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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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7 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Demo 5: RapidClave Technology Demonstrations – Round II (Task 2)

The purpose of this project task was to make automotive composite part manufacturing more cost competitive for low volume production and thereby drive composite application innovation. The strategy was to incorporate low-cost preforming, snap cure resins, and RapidClave® processing to create an alternative to conventional automotive composite manufacturing based on SMC. The program used RapidClave® technology from Globe Machine Manufacturing, fast-curing (“snap cure”) epoxy resins from Hexion, and conformable/stretchable glass fiber reinforcement mats produced by Owens Corning for rapid preforming. O’Gara Armoring retrofits vehicles to meet special security needs, such as larger doors to facilitate easier entry into the vehicle. O’Gara has a variety of custom vehicles in need of custom doors that require affordable tooling to produce approximately 100 ship sets/year. The project focused on a composite door panel application provided by O’Gara that is currently made by manual chopped fiber spray-up processing. UDRI reverse-engineered the current composite door panel and created tooling for use in the RapidClave®. UDRI designed an improved composite door using MultiMat fiberglass reinforcement from Owens Corning. UDRI made snap cure resin films from Hexion resin. Finally, UDRI conducted molding trials to compare autoclave processing with RapidClave® processing. The technical goals of the project were to reduce tooling cost by 50% as compared to SMC compression molding and to reduce cycle time by 50% compared to current manual spray-up process. The approach to reduce tool costs is based on use of single sided tooling for use at 100 psi, as compared to matched metal SMC tooling. An added benefit realized from the program is that the Owens Corning mat provided more uniform thickness and improved performance. Tensile and flexural strengths and moduli were increased by at least 50%. This task also demonstrated a 75% decrease in cycle time. O’Gara is evaluating the technology demonstrated in this project for some of their current production. Additionally, there are new products O’Gara is pursuing which require higher production rates than their current products. O’Gara has identified these new products as good candidates for the RapidClave® technology. The cost advantages demonstrated by this project would then lead to significant economic development. In conclusion, this task successfully combined the RapidClave® technology from Globe with a snap cure epoxy resin film system from Hexion and preform material from Owens Corning. Further research is needed to better map the technical limits such as cycle time of these technologies. Additionally, the technology should be extended in terms of size and shape to include large parts outside of automotive applications, such as a small aircraft fuselage.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Cure-rate data for silicone adhesive

Report describes work with concentrations down to 0.07 percent and is useful when applying adhesives in terrestrial and space applications. Cured Silicone retains low-outgassing properties as well as its snap, elongation, and resilience. Tests for hardness of silicone material also showed good results. No gross hysteresis observable on recovery from stretching nor was there any decrease in hardness.

Clatterbuck, C.↗
NASA NTRS1982

Unsymmetrically laminated composites

Classical lamination theory predicts that the room-temperature shapes of all elevated-temperature cure, unsymmetrically laminated composites are saddles. However, experimental observation indicates that the shapes are often cylindrical. In addition, a second cylindrical can sometimes be obtained from the first by a simple snap-through action. A geometrically nonlinear extension to classical lamination theory is used to explain this behavior. Approximate solutions to the nonlinear extension are obtained by using a Rayleigh-Ritz minimization of the laminate's total potential energy. A stability analysis explains the dual cylindrical shapes.

Hyer, M. W.↗
DOE OSTI2023

SR23012, A Pragmatic Approach to Laser Drilling and Rewelding of Fill Stems, SRNL-TR-2023-00551

The current approach to disposing unloaded reservoirs is to snap the remaining stem, and seal the hole with JB weld, a two-part epoxy mix that is messy to work with and that takes many hours to ensure it is property cured. During this time, reservoirs may be outgassing and cause higher than desired activity in the glovebox. This project will develop, characterize, and deploy a method to drill stems to unload the reservoirs (already in use in the facility, but may require some simple process / procedure modifications), demonstrate that the reservoirs are fully unloaded, and reweld stems by returning to the unloading station and firing the laser to weld the unloading hole closed.

Korinko, Paul S.↗
DOE OSTI2025

Multimaterial 3D Printing in Activating Bath Enables In Situ Polymerization of Thermosets with Intricate Geometries and Diverse Elastic Behaviors

Polydicyclopentadiene, p(DCPD), is a high‐performance thermoset valued for its exceptional toughness, strength, and stiffness. When copolymerized with 1,5‐cyclooctadiene (COD), its mechanical properties can be tuned from glassy to rubbery at room temperature. While frontal polymerization enables a rapid and energy‐efficient route to 3D print DCPD‐based materials, challenges such as ink shelf life and gravitational distortion, especially in direct ink writing of soft COD‐rich formulations, must be considered. Here, a complementary chemical strategy is presented, embedded 3D printing, that enables localized in situ polymerization of printed DCPD/COD inks within a reactive support matrix. The matrix provides both physical support and a reservoir of chemical activator, which diffuses into the ink, activates a latent bis(N‐heterocyclic carbene) Ru precatalyst, and initiates ring‐opening metathesis polymerization. Curing begins at the ink–matrix interface and propagates inward via diffusion, stabilizing the interface and preventing capillary‐driven deformation regardless of the matrix yield stress. This approach eliminates the need for cold storage, external curing, or photoinitiation, significantly expanding the processing window. Using this method, diverse thermosetting and elastomeric architectures are fabricated with features as small as 5 µm and aspect ratios of 100, including interlinked chains, shallow spherical shells exhibiting snap‐through buckling, and hair‐like fin arrays inaccessible through traditional techniques.

chemical activation↗
NASA NTRS1983

Nonlinear effects of elastic coupling in unsymmetric laminates

Classical lamination theory predicts the room-temperature shape of all unsymmetrically laminated, elevated-temperature cure composites to be a saddle shape. Experimental observation indicates, however, that in many cases the room-temperature shape is cylindrical. In addition, a second cylindrical shape can often be obtained from the first by a simple snap-through action. It is the elastic couplings between inplane and out-of-plane deformations which are inherent in unsymmetric laminates that are responsible for the room-temperature shape. However, the couplings are so strong that geometrically nonlinear effects are produced. These are not accounted for in the classical theory. This paper reviews a theory developed to explain the effects of the coupling on laminate shape. The theory is based on a minimization of the laminate's total potential energy. The theory accounts for geometric nonlinearities. Because the problem is nonlinear, approximate solutions are sought by using a Rayleigh-Ritz procedure. Because of the observed snap-through of some laminates, stability of the predicted shapes is examined. Numerical results and some limited experimental data are presented for several laminates.

Hyer, M. W.↗
NASA NTRS1982

The room-temperature shapes of four-layer unsymmetric cross-ply laminates

A geometrically nonlinear extension of classical lamination theory developed by Hyer (1981) for predicting the room-temperature shapes of unsymmetric laminates is reformulated using relaxed restrictions regarding the inplane strains. The inplane residual strains of unsymmetric laminates which have cooled from curing into a cylindrical room-temperature shape are examined numerically. Results show that the residual strains are compressive and practically independent of spatial location on the laminate. In addition, the room temperature shapes of the four-layer unsymmetric cross-ply laminates are predicted, and it is shown that the temperature shapes are a strong function of their size and their stacking arrangement. It is demonstrated that, depending on the parameters selected, the room-temperature shape of a four-layer cross-ply unsymmetric laminate can be a unique saddle shape, a unique cylindrical shape, or a cylindrical shape that can be snapped through to another cylindrical shape.

Hyer, M. W.↗