Additive Manufacturing for SLS and Beyond
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Additive Manufacturing↗
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Metal Additive Manufacturing for Spaceflight
Metal additive manufacturing (AM) is changing how complex aerospace parts are being designed and manufactured for rocket engines and launch vehicles. NASA has been leading AM efforts since the late 2000’s to mature specialty alloys for AM, advance AM processes, develop standards and infuse AM into rocket engines and the commercial supply chain. There are many types of AM processes and alloys in-use and this presentation will provide an overview of how NASA is applying these for rocket engines and the potential opportunities for AM in the future.
Additive Manufacturing↗
Introduction to Metal Additive Manufacturing for Propulsion Applications: Part I and II
Additive Manufacturing (AM) has become a prominent technology of interest for manufacturing propulsion components and gaining attention across the aerospace industry. AM is maturing at a rapid pace and providing new design opportunities, novel materials, new industries and supply chains resulting in programmatic and technical performance improvements. The successful use of AM requires a methodical and intentional approach to understanding the concept to utilization lifecycle for AM. This course will provide an overview of the various steps in AM process trades, design, build process, post-processing, certification and infusion of AM. This will provide various lessons learned and experiences that were captured in a recent AIAA textbook titled "Metal Additive Manufacturing for Propulsion Applications" by the session chairs and industry colleagues. This course will include propulsion examples and that went through the AM lifecycle including hot-fire testing.
Additive Manufacturing↗
Residual stress distribution in an additively manufactured complex structure by neutron diffraction measurement
Residual stress in an aerodynamically shaped Ni-based superalloy airfoil fabricated by laser powder bed fusion was measured by neutron diffraction. The experiment was conducted by considering the complex shape, implementing computer aided experiment planning, and automatic alignment at each rapid measurement. The 3-dimensional (3D) residual stress distribution in the airfoil is presented in this work, which lacks symmetry due to the complex geometry of the airfoil. In conclusion, the results provide theoretical thermal processing models a complete residual stress dataset of simulation validation on 3D shape complex structure.
Residual stress↗
Additive Manufacturing of Silicon Carbide-Based Ceramic Matrix Composites: Technical Challenges and Opportunities
Advanced SiC-based ceramic matrix composites offer significant contributions toward reducing fuel burn and emissions by enabling high overall pressure ratio (OPR) of gas turbine engines and reducing or eliminating cooling air in the hot-section components, such as shrouds, combustor liners, vanes, and blades. Additive manufacturing (AM), which allows high value, custom designed parts layer by layer, has been demonstrated for metals and polymer matrix composites. However, there has been limited activity on additive manufacturing of ceramic matrix composites (CMCs). In this presentation, laminated object manufacturing (LOM), binder jet process, and 3-D printing approaches for developing ceramic composite materials are presented. For the laminated object manufacturing (LOM), fiber prepreg laminates were cut into shape with a laser and stacked to form the desired part followed by high temperature heat treatments. For the binder jet, processing optimization was pursued through silicon carbide powder blending, infiltration with and without SiC nano powder loading, and integration of fibers into the powder bed. Scanning electron microscopy was conducted along with XRD, TGA, and mechanical testing. Various technical challenges and opportunities for additive manufacturing of ceramics and CMCs will be presented.
