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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

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DOE OSTI2025

Initial assessment of alternative carbon fiber geometries for design of cost-effective compressive performance: Size effect studies

Carbon fiber provides opportunity to reduce weight in structural composites, including wind turbine blades, due to the material's superior specific stiffness and specific strength compared to alternatives. Despite these advantages, cost and compressive performance are considered weaknesses for carbon fiber products available today. Studies to produce low-cost carbon fiber alternatives, including the use of textile-derived precursor systems, have shown progress and merit through the DOE/ORNL low-cost carbon fiber initiatives. Here, this work focuses on enabling increases in compressive strength through design of the carbon fiber geometry, applicable to both textile and conventional precursor systems, while also providing opportunities to reduce carbon fiber processing costs. Fiber-resin interface and fiber alignment are among the most frequently cited factors controlling composite compressive performance. However, it is believed that there is opportunity in traditionally unexplored routes to increasing compressive strength through alteration of the carbon fiber geometry by increasing the fiber area moment of inertia and/or the fiber perimeter and interfacial area. This paper presents initial results from manufacturing carbon fiber materials to assess the impacts of carbon fiber size on tested composite compressive performance with projected neutral or even beneficial impact on fiber and composite manufacturing economics. Carbon fiber systems with increasing size illustrate a favorable correlation for compressive performance greater than predicted from a micromechanical failure model. The manufacturing and mechanical test results support the hypothesis of this work that alterations to fiber geometry can be used to produce improvements of the compressive strength of carbon fiber reinforced polymers and provide incentive for related work in designing alternative shapes to further enhance compressive performance.

42 ENGINEERING↗

DOE OSTI2024

Low-Cost, High-Performance Carbon Fiber for Compressed Natural Gas Storage Tanks (Final Technical Report – Down Select Report)

The aim of this project is to reduce the cost of Type IV, carbon fiber (CF) composite overwrap compressed gas storage tanks by reducing the cost of CF and CF composites. The project team worked to reduce the cost of CF by exploring and testing opportunities for a low-cost alternative precursor material for CF production to supplant market-dominant and costly polyacrylonitrile (PAN). Concurrently, the team aimed to reduce the cost of the tanks at the composite level by improving the interfacial adhesion between the fibers and the matrix resin through the incorporation of low-cost nanoparticles recycled from waste materials, which would reduce the volume of costly CF required to achieve the same tank performance. At the end of the first year, the project team selected mesophase pitch as the primary precursor candidate from a field of materials based on the superior mechanical performance and cost-saving potential. During the second year, the team produced CFs derived from mesophase pitch achieving an average tensile strength of 365.6 ksi and average tensile modulus of 40.74 Msi. Facility availability for spinning and converting these fibers at greater scale has hindered scale-up demonstration, but the team has identified opportunities to conduct this work in the near term. Cost modeling shows that these mesophase pitch-derived CFs can be up to 40% less expensive than PAN-derived CFs due to the lower cost of the feedstock material, higher throughput, greater conversion yield, and lower cost spinning method and compared to PAN. Additionally, the team has demonstrated at lab-scale that nanoparticle coating CFs can significantly increase the interfacial shear strength and load transfer efficiency of CFs in a matrix. Single filament pull-out testing showed a 27% average increase in max interfacial shear strength due to this coating. A continuous method of applying these coatings to a tow of CF has been developed for scale-up. 26 m tows of coated CFs were produced using this system and formed into composite ring samples for ASTM ring burst testing. Issues with the testing protocol have limited assessment of these results. A prototype Type IV tank was designed to meet ANSI HGV2 standards, and the design criteria set out by DOE, using the CF properties developed by the team paired with a proprietary resin matrix, a polyamide liner, and aluminum end bosses. The tank weighs 153.1 kg and with a total capacity of 5.8 kg H2 (5.6 kg usable), which yields a gravimetric capacity of 1.17 kWh/kg. Cost modeling predicts that the tank will have a projected cost of $15.73/kWh. Tank performance modeling does not include considerations for fiber-matrix load transfer efficiency improvements offered by nanoparticle coating method.

