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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.↗
NASA NTRS1999

ANSYS Modeling of Hydrostatic Stress Effects

Classical metal plasticity theory assumes that hydrostatic pressure has no effect on the yield and postyield behavior of metals. Plasticity textbooks, from the earliest to the most modem, infer that there is no hydrostatic effect on the yielding of metals, and even modem finite element programs direct the user to assume the same. The object of this study is to use the von Mises and Drucker-Prager failure theory constitutive models in the finite element program ANSYS to see how well they model conditions of varying hydrostatic pressure. Data is presented for notched round bar (NRB) and "L" shaped tensile specimens. Similar results from finite element models in ABAQUS are shown for comparison. It is shown that when dealing with geometries having a high hydrostatic stress influence, constitutive models that have a functional dependence on hydrostatic stress are more accurate in predicting material behavior than those that are independent of hydrostatic stress.

Allen, Phillip A.↗
NASA NTRSDate not supplied

Investigating the Ability of Plastic Current Collectors to Isolate Internal Shorts

Metallized plastic current collectors in Li-ion cells reduce mass and reduce the internal short circuit hazard compared to aluminum and copper foils. Shorts induced by nail and by our internal short circuit device were performed on control 18650 cells and on cells with the collectors replaced with metallized polyester and aramid films. Tests were performed inside our fractional thermal runaway calorimeter to quantify the heat transferred and its distributions and those runs done at a synchrotron yielded fascinating very high speedX-ray videography. These show tolerance to nail penetration and activation of defect internal shorts and when thermally forced into thermal runaway, the heat output is significantly reduced. Very high resolutionCT scans, cross sections, and cell tear downs give insights into the thermal and mechanism for these plastic collectors.

Plastic Current Collectors↗
NASA NTRS1982

Method of bonding plasticized elastomer to metal and articles produced thereby

Plasticized elastomer was securely bonded to a metal surface by interposing between the adhesive-coated metal surface and the elastomer sheet of material obtained by combining adhesive with a portion of the elastomer that was treated to remove plasticizers therefrom and heating the assembly in a mold under pressure. The sheet material is made up by dissolving a portion of the plasticized elastomer in an organic solvent, casting the solution, exposing it to a vacuum to remove the solvent and plasticizers, dissolving the deplasticized material in liquid adhesive and casting and drying the resulting liquid.

White, W. T.↗
NASA NTRS1978

Food Packaging Materials

The photos show a few of the food products packaged in Alure, a metallized plastic material developed and manufactured by St. Regis Paper Company's Flexible Packaging Division, Dallas, Texas. The material incorporates a metallized film originally developed for space applications. Among the suppliers of the film to St. Regis is King-Seeley Thermos Company, Winchester, Ma'ssachusetts. Initially used by NASA as a signal-bouncing reflective coating for the Echo 1 communications satellite, the film was developed by a company later absorbed by King-Seeley. The metallized film was also used as insulating material for components of a number of other spacecraft. St. Regis developed Alure to meet a multiple packaging material need: good eye appeal, product protection for long periods and the ability to be used successfully on a wide variety of food packaging equipment. When the cost of aluminum foil skyrocketed, packagers sought substitute metallized materials but experiments with a number of them uncovered problems; some were too expensive, some did not adequately protect the product, some were difficult for the machinery to handle. Alure offers a solution. St. Regis created Alure by sandwiching the metallized film between layers of plastics. The resulting laminated metallized material has the superior eye appeal of foil but is less expensive and more easily machined. Alure effectively blocks out light, moisture and oxygen and therefore gives the packaged food long shelf life. A major packaging firm conducted its own tests of the material and confirmed the advantages of machinability and shelf life, adding that it runs faster on machines than materials used in the past and it decreases product waste; the net effect is increased productivity.

Source record↗
NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗
NASA NTRS2002

Hydrostatic Stress Effect On the Yield Behavior of Inconel 100

Classical metal plasticity theory assumes that hydrostatic stress has no effect on the yield and postyield behavior of metals. Recent reexaminations of classical theory have revealed a significant effect of hydrostatic stress on the yield behavior of notched geometries. New experiments and nonlinear finite element analyses (FEA) of Inconel 100 (IN 100) equal-arm bend and double-edge notch tension (DENT) test specimens have revealed the effect of internal hydrostatic tensile stresses on yielding. Nonlinear FEA using the von Mises (yielding is independent of hydrostatic stress) and the Drucker-Prager (yielding is linearly dependent on hydrostatic stress) yield functions was performed. In all test cases, the von Mises constitutive model, which is independent of hydrostatic pressure, overestimated the load for a given displacement or strain. Considering the failure displacements or strains, the Drucker-Prager FEMs predicted loads that were 3% to 5% lower than the von Mises values. For the failure loads, the Drucker Prager FEMs predicted strains that were 20% to 35% greater than the von Mises values. The Drucker-Prager yield function seems to more accurately predict the overall specimen response of geometries with significant internal hydrostatic stress influence.

Allen, Phillip A.↗