Results for “Advanced Manufacturing Technologies” — Page 11

DOE OSTI2025

Microstructure-Based Understanding of High-Temperature Deformation Behaviors in Laser Powder Bed Fusion (LPBF) 316H Stainless Steel

This report presents the results of high-temperature mechanical property testing and microstructural analysis of laser powder bed fusion (LPBF) 316H stainless steel (SS) conducted during Fiscal Year 2025 (FY25) under the U.S. Department of Energy, Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program. The study builds upon prior work by expanding the mechanical property test matrix and advancing a microstructure-based mechanistic understanding of LPBF 316H SS performance, with a focus on the solution annealed (SA, 1100°C for 1 hour) materials. High-temperature tension, creep, fatigue, and creep-fatigue tests were performed. Thermal aging studies were conducted. Advanced characterization techniques, including scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM), and high-energy synchrotron X-ray diffraction, were employed to investigate the microstructural evolution during thermal aging and mechanical testing. It was discovered that the as-built (AB) LPBF 316H SS exhibited precipitation kinetics during thermal aging that are 10–100 times faster than its wrought counterpart due to the presence of high densities of preferred nucleation sites, while the precipitation kinetics in SA LPBF 316H was under investigation. The accelerated precipitation of embrittling phases such as sigma phase in LPBF 316H SS compared to its wrought counterpart led to significant impacts on creep ductility. The influence of laser printing parameters and build orientations on fatigue and creep-fatigue performance was observed. In assessing the creep-fatigue performance, it was discovered that the SA LPBF 316H samples failed in less than 200 cycles under 595°C, 0.5% (strain amplitude) with a 60-minute hold time. This work establishes a mechanistic framework for predicting the long-term behavior of LPBF 316H SS, supporting its rapid qualification under the ASME BPVC. The findings contribute to the broader goal of enabling the deployment of advanced materials in next-generation nuclear energy systems. An outlook for FY26 work, including continued aging studies, mechanical testing, and microstructural characterization, is provided.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Irradiation And Post-Irradiation Examination Plan For A709

The Advanced Materials and Manufacturing Technologies program is proposing a neutron irradiation campaign for alloy 709 (A709) plate product developed by the Advanced Reactor Technologies program. This irradiation campaign will support the deployment of A709 (included welded components) by providing data of engineering importance, such as data that can be used for establishing end-of-life design parameters and knockdown factors for irradiated materials properties versus properties for non-irradiated material. It will also advance the scientific understanding of A709 irradiation behaviors and material property evolution, which is vital for deploying A709 components into reactors with different neutron spectra, neutron fluxes, and irradiation temperatures as well as accelerating the deployment of new product forms and weld procedures. This document presents the plan for the neutron irradiation and post-irradiation examination for A709 and the scientific and technical basis for the plan.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2016

Phase 1 Development Testing of the Advanced Manufacturing Demonstrator Engine

The Additive Manufacturing Development Breadboard Engine (BBE) is a pressure-fed liquid oxygen/pump-fed liquid hydrogen (LOX/LH2) expander cycle engine that was built and operated by NASA at Marshall Space Flight Center's East Test Area. The breadboard engine was conceived as a technology demonstrator for the additive manufacturing technologies for an advanced upper stage prototype engine. The components tested on the breadboard engine included an ablative chamber, injector, main fuel valve, turbine bypass valve, a main oxidizer valve, a mixer and the fuel turbopump. All parts minus the ablative chamber were additively manufactured. The BBE was successfully hot fire tested seven times. Data collected from the test series will be used for follow on demonstration tests with a liquid oxygen turbopump and a regeneratively cooled chamber and nozzle.

Case, Nicholas L.↗

DOE OSTI2023

Corrosion testing needs and considerations for additively manufactured materials in nuclear reactors

Metal additive manufacturing holds significant promise as an enabling technology for the 21st century nuclear energy industry. Metal additive manufacturing (MAM) can allow the fabrication of novel materials and innovative component designs that are not achievable through conventional manufacturing. Due to its very different fabrication methods, as-fabricated MAM components are characteristically different from conventionally manufactured components. MAM materials exhibit very different microstructures from conventional cast or wrought materials. For example, austenitic stainless steels fabricated by laser powder bed fusion exhibit columnar grain structures, dislocation cell structures, and melt pool fingerprints. In addition, MAM fabrication may result in defects such as porosity, incomplete processing of the feedstock (e.g., lack of fusion in melt-based methods), and oxide inclusions. Heat treatments may further evolve the microstructure, microsegregation, and stresses within the component. Furthermore, MAM components have a rough surface with feature sizes on the order of the feedstock material, as opposed to smooth surfaces resulting from conventional machining and forming operations. As a result, the corrosion behavior of MAM components will likely be significantly different from that of conventionally formed components. Corrosive environments for structural materials within advanced reactor environments include molten fluoride and chloride salts, liquid sodium and lead-bismuth, and high-temperature helium. The Advanced Materials and Manufacturing Technologies program within the Department of Nuclear Energy in the United States Department of Energy is assessing the unique concerns of MAM component corrosion and testing methodologies in advanced nuclear reactor environments. We discuss these concerns and testing strategies in this paper.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2002

