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At least 235 records · Page 13

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NASA NTRSDate not supplied

Lightweight Thrust Chamber Composite Overwrap Lessons Learned

The manufacturing, design, and analysis of filament wound carbon fiber/polymer composite overwraps for additively manufactured, copper combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. Ideally, the composite overwrap acts as a light-weight structural jacket and allows significant weight reduction of the high pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication schedules. Chamber assemblies for 2000 lb. (2k) and 7000 lb. (7k) of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware, such as the 2k and 7k chambers, will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide (BMI) materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. Recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.

Allison Clark↗

NASA NTRS2024

ECI Final Report: Closing of Critical Technology Gaps for Rotating Detonation Rocket Engines

NASA has successfully fired several configurations of a dual regenerative 10K lbf class Rotating Detonation Rocket Engines using cryogenic liquid methane, liquid hydrogen, and RP-1 as fuel and liquid or gaseous oxygen as the oxidizer. In addition, 3 hot fire test phases were conducted to evaluate parametrically varying combustor geometries using a subscale 500-1K lbf class thruster RDRE. Several studies were successfully completed to evaluate the impacts of contraction ratio, annulus L’, heat transfer through calorimetry, and varying injector designs. Laser powder bed fusion GRCop-42, GRX-810, and C-103 alloys were used for the outer bodies, inner bodies, nozzles, and injector variations. The development of RDRE technology is only now possible with additive manufacturing techniques and these specialized alloys. Critical design parameters, design rules of thumb, and operability limitations have been identified. Major lessons learned in the development of critical components have also been documented. All critical technology gaps have been demonstrated at one scale or another and closed. A major finding of this work is that the combustion efficiency of the RDRE is far superior to that of the traditional liquid rocket engine requiring an order of magnitude lower chamber volume and residence time to react. Because of this, the design trade space opens up significantly. More compact chamber geometries are now possible with potential mass savings and significant length savings possible to flight geometries. In addition, the ceiling for the technology, in terms of Isp, has not yet been reached. It is likely that an additional ~10% better Isp over equivalent state-of-the-art combustion devices may be achieved over the next decade should the technology continue to be developed. This technology has been shown to be viable for near term infusion (2-5 years) into space missions and enable cost effective space access for US industry. This final report documents all major findings from this early career initiative (ECI) project and lays out what is needed post ECI.

Thomas Teasley↗

DOE OSTI2026

Wire-arc Additive Manufacturing Benchmark

This is the dataset associated with the 2022 SRP Additive Manufacturing Prediction Challenge, originally hosted on Github at https://github.com/SRP-AM/SRP_AM_Prediction_Challenge. The benchmark was designed for validating prediction for the temperature history, residual stress, and distortion of an additively manufactured metal part with relatively simple geometry. A calibration problem with the same as-built geometry is provided with measured quantities of interest; including temperature histories at selective locations, post-build residual stress at selective locations, and overall distortion measurements. The challenge problem is presented with a different build sequence (i.e. thermal history). In this dataset, we include the actual recorded calibration and challenge measurements, as well as benchmark template files for testing predictions without incorporating the challenge data. Supplementary files around the materials and setup are available for transparency and reproducibility.

Bachus, Nicholas [UC Davis, Davis, CA]↗

DOE OSTI2024

Prediction of residual stresses in additively manufactured parts using lumped capacitance and classical lamination theory

Several industries are interested in Laser Powder Bed Fusion (L-PBF) Additively Manufactured (AM) metal parts because their designs can be made arbitrarily complex while retaining bulk-type material properties. However, the residual stresses (RS) and distortions caused by the heat gradients inherent to L-PBF processes are detrimental to the structural integrity of the parts and must be taken into consideration during the part design cycle. Predicting the state of stresses in as-built 3D printed parts is a difficult problem that is typically approached with the use of transient thermomechanical Finite Element Models (FEMs). However, the nonlinearities associated with AM processes are difficult to capture in these FEMs without increasing the computational cost of the simulation, limiting their ability to be incorporated into practical design cycles. This work presents a novel analytical framework that combines lumped capacitance nonlinear heat transfer with time dependent classical lamination theory to efficiently and accurately predict RS in as-built L-PBF parts without the need of FEMs. The simulation was compared to Neutron Diffraction (ND) residual strain measurements taken at Oak Ridge National Laboratories (ORNL) as well as Synchrotron X-ray Diffraction (XRD) strain data published by the National Institute of Standards and Technology (NIST). The simulation predictions and the experimental data showed excellent agreement for the in-plane strain directions, and general agreement for the out of plane strain component, highlighting an area where further development can be implemented.