ceramic matrix composites↗
Dissolution zone model of the oxide structure in additively manufactured dispersion-strengthened alloys
The structural evolution of oxides in dispersion-strengthened superalloys during laser-powder bed fusion is considered in detail. Alloy chemistry and process parameter effects on oxide structure are assessed through a parameter study on the model alloy Ni-20Cr, doped with varying concentrations of Y 2 O 3 and Al. Small angle neutron scattering measurements of the dispersoid size distribution show the dispersoid size increases with higher laser power, slower scan speed, and increasing Y 2 O 3 and Al content. Complementary electron microscopy measurements reveal reactions between Y 2 O 3 and Al, even in nanoscale dispersoids, and the presence of micron-scale oxide slag inclusions in select specimens. A scaling analysis of mass and momentum transport within the melt pool, presented here, establishes that diffusional structural evolution mechanisms dominate for nanoscale dispersoids, while fluid forces and advection become significant for larger slag inclusions. These findings are developed into a theory of dispersoid structural evolution, integrating quantitative models of diffusional processes – dispersoid dissolution, nucleation, growth, coarsening – with a reduced order model of time-temperature trajectories of fluid parcels within the melt pool. Calculations of the dispersoid size in single-pass melting reveal a zone in the center of the melt track in which the oxide feedstock fully dissolves. Within this zone the final Y 2 O 3 size is independent of feedstock size and determined by nucleation and growth kinetics. If the dissolution zones of adjacent melt tracks overlap sufficiently with each other to dissolve large oxides, formed during printing or present in the powder feedstock, then the dispersoid structure throughout the build volume is homogeneous and matches that from a single pass within the dissolution zone. Gaps between adjacent dissolution zones result in oxide accumulation into larger slag inclusions. Predictions of final dispersoid size and slag formation using this dissolution zone model match the present experimental data and explain process-structure linkages speculated in the open literature.
36 MATERIALS SCIENCE↗
Microstructure prediction for Ti-22Al-25Nb in laser powder bed fusion
This work presents a physics-informed framework for predicting solidification morphology and defect susceptibility in additively manufactured Ti–22Al–25Nb across a broad processing space. The framework integrates solidification microstructure selection (SMS) analysis with a single-track defect-based printability map to establish a unified methodology linking processing parameters to both interfacial morphology and manufacturability. Thermal gradients G and solidification rates R are first computed using the Thermo-Calc Additive Manufacturing (TC-AM) module, a finite-interface-dissipation (FID) phase-field (PF) model coupled with CALPHAD method is then employed to systematically distinguish planar and dendritic regimes as functions of $G$ and $R$. By superimposing the printability map onto the morphology projections, a comprehensive process–structure framework is obtained. Across most processing conditions, the predicted microstructure is predominantly dendritic, while planar growth emerges only under selected laser power $P$ and scan speed $v$ combinations. In addition to morphology classification, the framework quantifies the dendritic area fraction and introduces a width-based morphology descriptor to characterize the spatial extent of planar/dendritic regions within the melt pool. It provides mechanistic insight into the interplay between solidification physics and defect formation, offering practical guidance for parameter selection and microstructural control in Ti–22Al–25Nb additive manufacturing (AM).
36 MATERIALS SCIENCE↗
Performance Evaluation of LPBF Manufactured 316H Components
This work represents the continuation of a benchmark study that includes modeling, fabrication and characterization as demonstration to support industry’s adoption of advanced manufacturing processes in a variety of structures. This comprehensive study investigated the feasibility of using additive manufacturing (AM) technologies, specifically Laser Powder Direct Energy Deposition (LP-DED) and Laser Powder Bed Fusion (LPBF), to produce complex nuclear microreactor components using 316H stainless steel. The research focused on manufacturing an expanded elbow pipe component with transitioning sections, which are traditionally difficult and costly to produce through conventional manufacturing methods. The overall study’s primary objectives are therefore demonstrating AM viability for nuclear applications, optimizing process parameters, developing comprehensive material characterization protocols, validating computational modeling approaches, and establishing manufacturing guidelines for complex geometries. Although the initial work included the phased approach of cubical, upscaled cylindrical components, it is to enable to obtain more knowledge for the printing of the expanded elbow structure. The project achieved significant progress in process development by successfully optimizing LP-DED parameters to achieve 99.16-99.97% relative density in 316H stainless steel components. Through systematic evaluation of sixteen cube samples with varied laser powers (400-700W) and scan speeds (600-900 mm/min), optimal processing windows were identified at 500-550W with 600-700 mm/min or 650-700W with 650-900 mm/min scan speeds. The DED manufactured 316H demonstrated mechanical properties comparable or superior to wrought materials, with Young's modulus ranging from 153-208 GPa and controlled microstructural characteristics including greater than 95% face-centered cubic (FCC) phases and engineered cellular structures with sizes between 3.23-6.17 µm.
