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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
NASA NTRS2011

Characterization of Electron Beam Free-Form Fabricated 2219 Aluminum and 316 Stainless Steel

Researchers at NASA Langley Research Center have developed an additive manufacturing technology for ground and future space based applications. The electron beam free form fabrication (EBF3) is a rapid metal fabrication process that utilizes an electron beam gun in a vacuum environment to replicate a CAD drawing of a part. The electron beam gun creates a molten pool on a metal substrate, and translates with respect to the substrate to deposit metal in designated regions through a layer additive process. Prior to demonstration and certification of a final EBF3 part for space flight, it is imperative to conduct a series of materials validation and verification tests on the ground in order to evaluate mechanical and microstructural properties of the EBF3 manufactured parts. Part geometries of EBF3 2219 aluminum and 316 stainless steel specimens were metallographically inspected, and tested for strength, fatigue crack growth, and fracture toughness. Upon comparing the results to conventionally welded material, 2219 aluminum in the as fabricated condition demonstrated a 30% and 16% decrease in fracture toughness and ductility, respectively. The strength properties of the 316 stainless steel material in the as deposited condition were comparable to annealed stainless steel alloys. Future fatigue crack growth tests will integrate various stress ranges and maximum to minimum stress ratios needed to fully characterize EBF3 manufactured specimens.

Ekrami, Yasamin↗
NASA NTRS2002

Development of a Prototype Low-Voltage Electron Beam Freeform Fabrication System

NASA's Langley Research Center and Johnson Space Center are developing a solid freeform fabrication system utilizing an electron beam energy source and wire feedstock. This system will serve as a testbed for exploring the influence of gravitational acceleration on the deposition process and will be a simplified prototype for future systems that may be deployed during long-duration space missions for assembly, fabrication, and production of structural and mechanical replacement components. Critical attributes for this system are compactness, minimal mass, efficiency in use of feedstock material, energy use efficiency, and safety. The use of a low-voltage (less than 15kV) electron beam energy source will reduce radiation so that massive shielding is not required to protect adjacent personnel. Feedstock efficiency will be optimized by use of wire, and energy use efficiency will be achieved by use of the electron beam energy source. This system will be evaluated in a microgravity environment using the NASA KC-135A aircraft.

Watson, J. K.↗
DOE OSTI2025

Roadmap to an electron beam or X-ray center for industrial applications

Here, this paper introduces the topics that need consideration to allow an effective feasibility analysis of electron beams and/or X-rays technologies prior to potential investment and implementation of these technologies for industrial applications. It also highlights considerations for planning, developing and construction of an electron beam or X-ray facility The focus of this paper is on business topics and it provides details of where additional technical information can be found. The paper also describes current applications for electron beam and X-ray technologies to demonstrate their potential.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS1975

Investigation of electron dynamics in the magnetosphere with electron beams injected from sounding rockets

The Electron Echo experiments are described which were conducted with three sounding rockets to study the basic mechanisms by which electrons precipitate from the geomagnetic field to produce auroral X-rays during periods of geomagnetic activity. Echo I (1970) injected electron pulses at low latitude and successfully measured the returning pulses from the conjugate region. Echo II (1972) was launched from high latitude, studied the interaction of electron beams with background radiation as well as beam motion near the rocket, and obtained evidence for a beam plasma instability. Echo III (1974) detected a series of conjugate echoes during the presence of a strong convective field in the magnetosphere and conducted an unsuccessful search for beam bunching at the local plasma frequency. It is shown that the electric field measurement in the ionosphere, using incoherent backscatter radar and detectors on the rocket, was transferred to the equatorial plane as though field lines were equipotentials.

Winckler, J. R.↗
NASA NTRS1980

Electron-beam welder circle generator

Generator rotates electron beam and performs other convenient functions during welding process. Device eliminates time-consuming techniques relying heavily on operator's skill. Welding speed is varied with frequency selector, and amplitudes of x- and y-axes are varied by adjusting phase shift. Both high and low-range adjustments are available, and each axis can be separately controlled. Crosshair is provided for set-up and beam alinements.

Burley, R. K.↗
NASA NTRS1982

Material Protection During Electron-Beam Welding

Alumina pellets behind electron-beam weld joint protect other parts of assembly from beam and from spattered material. Alumina pellets may be cleaned and reused. Easily applied and removed in regions that are narrow or have complex shapes.