08 HYDROGEN↗

DOE OSTI2025

Quality Investigation of Pultruded Carbon Fiber Panels Subjected to Four-Point Flexure via Fiber Optic Sensing

Pultruded carbon fiber-reinforced composites are attractive to the wind energy industry due to the rapid production of highly aligned unidirectional composites with enhanced fiber volume fractions and increased specific strength and stiffness. However, high volume carbon fiber manufacturing remains cost-prohibitive. This study investigates the feasibility of a pultruded low-cost textile carbon fiber-reinforced epoxy composite as a promising material in spar cap production was undertaken based on mechanical response to four-point flexure loading. As spar caps are primarily subjected to flexural loading, large-span four-point flexure was considered, and coupon testing was restricted to tensile modulus and compression strength assessment. High-resolution spatial fiber optic strain sensing was utilized to determine spatial strain distribution during four-point flexure, revealing consistent strain along the length of the part and proved to be an excellent option for process manufacturing quality examination. Additionally, holes with diameters of 2.49 mm, 5.08 mm, and 1.93 mm were drilled through the thickness of full-width parts to determine the feasibility of structural health monitoring of pultruding parts internal to wind blades via fiber optic strain sensing.

Chemistry↗

DOE OSTI2025

Scale up production of carbon fibers from petroleum mesophase pitch

This work investigates the scale-up of pitch precursors for the carbon fiber market using mesophase pitch formulated and produced by Advanced Carbon Products Technologies’ (ACPT’s) patented mesophase pitch processing technology. Through use of its patented process, ACPT developed strategic materials by converting petroleum-based pitch into a high-value, low-cost, carbon-rich feedstock for carbon fiber and other materials critical to our national security. The team successfully developed processing criteria for the tailored mesophase pitch material that can be processed further into precursor and carbon fiber. Processability of the mesophase pitch into precursor and carbon fiber was demonstrated at scale. The resulting materials sequester the carbon that would otherwise be burned and released into the atmosphere, making this an environmentally friendly way to produce these materials in the United States.Pitch-based carbon fibers offer a promising pathway toward cost-effective, high-performance materials for structural and high-modulus composite applications; however, adoption has been limited by challenges in precursor processability and scale-up. In this work, tailored isotropic and mesophase petroleum-derived pitch materials were developed and evaluated for precursor and carbon fiber production through a collaborative effort between Oak Ridge National Laboratory (ORNL) and ACPT. Processing conditions were established at ORNL’s Carbon Fiber Technology Facility to enable stable melt-blowing of pitch-based precursors under continuous operation. Mesophase pitch precursor fibers were produced following oxidation and carbonization, corresponding to a diameter shrinkage of approximately 12%–13% and an estimated mass yield of about 75%–80%. Continuous melt-blowing steady-state operation was demonstrated over time, indicating robust process stability. Melt-blowing was achieved at throughput rates of approximately 20 lb/h⁻¹, validating the commercial viability of petroleum-derived pitch feedstocks for fiber production. Further studies are required to tailor carbon fiber microstructure and properties for specific composite applications.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS1995

