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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
NASA NTRS2016

Terrestrial Analogues for Lunar Impact Melt Flows

Lunar impact melt deposits have unique physical properties. They have among the highest observed radar returns at S-Band (12.6 cm wavelength), implying that they are rough at the decimeter scale. However, they are also observed in high-resolution optical imagery to be quite smooth at the meter scale. These characteristics distinguish them from well-studied terrestrial analogues, such as Hawaiian pahoehoe and ʻa ʻa lava flows. The morphology of impact melt deposits can be related to their emplacement conditions, so understanding the origin of these unique surface properties will help to inform us as to the circumstances under which they were formed. In this work, we seek to find a terrestrial analogue for well-preserved lunar impact melt flows by examining fresh lava flows on Earth. We compare the radar return and high-resolution topographic variations of impact melt flows to terrestrial lava flows with a range of surface textures. The lava flows examined in this work range from smooth Hawaiian pahoehoe to transitional basaltic flows at Craters of the Moon (COTM) National Monument and Preserve in Idaho to rubbly and spiny pahoehoe-like flows at the recent eruption at Holuhraun in Iceland. The physical properties of lunar impact melt flows appear to differ from those of all the terrestrial lava flows studied in this work. This may be due to (a) differences in post-emplacement modification processes or (b) fundamental differences in the surface texture of the melt flows due to the melts' unique emplacement and/or cooling environment. Information about the surface properties of lunar impact melt deposits will be critical for future landed missions that wish to sample these materials.

Earth↗
DOE OSTI2022

Controlling melt flow by nanoparticles to eliminate surface wave induced surface fluctuation

The high surface roughness is one of the major challenges encountered in laser metal additive manufacturing (AM) processes, which is closely related to the melt flow behavior. However, how to control the melt flow in laser metal AM processes to improve surface finish is unknown. Here we reveal the effects of nanoparticles on melt flow behavior at every location of melt pool during laser metal AM process for the first time using Al6061 + TiC nanoparticles system and achieve significant improvement of surface finish by using TiC nanoparticles to control the melt flow and damp the surface wave. Based on the in-situ x-ray imaging observation, the surface wave is fully damped after adding TiC nanoparticles, compared with only 56% damping without nanoparticles during LPBF of Al6061. Our in-depth in-situ x-ray imaging analysis and viscosity measurement enable us to identify that nanoparticle-induced increase of viscosity causes the fully damping of the surface wave by (1) increasing the internal fluid friction for more efficient wave amplitude reduction, (2) controlling the melt flow to increase the surface wave number, (3) controlling the melt flow to increase the wave damping time. Furthermore, we also quantified the relative contributions of increasing fluid friction, increasing wave number, and increasing damping time to wave damping, which account for 61%, 25%, and 14%, respectively. Furthermore, our research provides the mechanisms and potential method to address the surface finish challenge in laser metal AM processes.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Revealing melt flow instabilities in laser powder bed fusion additive manufacturing of aluminum alloy via in-situ high-speed X-ray imaging

Laser metal additive manufacturing technologies enable the fabrication of geometrically and compositionally complex parts unachievable by conventional manufacturing methods. However, the certification and qualification of additively manufactured parts are greatly hindered by the stochastic melt flow instabilities intrinsic to the process, which has not been explicitly revealed by direct observation. Here, we report the mechanisms of the melt flow instabilities in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-resolution synchrotron X-ray imaging. Here we identified powder/droplet impact, significant keyhole oscillation, and melting-mode switching as three major mechanisms for causing melt flow instabilities. We demonstrated the detrimental consequences of these instabilities brought to the process, and presented new understanding on the melt flow evolution and keyhole oscillation. This work provides critical insights into process instabilities during laser metal additive manufacturing, which may guide the development of instability mitigation approaches. The results reported here are also important for the development and validation of high-fidelity computational models.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Global Distribution of Lunar Impact Melt Flows

In this study, we analyzed the distribution and properties of 146 craters with impact melt deposits exterior to their rims. Many of these craters were only recently discovered due to their unusual radar properties in the near-global Mini-RF data set. We find that most craters with exterior deposits of impact melt are small, less than 20 kilometers, and that the smallest craters have the longest melt flows relative to their size. In addition, exterior deposits of impact melt are more common in the highlands than the mare. This may be the result of differing target properties in the highlands and mare, the difference in titanium content, or the greater variation of topography in the highlands. We find that 80 percent of complex craters and 60 percent of simple craters have melt directions that are coincident or nearly coincident with the lowest point in their rim, implying that pre-existing topography plays a dominant role in melt emplacement. This is likely due to movement during crater modification (complex craters) or breached crater rims (simple craters). We also find that impact melt flows have very high circular polarization ratios compared to other features on the Moon. This suggests that their surfaces are some of the roughest material on the Moon at the centimeter to decimeter scale, even though they appear smooth at the meter scale.