42 ENGINEERING↗

NASA NTRSDate not supplied

Establishing and Maintaining the Digital Thread of Additively Manufactured Materials and Applications

Additive Manufacturing (AM) and Integrated Computational Materials Engineering (ICME) are complementary enabling technologies for design and manufacturing of “fit-for-purpose” materials. Both technologies will impact rapid material design, reduction in cost- and time-to-market for new applications, and discovery and implementation of new materials. An ICME approach to design, however, requires experimentally validated material models at multiple length and time scales, an integrated framework that can connect analysis tools with one another to ensure the digital thread of an application is maintained, and the manufacturing (e.g., AM) capability to leverage processing-structure-property-performance (PSPP) relationships to achieve spatially varying material properties where desired. AM enables the implementation of the design of an optimized, spatially varying microstructure through careful selection of the processing parameters used during an additively manufactured build. In order to establish these PSPP relations, a large amount of data is necessary, and that data must be properly captured, analyzed and maintained in an information management system that can establish the required traceability between various aspects of the design process to ensure an application’s digital thread is maintained (from design to end of life). Such an information management system must be able to capture feedstock material pedigree, resulting microstructure from various build parameters, subsequent mechanical properties derived from testing, developed material models, and enable spatial variations in material assignment in an engineering application. Furthermore, the information management system should be easily integrated with traditionally engineered materials in a single, centralized platform to enable an ICME optimization tool to explore both types of manufacturing processes. At NASA GRC, a robust, 21st century materials information management system has been previously developed with a focus towards enabling ICME. In this work, GRC’s ICME schema is extended to accommodate additively manufactured materials, enabling storage of both traditionally and additively manufactured materials in the same construct. The methodology for properly capturing additively manufactured materials across the entire material lifecycle is presented, following the previously established database best practices, as a potential framework for establishing PSPP relationships for additively manufactured materials and applying them to engineering applications.

Data management↗

DOE OSTI2025

Seismic Performance of Conventional and Additively Manufactured U-Shaped Flexural Plates

U-shape flexural plates (UFPs) have gained significant attention in seismic structural design due to their ability to provide stable hysteresis behaviour and serve as effective energy-dissipating devices. Concurrently, Additive Manufacturing (AM) has advanced significantly, enabling the production of metallic components with mechanical properties comparable to those of conventionally manufactured cold-rolled materials. This study aims to explore the seismic response of single and double UFP fabricated through Laser Powder Based Fusion (LPBF) and conventional cold rolled 316L stainless steel (SS). The experimental results are evaluated based on force-displacement hysteresis behaviour, energy dissipation capacity, load-carrying capacity, and stiffness degradation. The findings confirm the efficacy of AM-fabricated UFPs for seismic energy dissipation. Additionally, the results suggest the potential for further improvement through the optimization of AM process parameters, such as laser scan speed, hatch spacing, and layer thickness, to enhance hysteretic performance and energy dissipation characteristics.

Risal, Kshitiz [Idaho State University]↗

DOE OSTI2026

Characterizing the Impact of Heliostat Size, Focus Method, and Optical Error on Concentrating Solar Tower Systems

Concentrating Solar Power (CSP) tower systems use heliostat fields to direct solar energy to a central receiver. The efficiency of the heliostat field is crucial for achieving thermal generation targets and is also the largest cost component, making up 30-40% of total project costs. Developers face a tradeoff: reducing heliostat costs may decrease optical performance and increase land use, while improving performance could raise manufacturing costs (through higher precision). The optimal design depends on land, labor, and manufacturing costs. Additionally, inherent performance limitations exist - optical errors result in larger solar images as heliostats move farther from the receiver, increasing spillage and attenuation losses. Ultimately, there exists a point where receiver design power can no longer be achieved at design conditions for a given solar field area. This point depends on key heliostat field design parameters including field layout, heliostats size, focus method, and heliostat optical error. In this work, we explore and characterize the performance trade-offs between heliostat size, focus method, and optical error using Monte Carlo ray-tracing simulations using NREL's high performance computing resources. The goal of this fundamental investigation is to understand practical heliostat design performance impacts that can be used to produce more cost-effective heliostat fields while still achieving plant thermal generation targets.

