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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

Acetolysis for Epoxy-Amine Carbon Fibre-Reinforced Polymer Recycling

Carbon fibre-reinforced polymers (CFRPs) are used in many applications in the global energy transition, including for lightweighting aircraft and vehicles and in wind turbine blades, shipping containers and gas storage vessels1,2,3,4. Given the high cost and energy-intensive manufacture of CFRPs5,6,7, recycling strategies are needed that recover intact carbon fibres and the epoxy-amine resin components. Here we show that acetic acid efficiently depolymerizes both aliphatic and aromatic epoxy-amine thermosets used in CFRPs to recoverable monomers, yielding pristine carbon fibres. Deconstruction of materials from multiple sectors demonstrates the broad applicability of this approach, providing clean fibres from 2 h reactions. The optimal conditions were scaled to 80.0 g of post-consumer CFRPs, and demonstrative composites were fabricated from the recycled carbon fibres, which were recycled two more times, maintaining their strength throughout. Process modelling and techno-economic analysis, with feedstock cost informed by wind turbine blade waste generation8, indicates this method is cost effective, with a minimum selling price of US$1.50 per kg for recycled carbon fibres whereas life cycle assessment shows process greenhouse gas emissions around 99% lower than virgin carbon fibre production. Overall, this approach could enable recycling of industrial CFRPs as it provides clean, mechanically viable recycled carbon fibres and recoverable resin monomers from the thermoset.

09 BIOMASS FUELS↗
DOE OSTI2023

Material and component developments for the DEMO divertor using fibre reinforcement and additive manufacturing

Within the research along the European Fusion Roadmap, water-cooled divertor PFCs are foreseen in the design of a first fusion demonstration power plant (DEMO) in order to provide reliable heat removal capability. In the frame of this concerted attempt, the Max Planck Institute for Plasma Physics is concentrating on the development and testing of composite materials based on tungsten (W, preferred armour material) and copper (Cu, preferred heat sink material). W fibres (W f ) as monofilaments and yarns as reinforcement play a central role in these investigations due to their extraordinary properties concerning ductility already at room temperature and high tensile strength. Recent investigations on the impact of radiation damage suggest that the fibres retain their ductility upon irradiation. W reinforced with W fibres (W f /W) allows to overcome the intrinsic brittleness of W. Quantitative mechanical fracture tests of W f /W confirm the basic mechanisms of fibre reinforcement and the increased resistance to mechanical fatigue. The good wettability of W with liquid Cu and the absence of any metallurgical solubility make up an ideal material pairing for composite production. W fibre-reinforced Cu (W f /Cu) cooling tubes provide a rather high thermal conductivity (> 250 W mK -1 ) and at least twice the strength of CuCrZr in hoop direction in the temperature range up to at least 500 °C. Very recent neutron irradiation experiments confirm the sustainment of ductility of the W f /Cu composite. Numerical simulations suggest that thermal stresses in W-Cu PFCs could be strongly reduced by tailoring the local W and Cu volume fraction. This 'freely' distributed material composition can be achieved by means of additively manufactured W skeletons consecutively infiltrated by Cu. Investigations with W preforms produced by Laser Beam Powder Bed Fusion and infiltrated by Cu demonstrate the feasibility of this approach while testing of specifically prepared specimen is ongoing.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Dual C–H functionalization of polyolefins for covalent adaptable network formation via cooperative electrolysis

The increasing demand for carbon fibre-reinforced polymer composites with polyolefin thermoset matrices will lead to the generation of large volumes of low molecular weight waste oligomers during the fibre recovery process. To address this challenge, we present a cooperative electrolytic dual C–H bond functionalization strategy for the one-step installation of two key functional groups essential for dynamic linkages of these deconstructed oligomers. Through direct competition studies, we reveal the predominance of tertiary allylic C–H activation along the complex, branched oligomer backbone. The resulting difunctionalized oligomers form covalently adaptable networks with exceptional circularity. By establishing a sustainable pathway for upcycling deconstructed oligomers from carbon fibre-reinforced polymer fibre recovery, this strategy introduces thermoset materials derived directly from waste. Here, it advances sustainable manufacturing practices, contributing to a net-zero waste synthetic ecosystem, and highlights the prospects of mediated electrolysis in macromolecular transformations.