A Pilot Computer-Aided Design and Manufacturing Curriculum that Promotes Engineering

Elizabeth City State University (ECSU) is located in a community that is mostly rural in nature. The area is economically deprived when compared to the rest of the state. Many businesses lack the computerized equipment and skills needed to propel upward in today's technologically advanced society. This project will close the ever-widening gap between advantaged and disadvantaged workers as well as increase their participation with industry, NASA and/or other governmental agencies. Everyone recognizes computer technology as the catalyst for advances in design, prototyping, and manufacturing or the art of machining. Unprecedented quality control and cost-efficiency improvements are recognized through the use of computer technology. This technology has changed the manufacturing industry with advanced high-tech capabilities needed by NASA. With the ever-widening digital divide, we must continue to provide computer technology to those who are socio-economically disadvantaged.

Source record↗

NASA NTRS2001

Proceedings of the 4th Conference on Aerospace Materials, Processes, and Environmental Technology

The next millennium challenges us to produce innovative materials, processes, manufacturing, and environmental technologies that meet low-cost aerospace transportation needs while maintaining US leadership. The pursuit of advanced aerospace materials, manufacturing processes, and environmental technologies supports the development of safer, operational, next-generation, reusable, and expendable aeronautical and space vehicle systems. The Aerospace Materials, Processes, and Environmental Technology Conference (AMPET) provided a forum for manufacturing, environmental, materials, and processes engineers, scientists, and managers to describe, review, and critically assess advances in these key technology areas.

Griffin, D. E.↗

DOE OSTI2025

Mechanical Characteristics of Additively Manufactured ODS 316L and 316H Alloys with and Without Post-build Processing

This research aims to explore an accelerated development path for oxide dispersion-strengthened (ODS) alloys by integrating additive manufacturing (AM) technologies with recent advances in ODS materials and traditional manufacturing methods. Novel AM and post-build processing routes have been developed for ODS austenitic alloys, specifically Fe-Cr-Ni alloys like 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the effects of process variables on microstructure and properties, aiming for an economically feasible route property optimization. Traditionally, ODS alloy production involves multi-day high-energy mechanical milling of alloy powder with yttria (Y 2 O 3 ) followed by powder consolidation via extrusion or other methods and additional thermomechanical processing (TMP) for property control. Here, to address these challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes focusing on AM and traditional TMP methods. The new ODS alloy processing routes have achieved up to a 400% increase in yield strength and a 60% increase in ultimate tensile strength compared to wrought stainless steels while still maintaining significant ductility and fracture toughness. This paper details the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.

Byun, Thak Sang [Oak Ridge National Laboratory (OR↗

DOE OSTI2024

Inaugural Molten Salt Technologies Workshop Powering the Future

The inaugural “Molten Salt Technologies – Powering the Future” Workshop marked a significant convergence of minds from diverse industries, each harnessing molten-salt technologies in innovative ways. Participants from sectors such as solar, geothermal, and advanced nuclear energy, as well as those involved in cutting-edge applications like thermal transport and rare-earth metals extraction, gathered to discuss their shared technical challenges and opportunities. Industry leaders in metal extraction and recycling, alongside experts in high-temperature sensor technology and advanced material manufacturing, also brought their unique perspectives to the table. This workshop served as a crucial platform for these varied industries to delve into the engineering intricacies that molten salt technologies entail. Common challenges such as understanding the thermophysical properties of salts, tackling corrosion mechanisms in harsh environments, and enhancing material resilience under extreme conditions were at the forefront of discussions. These technical sessions highlighted the critical need for cross-industry collaboration to address issues like salt life-cycle process engineering, impurity mitigation, and the development of durable, high-performance materials. By bringing together academia, industry, and representatives from national laboratories and the U.S. Department of Energy (DOE), the workshop facilitated a rich exchange of knowledge and experiences. This interaction not only fostered new partnerships but also strengthened the network among existing collaborators, setting the stage for joint solutions to the complex problems faced by all sectors using molten salt technologies. The event underscored the importance of collaborative efforts in overcoming common engineering challenges and advancing the application of molten-salt technologies across various industries. The workshop not only provided an essential forum for networking and idea exchange but also highlighted the collective drive towards innovative solutions that could benefit multiple fields.