14 SOLAR ENERGY↗

DOE OSTI2025

Topology Optimization of Curved Electrodes with Suggested Simplified Corrugated Designs

The demand for space-efficient energy storage, from grid to device scale, has soared with the rapid electrification of society. To increase energy density while maintaining high rate performance, shaping electrodes has been shown to be an effective strategy. Computational optimization can suggest designs that improve energy storage performance; however, generated designs are often complex, leading to manufacturing challenges. Additionally, most optimization is typically conducted in standard rectangular domains, whereas some applications, such as in the aerospace industry or in consumer electronics, may benefit from optimized electrodes that fit in a nonstandard form factor. Here, in this work, we use topology optimization to design capacitive full-cell electrodes in a curved domain. We propose a simplified corrugated electrode design based on the optimization results and show that the energy stored in the simplified design is only reduced by about 5–27% when compared to that in the fully optimized design, with more deviation occurring when ionic transport in the porous electrode is particularly impeded. Overall, we find that these simplified designs are promising, particularly given the more conventional manufacturing techniques required, and have a 42–369% increase in energy stored compared to monolithic electrodes.

Energy - Storage↗

NASA NTRS2019

Additive Manufacturing Technologies for Aerospace Applications

An overview will be provided on NASA GRC activities in additive manufacturing (AM) technology development for advanced high performance, propulsion component designs in electric motors and turbine engine systems in future electrified aircraft. AM offers significant benefits over conventional manufacturing to fabricate components that are more compact, lighter weight, geometrically complex, innovatively cooled, integrated, multi-material, and multifunctional. For turbine engine applications, silicon carbide (SiC) based composites are being pursued using binder jetting. For electric motor applications, additive processes are being applied toward optimized component designs to include the housing, rotor, and stators with 3-D printing and wire imbedded coils and with direct printed 3-phase coils. The will be an emphasis on capabilities in additive manufacturing.

Halbig, Michael C.↗

DOE OSTI2025

Unveiling Atomistic Mechanisms Governing Additive Manufacturing Processability and Mechanical Behavior of a Refractory Complex Concentrated Alloy

Extending the concept of complex concentrated alloys (CCAs) to the refractory alloys (solidus temperature over 2000 °C) space potentially facilitates the design of lightweight structural alloys with service temperatures that exceed those of Ni and Co‐based alloys. However, the room and elevated temperature tensile properties of the current refractory‐CCAs (R‐CCAs) are inferior to those of the Ni/Co‐based alloys. Furthermore, the manufacturing scalability of R‐CCAs remains challenging, in that cracks are prevalent in all R‐CCAs when processed using near‐net shape manufacturing processes, such as fusion‐based additive manufacturing (F‐BAM). Still, mechanisms governing the poor F‐BAM processability of R‐CCAs remain unexplored. Here, to this end, this work unveils the atomistic mechanisms underlying F‐BAM process‐induced cracking in a NbTiTaMoHfZrC R‐CCA. The implications of light elements’ presence for intrinsic ductility and grain boundary cohesion, and subsequently for F‐BAM processability and mechanical behavior, are revealed. Leveraging the insights, we accomplish what is, to the best of the knowledge, the first instance of crack‐free F‐BAM processing of any R‐CCA. Additionally, the R‐CCA exhibits over 20% tensile ductility and ≈160 MPa tensile yield strength at 1200 °C. In addition to facilitating the design of lightweight R‐CCAs, findings enable scalable manufacturing of these ultra‐high temperature alloys for structural applications.

Refractory alloys↗

NASA NTRS2018

Additively Manufactured Oxidizer Turbopump

Additive Manufacturing, or 3D printing, is a key technology for enhancing rocket engine designs and making them more affordable for future exploration missions. The Oxidzer Turbopump (OTP) offers the ability to demonstrate additively manufactured rotating, vaned, and critical pressure vessel components in relevant oxygen turbopump environments. The additively manufactured components of the OTP include the main housings, impeller, and turbine components. A key technology development goal is to understand the benefits and limitations of additive manufacturing as it applies to the complex geometries needed for a rocket engine turbopump.