Tomlinson, R. L.↗
NASA NTRS2009

Tensile Properties and Microstructure of Inconel 718 Fabricated with Electron Beam Freeform Fabrication (EBF(sup 3))

Electron beam freeform fabrication (EBF3) direct metal deposition processing was used to fabricate two Inconel 718 single-bead-width wall builds and one multiple-bead-width block build. Specimens were machined to evaluate microstructure and room temperature tensile properties. The tensile strength and yield strength of the as-deposited material from the wall and block builds were greater than those for conventional Inconel 718 castings but were less than those for conventional cold-rolled sheet. Ductility levels for the EBF3 material were similar to those for conventionally-processed sheet and castings. An unexpected result was that the modulus of the EBF3-deposited Inconel 718 was significantly lower than that of the conventional material. This low modulus may be associated with a preferred crystallographic orientation resultant from the deposition and rapid solidification process. A heat treatment with a high solution treatment temperature resulted in a recrystallized microstructure and an increased modulus. However, the modulus was not increased to the level that is expected for Inconel 718.

Bird, R. Keith↗
NASA NTRS1990

Pressure and current balance conditions during electron beam injections from spacecraft

Electrostatic charging level of a conducting surface in response to injections of electron beams into space plasma is investigated by means of one-dimensional Vlasov code. Injections of Maxwellian beams into a vacuum shows that the surface can charge up to an electric potential phi sub s greater than W sub b, where W sub b is the average electron beam energy. Since Maxwellian beams have extended trails with electrons having energies greater than W sub b, it is difficult to quantify the charging level in terms of the energies of the injected electrons. In order to quantitatively understand the charging in excess of W sub b, simulations were carried out for water-bag types of beam with velocity distribution functions described by f(V) = A for V sub min approx. less than V approx. less than V sub max and f(V) = O otherwise, where A is a constant making the normalized beam density unity. It is found that V sub max does not directly determine the charging level. The pressure distribution in the electron sheath determines the electric field distribution near the surface. The electric field in turn determines the electrostatic potential of the vehicle. The pressure distribution is determined by the beam parameters such as the average beam velocity and the velocity spread of the beam.

Hwang, K. S.↗
NASA NTRS2000

Effect of Geometric Azimuthal Asymmetries of PPM Stack on Electron Beam Characteristics

A three-dimensional (3D) beam optics model has been developed using the electromagnetic particle-in-cell (PIC) code MAFIA. The model includes an electron beam with initial transverse velocity distribution focused by a periodic permanent magnet (PPM) stack. All components of the model are simulated in three dimensions allowing several azimuthally asymmetric traveling wave tube (TWT) characteristics to be investigated for the first time. These include C-magnets, shunts, and magnet misalignment and their effects on electron beam behavior. The development of the model is presented and 3D TWT electron beam characteristics are compared in the absence of and under the influence of the azimuthally asymmetric characteristics described.

Kory, Carol L.↗
NASA NTRS2000

Effect of Geometric Azimuthal Asymmetrics of PPM Stack on Electron Beam Characteristics

A three-dimensional (3D) beam optics model has been developed using the electromagnetic particle-in-cell (PIC) code MAFIA. The model includes an electron beam with initial transverse velocity distribution focused by a periodic permanent magnet (PPM) stack. All components of the model are simulated in three dimensions allowing several azimuthally asymmetric traveling wave tube (TWT) characteristics to be investigated for the first time. These include C-magnets, shunts and magnet misalignment and their effects on electron beam behavior. The development of the model is presented and 3D TWT electron beam characteristics are compared in the absence of and under the influence of the azimuthally asymmetric characteristics described.

Kory, Carol L.↗
NASA NTRS1980

Viewing electron-beam welds in progress

With aid of optical filter, operator of electron-beam welding machine can view TV image of joint that is being welded and can make corrections as necessary. Operator can see when weld bead gets out of alinement, for example, and compensate for deflection of electron beam caused by changes in magnetic field.

Armenoff, C. T.↗
NASA NTRS2013

Thermal Imaging for Assessment of Electron-Beam Free Form Fabrication (EBF(sup 3)) Additive Manufacturing Welds

Additive manufacturing is a rapidly growing field where 3-dimensional parts can be produced layer by layer. NASA s electron beam free-form fabrication (EBF(sup 3)) technology is being evaluated to manufacture metallic parts in a space environment. The benefits of EBF(sup 3) technology are weight savings to support space missions, rapid prototyping in a zero gravity environment, and improved vehicle readiness. The EBF(sup 3) system is composed of 3 main components: electron beam gun, multi-axis position system, and metallic wire feeder. The electron beam is used to melt the wire and the multi-axis positioning system is used to build the part layer by layer. To insure a quality weld, a near infrared (NIR) camera is used to image the melt pool and solidification areas. This paper describes the calibration and application of a NIR camera for temperature measurement. In addition, image processing techniques are presented for weld assessment metrics.

Zalameda, Joseph N.↗