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NASA NTRS2008

Fiber Optic Sensing Monitors Strain and Reduces Costs

In applications where stress on a structure may vary widely and have an unknown impact on integrity, a common engineering strategy has been overbuilding to ensure a sufficiently robust design. While this may be appropriate in applications where weight concerns are not paramount, space applications demand a bare minimum of mass, given astronomical per-pound launch costs. For decades, the preferred solution was the tactic of disassembly and investigation between flights. Knowing there must be a better way, Dr. Mark Froggatt, of Langley Research Center, explored alternate means of monitoring stresses and damage to the space shuttle. While a tear-it-apart-and-have-a-look strategy was effective, it was also a costly and time consuming process that risked further stresses through the very act of disassembly and reassembly. An alternate way of monitoring the condition of parts under the enormous stresses of space flight was needed. Froggatt and his colleagues at Langley built an early-warning device to provide detailed information about even minuscule cracks and deformations by etching a group of tiny lines, or grating, on a fiber optic cable five-thousandths of an inch thick with ultraviolet light. By then gluing the fiber to the side of a part, such as a fuel tank, and shining a laser beam down its length, reflected light indicated which gratings were under stress. Inferring this data from measurements in light rather than in bonded gauges saved additional weight. Various shuttle components now employ the ultrasonic dynamic vector stress sensor (UDVSS), allowing stress detection by measuring light beamed from a built-in mini-laser. By measuring changes in dynamic directional stress occurring in a material or structure, and including phase-locked loop, synchronous amplifier, and contact probe, the UDVSS proved especially useful among manufacturers of aerospace and automotive structures for stress testing and design evaluation. Engineers could ensure safety in airplanes and spaceships with a narrower, not overbuilt, margin of safety. For this development, in 1997, Discover Magazine named Froggatt a winner in the "Eighth Annual Awards for Technological Innovation" from more than 4,000 entries.

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NASA NTRS2019

Investigating Additively Manufactured 17-4 PH for Structural Applications

17-4 is used regularly to manufacture force transducers particularly for wind tunnel testing. Such applications place demanding structural requirements on the transducers with static safety factors of 1.5 common and the potential for additional dynamic loads. Additive manufacturing (AM) of transducers is very appealing because of significant potential cost and time savings as well as increased design flexibility. This study looks at the processing of 17-4 powder using selective laser melting by two different facilities using their own best practices. Hot isostatic pressing (HIP) is used by both facilities as part of the thermomechanical processing following printing to explore whether it can improve the consistency of mechanical properties. Results revealed that HIP reduced average porosity of 17-4 parts and that the yield strength of parts following solutionization and aging met wrought material property targets. Strain to failure of one of the facilities parts was less than 5% compared to greater than 9% for the other facility. Inspection of failure surfaces revealed this discrepancy could be attributed to pores (2-4% area fraction) on the failure surface of the low ductility parts. Phase content varied between the facilities with one facility producing fully martensitic parts and the other containing some retained austenite. The phase content of the starting powder and a slower than air cooling rate following the final heat treatment above the austenite eutectoid temperature are likely sources of the retained austenite. Taken together these results suggest that the current state of the art in AM 17-4 processing is sufficient for many NASA force measurement applications, but that attention is required at each stage of processing to assure desired mechanical properties.

Burns, Devin E.↗

NASA NTRS1980

Atmospheric lidar multi-user instrument system definition study

A spaceborne lidar system for atmospheric studies was defined. The primary input was the Science Objectives Experiment Description and Evolutionary Flow Document. The first task of the study was to perform an experiment evolutionary analysis of the SEED. The second task was the system definition effort of the instrument system. The third task was the generation of a program plan for the hardware phase. The fourth task was the supporting studies which included a Shuttle deficiency analysis, a preliminary safety hazard analysis, the identification of long lead items, and development studies required. As a result of the study an evolutionary Lidar Multi-User Instrument System (MUIS) was defined. The MUIS occupies a full Spacelab pallet and has a weight of 1300 kg. The Lidar MUIS laser provides a 2 joule frequency doubled Nd:YAG laser that can also pump a tuneable dye laser wide frequency range and bandwidth. The MUIS includes a 1.25 meter diameter aperture Cassegrain receiver, with a moveable secondary mirror to provide precise alignment with the laser. The receiver can transmit the return signal to three single and multiple photomultiple tube detectors by use of a rotating fold mirror. It is concluded that the Lidar MUIS proceed to program implementation.

