collected. The next steps is to continue to collect more data to verify results and to test more variants of honeycomb, with different brazing, layers, and shape.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Additive manufacturing of sandwich panels with continuous fiber reinforced high modulus composite facings

Abstract An improved approach consisting of a combination of fiber placement and fused filament fabrication is introduced for the additive manufacture (AM) of structural grade sandwich beams. Here, sandwich beams are additively manufactured using in‐situ deposition and consolidation of continuous fiber unidirectional facings made from a commingled yarn system of e‐glass fiber (~50% vol.) and amorphous PET, and a hexagonal honeycomb core structure made from PETG. Both facings and the sandwich core are manufactured on a single machine, in one sequence (skin‐core‐skin), employing the benefit of matrix compatibility to create autohesion at the interfaces. Flexural and transverse shear rigidity are determined experimentally and compared with analytical predictions and show correlation to within 3%. Flexural strength and core shear strength are also measured. Post‐mortem examinations show that core fracture and core facing debond were the dominant failure mode in flexure. Single cantilever beam tests were performed to evaluate core facing debond toughness. Subsequently, surface preheat using infrared heaters was utilized to increase autohesion between core and facing. The results show debond toughness was increased 4 times using infrared heating. This research effort presents a manufacturing approach that has the potential for the AM of stiff, well bonded, structural grade sandwich beams, in an integrated sequence, employing in‐situ consolidation to the facings, without the need for the use of intermediate adhesives for skin‐to‐core bonding. Highlights An improved additive manufacturing technique for making sandwich panels is developed. Sandwich panel facings have fiber volume fractions of approximately 50%. Surface preheat improves core‐to‐facing debond toughness by a factor of 4. Top and bottom facings are consolidated during manufacture leading to better properties. Experimental results are compared to analytical predictions and show good correlation.

17 WIND ENERGY↗
DOE OSTI2022

5.1.6 Demo #6: NanoStitch (NAWAStitch) Multifunctional Composites Trade Validation

The overall objective of the NanoStitch Multifunctional Composites Trade Validation Demonstration project was to determine the value proposition of adding NanoStitch to rapid-cure composite systems for structures used in the expanding sector of advanced air mobility (AAM) and specifically electric vertical take-off and landing (eVTOL) aircraft. The expected value proposition was stronger composite parts, with new multifunctional attributes, that are lower cost to fabricate and maintain. NanoStitch is a new composite innovation where a contiguous vertically aligned carbon nanotube (VACNT) forest is located between each ply of a laminate composite resulting in improved mechanical properties as well as other multifunctional properties such as enhanced thermal and electrical conductivity. NanoStitch was originally distributed by N12, later acquired by NAWA Technologies, now called NAWAStitch, and henceforth referred to in this document as NAWAStitch. Two significant evaluations were framed to help meet the overall objective. First, was Task 1 to evaluate the effects that adding NAWAStitch to a rapid cure material system would have on the mechanical and processing properties of the material. Second, was Task 2 to evaluate the workability of adding NAWAStitch to practical flight demonstration articles. From previous research, it was already known that the application of NAWAStitch to a composite structure can enhance the mechanical properties of that structure. However, this project will help the engineering community understand those benefits and the basic structural strength values to apply when incorporating NAWAStitch material into composite structure that utilizes a rapid-cure resin system, which is novel. Testing showed that by adding NAWAStitch to the prepreg, most material properties were improved because the VACNTs strengthened the resin to fiber interface, and the interface itself, between plies. For example compression strength improved by more than 20%, and erosion resistance by more than 50%. The UDRI team identified two flight demonstration articles through discussions with Aurora Flight Sciences (Aurora) and reviewing literature on air mobility and the eVTOL market. The demonstration articles were a thin skin honeycomb panel and a section from an eVTOL propeller blade. The manufacturing and testing trials of the demonstration articles were as follows: • NAWAStitch added no manufacturing complexity or detriment to the article physical qualities, while at the same time added multifunctional properties such as enhanced rain erosion and electrothermal de-icing besides enhanced mechanical properties • VACNTs did not increase or hurt the mechanical properties of the interface between honeycomb core materials and the thin skin face sheet • Demonstrated successful de-icing function in an eVTOL propeller meeting real-world specifications in uniformity and endurance • Multifunctional eVTOL propeller cost analysis showed a cost savings of at least 67 % for a single propeller blade with multifunctional de-icing capability and improved mechanical properties which equates to a potential savings of $10,116 per eVTOL aircraft with six three-bladed propellers Overall, the results of this project can provide additional tools for the composite industry to optimize energy efficiency through faster and stronger composite parts that are lower cost to fabricate and maintain. Additionally, the results of this effort can help US industry like NAWA America set the stage for rapid growth and establishment of a manufacturing facility in Ohio. The project has given NAWA America the basic understanding of how the addition of VACNTs to a composite structure can affect the mechanical properties and hence point them to potential commercial applications. The project has also provided Teijin Carbon US with another potential material application for their rapid cure materials that are manufactured at the Renegade facility in Miamisburg, OH.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Catalytic converters having non-linear flow channels