36 MATERIALS SCIENCE↗
Additive Manufacturing of Lattice Structures for Catalyst Applications
Abstract The design and fabrication of Inconel 718 open-pore lattice structures via Laser Powder Bed Fusion (LPBF) has been investigated in this research, focusing on applications such as catalyst supports in jet fuel production. The study explores the impact of laser power and scanning speed on the geometrical resolution of these structures aiming to achieve high porosity (porosity > 60%) and specific pore sizes ranging from 500–1000 μm, intending to serve as catalyst supports, replacing conventionally manufactured foams to reduce costs. Results demonstrate the significant influence of processing parameters on the geometrical aspects of printed lattice structures, with laser power having a more pronounced effect on geometrical accuracy than scanning speed. Additionally, the mechanical properties of the printed lattice structures showed a correlation with the lattice strut sizes, as lattices with less porosity and thicker struts resulted in higher maximum shear stress.
Ghanadi, Nahal [Oregon State University] (ORCID:00↗
Laser powder bed fusion of oxide dispersion-strengthened IN718 alloys: A complementary study on microstructure and mechanical properties
In this study, two new grades of oxide dispersion strengthened (ODS) Inconel 718 (IN718) alloys were designed by the thermochemical CALPHAD method and produced by laser powder bed fusion (LPBF) technique. Alloys designated as IN718-YF and IN718-YFH, that consist Y 2 O 3 –FeO and Y 2 O 3 –FeO–Hf, respectively, were fabricated with >99.9 % densification using optimized process parameters. CALPHAD calculations were highly consistent with experimental findings, highlighting the formation of Al-containing Y–Ti–O and Y–Hf–O nano-oxides in both alloy types. Texture analyzes revealed no significant texture development in as-built (AB) or heat-treated (HT) alloys. Heat treatment was applied at 1050 °C for 1 h to enhance nano-oxide density. Further, the nano-oxide number density remained similar in IN718-YF while it decreased in IN718-YFH alloy as a result of carbide formation after the heat treatment. Besides, formation of secondary γ' particles was observed in the IN718-YFH/HT alloy. Even though the yield strengths of IN718-YF and IN718-YFH alloys in both AB and HT conditions were similar, the ductility of IN718-YFH was ~50 % less in almost all conditions compared to the ductility of IN718-YF. This has been shown to be as a result of irregular shaped micron-sized Y-Hf-O oxides, martensite formation in AB condition, increased amount of carbides and existence of secondary γ' particles in HT condition in IN718-YFH. High density of stacking faults (SF) forming at the interface of the nano-oxides have been detected in IN718-YF alloys. Besides dislocation/nanoparticle interactions, SFs which are responsible for the delocalization of the deformation improve the ductility of IN718-YF alloys. Overall, high temperature mechanical tests exhibit that both alloys have higher strength with improved ductility compared to the standard IN718 alloys, indicating the contribution of the nano-oxides.
36 MATERIALS SCIENCE↗
Advanced and Additive Manufacturing Technologies for Liquid Rocket Engine Components
Overview of advanced manufacturing and additive manufacturing development at NASA for liquid rocket engines. Presentation includes various material, process, design, and hot-fire testing developments demonstrating the use of advanced components for liquid rocket engines on launch vehicles and in-space systems.
Additive Manufacturing↗
A mechanistic study on environment gas in laser powder bed fusion
A variety of protective or reactive environmental gases have recently gained growing attention in laser-based metal additive manufacturing (AM) technologies due to their unique thermophysical properties and the potential improvements they can bring to the build processes. However, much remains unclear regarding the effects of different gas environments on critical phenomena in laser AM, such as rapid cooling, energy coupling, and defect generation. Through simultaneous high-speed synchrotron x-ray imaging and thermal imaging, we identify distinct effects of two environmental gases in laser AM and gained a deeper understanding of the underlying mechanisms. Compared to the commonly used protective gas, argon, it is found that helium has a negligible effect on cooling the part. However, helium can suppress unstable keyholes by decreasing effective energy absorption, thus mitigating keyhole porosity generation and reducing pore size under certain processing conditions. In conclusion, these observations provide guidelines for the strategic use of environmental gases in laser AM to produce parts with improved quality.