Greco, R. V.↗

NASA NTRS1991

Considerations of metal joining processes for space fabrication, construction and repair

A comprehensive evaluation is conducted of candidate processes for metalworking in orbital (vacuum-microgravity) conditions. Attention is given to electron-beam welding, brazing, gas-tungsten arc welding, laser welding, plasma arc welding, and gas-metal arc welding. It is established that several of these processes will be required to cover all foreseeable requirements. Microgravity effects are considered minor, and efforts are being concentrated on problems associated with vacuum conditions and with process-operator safety.

Russell, C.↗

NASA NTRSDate not supplied

Development of a Ground Multi-Mission Low-Cost Optical Terminal (LCOT) for Free-Space Optical Communications

Once confined to the realm of laboratory experiments and theoretical papers, space-based laser communications (lasercomm) are on the verge of achieving mainstream status. Organizations from Facebook to NASA, and missions from cubesats to Orion are employing lasercomm to achieve gigabit communication speeds at mass and power requirements lower than that of traditional radio frequency (RF) methods. Since first demonstrating free-space optical communications services with Lunar Laser Communications Demonstration (LLCD) in 2013, NASA has invested in developing optical communications technologies and capabilities to enhancing its space communications networks. Along with evolving optical space terminals, NASA is also developing lasercomm grounds stations capable of meeting the rapidly increasing data volume demands of upcoming missions, from low-earth to lunar orbits and beyond and integrating these advanced capabilities into its Near-Space and Deep Space Networks. To meet this emerging need, the Low-Cost Optical Terminal (LCOT) project at NASA’s Goddard Space Flight Center (GSFC) is designing, building and validating a prototype for a flexible, multi-mission, and economical optical ground terminal that could be used as a blueprint for a global network of optical ground stations, capable of supporting a wide variety of missions. To date a major impediment to widespread adoption of laser communication has been the lack of an existing ground network infrastructure. A mission that wishes to take advantage of laser communication not only needs to invest in an optical space terminal, but it must also finance the creation of ground terminals to receive the downlink signal. This adds significant additional cost. Missions that do decide to incur the cost of financing a network of ground terminals end up building highly specialized optical receivers that are operable as receivers for that specific mission only. Significant Non-Recurring Engineering (NRE) cost is invested to build highly specialized one-of-a-kind ground terminals that go into storage after that particular mission is over. This is not an economical approach and does nothing to grow the number of optical ground stations available to future missions. In essence each mission that wants to take advantage of the benefits of lasercom has to start from scratch to provide a ground terminal network to support it. As long as this is the case, the cost for using laser communications will be too high for most missions to consider. LCOT intends to close this gap in technology by designing and developing a standard optical ground terminal design that is flexible enough to serve as a receiver for a wide range of future missions – a ground terminal that can be quickly reconfigured to receive downlinks at different wavelengths using different signal formats. Not only does LCOT have the industry-building objectives of utilizing commercial-off-the-shelf (COTS) components to the maximum extent possible, but also spurs the commercial development of other necessary lasercomm components not currently offered by industry. Finally, LCOT will give NASA scientists and engineers a facility where they can gain real-world experience with optical communications. It will give engineers a cost-effective way to try out new concepts and processes by providing the infrastructure for such testing. In this way it is hoped LCOT will serve as a stimulus for innovation in optical communications