Effects of Yarn Crimping on Braided Composite Design Allowables

Braided composite materials are currently being evaluated for wing skin stiffeners on commercial aircraft. These carbon-fiber/epoxy materials allow for low-cost manufacturing while maintaining high strength-to-weight and stiffness-to-weight ratios. The proposed braid architecture consists of axial carbon fiber yarns and braider carbon fiber yarns making 60 deg to 70 deg angles with respect to the axial yarns. These 2-D triaxial braids are produced as long, continuous tubes, which are flattened, cut, and stacked to produce the desired part thickness and shape. When infiltrated with epoxy resin and cured under a compaction pressure, the fiber yarns become crimped, allowing for higher fiber packing. Although high fiber packing is desirable, yarn crimping (especially in the axial fiberyarns) is undesirable. Significant axial yarn crimp angles (greater than 10 deg) have been measured in braided composites. Comparable levels of crimping have been found to produce significant compressive strength reductions in laminated composites consisting of planar fiber sheets. Thus, axial yarn crimping is suspected of producing significant reductions in compressive strength allowables for braided composites. The objective of this research is to quantify the reduction in compressive strength as a function of axial yarn crimp severity. Since crimp severity can be reduced by lowering the compaction pressure during curing, the resulting compressive strengths may be used to determine optimum processing conditions. A 'cure-on-the-loom' manufacturing process was developed to produce braided composites with controlled levels of crimping. This method allowed for controlled levels of tension to be placed on the axial yarns and maintained during the curing process. With increasing tension, the crimp severity in the axial yarns was reduced. Thus, varying crimp severities were produced ranging from conventional levels (greater than 10 deg) to virtually straight axial yarns. Test results indicate that a 30% increase in compressive strength is obtainable by eliminating axial yarn crimping. Further compression testing is underway to quantify the relationship between crimp severity and compressive strength. Additional testing is planned to investigate the effect of crimping on the open-hole compressive strength, often considered a more significant design allowable.

Adams, Dan↗

DOE OSTI2025

Wind-Driven Direct Air Capture System Using 3D Printed, Passive, Amine-Loaded Contactors (WEDAC)

This project advanced the development of a novel wind-driven direct air capture (WEDAC) system for removing carbon dioxide (CO 2 ) from the atmosphere. Our research focused on combining passive air contact with electrothermal desorption using specially designed carbon fiber modules, aiming to provide a scalable, low-cost, and energy-efficient alternative to conventional carbon capture systems.

36 MATERIALS SCIENCE↗

DOE OSTI2025

A Synthetic Pathway for Producing Carbon Dots for Detecting Iron Ions Using a Fiber Optic Spectrometer

Iron detection is of growing importance in the critical minerals sector, where unwanted iron ions are typically removed during the processing of target critical metals. The ideal sensor should utilize inexpensive, scalable materials along with a low-cost, robust, and easy-to-use analysis platform. Here, we demonstrate a simple acid–base synthesis of luminescent iron-responsive carbon dots by reacting ethanolamine, phosphoric acid, and m-phenylenediamine. The carbon dots exhibit selective, iron-specific emission quenching, with the ability to detect part-per-billion levels of iron ions even in 0.1 M HCl. After benchmarking the purified materials using a commercial spectrometer, a “low-cost” process is demonstrated in which carbon dots with minimal purification are coupled with a portable fiber-optic spectrometer for analyzing iron content. Carbon dot-coated paper strips are also evaluated as another convenient platform for iron analysis. Taken together, the sensing material and platforms demonstrated here are well-suited for detecting trace quantities of iron in environmentally relevant conditions, with potential applications in tracking iron removal processes during critical mineral production as one exciting area of interest.

acid mine draining↗

NASA NTRS1993

Using rapid infrared forming to control interfaces in titanium-matrix composites

Control of the fiber-matrix reaction during composite fabrication is commonly achieved by shortening the processing time, coating the reinforcement with relatively inert materials, or adding alloying elements to retard the reaction. To minimize the processing time, a rapid IR forming (RIF) technique for metal-matrix composite fabrication has been developed. Experiments have shown that the RIF technique is a quick, simple, and low-cost process to fabricate titanium-alloy matrix composites reinforced with either silicon carbide or carbon fibers. Due to short processing times (typically on the order of 1-2 minutes in an inert atmosphere for composites with up to eight-ply reinforcements), the interfacial reaction is limited and well controlled. Composites fabricated by this technique have mechanical properties that are comparable to (in several cases, superior to) those made with conventional diffusion-bonding techniques.