Disclosed is a honeycomb catalyst substrate core having geometrically non-linear flow channels. In an embodiment, the honeycomb catalyst substrate core includes helical flow channels. In another embodiment, the honeycomb catalyst substrate core includes sinusoidal flow channels. In yet another embodiment, the honeycomb catalyst substrate core includes helical plus sinusoidal flow channels. The honeycomb catalyst substrate core comprises a plurality of parallel non-linear flow channels formed along a longitudinal axis of symmetry of the catalyst substrate core, each non-linear flow channel configured such that eddies occurs during engine exhaust gas flow. Also disclosed is a method for manufacturing a ceramic honeycomb having non-linear flow channels, comprising the steps extrusion soft ceramic material through a die whilst the die moves through six degrees of freedom along its axis of symmetry. Disclosure includes a method for manufacturing a ceramic honeycomb having non-linear flow channels using three-dimensional printing.

Masoudi, Mansour↗
DOE OSTI2020

Catalytic converters having non-linear flow channels

Disclosed is a honeycomb catalyst substrate core having geometrically non-linear flow channels. In an embodiment, the honeycomb catalyst substrate core includes helical flow channels. In another embodiment, the honeycomb catalyst substrate core includes sinusoidal flow channels. In yet another embodiment, the honeycomb catalyst substrate core includes helical plus sinusoidal flow channels. The honeycomb catalyst substrate core comprises a plurality of parallel non-linear flow channels formed along a longitudinal axis of symmetry of the catalyst substrate core, each non-linear flow channel configured such that a turbulent vortical flow occurs during engine exhaust gas flow. Also disclosed is a method for manufacturing a ceramic honeycomb having non-linear flow channels, comprising the steps extrusion soft ceramic material through a die whilst the die moves through six degrees of freedom along its axis of symmetry. Disclosure includes a method for manufacturing a ceramic honeycomb having non-linear flow channels using three-dimensional printing.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

A Novel Honeycomb-DD Multi Coil Design for Wireless Power Transfer Systems

Wireless power transfer (WPT) technology has received significant attention recently as an alternative charging method for batteries in a wide range of power levels. In the literature, many types of coil structures have been well-studied. Honeycomb coil arrays, which have been used mostly for low-power applications, have not been well-studied for high-power-level applications. In this paper, a novel honeycomb-DD coil design is proposed for high-power wireless battery charging systems. The proposed coil design with step by step design process is given and Finite Element Analysis (FEA) was performed to observe the full performance characteristics of the system for a 100 kW system. In addition, the misalignment tolerance of the proposed system was observed by shifting the secondary side charging pad at different misalignment positions, and the electromagnetic compatibility to the standards was investigated. The core and strand losses were obtained. The results show that the honeycomb coil array provides high coupling coefficient and better misalignment tolerance, making it a potential coil topology for WPT applications.