Manufacturing↗

NASA NTRS2023

Reactive Additive Manufacturing for Fourth Industrial Revolution Exploration Systems (Ramfire) Aluminum 6061-Ram2 Nozzle Testing

The NASA Marshall Space Flight Center (MSFC) has applied various forms of metallic additive manufacturing (AM) in liquid rocket engine component design, development, and testing since 2010. These AM techniques reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing unconventional design. The RAMFIRE project, funded under Space Technology Mission Directorate (STMD) Game Changing Development (GCD) Program, has furthered the use of novel AM liquid rocket nozzles in collaboration with Elementum 3D. The project advanced novel large-scale AM aluminum material technology for significant weight savings in rocket engines and launch vehicles. Previously, aluminum alloys were difficult to weld and print using additive manufacturing. Elementum 3D’s patented Aluminum 6061-RAM2 alloy allows for aluminum alloys to be printed using various AM techniques and at various scales. The alloy can be leveraged for welding wire, showing drastic improvements in aluminum weldability. The RAMFIRE project focuses on five key areas: 1) Laser Powder Directed Energy Deposition (LP-DED) AL6061-RAM2 feedstock specification and verification, 2) LP-DED process development and validation, 3) LP-DED printed AL6061-RAM2 microstructural and mechanical property characterization, 4) Hot-fire test a 7k-lbf thrust class regeneratively cooled nozzle, 5) Print large scale regeneratively cooled nozzle. Hot-fire testing demonstrates potential of advanced space technologies to NASA and potential users by providing the relevant environments to advance TRL levels to the 5/6 range.

Al6061-RAM2↗

DOE OSTI2024

Techno‐Economic Analysis of Additively‐Manufactured Wind Turbine Blade Tips That Enable Technology Integration

The Additively‐Manufactured, System‐Integrated Tip (AMSIT) project is leveraging the flexibility of 3D printing to integrate several technologies in a wind turbine blade tip, while reducing the levelized cost of electricity (LCOE) produced. The design integration is demonstrated for a 200‐kW–scale turbine with 13‐m blades, with the outer 15% of the blade replaced with a 3D‐printed design. Aerodynamic performance is enhanced without increasing swept area through inclusion of a winglet and surface texturing, both challenging for traditional manufacturing. Longevity and durability are improved through integrated lightning and leading edge erosion protection. Increased power, reduced repair frequency, and ease of repair through blade modularity all contribute to reduced LCOE. The analysis is also extended to modern MW‐scale designs to estimate the impact of the technology at scale, demonstrating the potential to reduce LCOE significantly for modern onshore turbines, with even higher potential savings offshore.

3D printing↗

NASA NTRSDate not supplied

In-Situ Alloying of GRCop-42 via Additive Manufacturing: Precipitate Analysis

GRCop-42, a Cu-4at% Cr-2at% Nb alloy, was designed as a high temperature, high strength, high heat flux material for rocket engine combustion chamber liners by NASA Glenn Research Center. In situ alloying of GRCop-42 (ISGRCop-42) using powder bed fusion (PBF) additive manufacturing (AM) takes elemental powders of Cu, Cr, and Nb to be introduced into the PBF environment and develop the GRCop alloy while simultaneously building an AM component. Elemental powders were milled together prior to printing in an effort to facilitate the alloying process. Success of the in situ alloying process may provide lower cost, faster lead times, alloying optimization, and more design freedom in the development of regeneratively-cooled rocket propulsion systems. Evaluation of the ISGRCop-42 was conducted using a phase extraction procedure to isolate the Cr2Nb precipitates from the pure Cu matrix. The isolated precipitates were then examined using x-ray powder diffraction (XRD), scanning electron microscopy (SEM), and energy dispersion spectroscopy (EDS). It was found that ISGRCop-42 successfully and repeatedly formed Cr2Nb at a yield as high as 89% of potential Cr2Nb. Further, it was identified that the preparation of the powder was the most influential factor in alloying success, and the second most influential factor was the laser power.