and speed its widespread adoption by future missions. The LCOT is comprised of five subsystems: Free-Space Optical, Transceiver, Amplifier, Monitor and Control, and Observatory Infrastructure. In August 2021, the LCOT team installed a 70 cm telescope, developed by Planewave Instruments that was optimized for optical communications. Free-Space Optical subsystem comprises of the telescope and its associated hardware, including a transmitter optical assembly, wide field cameras, two optical benches, and an adaptive optics subsystem. The transmit optical assembly, a unique concept design, is a cluster of four functionally independent transmit subassemblies located on the receive telescope. In addition to receiving optical signals and directing the expanded beam with high precision to the space terminal, it also performs tracking functions. The transmit optical assembly will support operations from Low Earth Orbit (LEO) through lunar and will be used as a template for industry manufacturing. The Optical Infrastructure subsystem is responsible for providing environmentally controlled shelters for LCOT equipment and various other systems. To maintain the safety and proper functionality of the telescope, a 16 ft Astrohaven clamshell dome procured which provides all-sky coverage without the need to rotate the dome. Additionally, Atmospheric Monitoring Assembly (AMA) will be part of optical infrastructure subsystem to ensure accurate performance of the LCOT. Like existing optical ground stations, LCOT will measure standard weather station parameters, infrared all sky image of cloud cover, and cloud height. LCOT, however, adds requirements for measuring night time seeing and, in the future, daytime seeing. Unlike other optical ground terminals, the LCOT is transceiver agnostic; user transceivers may be duplex transceivers, standalone receivers, or standalone transmitters with or without acquisition beacon functionality. As such, the LCOT project accommodates testing with external customer transceivers in a flexible manor, further complimenting its intended multi-mission goals. Another unique component of LCOT is the use of a new amplifier technology – the Very Large Mode Area (VLMA) amplifiers. This new technology allows LCOT to avoid the issues faced by previous laser communications ground terminals, gives users more flexibility and modular capability, and is capable of reaching an order of magnitude higher peak power than traditional High Power Optical Amplifiers (HPOA). One drawback of the VLMA HPOA approach is that the amplified light is output into free-space. The solution developed by LCOT is an optics train that couples the output of the VLMA amplifier into a short fiber for transport to the transmit telescopes with high efficiency. Like many of the LCOT components, a set of detailed manufacturing drawings have been created for the optics train to allow any machine shop with a multi-axis Computer Numerical Control (CNC) machine to fabricate the piece parts from commonly available materials. In line with the goals of LCOT, the monitor and control functions are developed as a modular and flexible system with the ability to support future hardware or algorithm changes, minimizing disruptions. A main priority of development in the Monitor and Control Subsystem (MCS) is the safety monitor system.

laser communication↗

NASA NTRS1993

Calibrating Airplane Instrumentation To Measure Winds

Elaborate combination of techniques used to calibrate wind-measuring instrumentation aboard F104 airplane. Obtains wind profiles more rapidly. Airplane equipped with standard NACA research nose boom, including pressure probes and flow vanes yielding data on static and total pressures, angle of attack, and angle of sideslip. Has ring-laser-gyroscope inertial reference unit, giving linear and angular velocities, linear acceleration, and orientation of airplane. Body-mounted total-temperature sensor also used. Improved method of calibration devised to determine whether winds aloft at and shortly after time of measurement allow safe launch of Space Shuttle. Proves beneficial in other safety- or research-oriented applications in which wind velocities over range of altitudes must be determined in nearly real time.