Aydin, Emrullah↗
DOE OSTI2023

1D Magnetic MX 3 Single-Chains (M = Cr, V and X = Cl, Br, I)

Magnetic materials in reduced dimensions are not only excellent platforms for fundamental studies of magnetism, but they play crucial roles in technological advances. The discovery of intrinsic magnetism in monolayer 2D van der Waals systems has sparked enormous interest, but the single-chain limit of 1D magnetic van der Waals materials has been largely unexplored. This paper reports on a family of 1D magnetic van der Waals materials with composition MX 3 (M = Cr, V, and X = Cl, Br, I), prepared in fully-isolated fashion within the protective cores of carbon nanotubes. Atomic-resolution scanning transmission electron microscopy identifies unique structures that differ from the well-known 2D honeycomb lattice MX 3 structure. Density functional theory calculations reveal charge-driven reversible magnetic phase transitions.

1D materials↗
DOE OSTI2023

Topological electride phase of sodium at high pressures and temperatures

Sodium, a textbook example of a nearly-free-electron metal, exhibits unforeseen pressure-induced behavior including the stabilization of numerous polymorphs—some possessing extremely complex unit cells—as well as a metal-to-insulator transition to the iconic hP4 phase. However, until recently, most of the experimental and theoretical studies on solid sodium have been restricted to the low-temperature regime. In this work, using ab initio evolutionary structure searches coupled with quasiharmonic calculations, we discover seven new phases of sodium that are more stable than the known hP4 phase at pressure-temperature conditions that were recently attained in ramp-compression experiments. From these, our calculations suggest that P6 3 /m Na is the ground state between ≈250 GPa at 710 K and ≈350 GPa at 1900 K. Electronic structure calculations show that this phase is a topological semimetal with a Dirac nodal surface that is protected by a nonsymmorphic symmetry S 2z and an electride owing to its non-nuclear charge localized within one-dimensional honeycomb channels and zero-dimensional cages. Our results highlight the complexity of dense sodium's free-energy landscape and intricate electronic structure that emerges at finite temperatures and conditions where ionic cores overlap.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

A combination interferometric and morphological image processing approach to rapid quality assessment of additively manufactured cellular truss core components

Advanced manufacturing (AM) processes such as laser powder bed fusion (LPBF) are increasingly capable of fabricating components with useful and unprecedented mechanical properties by incorporating complex internal bracing structures. From the standpoint of quality control and assessment, however, internally complex assemblies present significant build-verification challenges. Here we propose a hybrid approach to the inspection involving the application of computer-aided speckle interferometry (CASI) and morphological image processing as a rapid, inexpensive, and facile method for AM quality control. The described methodology has low capital equipment costs, is full-field and non-contact, can be used in an industrial setting, and has very low requirements in terms of operator training and expertise. Consisting primarily of the combination of image processing software with a simple optical system of variable sensitivity, the method is shown to be effective for inspection of a titanium honeycomb component subjected to differential pressure. Results are compared to those achieved with computed tomography (CT), immersion ultrasound testing (UT), and optical holographic interferometry. Here we propose several possible processing strategies for automated quality assessment based on this powerful hybrid approach.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Logical Majorana zero modes in a nanowire network

We present a scheme to use physical Majorana quasizero modes at each junction of a two-dimensional nanowire network to build a logical Majorana zero mode, the location of which is controllable through gate voltages. The wire network is a way to realize a recent proposal to imprint a Kekulé vortex pattern on a honeycomb lattice via gate voltages. We show that a specific type of junction, other than a naive Y or T junction, is needed to realize, without breaking time-reversal symmetry, an artificial “graphene” system with Majorana fermions instead of complex ones at each site. The junction we propose (i) traps exactly one physical Majorana (quasi)zero mode at each site of either a brick wall or honeycomb lattice and (ii) allows this mode to hybridize with all three neighboring sites. Using a lattice of these junctions and starting from an electronic, tight-binding model for the wires, we imprint the voltage patterns corresponding to the Kekulé vortex and observe the emergence of the logical Majorana zero mode at the vortex core. By suitable adiabatic modulations of gate voltages as a function of time, the positions of individual Kekulé vortices can be moved, and in this manner, non-Abelian braiding of the logical Majoranas bound to the vortex cores can be performed. We provide the range of parameters where these excitations could be realized experimentally.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Nanoporous Wood Chips Based Sizable, Robust, and Low-Cost Honeycomb Vacuum Insulation Panels (DOE BENEFIT Final Research Performance Progress Report (RPPR))