In Situ alloying↗

NASA NTRSDate not supplied

Thin-wall Internal Channel Geometry and Surface Enhancements for Heat Exchangers using Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations, surface texture, and post-processing surface enhancements for specific application requirements. One possible application area of AM are components using thin-wall (~1 mm) microchannel heat exchangers for subsystems across aerospace and industrial applications. Laser Powder Bed Fusion (L-PBF) is a common process for complex internal channels but the build diameter is limited to approximately 600 mm. Laser Powder Directed Energy Deposition (LP-DED) is being evaluated to produce thin-wall microchannel heat exchangers at scales beyond the L-PBF process. Successful deployment of the LP-DED technology requires characterization of geometric features from the process and potential improvements to the surface using post-processing. Surface texture, inclusive of roughness and waviness, is one of the critical attributes of AM that effects the friction factor and pressure drop within a heat exchanger and lacks data for the LP-DED process. This presentation will provide an overview of the characterization work completed of the LP-DED process for thin-walls and small channel geometry representative of various high performance alloys including NASA HR-1 and GRCop-42. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various internal channel geometry, geometric build features, and resulting surface texture will be provided along with a summary of conclusions from these experiments. This study presents characterization of 2.5 mm microchannels using LP-DED, mechanisms that cause the surface texture which include powder adherence and material droop, and angled walls have a significant impact on the thickness and surface texture. Results will also be presented on various surface enhancement processes that allow for tuning of the wetting surface for friction factor, heat transfer, or fatigue life performance requirements.

Additive Manufacturing↗

NASA NTRS2019

Fracture Control for Additively Manufactured Spacecraft Structures

This paper describes how the intent of current NASA fracture control requirements may be applied to “fracture critical” additively manufactured spacecraft hardware. Fracture control is a multi-discipline design and certification methodology that is applied in order to mitigate catastrophic failure of structures resulting from growth of an undetected crack-like defect. The methodology is defined in existing NASA standards and is required on all human-rated space structures. As legacy spacecraft structures have been built using primarily metallic and composite materials manufactured using well established methods, guidance for application of fracture control to parts composed of these material types has been established and is documented in several NASA requirements. Additive manufactured structures offer advantages in design flexibility and manufacturing efficiency and as a result are expected to continue to be used more and more in the future. Recently, relevant guidance has been published by NASA to define materials and processes requirements for certain additive manufactured hardware, but procedures for fracture control are not addressed yet in any requirements or guidance document. While use of additive manufactured parts in non-critical scenarios may be of relatively low concern in current structural certification processes, there is a need for new fracture control guidance in order to use and certify additively manufacture hardware that is “fracture critical” where failure of the part may result in loss of life or loss of vehicle. Assurance of damage tolerance, i.e., that as-built flaws in a given part either do not exist or will not grow to become catastrophic, is of particular interest to the fracture control community. This poses a challenge due to the fact that damage tolerance behavior is not well understood in additive manufactured parts compared to legacy material types and manufacturing techniques. The discussion contained herein is necessary at this time as new guidance in this area should be founded collaboratively by the technical community at large. Different hardware types (e.g., pressure vessel, structural member) are described to highlight specific challenges and solutions for each. The discussion concludes with considering specific disciplines within fracture control (non-destructive evaluation, materials & processes, fracture mechanics, and structural certification) in a proposed extension of existing fracture control requirements to additive manufactured parts.

McElroy, Mark↗

NASA NTRS2019

Fracture Control for Additive Manufactured Spacecraft Structures

McElroy, Mark↗

DOE OSTI2025

Ink-based laser powder bed fusion of barium titanate

Barium titanate (BTO) is a lead-free functional ceramic that is widely used in sensors, transducers, and actuators. The increasing demand for complex geometries and quick design iterations motivates the use of additive manufacturing techniques. Laser powder bed fusion (L-PBF) additive manufacturing technique enables the net-shape or near-net-shape fabrication of metals and alloys. Ceramic L-PBF remains challenging due to their high melting temperature. Here, to address this challenge, a nanoparticle ink feedstock was incorporated into the L-PBF process to allow low power melting of BTO. Key print parameters (i.e. laser power, scanning speed, and hatching spacing) were optimized to fabricate millimeter-scale BTO parts. The printed BTO samples possessed an inhomogeneous equiaxed-columnar-cellular microstructure. Semiconducting current-voltage behavior was observed in as-printed samples, which was attributed to the creation of oxygen vacancies. The piezoelectric d 33 coefficient was measured to be 4.6 pC/N.

Dielectrics↗