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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

Lattice Structured Lightweight Structural Materials

The development of lightweight structural materials is crucial for enhancing the performance and deployment feasibility of fission batteries. This study aims to produce lightweight structural materials whose strength-to-weight ratios exceed those of current widely used structural materials. To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structured models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The modeling results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison to the solid material; the increase in solid shell thickness and blend radius enhances the mechanical performance; and the effect of unit cell size on macro scale stress is minimal. Tensile testing was conducted on the solid and lattice-structured materials fabricated by laser powder bed fusion (LPBF) additive manufacturing. The experimental results agreed well with the model prediction. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for new material development.

lightweight material↗
NASA NTRS1981

Lightweight structural columns

Lightweight half-lengths of columns for truss structures are described. The columns are adapted for nestable storage and transport to facilitate fabrication of large area truss structures at a remote site and particularly adaptable for space applications.

Bush, H. G.↗
NASA NTRS1990

Making Lightweight Structures By Vapor Deposition

Technique developed for fabrication of stiff, strong, lightweight structures of silicon carbide or other materials by any of several deposition processes. Structures made by method can have complicated shapes. Ability to manufacture complex shape from pure deposited SiC useful and leads to new products in several fields. These lightweight structures used as backup structures for optical components, as structural components in automotive, aerospace, and outer space applications, and as lightweight parts of furniture for outer space.

Goela, Jitendra S.↗
NASA NTRS2013

Multi-Scale CNT-Based Reinforcing Polymer Matrix Composites for Lightweight Structures

Reinforcing critical areas in carbon polymer matrix composites (PMCs), also known as fiber reinforced composites (FRCs), is advantageous for structural durability. Since carbon nanotubes (CNTs) have extremely high tensile strength, they can be used as a functional additive to enhance the mechanical properties of FRCs. However, CNTs are not readily dispersible in the polymer matrix, which leads to lower than theoretically predicted improvement in mechanical, thermal, and electrical properties of CNT composites. The inability to align CNTs in a polymer matrix is also a known issue. The feasibility of incorporating aligned CNTs into an FRC was demonstrated using a novel, yet commercially viable nanofiber approach, termed NRMs (nanofiber-reinforcing mats). The NRM concept of reinforcement allows for a convenient and safe means of incorporating CNTs into FRC structural components specifically where they are needed during the fabrication process. NRMs, fabricated through a novel and scalable process, were incorporated into FRC test panels using layup and vacuum bagging techniques, where alternating layers of the NRM and carbon prepreg were used to form the reinforced FRC structure. Control FRC test panel coupons were also fabricated in the same manner, but comprised of only carbon prepreg. The FRC coupons were machined to size and tested for flexural, tensile, and compression properties. This effort demonstrated that FRC structures can be fabricated using the NRM concept, with an increased average load at break during flexural testing versus that of the control. The NASA applications for the developed technologies are for lightweight structures for in-space and launch vehicles. In addition, the developed technologies would find use in NASA aerospace applications such as rockets, aircraft, aircraft/spacecraft propulsion systems, and supporting facilities. The reinforcing aspect of the technology will allow for more efficient joining of fiber composite parts, thus offering additional weight savings. More robust structures capable of withstanding micrometeoroid and space debris impacts will be possible with the enhanced mechanical properties imparted by the aligned CNTs incorporated into the fiber composite structure, as well as the potential for improved electrical and thermal properties. The materials fabrication approach developed in the present effort is a platform for customer applications where additional reinforcement is required or would be beneficial, especially in FRC structures and component parts. Depending upon the specific customer application, the NRM could be tailored to the specific matrix resin and desired property enhancement.

Eberly, Daniel↗
NASA NTRS2011

Overview of Lightweight Structures for Rotorcraft Engines and Drivetrains

This is an overview presentation of research being performed in the Advanced Materials Task within the NASA Subsonic Rotary Wing Project. This research is focused on technology areas that address both national goals and project goals for advanced rotorcraft. Specific technology areas discussed are: (1) high temperature materials for advanced turbines in turboshaft engines; (2) polymer matrix composites for lightweight drive system components; (3) lightweight structure approaches for noise and vibration control; and (4) an advanced metal alloy for lighter weight bearings and more reliable mechanical components. An overview of the technology in each area is discussed, and recent accomplishments are presented.

