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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 NTRS2019

Metallized Plastic Current Collectors

Metallized plastic current collectors are an innovation patented by the Soteria Battery Innovation Group with the promise of isolating active material involved in an internal short by vaporizing and isolating the short from the rest of the cell electrode jellyroll or stack. Partnering with NREL, UCL, Coulometrics, and Soteria, NASA is leading a research effort into demonstrating the merits and understanding the phenomena of this safety innovation using prototype 18650 cylindrical cells vs control cells with standard metal foil current collectors. Cells with and without the plastic collector, with and without the on-demand internal short circuit device, and with polymer or cellulose separators were made. Safety evaluations were done with driving cells into thermal runaway (TR) with thermal and nail penetration triggers while inside our TR calorimeter and with ultra high speed X-ray videography provided at Synchrotrons. Preliminary results suggests that the thermally unstable plastic current collector innovation has great promise for preventing TR or reducing the severity of the TR output.

Li-ion cell↗
NASA NTRS1999

Hydrostatic Stress Effects in Metal Plasticity

Since the 1940s, the theory of plasticity has assumed that hydrostatic stress does not affect the yield or postyield behavior of metals. This assumption is based on the early work of Bridgman. Bridgman found that hydrostatic pressure (compressive stress) does not affect yield behavior until a substantial amount of pressure (greater than 100 ksi) is present. The objective of this study was to determine the effect of hydrostatic tension on yield behavior. Two different specimen geometries were examined: an equal-arm bend specimen and a double edge notch specimen. The presence of a notch is sufficient to develop high enough hydrostatic tensile stresses to affect yield. The von Mises yield function, which does not have a hydrostatic component, and the Drucker-Prager yield function, which includes a hydrostatic component, were used in finite element analyses of the two specimen geometries. The analyses were compared to test data from IN 100 specimens. For both geometries, the analyses using the Drucker-Prager yield function more closely simulated the test data. The von Mises yield function lead to 5-10% overprediction of the force-displacement or force-strain response of the test specimens.

Wilson, Christopher D.↗
NASA NTRS1986

Ultrasonic Bonding to Metalized Plastic

New technique makes it possible to bond wires ultrasonically to conductor patterns on such soft substrates as plain or ceramic-filled polytetrafluoroethylene. With ultrasonic bonding, unpackaged chips attached to soft circuit boards. Preferred because chips require substrate area and better matched electrically to circuit board at high frequencies.

Conroy, B. L.↗
NASA NTRS1991

Ceramic susceptor for induction bonding of metals, ceramics, and plastics

A thin (.005) flexible ceramic susceptor (carbon) was discovered. It was developed to join ceramics, plastics, metals, and combinations of these materials using a unique induction heating process. Bonding times for laboratory specimens comparing state of the art technology to induction bonding were cut by a factor of 10 to 100 times. This novel type of carbon susceptor allows for applying heat directly and only to the bondline without heating the entire structure, supports, and fixtures of a bonding assembly. The ceramic (carbon film) susceptor produces molten adhesive or matrix material at the bond interface. This molten material flows through the perforated susceptor producing a fusion between the two parts to be joined, which in many instances has proven to be stronger than the parent material. Bonding can be accomplished in 2 minutes on areas submitted to the inductive heating. Because a carbon susceptor is used in bonding carbon fiber reinforced plastics and ceramics, there is no radar signature or return making it an ideal process for joining advanced aerospace composite structures.

Fox, Robert L.↗
NASA NTRS1980

Forming complex cavities in clear plastic

Metal casting "lost wax" process is used to mold plastic parts. Highly economical technique produces optically-clear components of complex shapes, which can be used in complex combustion and manifold systems.

Riley, T.↗
NASA NTRSDate not supplied

The Repair Maintenance and Fabrication Facility in the Common Habitat Architecture

The Common Habitat Architecture seeks to increase the habitability of long-duration human spaceflight systems. A key aspect of this is vehicle survivability. Missions beyond low Earth orbit need onboard capabilities for Repair, Maintenance, And Fabrication (RMAF) to overcome potential contingency scenarios. Strategies employed in historic human spaceflight such as redundancy management, reliability, sparing, orbital replacement units, and aborts may be insufficient by themselves. Based on subject matter input, a list of 53 critical failures defining a set of incidents that can render a key spacecraft subsystem inoperable were generated. A subsequent analysis found that a robust in-space RMAF system capable of performing 14 key functions can potentially repair a subsystem plagued by any of these failures. An ancillary benefit is this capability may provide psychological benefits to the crew, by enabling greater self-sufficiency in earth-independent problem solving. A basic RMAF facility has been defined for the Common Habitat, consisting of five workstations. A work bench and computer workstation provide a multipurpose horizontal work surface, computing interface, and tools storage. A CNC machining center provides a subtractive manufacturing capability for metals and plastics. A multi-material 3D printing facility provides additive manufacturing capabilities for plastic, metals, and printed electronics. A welding facility is used for joining metal components where a higher strength is needed than can be achieved with fasteners or adhesives. A glovebox facility is used to perform work that is too hazardous for any of the other workstations. This may include hardware brought in from outside the spacecraft that could potentially contaminate the cabin environment. Forward work includes considering the accommodation of additional manufacturing processes not modeled in the current system, assessing the ability of systems to operate in partial gravity and microgravity environments, incorporation of the system into the Common Habitat Computer Aided Design (CAD) model, bottoms-up mass estimating, and a crew time analysis.

Habitat↗
NASA NTRS1991

Rapid induction bonding of composites, plastics, and metals

The Toroid Bonding Gun is and induction heating device. It is a self contained, portable, low powered induction welding system developed for bonding or joining plastic, ceramic, or metallic parts. Structures can be bonded in a factory or in a the field. This type of equipment allows for applying heat directly to the bond lines and/or to the adhesives without heating the entire structure, supports, and fixtures of a bonding assembly. The induction heating gun originally developed for use in the fabrication of space Gangs of bonders are now used to rapidly join composite sheet and structural components. Other NASA-developed applications of this bonding technique include the joining of thermoplastic composites, thermosetting composites, metals, and combinations of these materials.

Buckley, John D.↗
NASA NTRS1982

Polymeric metallic electrodes for rechargeable battery applications

A review is presented on the status of plastic metal electrodes, emphasizing the use of polyacetylene as a prototype polymeric material. The electrochemical characteristics of polyacetylene are examined; and the potential use of this material, as well as other types of plastic metal electrodes, in batteries is evaluated. Several problem areas which must be solved before polyacetylene can be widely used in battery applications are discussed, including the problem of electrolyte stability, the problem that the depth of discharge and the energy density is limited by the metal-semiconductor transition, and also the poor electrochemical performance of impure material.

Somoano, R.↗