Conventional vacuum insulation panels (VIPs) suffer from severe limitations including high cost, vulnerability to perforation, and significant performance degradation over time due to vacuum loss. InventWood Inc. (IW) and partnering teams completely re-engineered the VIP structure by constructing arrays of isolated vacuum-cells to enable limited cutting at designated areas (in between vacuum cells) and reduced consequential vacuum loss due to puncture. The teams also replaced the expensive vacuum insulation core materials with a low-cost commercial wood pulp and recycled long fiber. The wood pulp derived VIP can deliver an overall panel insulation of R15 (<0.01W/m·K) with over 90% thermal resistance retention after cutting (R13.5 overall, R5 along the cut edges). In addition, the vacuum-cell-array design minimizes edge losses, resulting in more durable performance, longer service life (>50 years), and higher R-value per dollar towards a cost target of <$1/ft 2 ·in. It is anticipated that the Nanochip-VIP will attract strong market interest and become an affordable insulation solution for energy efficient buildings and retrofits, leading to significant reductions in energy usage.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Chemical Design of Spin Frustration to Realize Topological Spin Glasses

Patterning spins to generate collective behavior is at the core of condensed matter physics. Physicists develop techniques, including the fabrication of magnetic nanostructures and precision layering of materials specifically to engender frustrated lattices. As chemists, we can access such exotic materials through targeted chemical synthesis and create new lattice types by chemical design. Here, in this study, we introduce a new approach to induce magnetic frustration on a modified honeycomb lattice through a competition of alternating antiferromagnetic (AFM) and ferromagnetic (FM) nearest-neighbor interactions. By subtly modulating these two types of interactions through facile synthetic modifications, we created two systems: (1) a topological spin glass and (2) a frustrated spin-canted magnet with low-temperature exchange bias. To design this unconventional magnetic lattice, we used a metal–organic framework (MOF) platform, Ni 3 (pymca) 3 X 3 (NipymcaX where pymca = pyrimidine-2-carboxylato and X = Cl, Br). We isolated two MOFs, NipymcaCl and NipymcaBr, featuring canted Ni 2+ -based moments. Despite this similarity, differences in the single-ion anisotropies of the Ni 2+ spins result in distinct magnetic properties for each material. NipymcaCl is a topological spin glass, while NipymcaBr is a rare frustrated magnet with low-temperature exchange bias. Density functional theory calculations and Monte Carlo simulations on the NipymcaX lattice support the presence of magnetic frustration as a result of alternating AFM and FM interactions. Our calculations enabled us to determine the ground-state spin configuration and the distribution of spin–spin correlations relative to paradigmatic kagomé and triangular lattices. This modified honeycomb lattice is similar to the electronic Kekulé-O phase in graphene and provides a highly tunable platform to realize unconventional spin physics.

Exchange bias↗
DOE OSTI2020

High‐Performance Fluorinated Fused‐Ring Electron Acceptor with 3D Stacking and Exciton/Charge Transport

Abstract A new fluorinated electron acceptor (FINIC) based on 6,6,12,12‐tetrakis(3‐fluoro‐4‐hexylphenyl)‐indacenobis(dithieno[3,2‐ b ;2 ′ ,3 ′ ‐ d ]thiophene) as the electron‐donating central core and 5,6‐difluoro‐3‐(1,1‐dicyanomethylene)‐1‐indanone as the electron‐deficient end groups is rationally designed and synthesized. FINIC shows similar absorption profile in dilute solution to the nonfluorinated analogue INIC. However, compared with INIC, FINIC film shows red‐shifted absorption, down‐shifted frontier molecular orbital energy levels, enhanced crystallinity, and more ordered molecular packing. Single‐crystal structure data show that FINIC molecules pack into closer 3D “network” motif through H‐bonding and π–π interaction, while INIC molecules pack into incompact “honeycomb” motif through only π–π stacking. Theoretical calculations reveal that FINIC has stronger electronic coupling and more molecular interactions than INIC. FINIC has higher electron mobilities in both horizontal and vertical directions than INIC. Moreover, FINIC and INIC support efficient 3D exciton transport. PBD‐SF/FINIC blend has a larger driving force for exciton splitting, more efficient charge transfer and photoinduced charge generation. Finally, the organic solar cells based on PBD‐SF/FINIC blend yield power conversion efficiency of 14.0%, far exceeding that of the PBD‐SF/INIC‐based devices (5.1%).