Roberts, Gary D.↗
NASA NTRS2004

Design and Experimental Verification of Deployable/Inflatable Ultra-Lightweight Structures

Because launch cost of a space structural system is often proportional to the launch volume and mass and there is no significant gravity in space, NASA's space exploration programs and various science missions have stimulated extensive use of ultra-lightweight deployable/inflatable structures. These structures are named here as Highly Flexible Structures (HFSs) because they are designed to undergo large displacements, rotations, and/or buckling without plastic deformation under normal operation conditions. Except recent applications to space structural systems, HFSs have been used in many mechanical systems, civil structures, aerospace vehicles, home appliances, and medical devices to satisfy space limitations, provide special mechanisms, and/or reduce structural weight. The extensive use of HFSs in today's structural engineering reveals the need of a design and analysis software and a database system with design guidelines for practicing engineers to perform computer-aided design and rapid prototyping of HFSs. Also to prepare engineering students for future structural engineering requires a new and easy-to- understand method of presenting the complex mathematics of the modeling and analysis of HFSs. However, because of the high flexibility of HFSs, many unique challenging problems in the modeling, design and analysis of HFSs need to be studied. The current state of research on HFSs needs advances in the following areas: (1) modeling of large rotations using appropriate strain measures, (2) modeling of cross-section warpings of structures, (3) how to account for both large rotations and cross- section warpings in 2D (two-dimensional) and 1D structural theories, (4) modeling of thickness thinning of membranes due to inflation pressure, pretension, and temperature change, (5) prediction of inflated shapes and wrinkles of inflatable structures, (6) development of efficient numerical methods for nonlinear static and dynamic analyses, and (7) filling the gap between geometrically exact elastic analysis and elastoplastic analysis. The objectives of this research project were: (1) to study the modeling, design, and analysis of deployable/inflatable ultra-lightweight structures, (2) to perform numerical and experimental studies on the static and dynamic characteristics and deployability of HFSs, (3) to derive guidelines for designing HFSs, (4) to develop a MATLAB toolbox for the design, analysis, and dynamic animation of HFSs, and (5) to perform experiments and establish an adequate database of post-buckling characteristics of HFSs.

Pai, P. Frank↗
DOE OSTI2025

Enabling Next Generation Reaction Injection Molding (RIM) for Lightweight Structures

Replacing metal components in trucks, trailers, and buses with lightweight polymer composites is challenging due to high temperatures and complex manufacturing. The Reaction Injection Molding (RIM) process using Dicyclopentadiene (DCPD) resin offers a solution by producing robust parts with excellent stiffness, impact strength, and resistance properties. Simulations are essential for optimizing this process, predicting defects, and improving quality. However, most commercial software is tailored for thermoplastics, requiring thermoset users to generate their own datasets. In this project, a material data card for DCPD was developed to perform RIM simulations. Design of Experiments (DOE) was used to identify key factors affecting filling, curing, and warpage, aiming to minimize cycle time and defects. The simulations explored varying injection gate parameters (size, location, number) and process conditions (mold/resin temperature, injection/curing pressure). Results showed that gate design significantly impacts filling behavior and defects. A single central gate provided balanced flow with fewer defects, while two corner gates led to more defects. Additionally, lower injection pressure increased filling time, while higher mold temperature accelerated curing but led to more warpage. This optimization framework aims to enhance DCPD part performance and promote sustainable manufacturing by reducing waste and energy consumption. This research has been performed in collaborations with McClarin Composites. The research outcome has been submitted to the Journal of Manufacturing Processes.

36 MATERIALS SCIENCE↗
NASA NTRS1987

High speed, precision motion strategies for lightweight structures

Abstracts of published papers and dissertations generated during the reporting period are compiled. Work on fine motion control was completed. Specifically, real time control of flexible manipulator vibrations were experimentally investigated. A linear model based on the application of Lagrangian dynamics to a rigid body mode and a series of separable flexible modes was examined with respect to model order requirements, and modal candidate selection. State feedback control laws were implemented based upon linear quadratic regulator design. Specification of the closed loop poles in the regulator design process was obtained by inclusion of a prescribed degree of stability in the manipulator model. Work on gross motion planning and control is also summarized. A systematic method to symbolically derive the full nonlinear dynamic equations of motion of multi-link flexible manipulators was developed.

Book, Wayne J.↗
NASA NTRS1987

High speed precision motion strategies for lightweight structures

Work during the recording period proceeded along the lines of the proposal, i.e., three aspects of high speed motion planning and control of flexible structures were explored: fine motion control, gross motion planning and control, and automation using light weight arms. In addition, modeling the large manipulator arm to be used in experiments and theory has lead to some contributions in that area. These aspects are reported below. Conference, workshop and journal submissions, and presentations related to this work were seven in number, and are listed. Copies of written papers and abstracts are included.