Haering, Edward A., Jr.↗

NASA NTRS2001

Good Vibrations

A Small Business Innovation Research (SBIR) sponsorship from NASA's Dryden Flight Research Center, assisted MetroLaser, of Irvine, California, in the development of a self-aligned laser vibrometer system. VibroMet, capable of measuring surface vibrations in a variety of industries, provides information on the structural integrity and acoustical characteristics of manufactured products. This low-cost, easy-to-use sensor performs vibration measurement from distances of up to three meters without the need for adjustment. The laser beam is simply pointed at the target and the system then uses a compact laser diode to illuminate the surface and to subsequently analyze the reflected light. The motion of the surface results in a Doppler shift that is measured with very high precision. VibroMet is considered one of the many behind-the-scenes tools that can be relied on to assure the quality, reliability and safety of everything from airplane panels to disk brakes

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NASA NTRS1984

Doppler radiation sensing of Shuttle angle of attack and TAS during entry

Space Shuttle true airspeed, angle of attack, and sideslip angle are currently derived from inertial guidance information. A new method is proposed which offers a potential improvement in Shuttle safety during entry. Angle of attack, sideslip angle and true airspeed could be measured directly at heights from 120 km down to 20 km by Doppler sensing three independent true airspeeds along the Shuttle body axes. Two types of Doppler measurement sensors, employing either passive detection of atmospheric radiation or coherent detection of scattered laser light are discussed. The proposed technique is essentially solid-state and robust, and is well suited for use in future small hypersonic vehicles that require flight control in the Upper Atmosphere of the earth or in probes destined for the other planets.

Foale, C. M.↗

NASA NTRS2013

Destructive Single-Event Failures in Diodes

In this summary, we have shown that diodes are susceptible to destructive single-event effects, and that these failures occur along the guard ring. By determining the last passing voltages, a safe operating area can be derived. By derating off of those values, rather than by the rated voltage, like what is currently done with power MOSFETs, we can work to ensure the safety of future missions. However, there are still open questions about these failures. Are they limited to a single manufacturer, a small number, or all of them? Is there a threshold rated voltage that must be exceeded to see these failures? With future work, we hope to answer these questions. In the full paper, laser results will also be presented to verify that failures only occur along the guard ring.

Casey, Megan C.↗

DOE OSTI2026

Nondestructive Modular Leak Detection in 3D Printed 316L Stainless Steel Pipes via Laser Powder Bed Fusion

This research investigates the leak detection features of 316L Stainless Steel pipe structures manufactured via Laser Powder Bed Fusion (LPBF). This work involves the design of a modular sensor system integrating nondestructive evaluation (NDE) methods, including thermal imaging and ultrasonic frequency detection to detect and characterize leaks in components. This aims to improve leak detection sensitivity within medium-pressure gas systems, during continuous operation without halting flow or introducing safety risks. The system could be adaptable for use on unmanned aerial vehicles (UAVs), enabling remote leak detection in active environments. A custom pneumatic system incorporating temperature and pressure sensors was assembled to detect leaks in LPBF-printed 316L SS tee pipes. Experimental results and simulations confirm the system’s effectiveness in leak detection and material evaluation. This research program also integrated a Python-based image recognition platform based on a metallography and optical microscopy to assess the porosity and complement the leak detection data on the printed structures. This allows a detailed analysis of pore distribution and internal leak paths, which could compromise structural integrity, critical for quality control during manufacturing. Findings suggest that the investigated approach holds potential for enhancing leak detection technologies and adapt them for advanced manufactured parts.

36 MATERIALS SCIENCE↗

NASA NTRS1980

AMTV headway sensor and safety design

A headway sensing system for an automated mixed traffic vehicle (AMTV) employing an array of optical proximity sensor elements is described, and its performance is presented in terms of object detection profiles. The problem of sensing in turns is explored experimentally and requirements for future turn sensors are discussed. A recommended headway sensor configuration, employing multiple source elements in the focal plane of one lens operating together with a similar detector unit, is described. Alternative concepts including laser radar, ultrasonic sensing, imaging techniques, and radar are compared to the present proximity sensor approach. Design concepts for an AMTV body which will minimize the probability of injury to pedestrians or passengers in the event of a collision are presented.