Cratering↗
NASA NTRS1992

Melt flow properties of LARC-TPI 1500 series mixtures

This study examines the melt-flow properties of 50/50 mixtures of high flow grade/medium flow grade LARC-TPI 1500 series pellets and a new form (94/6), of medium flow grade material which contains 6 percent of a low molecular weight imide additive. The flow properties are compared with previously reported flow properties of mixtures of earlier batches of high and medium flow grade TPI 1500 materials. Unlike the earlier batches of materials, the later materials were synthesized and mixed at Mitsui Toatsu Chemicals, Inc., Japan, and made into pellets before NASA received them for characterization. They exhibited a lower melt viscosity as well as improved melt stability.

Burks, H. D.↗
NASA NTRS1990

Improved melt flow and physical properties of Mitsui Toatsu's LARC-TPI 1500 series polyimide

The basic thermal properties and melt behavior of an improved form of LARC-TPI polyimide, LARC-TPI 1500, are investigated and compared with those of LARC-TPI 1000 and 2000. The LARC-TPI 1500 powders are thermally stable and melt processable. The absolute molecular weight of the polymer varies from 20,000 to 30,000, indicating recurring unit numbers of about 40-60. The melt flow properties of LARC-TPI 1500 are comparable to those of other engineering plastics, such as PEEK, PSU, and PES. The flexural modulus of injection molded parts of LARC-TPI 1500 is the highest among commercial thermoplastic polymers.

Ohta, Masahiro↗
DOE OSTI2020

Numerical benchmark of transient pressure-driven metallic melt flows

Fluid dynamics simulations of melting and crater formation at the surface of a copper cathode exposed to high plasma heat fluxes and pressure gradients are presented. The predicted deformations of the free surface and the temperature evolution inside the metal are benchmarked against previously published simulations. Despite the physical model being entirely hydrodynamic and ignoring a variety of plasma–surface interaction processes, the results are also shown to be remarkably consistent with the predictions of more advanced models, as well as experimental data. This provides a sound basis for future applications of similar models to studies of transient surface melting and droplet ejection from metallic plasma-facing components after disruptions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Predicting Selective Laser Printing Print Quality of Polymer Powders through Melt Flow Index

Selective Laser Sintering (SLS) uses a precisely controlled laser to fuse polymer powder to build complex 3D shapes. While SLS covers a wide application space, the processing knowledge of polymer powder is limited, restricting the number of commercial powders available. This study serves to expand the processing knowledge of polypropylene and polyethylene in parallel with a “mature” SLS feedstock, nylon, through melt flow index (MFI) characterization. Differential Scanning Calorimetry (DSC) was used to explore the sintering window of the polymers. Polyethylene and polypropylene exhibited a relatively narrow sintering window between 4 – 5 °C, whereas the sintering window of nylon was much wider, between 23 – 24 °C. This suggests that the print quality between polyethylene and polypropylene would be similar; however, X-ray computed tomography revealed a higher volume of print defects, voids, and de lamination in polyethylene than in polypropylene. MFI analysis provided additional insight into the difference in print quality, as the MFI of polyethylene was 7.16 g/10 min, 9.95 g/10 min for polypropylene, and 17.23 g/10 min for nylon. MFI is inversely correlated to melt viscosity, and a low melt viscosity is desired for proper coalescing between the layers and particles. These results suggest that MFI is a promising tool, in conjunction with traditional thermal analysis, for screening candidate powder feedstocks for SLS and optimization of print parameters for novel powders.

36 MATERIALS SCIENCE↗
NASA NTRS2001

Triamine-Modified Polyimides Having Improved Processability and Low Melt Flow Viscosity

Addition-cured polyimides that contain the reaction product of an aromatic triamine or trianhydride analogue thereof, a reactive end group such as 5-norbornene-2, 3-dicarboxylic acid, ester derivatives of 5-norbornene-2, 3-dicarboxylic acid, anhydride derivatives of 5-norbornene-2, 3-dicarboxylic acid, or 4-phenylethynylphthalic anhydride, an aromatic diamine, and a dialkyl ester of an aromatic tetracarboxylic acid. The resultant starlike polyimides; exhibit lower melt flow viscosity than its linear counterparts, providing for improved processability of the polyimide. Also disclosed are methods for the synthesis of these polyimides as well as composite structures formed using these polyimides.