Electrocatalysis↗
DOE OSTI2025

Tandem CO 2 valorisation to polycarbonate vitrimer and ethylene carbonate

The need for renewably sourced polymers has intensified with the worsening of global challenges such as emissions and plastic pollution. Here, we report a CO 2 -based poly(cyclohexene carbonate) (PCHC) vitrimer cured with zinc stearate that directly addresses both issues. Enhanced zinc dispersion within the network enabled faster curing and reprocessing than possible with zinc acetate systems, while maintaining consistent T g and mechanical integrity across multiple cycles. The vitrimer undergoes rapid glycolysis in ethylene glycol, valorisation into ethylene carbonate with up to 97% yield without additional catalyst. When applied to carbon fibre-reinforced polymers (CFRPs), applying this strategy enabled the development of sustainable CO 2 -based CFRP that can undergo full resin valorisation and recovery of clean, damage-free fibres. Collectively, this tandem CO 2 valorisation strategy—from vitrimer synthesis to fibre-reinforced composites and subsequent chemical valorisation—establishes multiple recycling and valorisation pathways and provides a promising routte for carbon capture and utilization as well as material recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Irradiation effects in tungsten—From surface effects to bulk mechanical properties

Advanced materials such as tungsten fibre-reinforced composites allow to overcome severe weaknesses of the baseline materials for plasma-facing components — copper and tungsten. The effect of the fusion environment on the mechanical properties of these materials, e.g. the embrittlement by neutron irradiation, plays a key role for the development of future fusion reactors. To simulate this effect, high-energy ions are used as a substitute for the displacement damage by neutrons. We propose the use of very fine tungsten wire as a possibility of studying the influence of irradiation damage on the mechanical properties. This is possible as they allow full-depth irradiation of almost the entire volume despite the limited penetration depth of ions. Geometrical size effects are mitigated due to the nanoscale microstructure of the wire. In addition, similar wire is used in tungsten fibre-reinforced composites. Thus, the investigation of irradiated wire can directly be used for the prediction of the bulk composite properties. For the proof of this concept tungsten wire with a diameter of 16 μm was electrochemically thinned to 5 μm and irradiated with 20.5 MeV W 6+ ions. The mechanical properties were subsequently determined by macroscopic tensile testing. Irradiation to 0.3, 1 and 9 dpa did not lead to a change of the mechanical behaviour. Both strength and ductility, the latter indicated by the reduction of area, were similar to the as-fabricated state.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effect of moderate temperatures on compressive strength of ultra-high-performance concrete: A microstructural analysis

Highlights: • All coarse aggregates and steel fibres were surrounded by the binder. • X-ray diffraction is useful for explaining the increase in compressive strength with increasing temperature. • Rosenhahnite and/or quartz Dauphiné-twinned phases improved the compressive strength. • Polypropylene fibres prevented spalling and preserved the compressive strength. • Concrete with steel and polypropylene fibres did not exhibit spalling at 300 °C. Concrete with two types of steel fibres and a polypropylene fibre prevented spalling and preserved the compressive strength at 300 °C, which makes these concretes suitable for long-term applications up to 300 °C, such as for steam collectors or thermal energy storage systems. The compressive strength behaviour of three types of ultra-high-performance fibre-reinforced concrete manufactured with the same matrix was investigated. For this purpose, a complete characterisation of all the raw materials and the three types of fibres used was performed. The morphology of all concrete mixtures at room temperature was analysed using scanning electron microscopy–energy-dispersive X-ray spectroscopy. From the results, it was ascertained that the steel fibres and coarse siliceous aggregates were not in contact (being separated by ≥3.41 μm) and were surrounded by the binder (of ≥1 μm in thickness) for all the mixtures studied. Rosenhahnite and/or quartz Dauphiné-twinned phases improved the compressive strength (as determined by X-ray diffraction).