Johnston, A. R.↗

DOE OSTI2020

CISME report on experiments with HMX powder, PBX 9501 prills, and heated PBX 9501

The ability to predict post-ignition explosive response is relevant to explosives safety, particularly weapons assembly/disassembly operations that must operate under a sufficiently conservative safety basis to meet risk mitigation criteria for inadvertent nuclear detonation (IND). In particular, hazard determinations hinge on whether the PBX 9501 main charge can ultimately attain detonation from an initial, non-shock, ignition stimulus. The CISME experiment uses a spherical explosive charge, which is thermally ignited in the center using a fiber-delivered infrared laser pulse. This ignition mechanism - i.e. a localized thermal hotspot - is representative of the ignition-causing insults typical in accident scenarios, including low-velocity impact, drop, skid, and punch events. In fiscal year 2018 CISME experiments were conducted with pristine PBX 9501 spheres, confined and unconfined. Sub-detonative, low-violence reactions were observed. Here we report experiments conducted since 2018. The explosive charge was varied: experiments were conducted with room temperature pour-density HMX powder and prills of PBX 9501, and heated, thermally damaged PBX 9501. Experiments were conducted in a confined configuration, with two 4 mm-thick stainless-steel hemispherical shells bolted around the sphere. Detonation, via DDT (deflagration-to-detonation transition) was observed in the 3-inch diameter powdered HMX and the 6-inch diameter heated and thermally-damaged PBX 9501 tests. No transition to DDT was observed in smaller diameters for those configurations, and no DDT was observed for pour-density prills of PBX 9501 of any diameter. The original test series demonstrated that the response of pristine, undamaged PBX 9501 to a central ignition is relatively benign. This new test series shows that increased porosity, lack of polymer binders and thermal damage can greatly increase the violence of the post-ignition response, up to and including detonation. These results bridge the explosive response of PBX 9501 from sub-detonative through detonation as a function of diameter and provide valuable test cases for modeling efforts that strive to capture the DDT threshold. By exploring explosive response in a more representative 3D geometry, we can also benchmark these new results to more plentiful DDT datasets generated from testing in 1D tube confinement (the historical test configuration)–the configuration upon which almost all DDT models were developed.

42 ENGINEERING↗

DOE OSTI2020

The Role of Interfacial Thermal Resistance in Li-Ion Battery Thermal Management: Preprint

Temperature critically affects the performance, life and safety of lithium-ion batteries. Therefore, it is essential to understand heat generation and dissipation within individual battery cells and battery packs to plan a proper thermal management strategy. One of the key challenges is that interfacial heat transfer of a battery unit is difficult to quantify. The steady-state absolute method and the transient laser-flash-diffusivity method were employed to measure heat conductivities of battery layer stacks and individual battery layer separately. Results show flash diffusivity method gives higher thermal conductivity at both cross-plane and in-plane directions. The difference is primarily caused by interfacial thermal resistance so that it can be estimated by steady-state and transient measurements. To investigate the effects of interfacial thermal transport beyond individual cell level, a multiphysics battery model is used. The model is built upon a multi-scale multi-domain modeling framework for battery packs that accounts for the interplay across multiple physical phenomena. Benefits of a battery module using thermal management materials are quantified through numerical experiments. During a thermal runaway event, it is found interfacial thermal resistance can mitigate thermal runaway in a battery module by significantly reducing heat transfer between cells.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1997

