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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Three-Dimensional Printable, Extremely Soft, Stretchable, and Reversible Elastomers from Molecular Architecture-Directed Assembly

3D printing elastomers enables the fabrication of many technologically important structures and devices such as tissue scaffolds, sensors, actuators, and soft robots. However, conventional 3D printable elastomers are intrinsically stiff; moreover, the process of printing often requires external mechanical support and/or post-treatment. In this work, we exploit the self-assembly of a responsive linear-bottlebrush-linear triblock copolymer to create stimuli-reversible, extremely soft, and stretchable elastomers and demonstrate their applicability as inks for in situ direct-write printing 3D structures without the aid of external mechanical support or post-treatment. By developing a procedure for controlled synthesis of such architecturally designed block copolymers, we create elastomers with extensibility up to 600% and Young’s moduli down to ~10 2 Pa, 10 6 times softer than plastics and more than 102 times softer than all existing 3D printable elastomers. Moreover, the elastomers are thermostable and remain to be solid up to 180 °C, yet they are 100% solvent-reprocessable. Their extreme softness, stretchability, thermostability, and solvent-reprocessability bode well for future applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

3D printing synthesis of catalysts

The catalyst industry generates approximately $20 billion every year globally and plays a major role in the energy production sector. Traditional industrial catalysts (e.g., pellets) typically have mass and heat transfer limitations, and cause a pressure drop in continuous-flow reactors, lowering the efficiency of the catalytic processes. 3D printing technology has evolved rapidly over the past decade, and the 3D printing of catalysts with desired geometries can address many of the above-stated challenges with traditional catalysts. However, challenges remain to be addressed and opportunities remain to be explored before the full potential in the design and 3D printing of novel catalysts can be realized. Herein this article reviews the recent development in the 3D printing of catalysts. It summarizes the 3D printing design, dimension, property, and performance of 3D printed catalysts. The applications of 3D printed catalysts, such as reforming, wastewater treatment, and CO 2 capture and removal, are discussed, with a techno-economic analysis and life cycle analysis. Future research directions and opportunities for 3D printing of catalysts are also highlighted.

25 ENERGY STORAGE↗
DOE OSTI2023

Real-time process monitoring for direct ink write additive manufacturing

Direct ink write (DIW) printing of reactive resins presents a unique challenge due to the time-dependent nature of the rheological and chemical properties of the ink. As a result, careful print optimization or process control is important to obtain consistent, high quality prints. The present invention uses a flow-through characterization cell for in situ chemical monitoring of a resin ink during DIW printing. Additionally, in-line extrusion force monitoring can be combined with off-line post inspection using machine vision. By combining in-line spectroscopy and force monitoring, it is possible to follow reaction kinetics (for example, curing of a reactive resin) and viscosity changes during printing, which can be used for a closed-loop process control. Additionally, the capability of machine vision to automatically identify and quantify print artifacts can be incorporated on the printing line to enable real-time, AI-assisted quality control of the printed products. Together, these techniques can form the building blocks of an optimized process control strategy when complex reactive ink must be used to produce printed hardware.

Cook, Adam W.↗
NASA NTRSDate not supplied

Additive Manufacturing Model-Based Process Metrics: Reduced Order Modeling of the Laser Powder Bed Fusion Process

The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. In this work, we describe a fully parallel reduced order modeling approach that has been developed to evaluate the evolution of AM processes, termed the AM moment measure method. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology and terminology of the approach will be described, and computed build maps will be calculated and compared for various laser powder bed fusion (LPBF) builds of Ti-6Al-4V. Such comparative results develop understanding of how the sequential process actions can affect the LPBF-AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
NASA NTRS1990