Department of Energy↗

DOE OSTI2024

Inaugural Molten Salt Technologies Workshop Powering the Future

The inaugural “Molten Salt Technologies – Powering the Future” Workshop marked a significant convergence of minds from diverse industries, each harnessing molten-salt technologies in innovative ways. Participants from sectors such as solar, geothermal, and advanced nuclear energy, as well as those involved in cutting-edge applications like thermal transport and rare-earth metals extraction, gathered to discuss their shared technical challenges and opportunities. Industry leaders in metal extraction and recycling, alongside experts in high-temperature sensor technology and advanced material manufacturing, also brought their unique perspectives to the table. This workshop served as a crucial platform for these varied industries to delve into the engineering intricacies that molten salt technologies entail. Common challenges such as understanding the thermophysical properties of salts, tackling corrosion mechanisms in harsh environments, and enhancing material resilience under extreme conditions were at the forefront of discussions. These technical sessions highlighted the critical need for cross-industry collaboration to address issues like salt life-cycle process engineering, impurity mitigation, and the development of durable, high-performance materials. By bringing together academia, industry, and representatives from national laboratories and the U.S. Department of Energy (DOE), the workshop facilitated a rich exchange of knowledge and experiences. This interaction not only fostered new partnerships but also strengthened the network among existing collaborators, setting the stage for joint solutions to the complex problems faced by all sectors using molten salt technologies. The event underscored the importance of collaborative efforts in overcoming common engineering challenges and advancing the application of molten-salt technologies across various industries. The workshop not only provided an essential forum for networking and idea exchange but also highlighted the collective drive towards innovative solutions that could benefit multiple fields.

Department of Energy↗

NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses market needs to advance structural aircraft composite manufacturing technologies to significantly increase production rates. Dry, non-crimp fabric (NCF) carbon materials infused with advanced resin systems offer a promising solution to these manufacturing demands. Northrop Grumman’s Automated Stiffener Forming (ASF) technology has been adapted for ply-by-ply, in-situ processing of NCF materials. The modular ASF process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for NCF materials, heating technologies and roller compaction processes were designed and tested on representative structural aircraft part geometries. Key success criteria for the ASF process with NCF materials is forming quality and preform compaction. Trials were performed with multiple NCF materials: unidirectional up to quad-axial formats. The NCF constituents, veils, stitching, and binders, were evaluated with the ASF process. The material performance in the ASF process and the resulting preform quality are presented.

dry carbon fiber materials↗

NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses market needs to advance structural aircraft composite manufacturing technologies to significantly increase production rates. Dry, non-crimp fabric (NCF) carbon materials infused with advanced resin systems offer a promising solution to these manufacturing demands. Northrop Grumman’s Automated Stiffener Forming (ASF) technology has been adapted for ply-by-ply, in-situ processing of NCF materials. The modular ASF process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for NCF materials, heating technologies and roller compaction processes were designed and tested on representative structural aircraft part geometries. Key success criteria for the ASF process with NCF materials is forming quality and preform compaction. Trials were performed with multiple NCF materials: unidirectional up to quad-axial formats. The NCF constituents, veils, stitching, and binders, were evaluated with the ASF process. The material performance in the ASF process and the resulting preform quality are presented.

dry carbon fiber materials↗

DOE OSTI2024

Neutron Irradiation Experiments

This presentation discusses the ongoing and upcoming neutron irradiation experiments within the Advanced Materials and Manufacturing Technologies (AMMT) program for the 2024 AMMT program review meeting. Ongoing and upcoming neutron irradiation of additively manufactured 316 stainless steel and A709 in the High Flux Isotope Reactor and Advanced Test Reactor are described.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1990

Potential for integrated optical circuits in advanced aircraft with fiber optic control and monitoring systems