36 MATERIALS SCIENCE↗
DOE OSTI2021

Monitoring steel fibre orientation in self-compacting cementitious composite slabs during pouring with dynamic X-ray radiography

This paper presents a new technique based on dynamic X-ray radiography that can be used to assess fibre orientation during pouring of steel fibre reinforced cementitious composites. Synthetic examples were used to assess the suitability and robustness of the technique, which was shown to provide reliable measurements of fibre orientation even when the signal-to-noise ratio is relatively high. A study was then carried out on the effect of formwork aspect ratio, time/duration of pouring, and rebar placement on the fibre orientation while pouring self-compacting cementitious composite slabs. Results demonstrated the ability of the technique in monitoring the movements of fibres while pouring, and the strong effect of the flow in inducing preferential fibre alignment within the slabs. Fibre orientation was found to vary progressively over time and could take about half of the duration of pouring to fully stabilise.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Simplifying the creation of thermal decomposition mechanisms for designing mixed fibre composites

Among the most challenging aspects of simulating thermal decomposition of fibre reinforced polymers is the determination of appropriate reaction parameters. Thermogravimetric analysis is typically used to generate decomposition data, to which the reaction parameters are then fit. When designing mixed fibre materials (e.g. combinations of glass and carbon fibres), the number of TGA experiments needed to explore the entire design space may be intractable. Here, we demonstrate the creation of two candidate proxy mixed fibre mechanisms and compare them to a mechanism created by fitting parameters from TGA on the mixed fibre composite. These mechanisms are then demonstrated in a 2D axisymmetric numerical decomposition, heat transfer, and porous flow model. We find a maximum 11% uncertainty in mass and 4% in temperature difference when using a proxy mechanism.

Scott, Sarah N. [Sandia National Lab. (SNL-CA), Li↗
DOE OSTI2021

Composites and additive manufacturing for high-field coil supports for stellarators

The utilization of composites layered on an additive manufactured substrate, for the production of coil supports for modular coils in small or middle size experimental stellarators is assessed. The focus of the study is a monolithic coil support comprising the coils of a half-period of a stellarator, somewhat similar to the ones in UST_2 and ARIES-CS stellarators. However, the concept may be applicable to quasi-monolithic coil supports (coil forms of NCSX type) or individual coil casings (W7-X type).Coil supports for stellarators require high precision, stiffness and strength for large contorted parts. Traditionally, monolithic coil supports are produced by steel casting/forging and final machining. This production method and material gives accurate, stiff and strong coil supports, but the method may be expensive for monolithic supports due to the geometrical complexity and required accuracy of the structure. In relation to those matters, this work investigates whether a monolithic coil support comprising an additive manufactured resin substrate, which is externally (outward from the coils) surrounded with a thick layer of fibre-reinforced resin, may achieve enough strength and stiffness under middle/high magnetic fields. Finite element calculations are produced to obtain the direction of the principal stresses and their values in compression and tension at different areas of the monolithic support, which is relevant for anisotropic materials. The feasibility of directional application of (carbon) fibres on the winding surface of the stellarator outward from the coils is experimentally tested on a scaled-down additively manufactured prototype of a monolithic support. The strength and stiffness of the composite structure appears sufficient for common magnetic fields in experimental stellarators, and the 3D-composite design and manufacturing was technically feasible.

Queral, Vicente↗
DOE OSTI2023

In situ high-temperature 3D imaging of the damage evolution in a SiC nuclear fuel cladding material

Silicon carbide (SiC)-based nuclear fission fuel rod cladding has been considered as one of the possible designs for accident tolerant fuels. It is in the form of a SiC fibre reinforced SiC matrix composite tube (SiC f -SiC m ) with monolithic SiC outer and/or inner coating layers. This study focuses on the deformation and fracture processes in this material using in situ X-ray micro-computed tomography (XCT) at room temperature (RT) and 1200 °C in an inert gas environment in a C-ring compression loading configuration. Prior to testing, local properties and residual stresses were characterised using nanoindentation and Raman spectroscopy since they can impact the mechanical behaviour of the material. The 3D strain distribution, crack formation and propagation processes including the toughening mechanisms (e.g., crack deflection, micro-cracking, crack bridging and bifurcation) are investigated in the coating and underlying composites at RT and 1200 °C. There is no particular sequence which toughening mechanism occurs first – this is very different from the conventional toughening theory in ceramic-matrix composites under uniaxial tension loading. Indeed, no evidence of fibre pull-out or fibre fracture was observed in this SiC f -SiC m nuclear cladding material in the current C-ring compression configuration. The correlation between local measurements and bulk mechanical behaviour are discussed.