Warrier, Sunil G.↗

DOE OSTI2024

Coal-derived carbon anodes for lithium-ion batteries: Development, challenges, and prospects

Lithium-ion battery (LIB) development has increased rapidly, requiring low-cost anode materials with a high capacity, high-rate performance, and stable lifespan. Carbon-based anodes possess various exceptional morphologies and structures, making them promising candidates for meeting the technical demands; however, conventional synthetic carbon anode processes need expensive feedstocks that increase anode cost and limit commercialization. Coal, the most affordable and abundant carbon resource, has attracted increasing attention as the primary feedstock for producing high-value carbon anode materials. This article reviews the lithium storage mechanisms, characteristics, and productions of some high-valuable carbon anode materials for LIBs from coal and coal derivatives. The high-value carbon anode materials reviewed in this article are graphite, graphene, mesophase microbeads (MCMB), carbon fiber, and hard carbons. Furthermore, the remaining challenges and prospects of using coal-derived carbon materials to create high-performance and low-cost lithium-ion batteries are also discussed.

25 ENERGY STORAGE↗

DOE OSTI2025

Energy-efficient carbon capture from industrial point sources via commercially available green solvent and hollow fiber membrane contactors

Solvent-based absorption systems have emerged in the carbon capture space due to their high absorption capacities, reusability, and favorable energy requirements. Using diethyl sebacate as a solvent for pre- and post-combustion carbon capture has advantages over other solvents, including high hydrophobicity, low viscosity, low vapor pressure, high CO 2 solubility, high CO 2 selectivity, and being commercially available in large quantities. Despite these advantageous properties, the use of diethyl sebacate as a solvent for post-combustion carbon capture has not been studied in detail. To examine the capability of diethyl sebacate, a scalable, energy-efficient, hollow fiber membrane (microporous polypropylene and polyvinylidene fluoride) contactor (HFMC)-based process with low-cost and high surface area is investigated. A purity of 95.3 % CO 2 with 46 % recovery in one absorption stage was achieved, with a permeate flux over one magnitude greater than using a deep eutectic solvent in the same system. Technoeconomic analysis determined a ∼ 0.8 GJ per ton of CO 2 at a processing cost of ∼$93 per ton of CO 2 . Results from this work underscore the potential for utilizing green solvents in HFMC-based separation processes for effective carbon capture and provide a pathway towards practical deployment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1972

Development of moldable carbonaceous materials for ablative rocket nozzles.

Description of a materials system developed for use as low-cost ablative nozzles for NASA's 260-in. solid rocket motor. Petroleum coke and carbon black fillers were employed; high density was achieved by controlling particle size distribution. An alumina catalyzed furfuryl ester resin which produced high carbon residues after pyrolysis was employed as the binder. Staple carbon fibers improved the strength and crack resistance of molded bodies. In static firing tests of two subscale nozzles, this material compared favorably in erosion rate with several other ablative systems.

Lockhart, R. J.↗

DOE OSTI2025

Microwave Catalysis for Process Intensified Modular Production of Carbon Nanomaterials from Natural Gas

The objective of this project was to develop a novel, low-cost process intensified modular process to directly convert flare gas or stranded gas to carbon nanomaterials and co-product hydrogen (H 2 ) with high conversion, selectivity, and stability. The proposed project was based on our exciting exploratory research on a patent pending technology for one-step conversion of natural gas to carbon nanotubes (CNTs) and carbon fibers (CNFs) without emitting CO 2 : CH 4 → H 2 + C (CNT, Carbon Fibers).