Michael A Meador↗
NASA NTRS2003

Melt Flow Control in the Directional Solidification of Binary Alloys

Our main project objectives are to develop computational techniques based on inverse problem theory that can be used to design directional solidification processes that lead to desired temperature gradient and growth conditions at the freezing front at various levels of gravity. It is known that control of these conditions plays a significant role in the selection of the form and scale of the obtained solidification microstructures. Emphasis is given on the control of the effects of various melt flow mechanisms on the local to the solidification front conditions. The thermal boundary conditions (furnace design) as well as the magnitude and direction of an externally applied magnetic field are the main design variables. We will highlight computational design models for sharp front solidification models and briefly discuss work in progress toward the development of design techniques for multi-phase volume-averaging based solidification models.

Zabaras, Nicholas↗
NASA NTRS1986

Polyimide of Modified Melt Flow and Toughness

Linear aromatic polyphenylene ether sulfideimide (BDSDA/APB) polymer molded, used as resin, and cast into thin films. In effort to improve further both use properties and amenability to process BDSDA/APB, molecular weight of polymer varied by variations in percentage of end capping. Effect of end capping BDSDA/APB determined by measurement of polymer melt viscosity and fracture-energy values for different number average synthesized molecular weights.

St. Clair, T. L.↗
NASA NTRS1985

Kevlar reinforced neoprene composites

Kevlar/neoprene composites were prepared by two techniques. One method involved the fabrication of a composite from a rubber prepreg prepared by coating Kevlar with viscous neoprene solution and then allowing the solvent to evaporate (solution impregnation technique). The second method involved heating a stack of Kevlar/neoprene sheets at a temperature sufficient to cause polymer flow (melt flow technique). There was no significant difference in the breaking strength and percent elongation for samples obtained by the two methods; however the shear strength obtained for samples fabricated by the solution impregnation technique (275 psi) was significantly higher than that found for the melt flow fabricated samples (110 psi).

Penn, B. G.↗
NASA NTRS2011

Initial Observations of Lunar Impact Melts and Ejecta Flows with the Mini-RF Radar

The Mini-RF radar on the Lunar Reconnaissance Orbiter's spacecraft has revealed a great variety of crater ejecta flow and impact melt deposits, some of which were not observed in prior radar imaging. The craters Tycho and Glushko have long melt flows that exhibit variations in radar backscatter and circular polarization ratio along the flow. Comparison with optical imaging reveals that these changes are caused by features commonly seen in terrestrial lava flows, such as rafted plates, pressure ridges, and ponding. Small (less than 20 km) sized craters also show a large variety of features, including melt flows and ponds. Two craters have flow features that may be ejecta flows caused by entrained debris flowing across the surface rather than by melted rock. The circular polarization ratios (CPRs) of the impact melt flows are typically very high; even ponded areas have CPR values between 0.7-1.0. This high CPR suggests that deposits that appear smooth in optical imagery may be rough at centimeter- and decimeter- scales. In some places, ponds and flows are visible with no easily discernable source crater. These melt deposits may have come from oblique impacts that are capable of ejecting melted material farther downrange. They may also be associated with older, nearby craters that no longer have a radar-bright proximal ejecta blanket. The observed morphology of the lunar crater flows has implications for similar features observed on Venus. In particular, changes in backscatter along many of the ejecta flows are probably caused by features typical of lava flows.

Carter, Lynn M.↗
DOE OSTI2021

Polymer, Additives, and Processing Effects on N95 Filter Performance

The current severe acute respiratory syndrome coronavirus 2 (SARS-COV-2) pandemic has highlighted the need for personal protective equipment, specifically filtering facepiece respirators like N95 masks. While it is common knowledge that polypropylene (PP) is the industry standard material for filtration media, trial and error is often required to identify suitable commercial precursors for filtration media production. This work aims to identify differences between several commercial grades of PP and demonstrate the development of N95 filtration media with the intent that the industry partners can pivot and help address N95 shortages. Three commercial grades of high melt flow index PP were melt blown at Oak Ridge National Laboratory and broadly characterized by several methods including differential scanning calorimetry (DSC), X-ray diffraction (XRD), and neutron scattering. Despite the apparent similarities (high melt flow and isotacticity) between PP feedstocks, the application of corona charging and charge enhancing additives improve each material to widely varying degrees. From the analysis performed here, the most differentiating factor appears to be related to crystallization of the polymer and the resulting electret formation. Materials with higher crystallization onset temperatures, slower crystallization rates, and larger number of crystallites form a stronger electret and are more effective at filtration.

36 MATERIALS SCIENCE↗