3D imaging↗
DOE OSTI2025

Improved damage tolerance of SiC-based nuclear fuel cladding with novel multi-layered SiC coating design at 1200 °C

Continuous SiC fibre reinforced SiC matrix composites (SiC f -SiC m ) with monolithic SiC outer coatings are considered as a damage-tolerant cladding design for loss of coolant accident (LOCA) conditions in light water reactors. However, monolithic SiC coatings are brittle and prone to catastrophic failure. In this study, a SiC f -SiC m cladding with a novel multi-layer SiC outer coating (11 sub-layers, ∼260 µm in total thickness) was investigated under C-ring compression at room temperature and 1200 °C in argon environment. Real-time synchrotron X-ray computed tomography (XCT) was employed to capture crack initiation and propagation processes. Compared to conventional monolithic SiC outer coatings, the multi-layer coating structure facilitated crack deflection and bifurcation enhancing its damage tolerance at both temperatures. Despite pre-existing surface cracks, claddings exhibited stable mechanical-performance at both temperatures. These initial cracks did not critically affect the failure processes as they were not aligned with the maximum stress direction. Furthermore, the microstructure, distribution of residual stresses, and local properties of individual components in the material were thoroughly characterized, and compared with open literature on conventional claddings with monolithic outer coatings. These results provide new insights into the failure mechanisms of multi-layer SiC coatings and offer guidance for the future design of accident-tolerant nuclear fuel claddings.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Chain entanglements enable regeneration of high-performance thermosets

Thermoset plastics underpin structural materials, electronics and transportation, yet the permanent covalent networks that prevent flow and provide dimensional stability also make them difficult to recycle without sacrificing performance. In this work we show that high-performance thermosets can be built around dense chain entanglements, the physical interlacing of long polymer strands, rather than dense permanent crosslinks, with only a small number of selectively cleavable junctions preserving connectivity. Long, rigid, entangled polyolefin backbones generated by frontal polymerization form glassy polymers with high stiffness, high toughness and excellent creep suppression yet can be fully deconstructed into soluble, linear oligomers. Varying oligomer length and end-group chemistry enables their reuse as re-entangling building blocks that regenerate thermosets with thermal and mechanical properties that remain unchanged across generations. The strategy further extends to high-temperature fibre-reinforced composite matrices and additively manufactured structures, establishing chain entanglement as a design principle for durable, regenerable thermosets.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Sulphate resistance of low‐clinker engineered cementitious composites examined by MicroXRF imaging

Abstract Engineered cementitious composites (ECC) are a class of high‐performing fibre‐reinforced cementitious materials recognised for their increased ductility and durability compared to conventional cement‐based materials, owing to their autogenously controlled tight crack widths, even when subjected to high strains. To reduce ECC's environmental impact, this research examines the use of a low‐clinker binder − limestone‐calcined clay cement (LC3) − as an alternative to portland cement (PC), along with fly ash to further reduce the clinker proportion and the embodied CO 2 of the formulations. In conventional concrete, LC3 hydrates to a denser microstructure resulting from the synergistic reaction between limestone and calcined clay. At the lower water contents typical of ECC and with the presence of fly ash, the influence of the binder composition on the microstructure is difficult to anticipate. To examine the influence of these compositional variables on microstructure, permeability and durability, the sulphate resistance of LC3‐based ECC is explored. Specifically, the ECC‐LC3 blends are designed with high clinker replacement rate of 75% by mass of binder and contain either conventional fly ash or reclaimed fly ash at 50% by mass of binder. Expansion of ECC‐LC3 samples subjected to standard sodium sulphate test conditions was measured up to 12 months and the depth of penetration of sulphates into the ECC‐LC3 of varying compositions was quantified using micro‐X‐Ray Fluorescence (microXRF) imaging and modelling. The expansion results show that the ECC‐LC3 formulations performed better than the PC samples and can provide adequate resistance to external sulphate attack, even when reclaimed fly ashes are used in place of the conventional ash. In addition, the shallow penetration of sulphate into these cementitious composites demonstrates the low diffusion coefficients values that were determined using the quantitative data from MicroXRF imaging.