Quantitative Measurement of Oxygen in Microgravity Combustion

A low-gravity environment, in space or in ground-based facilities such as drop towers, provides a unique setting for studying combustion mechanisms. Understanding the physical phenomena controlling the ignition and spread of flames in microgravity has importance for space safety as well as for better characterization of dynamical and chemical combustion processes which are normally masked by buoyancy and other gravity-related effects. Due to restrictions associated with performing measurements in reduced gravity, diagnostic methods which have been applied to microgravity combustion studies have generally been limited to capture of flame emissions on film or video, laser Schlieren imaging and (intrusive) temperature measurements using thermocouples. Given the development of detailed theoretical models, more sophisticated diagnostic methods are needed to provide the kind of quantitative data necessary to characterize the properties of microgravity combustion processes as well as provide accurate feedback to improve the predictive capabilities of the models. When the demands of space flight are considered, the need for improved diagnostic systems which are rugged, compact, reliable, and operate at low power becomes apparent. The objective of this research is twofold. First, we want to develop a better understanding of the relative roles of diffusion and reaction of oxygen in microgravity combustion. As the primary oxidizer species, oxygen plays a major role in controlling the observed properties of flames, including flame front speed (in solid or liquid flames), extinguishment characteristics, flame size and flame temperature. The second objective is to develop better diagnostics based on diode laser absorption which can be of real value in both microgravity combustion research and as a sensor on-board Spacelab as either an air quality monitor or as part of a fire detection system. In our prior microgravity work, an eight line-of-sight fiber optic system measured water vapor mole fractions in the NASA Lewis 2.2-sec Drop Tower. In that system, the laser and all electronics resided at the top of the drop tower and was connected via a fiber optic cable to the rig, on which a 'pitch and catch' set of fiber collimating lenses were used to transmit the laser beam across a jet diffusion flame. This system required eight independent detection/demodulation units and had poor spatial resolution. This research builds on this earlier work, resulting in an improved capability for quantitative, nonintrusive measurement of major combustion species. A vertical cavity surface-emitting diode laser (VCSEL) and a continuous spatial scanning method permit the measurement of temporal and spatial profiles of the concentrations and temperatures of molecular oxygen. High detection sensitivity is achieved with wavelength modulation spectroscopy (WMS). One-g experiments are performed using a slot diffusion flame. Microgravity measurements on a solid fuel (cellulose sheet) system are planned for the NASA Lewis 2.2-second Drop Tower Facility.

Silver, Joel A.↗

NASA NTRS2003

Optical and Probe Diagnostics Applied to Reacting Flows

The general theme of the research my NASA colleague and I have planned is "Optical and probe diagnostics applied to reacting flows". We plan to explore three major threads during the fellowship period. The first interrogates the flame synthesis of carbon nanotubes using aerosol catalysts. Having demonstrated the viability of the technique for nanotube synthesis, we seek to understand the details of this reacting system which are important to its practical application. Laser light scattering will reveal changes in particle size at various heights above the burner. Analysis of the flame gas by mass spectroscopy will reveal the chemical composition of the mixture. Finally, absorption measurements will map the nanotube concentration within the flow. The second thread explores soot oxidation kinetics. Despite the impact of soot on engine performance, fire safety and pollution, models for its oxidation are inhibited by uncertainty in the values of the oxidation rate. We plan to employ both optical and microscopic measurements to refine this rate. Cavity ring-down absorption measurements of the carbonaceous aerosol can provide a measure of the mass concentration with time and, hence, an oxidation rate. Spectroscopic and direct probe measurements will provide the temperature of the system needed for subsequent modeling. These data will be benchmarked against changes in soot nanostructures as revealed by transmission electron microscopic images from directly sampled material.

Ticich, Thomas M.↗

NASA NTRS2006

Laser Mapping for Visual Inspection and Measurement

Each space shuttle orbiter has 38 Primary Reaction Control System (PRCS) thrusters to help power and position the vehicle for maneuvers in space, including reentry and establishing Earth orbit. Minor flaws in the ceramic lining of a thruster, such as a chip or crack, can cripple the operations of an orbiter in space and jeopardize a mission. The ability to locate, measure, and monitor tiny features in difficult-to-inspect PRCS thrusters improves their overall safety and lifespan. These thrusters have to be detached and visually inspected in great detail at one of two NASA facilities, the White Sands Test Facility or the Kennedy Space Center, before and after each mission, which is an expense of both time and money.