High Tc superconducting materials and devices

The high Tc Y1Ba2Cu3O(7-x) ceramic materials, initially developed in 1987, are now being extensively investigated for a variety of engineering applications. The superconductor applications which are presently identified as of most interest to NASA-LaRC are low-noise, low thermal conductivity grounding links; large-area linear Meissner-effect bearings; and sensitive, low-noise sensors and leads. Devices designed for these applications require the development of a number of processing and fabrication technologies. Included among the technologies most specific to the present needs are tapecasting, melt texturing, magnetic field grain alignment, superconductor/polymer composite fabrication, thin film MOD (metal-organic decomposition) processing, screen printing of thick films, and photolithography of thin films. The overall objective of the program was to establish a high Tc superconductivity laboratory capability at NASA-LaRC and demonstrate this capability by fabricating superconducting 123 material via bulk and thin film processes. Specific objectives include: order equipment and set up laboratory; prepare 1 kg batches of 123 material via oxide raw material; construct tapecaster and tapecaster 123 material; fabricate 123 grounding link; fabricate 123 composite for Meissner linear bearing; develop 123 thin film processes (nitrates, acetates); establish Tc and Jc measurement capability; and set up a commercial use of space program in superconductivity at LaRC. In general, most of the objectives of the program were met. Finally, efforts to implement a commercial use of space program in superconductivity at LaRC were completed and at least two industrial companies have indicated their interest in participating.

Haertling, Gene H.↗
NASA NTRSDate not supplied

Additively Manufactured Ink-based Cell Batteries for Flexible Conformational Applications

With the rise of additively manufactured electronics, the importance of thin, flexible printed batteries has increased for shape-conformal electronics. Traditionally, battery cells such as industry-standard lithium-ion batteries, have been rigid and therefore unable to conform to time-variant surfaces such as smart cards/RFID devices, disposable battery-powered skin patches, foldable electronic devices, and IoT nodes. Aligned with the effort to advance technologies on printed electronics for habitat systems and advanced manufacturing, this proof-of-concept will focus on printing a 50 mAh Zn-Ag battery implementing a DIW Technique. After prototype manufacturing, electrical and environmental testing on the flexible battery cell will be conducted to the evaluate energy and power density over 50 charge cycles under standard atmosphere conditions. The project aims to provide PCB designers, fabricators, and assemblers an integrated battery package to eliminate external batteries, external wiring and connectors, and conformational complexity. Potential end uses of the printed battery process will be within Martian and lunar habitat systems, Gateway, and surface vehicles, or aerial robots where space and geometry is a restriction.

Printed Electronics↗
DOE OSTI2021

Effect of process route on powder three-dimensional-printing of metal powders

The purpose of this study is to investigate the effect of two unique processing routes (solvent jetting (SJ) and binder jetting (BJ)), on the green density of printed stainless steel 316L (SS316L) and Nickel (Ni) powders. In the SJ processing route, a solvent is jetted unto the powder/binder mixture to selectively activate the binder, layer by layer. In the BJ processing route, a solution of the binder mixture is jetted onto the powder bed to selectively bind powder particles. The effects of printing parameters such as layer height, roller speed, shaker speed and nozzle temperature on the green density of printed components are investigated and compared for both processing routes. Results show that layer height and nozzle temperature affect the relative density of the printed compact for both processing routes. Slightly higher relative densities were achieved via the SJ route, with the overall highest relative density being 42.7% at 100 µ m layer height and 70% nozzle temperature for the SS316L components and 43.7% at 150 µ m layer height and 90% nozzle temperature for the Ni components, respectively. Results also show an increase in the final sintered relative density with an increase in green (printed) relative density of the solvent jetted SS316L components, with the highest relative density being 87.2%. The paper studies the influence of printing parameters on the green density of printed SS316L and Ni samples in an unprecedented effort to provide a comparative understanding of the process-property relationships in BJ and SJ of SS316L and Ni components to the additive manufacturing research community.

Engineering↗
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.↗
DOE OSTI2023

Extrusion parameter control optimization for DIW 3D printing using image analysis techniques