03 NATURAL GAS↗

DOE OSTI2024

Multiparameter optical fiber sensing for energy infrastructure through nanoscale light–matter interactions: From hardware to software, science to commercial opportunities

Monitoring of energy infrastructure through robust yet economical sensing platforms is becoming an area of increased importance, with ubiquitous applications including the electrical grid, natural gas and oil transportation pipelines, H2 infrastructure (storage and transportation), carbon storage, power generation, and subsurface environments. Plasmonic and functional nanomaterial enabled fiber optic sensors show excellent promise for a wide range of sensing applications due to their versatility to be engineered for specific analytes of interest while retaining inherent advantages of the optical fiber sensor platform. Through the design of novel sensing layers, the optical transduction mechanism and wavelength dependence can also be tailored for ease of integration with low-cost interrogation systems enabling an inexpensive yet highly functional optical fiber sensing platform. In addition, recent advances in artificial intelligence and machine learning theoretical methods have been leveraged to simultaneously extract multiple parameters through multi-wavelength interrogation such that unique wavelengths can also serve as unique sensing elements, analogous to electronic nose sensor technologies. The concept of an optical fiber based “photonic nose” via multiple interrogation wavelengths and/or sensor nodes offers a compelling platform technology to realize multiparameter speciation of chemical analytes within complex gas mixtures. In this Perspective, we further generalize the notion of multiparameter sensing through the novel “photonic nervous system” concept based upon low-cost, functionalized optical fiber sensor probes monitoring a variety of distinct analyte classes (physical, chemical, electromagnetic, etc.) simultaneously to provide broad situational awareness via integrated sensors.

Su, Yang-Duan (ORCID:0000000214820902)↗

DOE OSTI2025

Low-cost, portable optical sensors for critical mineral prospecting and process monitoring

A combination of projected demand increases for economically critical minerals and a monopolistic global marketplace for these minerals has caused concern over supply chain vulnerabilities, which would impact energy, national defense, and advanced technology production. Domestic production of critical minerals is hindered by expensive and non-portable methods for analyzing metal concentration, which is vital both for resource prospecting and process monitoring. Here, a suite of luminescent materials along with portable instrumentation is presented for fluorescence-based detection of trace concentrations of critical minerals (cobalt, rare earth elements, and aluminum) as well as common gangue metals that are removed during processing (iron and aluminum). A metal-organic framework comprised of zinc, adenine, and trimesic acid immobilized on a fiber optic tip is capable of sensing part-per-billion concentrations of terbium, europium, dysprosium, and samarium through a sensitization approach, in which individual elements produce characteristic emission bands enabling multiple rare earths to be simultaneously detected and distinguished. A deep-UV light emitting diode is used as the excitation source, while a portable spectrometer is used to detect the emitted light. A similar optical set-up is coupled with two different carbon dot materials, which can detect low part-per-million concentrations of cobalt and iron in acidic environments. Metal-organic framework thin films comprised of copper and 2-aminoterephthalic acid are used in tandem with a portable optical set-up to further detect aluminum, with successful deployment in real fly ash leachates. Taken together, these technologies provide an inexpensive and sensitive path towards characterizing economically critical metals.

characterization and extraction of rare earth elem↗

NASA NTRS1985

Iron rich low cost superalloys

An iron-rich low-cost superalloy was developed. The alloy, when processed by conventional chill casting, has physical and mechanical properties that compare favorably with existing nickel and cobalt based superalloys while containing significantly lower amounts of strategic elements. Studies were also made on the properties of Cr(20)-Mn(10)-C(3.4)-Fe(bal.), a eutectic alloy processed by chill casting and directional solidification which produced an aligned microstructure consisting of M7C3 fibers in a gamma-Fe matrix. Thermal expansion of the M7C3 (M = Fe, Cr, Mn) carbide lattice was measured up to 800 C and found to be highly anisotropic, with the a-axis being the predominant mode of expansion. Repetitive impact sliding wear experiments performed with the Fe rich eutectic alloy showed that the directionally solidified microstructure greatly improved the alloy's wear resistance as compared to the chill cast microstructure and conventional nickel base superalloys. Studies on the molybdenum cementite phase prove that the crystal structure of the xi phase is not orthorhombic. The crystal structure of the xi phase is made up of octahedra building elements consisting of four Mo and two Fe atoms and trigonal prisms consisting of four Fe and two Mo atoms. The voids are occupied by carbon atoms. The previous chemical formula for the molybdenum cementite MoFe2C is now clearly seen to be Mo12Fe22C10.