Dai, Shuixing↗
DOE OSTI2021

Regiospecific N -alkyl substitution tunes the molecular packing of high-performance non-fullerene acceptors

The rapid development of non-fullerene acceptors (NFAs) with strong near-infrared absorption has led to remarkably enhanced short-circuit current density (J sc ) values in organic solar cells (OSCs). NFAs based on the benzotriazole (Bz) fused-ring π-core have great potential in delivering both high J sc and decent open-circuit voltage values due to their strong intramolecular charge transfer with reasonably low energy loss. Here in this work, we have designed and synthesized a series of Bz-based NFAs, PN6SBO-4F, AN6SBO-4F and EHN6SEH-4F, via regiospecific N-alkyl engineering based on the high-performance NFA mBzS-4F that was reported previously. The molecular packing of mBzS-4F, AN6SBO-4F, and EHN6SEH-4F single crystals was analyzed using X-ray crystallography in order to provide a comprehensive understanding of the correlation between the molecular structure, the charge-transporting properties, and the solar cell performance. Compared with the typical honeycomb single-crystal structure of Y6 derivatives, these NFAs exhibit distinctly different molecular packing patterns. The strong interactions of terminal indanone groups in mBzS-4F and the J-aggregate-like packing in EHN6SEH-4F lead to the formation of ordered 3D networks in single-crystals with channels for efficient charge transport. Consequently, OSCs based on mBzS-4F and EHN6SEH-4F show efficient photon-to-current conversions, achieving the highest power conversion efficiency of 17.48% with a Jsc of 28.83 mA cm -2 .

36 MATERIALS SCIENCE↗
DOE OSTI2020

Defects in epitaxial Ru(0001) on Al2O3(0001): Dislocations, stacking faults, and deformation twins

In this study, defects in epitaxial Ru(0001) films on c-plane sapphire, with nominal thicknesses of 10–80 nm, deposited at 350 °C and step-annealed to 950 °C, were characterized using transmission electron microscopy. The variation of Ru and sapphire lattice parameters with temperature is such that the misfit strain for the observed 30° rotated-honeycomb epitaxial relationship is essentially constant with temperature at 1.5%, resulting in a biaxial stress of 10.0 GPa and an energy density of 150 MJ m –3 in unrelaxed films. Stress relaxation occurs by the formation of defects. For the 20–80 nm thick films, the defects are a- and c-type dislocations and stacking faults, argued to be of I 2 type. In addition, the films show the surprising presence of $\{11\bar{2}1\}1/3\langle11\bar{2}\bar{6}\rangle$ deformation twins. The 10 nm-thick films were found to be defect free. The critical thickness for misfit strain relaxation via the formation of threading and misfit dislocations is computed as 7±2 nm, depending on the choice of the dislocation core radius. Energetic analysis of twin formation, using both the infinite-matrix and the finite-matrix (Mori–Tanaka) approaches, provides values of the twin aspect ratios, assumed to be ellipsoidal, and shows that the latter but not the former approach can qualitatively explain the formation of the observed twins. In addition to providing the maximum strain relief compared to other potential twin types, $\{11\bar{2}1\}1/3\langle11\bar{2}\bar{6}\rangle$ twins do not require lattice shuffles and have a boundary that is a special boundary, namely, a 35° tilt boundary with a-type dislocations every other {0002} plane, that may also favor their formation.

36 MATERIALS SCIENCE↗