Fiber optic technology is expected to be used in future advanced weapons platforms as well as commercial aerospace applications. Fiber optic waveguides will be used to transmit noise free, high speed data between a multitude of computers as well as audio and video information to the flight crew. Passive optical sensors connected to control computers with optical fiber interconnects will serve both control and monitoring functions. Implementation of fiber optic technology has already begun. Both the military and NASA have several programs in place. A cooperative program, called FOCSI (Fiber Optic Control System Integration), between NASA Lewis and the NAVY to build, environmentally test and flight demonstrate sensor systems for propulsion and flight control systems is currently underway. Integrated Optical Circuits (IOC's) are also being given serious consideration for use in advanced aircraft systems. IOC's will result in miniaturization and localization of components to generate, detect optical signals and process them for use by the control computers. In some complex systems IOC's may be required to perform calculations optically if the technology is ready, replacing some of the electronic systems used today. IOC's are attractive because they will result in rugged components capable of withstanding severe environments in advanced aerospace vehicles. Manufacturing technology developed for microelectronic integrated circuits applied to IOC's will result in cost effective manufacturing. This paper reviews the current FOCSI program and describes the potential role of IOC's in FOCSI applications.

Robert Baumbick↗

DOE OSTI2024

2023 Peer Review Final Report

The U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy requires each of its programs to conduct periodic peer reviews to enhance EERE program planning. May 16–18, 2023, the Advanced Materials and Manufacturing Technologies Office (AMMTO) held an in-person peer review of its program activities in which an independent panel of experts provided AMMTO with feedback on how well the new office’s programs align with its overarching goals and mission statement, identified possible course correction, and shared information. This review marks AMMTO’s first in-person peer review since the Advanced Manufacturing Office evolved into AMMTO and the Industrial Decarbonization and Efficiency Office. A detailed summary of observations, findings, impact, and recommendations is contained in the following report.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1984

ACEE composite structures technology

The NASA Aircraft Energy Efficiency (ACEE) Composite Primary Aircraft Structures Program has made significant progress in the development of technology for advanced composites in commercial aircraft. Commercial airframe manufacturers have demonstrated technology readiness and cost effectiveness of advanced composites for secondary and medium primary components and have initiated a concerted program to develop the data base required for efficient application to safety-of-flight wing and fuselage structures. Oral presentations were compiled into five papers. Topics addressed include: damage tolerance and failsafe testing of composite vertical stabilizer; optimization of composite multi-row bolted joints; large wing joint demonstation components; and joints and cutouts in fuselage structure.

Klotzsche, M.↗

DOE OSTI2020

Plastics for a Circular Economy Workshop: Summary Report

This report summarizes the results of a public workshop sponsored by the Bioenergy Technologies Office, the Advanced Manufacturing Office, and Mars held on December 11–12, 2019 in Golden, Colorado. The Plastics for a Circular Economy Workshop brought together experts from industry, academia, and national laboratories to discuss opportunities and challenges facing the development of new technologies to address plastic waste.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Advanced Airfoil Cooling Schemes to Increase Efficiency in Gas Turbines for Combined Heat and Power Applications

This report describes a three-year interdisciplinary effort funded by the U.S. Department of Energy’s (DOE) Energy Efficiency and Renewable Energy/Advanced Manufacturing Office (EERE/AMO) to promote market penetration of combined heat and power (CHP) technologies. Prior studies have shown the technical potential for CHP in the United States is much larger than the current deployment of CHP systems. A large portion of the technical potential CHP market aligns with small (<20 MWe) gas turbines. CHP systems are an attractive alternative to reduce greenhouse gas (GHG) emissions. For example, CHP systems can reduce GHG emissions by 30–40% relative to a conventional boiler and power configuration. These GHG emission reductions are “avoided emissions” which means no CO 2 separation or sequestration is required. This report describes an effort to use additive manufacturing (AM) technologies and advanced airfoil cooling designs to increase the turbine inlet temperature by 100 °C for small gas turbines typically used in CHP systems. At the beginning of this effort, baseline performance data for small gas turbines was not available, and the potential benefits of cooling system improvements were not quantified in the available literature.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2014

TPSAS-NF1676L-19134-DND

Composite materials and structures are state-of-art enabling technology for modern aerospace vehicles, reducing weight and maintenance requirements, and increasing performance and reliability. Numerical-control manufacturing systems, including automated fiber placement (AFP), are widely used to fabricate these components. However, the challenging weight and performance requirements necessary for the next generation of aerospace vehicles will push the composites state-of-art even further, and require development of even more advanced materials, manufacturing, and structures technologies that are more affordable and more efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address many of NASA's critical research needs in the field of advanced composites. The baseline ISAAC system, combining a commercial robot with multiple degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, will enable very precise and accurate additive manufacturing of composite structures. One promising area of research enabled by the ISAAC system is advanced composite tow-steered structures that have tailored structural load paths. Several examples are presented that describe these tow-steered composite structures in more detail.

Brian K Stewart↗