Material extrusion is a well-recognized facet of additive manufacturing that involves the fabrication of parts through the deposition of structural material from an extrusion head from a bulk supply. In the subdivision of Direct Ink Writing (DIW) additive manufacturing, challenges arise when the structural material is flowable, synchronous extrusion control and tool movement becomes critical for achieving high-quality parts with low defect populations. DIW techniques are most used in laboratory settings using expensive custom instruments and may require specialized 3D slicing software. Here, in this study, the fabrication of an inexpensive, consumer-friendly progressive cavity pump dispensing system is detailed, in which can create high-quality parts by executing G-code commands produced from a commercial slicing software. The precision and repeatability of the movement-synchronized material extrusion is demonstrated through a series of optimization schemes, entailing the alteration of various control parameters, which directly affect the extrusion properties demonstrated during a print. In situ diagnostics were implemented to evaluate the results of the established optimization experiment. Using a machine vision technique, images of the optimization prints are processed. Following this, a supervised machine learning model was trained to autonomously judge whether or not the extrusion parameters produced a passing or failing result. The machine learning scheme serves as a preliminary benchmark for future layer-by-layer evaluation of more complex DIW parts. The construction of the printer and development of in situ characterization capabilities demonstrates the ability for this printer to create high-fidelity DIW parts for a fraction of the price of other systems.

42 ENGINEERING↗
DOE OSTI2023

Investigation of Reactive Silver Ink Formula for Reduced Silver Consumption in Silicon Heterojunction Metallization

Silver is the most expensive non-silicon component in photovoltaic cells. This is particularly salient for silicon heterojunction (SHJ) cells, which rely on large quantities of low-temperature silver pastes (LT-SP). SHJ cells would benefit greatly from an industrially scalable metallization process that simultaneously offers low silver consumption, low finger resistivities (<20 μΩ·cm), and low processing temperatures. Printed reactive silver inks (RSI) are an innovative candidate to this end. Furthermore, this work furthers the research on RSI metallization by investigating the impact of ink formula on properties pertinent to SHJ cells, including electrical properties, line width, ink splatter, silver consumption, cell performance, and adhesion. We introduce a scalable, high-throughput flexible needle contact printing approach for metallization that solves many of the issues associated with drop-on-demand printing. The printed silver fingers are characterized using electrical measurements and top-down and cross-sectional microscopy. The best performing ink, consisting of silver acetate, ethylamine, and formic acid, achieved silver fingers with total resistivities of 3.1 μΩ·cm and contact resistivities of 3.2 mΩ·cm 2 when printed at 61 °C. This ink metallized a full-sized 156 mm × 156 mm SHJ cell. This is the first reported data for RSI metallization of a full-sized SHJ cell and shows how an optimized RSI can achieve similar performances to LT-SP while consuming 80–90% less silver.

14 SOLAR ENERGY↗
DOE OSTI2025

Progress toward hydro-equivalent ignition in OMEGA direct-drive DT-layered implosions

Considerable progress has been made in deuterium-tritium-layered implosion experiments on the OMEGA Laser System, bringing the prospects for thermonuclear ignition in direct-drive configurations with megajoule-class lasers closer to reality. Doing so has required navigating the balance between improved 1D performance and multidimensional stability. Using statistical modeling based on over 350 cryogenic implosions to identify various degradation mechanisms, and combined with multidimensional simulations and experimental techniques such as target offsets to combat residual flows, core conditions have repeatably been achieved that extrapolate to the burning-plasma state when scaled to 2.15 MJ of symmetric laser illumination. Using high implosion velocities (⁠> 450 km/s) and moderately high adiabats (⁠~5⁠), these experiments produced record-high scaled Lawson parameters in direct drive equal to 89 ± 2% of that required for ignition with expected yields of up to 1.5 ± 0.2 MJ. To improve these results still further, focused physics studies are performed to improve physics understanding and identify routes to even greater performance. Recent studies include investigations into the impact of mounting features, laser imprint, reduced fuel temperatures, and greater on-target intensities through subscale experiments. This manuscript gives a summary of the cryogenic direct-drive program on the OMEGA laser, including routes taken to achieve the current best performance, the status of recent focused physics investigations, and future designs—such as target solutions to laser imprint and reducing vapor density to increase convergence—that are expected lead to the demonstration of hydro-equivalent ignition on OMEGA.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Volumetric Additive Manufacturing of Gradient Composition Glass