Wayne, S. F.↗

DOE OSTI2026

Accelerating Laboratory-Based, All-Solid-State Battery Research and Development: Industrially Relevant Small-Batch Dry-Processing, Small and Low-Cost Test Fixtures, and Short-Tolerant Separators

This work presents improvements to mixing (for dry-processed electrodes), separator robustness, and cell testing jigs for all-solid-state batteries (ASSBs). These developments combine synergistically to enable rapid research and development of ASSB catholytes. A mechanical "kneader" is designed and built which emulates the mixing and fibrillation of poly-tetrafluoroethylene binder that occurs in industrially relevant twin-screw extruders. A modest improvement in the mixing and dispersion catholyte materials is observed using micro-resolution X-ray computed tomography (X-ray CT). Catholytes are paired with an In-metal anode and separated by a novel, dual-layer, polyaramid-fiber-supported, sulfide-solid electrolyte (Li6 PS5 Cl) separator. This separator achieves high short tolerance which enabled a 95% success rate across 20 attempted cells and to date over 100 successful cells have been built. ASSBs were tested in a 2032 coin-cell format. Simultaneous cycling of a large number of cells is further enabled by a compact and low cost (~ 38 USD per jig) pressure application jig of which 100 have been constructed to date. The utility of these advances is demonstrated through a brief study on the effect cathode-side conductive carbon and current collector type has on capacity and rate performance.

25 ENERGY STORAGE↗

NASA NTRS1980

Risk to the public from carbon fibers released in civil aircraft accidents

Because carbon fibers are strong, stiff, and lightweight, they are attractive for use in composite structures. Because they also have high electrical conductivity, free carbon fibers settling on electrical conductors can cause malfunctions. If released from the composite by burning, the fibers may become a hazard to exposed electrical and electronic equipment. As part of a Federal study of the potential hazard associated with the use of carbon fibers, NASA assessed the public risk associated with crash fire accidents of civil aircraft. The NASA study projected a dramatic increase in the use of carbon composites in civil aircraft and developed technical data to support the risk assessment. Personal injury was found to be extremely unlikely. In 1993, the year chosen as a focus for the study, the expected annual cost of damage caused by released carbon fibers is only $1000. Even the worst-case carbon fiber incident simulated (costing $178,000 once in 34,000 years) was relatively low-cost compared with the usual air transport accident cost. On the basis of these observations, the NASA study concluded that exploitation of composites should continue, that additional protection of avionics is unnecessary, and that development of alternate materials specifically to overcome this problem is not justified.

Source record↗

NASA NTRS1998

Low-Cost Production of Composite Bushings for Jet Engine Applications

The objectives of this research program were to reduce the manufacturing costs of variable stator vane bushings by 1) eliminating the expensive carbon fiber braiding operation, 2) replacing the batch mode impregnation, B-stage, and cutting operations with a continuous process, and 3) reducing the molding cycle and machining operations with injection molding to achieve near-net shapes. Braided bushings were successfully fabricated with both AMB-17XLD and AMB-TPD resin systems. The composite bushings achieved high glass transition temperature after post-cure (+300 C) and comparable weight loss to the PNM-15 bushings. ANM-17XLD bushings made with "batch-mode" molding compound (at 0.5 in. fiber length) achieved a +300 lb-force flange break strength which was superior to the continuous braided-fiber reinforced bushing. The non-MDA resin technology developed in this contract appears attractive for bushing applications that do not exceed a 300 C use temperature. Two thermoplastic polyimide resins were synthesized in order to generate injection molding compound powders. Excellent processing results were obtained at injection temperatures in excess of 300 C. Micro-tensile specimens were produced from each resin type and the Tg measurements (by TMA) for these samples were equivalent to AURUM(R). Thermal Gravimetric Analysis (TGA) conducted at 10 C/min showed that the non-MDA AMB-type polyimide thermoplastics had comparable weight loss to PMR-15 up to 500 C.

Gray, Robert A.↗