36 MATERIALS SCIENCE↗
Machining of Thin-Walled Structures From Stiffness-Driven Additively Manufactured Preform Geometry
Additive manufacturing provides the means to build component preforms with reduced excess material to create functional parts. In the case of aero-structural and aero-engine components, additive manufacturing technologies offer the possibility to substantially reduce the volume of material to be removed by machining operations. To achieve this objective, the preform must be built with the minimum material necessary to contain the final geometry and simultaneously provide enough stiffness to withstand the magnitude of the machining forces. This work describes a computationally efficient method to calculate the geometry required from the preform to reliably manufacture typical thin-walled structures via finish machining processes. This is achieved by defining the preform with near constant static stiffness across the width of the preform, in combination with a prescribed magnitude of stiffness at the top edge of the preform. The prescribed static stiffness is the function of the machining force magnitude, a direct consequence of the preselected cutting conditions. In conclusion, this article illustrates the application of the method to a straight single boundary thin-walled structure as an introduction case and for ease of description.
Additive manufacturing↗
Uncertainty Analysis of Experimental Discharge Coefficients in Additively Manufactured Liquid Injector Elements
Screening of two additively manufactured liquid injector designs was conducted in the UAH high pressure spray facility. Four variants of each geometry with slightly different dimensions were obtained from eleven separate commercial additive manufacturing services. The devices were manufactured from Inconel 625 using the selective laser melting (SLM) powder bed process. The devices were cold flowed with water over a range of relevant pressure drops (75 psi to 1500 psi) to produce water flow rates from 0.037 to 1.75 lbm/s into ambient back pressure. Discharge coefficients determined from the testing along with the associated uncertainties provide insight into characteristic flow performance variabilities that can be expected from the SLM process for similar geometries.
Venters, James P.↗
The Influence of Heat Treatments on the Microstructure and Tensile Properties of Additively Manufactured Inconel 939
This study investigated the effect of heat treatment variations on the microstructure and tensile properties of laser powder bed fused Inconel 939 manufactured via laser powder bed fusion. Three different heat treatment schedules, all of which comprise stress relief, hot isostatic pressing, solution annealing, and aging, were followed, and resulting changes in microstructure were analyzed using scanning electron microscopy. Tensile tests were conducted on specimens subjected to different heat treatments to evaluate the mechanical properties at room temperature. Microstructural results showed that solution treatment at 1190 °C for 4 h led to better removal of dendritic microstructure, while second-step aging at 850 °C resulted in monomodal distribution of precipitates. However, the second-step aging temperatures from 750 to 800 °C resulted in bi-modal distribution. The optimal heat treatment schedule, which yielded a superior combination of strength and ductility, involved solution treatment at 1190 °C for 4 h and two-step aging at 1000 °C for 6 h and 800 °C for 4 h.
Laser powder bed fusion (L-PBF)↗
AM Processes Part 2: Principles of Directed Energy Deposition
Directed Energy Deposition (DED) is one of the metal additive manufacturing processes which finds wider industrial applications, particularly for repair and reclamation, and for large structures. This course helps the attendees to understand the fundamental concepts of DED process and covers the topics such as, how the technology works, different DED processes, materials used, and typical applications where this technology is used. The discussion will have a focus on ASTM F3187 – Standard guide for Directed Energy Deposition of Metals. After completing this webinar the attendees will achieve the following: · Identify and understand the different types of DED processes · Understand how to select a DED process and trade criteria · Understand the various materials used for DED processes · Understand the core parameters for the DED processes · Determine potential parts and end application of DED technology
Additive Manufacturing↗
Additive Manufacturing (AM) Process-Structure-Property (PSP) Frameworks
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Additive Manufacturing↗
Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines
Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.
Additive Manufacturing↗