Microscopy↗
DOE OSTI2021

Substitution of virgin carbon fiber with low-cost recycled fiber in automotive grade injection molding polyamide 66 for equivalent composite mechanical performance with improved sustainability

Recycled carbon fiber has historically proven challenging to integrate into composite manufacturing due in no small part to the low-density, randomly oriented, discontinuous fiber format that results from typical recycling. Discontinuous fiber requires the use of alternative technologies than those traditionally applied to continuous fiber (e.g., hand lay-up, winding). Extrusion compounding is one such applicable technology, but material transfer into the system requires alternative feeding equipment or the use of an altered procedure as trialed in this research. In this study, an injection molding compound for automotive applications was prepared with recycled carbon fiber and compared against an existing commercial compound. Input fibers and molded compound were evaluated for mechanical performance, while relevant variables such as compounded fiber alignment and aspect ratio were compared to the existing baseline material to confirm a like-for-like composite material structure. Overall, analysis indicates that recycled fiber performs similarly to virgin fiber reinforcement, demonstrating that recycled fiber may be a viable drop-in replacement for short-fiber discontinuous applications.

42 ENGINEERING↗
DOE OSTI2021

Development of a compressive failure model for carbon fiber composites and associated uncertainties.

An approach to increase the value of carbon fiber for wind turbines blades, and other compressive strength driven designs, is to identify pathways to increase its cost-specific compressive strength. A finite element model has been developed to evaluate the predictiveness of current finite element methods and to lay groundwork for future studies that focus on improving the cost-specific compressive strength. Parametric studies are conducted to understand which uncertainties in the model inputs have the greatest impact on compressive strength predictions. Furthermore, a statistical approach is also presented that enables the micromechanical model, which is deterministic, to efficiently account for statistical variability in the fiber misalignment present in composite materials; especially if the results from the hexagonal and square pack models are averaged. The model was found to agree well with experimental results for a Zoltek PX-35 pultrusion. The sensitivity studies suggest that the fiber packing and the interface shear strength have the greatest impact on compressive strength prediction for the fiber reinforced polymer studied here. Based on the performance of the modeling approach presented in this work, it is deemed sufficient for future work which will seek to identify carbon fiber composites with improved cost-specific compressive strength.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Supersonic hot jet ablative testing and analysis of boron nitride nanotube hybrid composites

Boron nitride nanotubes (BNNTs) are high-strength, high-modulus nanotubes with high thermal and oxidative stabilities. Two hybrid composites were prepared with satin weave carbon fiber (CF) and resole-type phenolic resin: one with surface layers of BNNTs and one with alternating interlayers of BNNTs. The samples were subjected to hot jet tests that simulate realistic high-pressure-temperature conditions to understand the behavior of BNNTs under high-pressure erosion. Adding BNNTs to CF/phenolic laminates enhanced the ablation resistance by reinforcing the char material and mitigated localized thermal damage. Hybrid laminates exhibited up to 14% lower weight loss, 55% increase in flexural modulus, higher thermal diffusivity, and improved char yield and microstructure compared to CF/phenolic samples. The surface layer hybrid had many surviving nanotubes reinforcing the char and crystalline oxide structures that could mitigate further oxygen diffusion. Further, various characterization methods were used to deduce possible mechanisms and their products, indicating that BNNTs could serve as growth templates for direct crystalline boron oxide formation. Overall, hybrid BNNT/CF/phenolic laminates displayed better ablation resistance and favorable microstructure evolution under high-pressure conditions.

42 ENGINEERING↗