Book, Wayne J.↗
NASA NTRS1988

Lightweight structural design of a bolted case joint for the Space Shuttle Solid Rocket Motor

This paper presents the structural design of a bolted joint with a static face seal which can be used to join Space Shuttle Solid Rocket Motor (SRM) case segments. Results from numerous finite element parametric studies indicate that the bolted joint meets the design requirement of preventing joint opening at the O-ring locations during SRM pressurization. A final design recommended for further development has the following parameters: 180 1-inch-diameter studs, stud center line offset of .5 inches radially inward from the shell wall center line, flange thickness of 0.75 inches, bearing plate thickness of 0.25 inches, studs prestressed to 70 percent of ultimate load, and the intermediate alcove. The design has a mass penalty of 1096 lbm, which is 164 lbm greater than the currently proposed capture tang redesign.

Dorsey, John T.↗
NASA NTRS1988

Lightweight structural design of a bolted case joint for the space shuttle solid rocket motor

The structural design of a bolted joint with a static face seal which can be used to join Space Shuttle Solid Rocket Motor (SRM) case segments is given. Results from numerous finite element parametric studies indicate that the bolted joint meets the design requirement of preventing joint opening at the O-ring locations during SRM pressurization. A final design recommended for further development has the following parameters: 180 one-in.-diam. studs, stud centerline offset of 0.5 in radially inward from the shell wall center line, flange thickness of 0.75 in, bearing plate thickness of 0.25 in, studs prestressed to 70 percent of ultimate load, and the intermediate alcove. The design has a mass penalty of 1096 lbm, which is 164 lbm greater than the currently proposed capture tang redesign.

Dorsey, John T.↗
NASA NTRS1989

High speed, precision motion strategies for lightweight structures

Research on space telerobotics is summarized. Adaptive control experiments on the Robotic Arm, Large and Flexible (RALF) were preformed and are documented, along with a joint controller design for the Small Articulated Manipulator (SAM), which is mounted on the RALF. A control algorithm is described as a robust decentralized adaptive control based on a bounded uncertainty approach. Dynamic interactions between SAM and RALF are examined. Unstability of the manipulator is studied from the perspective that the inertial forces generated could actually be used to more rapidly damp out the flexible manipulator's vibration. Currently being studied is the modeling of the constrained dynamics of flexible arms.

Book, Wayne J.↗
NASA NTRS2001

Lightweight Structures

Present structural concepts for hot static structures are conventional "sheet & stringer" or truss core construction. More weight-efficient concepts such as honeycomb and lattice block are being investigated, in combination with both conventional superalloys and TiAl. Development efforts for components made from TiAl sheet are centered on lower cost methods for sheet and foil production, plus alloy development for higher temperature capability. A low-cost casting technology recently developed for aluminum and steel lattice blocks has demonstrated the required higher strength and stiffness, with weight efficiency approach- ing honeycombs. The current effort is based on extending the temperature capability by developing lattice block materials made from IN-718 and Mar-M247.

Whittenberger, J. Daniel↗
NASA NTRS2018

Bipedal Isotropic Lattice Locomoting Explorer: Robotic Platform for Locomotion and Manipulation of Discrete Lattice Structures and Lightweight Space Structures

A robotic platform for traversing and manipulating a modular 3D lattice structure is described. The robot is designed specifically for its tasks within a structured environment, and is simplified in terms of its numbers of degrees of freedom (DOF). This allows for simpler controls and a reduction of mass and cost. Designing the robot relative to the environment in which it operates results in a specific type of robot called a "relative robot". Depending on the task and environment, there can be a number of relative robots. This invention describes a bipedal robot which can locomote across a periodic lattice structure made of building block parts. The robot is able to handle, manipulate, and transport these blocks when there is more than one robot. Based on a general inchworm design, the robot has added functionality while retaining minimal complexity, and can perform numerous maneuvers for increased speed, reach, and placement.

Jenett, Benjamin↗
NASA NTRS1985

Inflatable Column Structure

Lightweight structural member easy to store. Billowing between circumferential loops of fiber inflated column becomes series of cells. Each fiber subjected to same tension along entire length (though tension is different in different fibers). Member is called "isotensoid" column. Serves as jack for automobiles or structures during repairs. Also used as support for temporary bleachers or swimming pools.

Hedgepeth, J. M.↗