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NASA NTRS1981

Fabrication and testing of a prototype longwall face alignment system

Fabrication and testing of a laser system for instantaneous location of a longwall shearer are summarized. Calculations and measurements for the design of a laser based system for monitoring and controlling the trajectory of the shearing machine as it progresses along the longwall face are reported. An early version was fabricated by employing simple mechanical contrivances and a standard miners lamp. It is concluded that the advantages of the early version is the ability to test the longwall face without approval from the Mine Safety and Health Administration.

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DOE OSTI2024

Effect of Heat Treatment on Microstructure and Mechanical Property of 316L Stainless Steel Produced by Laser Powder Bed Fusion

The advanced non-light water reactor designs (Gen IV reactors), including molten salt/ very high temperature/ sodium-cooled and lead-cooled fast reactors, typically operate at higher temperatures and more extreme radiation conditions than light water reactors. An intrinsic part of the deployment and progress of Gen IV reactor designs is selecting the most suitable structural material for a specific application. Additive manufacturing (AM), a fairly new process of making physical, three-dimensional objects from a computer design file, is going to completely change the way of design, build and certify nuclear systems. It offers a range of opportunities to produce complex geometries from existing materials, offers new routes for processing of previously difficult to process materials, allows for design of new high-performance materials, and finally facilitates hybridization of dissimilar materials. This emerging technology has successfully produced cars, wind turbine blade molds and even live cells. It could also open up big opportunities for the nuclear industry to quickly deploy technologies at a fraction of the cost. So far, AM techniques have been preliminarily applied in the field of nuclear reactors, including the classical parts such as the pressure vessel of a small reactor with 508-III steel, the bottom nozzle of a fuel assembly with 304L steel, the fuel cladding with zirconium alloy and the integrated impeller of a pump and the multi-channel valve body with 316L steel [6,7]. The AM applications for operating nuclear reactors started in auxiliary plant components and have slowly migrated to metallic reactors and core components, but many of these are not safety critical components. Although many parts used for nuclear reactors have been fabricated by AM techniques, practical applications in engineering are still a long way off due to the uncertainty factors focused on the processing, material properties, analysis methods and application standards, which feeds the safety and life-cycle of the nuclear reactor. Due to rapid, repeated heating and cooling during production, a high dislocation density was present in the AM material. This microstructure feature is unstable at elevated temperature while high temperature is one of the typical operation environments for nuclear reactors. Thus, it is important to understand the thermal effect on the microstructure of AM material. The objectives of this study are to investigate the effect of heat treatment on the microstructure and mechanical properties of 316L stainless steel produced by laser powder bed fusion additive manufacturing, and to determine an appropriate heat treatment practice that will be applied to the lightweight AM lattice-structured material with the same chemistry. The heat treatment study consisted of annealing the samples at a temperature range of 800 to 1200 oC with a 50 oC increment for different times (1-24 hours), followed by vacuum or air cooling. Microstructural characterization was carried out by Scanning Electron Microscope (SEM). Grain size and crystallographic orientation were investigated by Electron Backscatter Diffraction (EBSD). Vickers hardness tests with a 0.5 kg load were employed to determine the hardness of samples after different heat treatments. After heat treatment, the random crystallographic orientation was preserved, and the volume fraction of high-angle grain boundaries (grain boundary misorientation =15 oC) remained the same. The dislocation density decreased with annealing temperature due to recovery. The fine subgrain structures in the as-printed specimen were quite stable up to 1200 oC. Minimal recrystallization was observed up to 1200 oC. Recrystallization initiated only after 8.5 hours at 1200 oC. The SEM images did not show obvious dependence of microstructure on cooling rate. The hardness of the specimens decreased with increasing annealing temperature as a result of the decrease in dislocation density. It is interesting to note that the AM material showed very similar hardness to the wrought material when annealing at similar temperature, although the microstructures are very different. Annealing at 1050 oC for 1 hour followed by air cooling was selected as the heat treatment procedure for the lattice designed lightweight AM 316L material.

36 MATERIALS SCIENCE↗