Advanced optics, such as lasers or cameras, are currently limited by geometric or compositional restrictions on the silica glass components that act as focusing or refracting lenses. Currently, these glass components must be made of one homogenous material in a range of shapes and sizes limited by a few specialized vendors. However, additional flexibility and customization of these optical components could significantly improve the performance of these devices and expand the design space available to optics engineers, as would the capability to locally change the optical properties of these glass components by changing the composition of the glass as a function of location. To this end, we have developed a method to print and process gradient composition glass, using volumetric additive manufacturing (VAM) and direct ink writing (DIW), on-site at Lawrence Livermore National Lab.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Multi-level Simulation of a Real Time Vibration Monitoring System Component

This paper describes the development of a custom built Digital Signal Processing (DSP) printed circuit board designed to implement the Advanced Real Time Vibration Monitoring Subsystem proposed by MSFC Transportation Directorate in 2000 for the Space Shuttle Main Engine Advanced Health Management System (AHMS). This Real Time Vibration Monitoring System (RTVMS) is being developed for ground use as part of the AHMS Health Management Computer-Integrated Rack Assembly (HMC-IRA). The HMC-IRA RTVMS design contains five DSPs which are highly interconnected through individual communication ports, shared memory, and a unique communication router that allows all the DSPs to receive digitized data from two multi-channel analog boards simultaneously. This paper will briefly cover the overall board design but will focus primarily on the state-of-the-art simulation environment within which this board was developed. This 16-layer board with over 1800 components and an additional mezzanine card has been an extremely challenging design. Utilization of a Mentor Graphics simulation environment provided the unique board and system level simulation capability to ascertain any timing or functional concerns before production. By combining VHDL, Synopsys Software and Hardware Models, and the Mentor Design Capture Environment, multiple simulations were developed to verify the RTVMS design. This multi-level simulation allowed the designers to achieve complete operability without error the first time the RTVMS printed circuit board was powered. The HMCIRA design has completed all engineering unit testing and the deliverable unit is currently under development.

Roberston, Bryan↗
NASA NTRS2005

Multi-level Simulation of a Real Time Vibration Monitoring System Component

This paper describes the development of a custom built Digital Signal Processing (DSP) printed circuit board designed to implement the Advanced Real Time Vibration Monitoring Subsystem proposed by Marshall Space Flight Center (MSFC) Transportation Directorate in 2000 for the Space Shuttle Main Engine Advanced Health Management System (AHMS). This Real Time Vibration Monitoring System (RTVMS) is being developed for ground use as part of the AHMS Health Management Computer-Integrated Rack Assembly (HMC-IRA). The HMC-IRA RTVMS design contains five DSPs which are highly interconnected through individual communication ports, shared memory, and a unique communication router that allows all the DSPs to receive digitized data fiom two multi-channel analog boards simultaneously. This paper will briefly cover the overall board design but will focus primarily on the state-of-the-art simulation environment within which this board was developed. This 16-layer board with over 1800 components and an additional mezzanine card has been an extremely challenging design. Utilization of a Mentor Graphics simulation environment provided the unique board and system level simulation capability to ascertain any timing or functional concerns before production. By combining VHDL, Synopsys Software and Hardware Models, and the Mentor Design Capture Environment, multiple simulations were developed to verify the RTVMS design. This multi-level simulation allowed the designers to achieve complete operability without error the first time the RTVMS printed circuit board was powered. The HMC-IRA design has completed all engineering and deliverable unit testing. P

Robertson, Bryan A.↗
DOE OSTI2023

High resolution, high conductivity components by aerosol jet printing

Highly conductive electrical traces formed over mechanical steps or on non-planar surfaces with linewidths of 10 to 100 μm and a method for forming such electrical traces are disclosed. The method employs two steps, with the first step using an aerosol jet printing (AJP) process to form thin electrical traces that serve as the seed layers for the second step. The first step preferably employs multiple passes with the AJP to create multiple seed sub-layers with improved continuity and conductivity. In the second step, the seed layers are subjected to an electrodeposition process that forms the bulk of the thickness of the electrical traces. The electrodeposition process may include one, two, or three phases at corresponding low or high biases, with low biases providing denser, more highly conductive plating sub-layers, while high biases provide plating sub-layers having better gap bridging properties.

Lavin, Judith Maria↗