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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 289 records · Page 16

Army (MANTECH) Thrust Area Concept: Optics Thrust Area

With the shrinking of the U.S. Army's material needs and the compression of defense requirements, the Army Manufacturing Technology (MANTECH) Program has the opportunity to advance the manufacturing state-of-the-art and solve near term production problems of the U.S. industrial base. To exploit this opportunity, the Army restructured its MANTECH efforts in FY 90 based on a thrust area concept. Each of the ten current thrusts, directed by a thrust area manager, has a broad technical objective selected to improve specific manufacturing processes. The manager is charged with setting objectives, selecting tasks, monitoring execution, leveraging external resources, and establishing microfactories to promote technology transfer. The Optics Manufacturing Thrust is an example of the concept. It is currently directed at revitalizing the domestic precision optics manufacturing base, now characterized by high labor costs and 1940's technology, through introduction of revolutionary machines, new processes, and Computer Integrated Manufacturing (CIM) principles. Leveraging of MANTECH dollars with those of industry, academia, and state governments led to the establishment of the center for Optics Manufacturing and plans for regional centers. Recognition of the U.S. as a world leader in precision optics manufacturing and a dramatic reduction of both manufacturing time and cost should accrue from thrust area efforts.

Kopacz, Stanley P.↗

Manufacturing and producibility technology

Activities of the manufacturing/producibility working group within the Advanced High-Pressure O2/H2 Technology Program are summarized. The objectives of the M/P working group are: to develop and evaluate process and manufacturing techniques for advanced propulsion hardware design and selected materials; and to optimize the producibility of (SSME) components and assemblies by improved performance, increased life, greater reliability, and/or reduced cost. The technologies being developed include: plasma arc, laser, and inertia welding; combustion chamber and turbine blade coatings; coating processes; high performance alloy electroforming; and process control technology.

Hankins, J. D.↗

Development of Mission Adaptive Digital Composite Aerostructure Technologies (MADCAT)

This paper reviews the development of the Mission Adaptive Digital Composite Aerostructures Technologies (MADCAT) v0 demonstrator aircraft, utilizing a novel aerostructure concept that combines advanced composite materials manufacturing and fabrication technologies with a discrete construction approach to achieve high stiffness-to-density ratio ultra-light aerostructures that provide versatility and adaptability. This revolutionary aerostructure concept has the potential to change how future air vehicles are designed, built, and flown, with dramatic reductions in weight and manufacturing complexity the number of types of structural components needed to build air vehicles while enabling new mission objectives. We utilize the innovative digital composite materials and discrete construction technologies to demonstrate the feasibility of the proposed aerostructure concept, by building and testing a scaled prototype UAV, MADCAT v0. This paper presents an overview of the design and development of the MADCAT v0 flight demonstrator.

Digital composite↗

National Rocket Propulsion Materials Plan: A NASA, Department of Defense, and Industry Partnership

NASA, Department of Defense, and rocket propulsion industry representatives are working together to create a national rocket propulsion materials development roadmap. This "living document" will facilitate collaboration among the partners, leveraging of resources, and will be a highly effective tool for technology development planning. The structuring of the roadmap, and development plan, which will combine the significant efforts of the Integrated High Payoff Rocket Propulsion Technology (IHPRPT) Program, and NASA's Integrated Space Transportation Plan (ISTP), is being lead by the IHPRPT Materials Working Group (IMWG). The IHPRPT Program is a joint DoD, NASA, and industry effort to dramatically improve the nation's rocket propulsion capabilities. This phased program is structured with increasingly challenging goals focused on performance, reliability, and cost to effectively double rocket propulsion capabilities by 2010. The IHPRPT program is focused on three propulsion application areas: Boost and Orbit Transfer (both liquid rocket engines and solid rocket motors), Tactical, and Spacecraft. Critical to the success of this initiative is the development and application of advanced materials, processes, and manufacturing technologies. NASA's ISTP is a comprehensive strategy focusing on the aggressive safety, reliability, and affordability goals for future space transportation systems established by the agency. Key elements of this plan are the 2 nd and 3 d Generation Reusable Launch Vehicles (RLV). The affordability and safety goals of these generational systems are, respectively, 10X cheaper and 100X safer by 2010, and 100X cheaper and 10,000X safer by 2025. Accomplishment of these goals requires dramatic and sustained breakthroughs, particularly in the development and the application of advanced material systems. The presentation will provide an overview of the IHPRPT materials initiatives, NASA's 2nd and 3 rd Generation RLV propulsion materials projects, and the approach for the development of the national rocket propulsion materials roadmap.

Clinton, Raymond G., Jr.↗

The Role of Advanced Materials and Manufacturing in Future NASA Exploration Missions

Future NASA missions to the Moon and Mars will require significant advances in materials and manufacturing technologies. These missions will likely be constrained in mass and volume. Lightweight, high strength materials will be required to reduce the mass of launch vehicles and spacecraft in order to maximize the amount of supplies and equipment that can be transported to the surface of the planet. Additive manufacturing and advanced in-space assembly methods will be needed to fabricate spare parts and build habitats for the astronauts. Methods to convert resources on the planet and recycle waste into materials, parts, and fuel will also be required. This presentation will discuss some of these needs, potential solutions currently being explored, and research opportunities for students, faculty, and researchers from industry and government to help address these needs.

chemistry↗

Development of self-sensing materials for extreme environments based on metamaterial concept and additive manufacturing

Structural health monitoring of an engineered component in a harsh environment is critical for multiple DOE missions including nuclear fuel cycle, subsurface energy production/storage, and energy conversion. Supported by a seeding Laboratory Directed Research & Development (LDRD) project, we have explored a new concept for structural health monitoring by introducing a self-sensing capability into structural components. The concept is based on two recent technological advances: metamaterials and additive manufacturing. A self-sensing capability can be engineered by embedding a metastructure, for example, a sheet of electromagnetic resonators, either metallic or dielectric, into a material component. This embedment can now be realized using 3-D printing. The precise geometry of the embedded metastructure determines how the material interacts with an incident electromagnetic wave. Any change in the structure of the material (e.g., straining, degradation, etc.) would inevitably perturbate the embedded metastructures or metasurface array and therefore alter the electromagnetic response of the material, thus resulting in a frequency shift of a reflection spectrum that can be detected passively and remotely. This new sensing approach eliminates complicated environmental shielding, in-situ power supply, and wire routing that are generally required by the existing active-circuit-based sensors. The work documented in this report has preliminarily demonstrated the feasibility of the proposed concept. The work has established the needed simulation tools and experimental capabilities for future studies.

36 MATERIALS SCIENCE↗

Durability of commercial aircraft and helicopter composite structures

The development of advanced composite technology during the past decade is discussed. Both secondary and primary components fabricated with boron, graphite, and Kevlar composites are evaluated. Included are spoilers, rudders, and fairings on commercial transports, boron/epoxy reinforced wing structure on C-130 military transports, and doors, fairings, tail rotors, vertical fins, and horizontal stabilizers on commercial helicopters. The development of composite structures resulted in advances in design and manufacturing technology for secondary and primary composite structures for commercial transports. Design concepts and inspection and maintenance results for the components in service are reported. The flight, outdoor ground, and controlled laboratory environmental effects on composites were also determined. Effects of moisture absorption, ultraviolet radiation, aircraft fuels and fluids, and sustained tensile stress are included. Critical parameters affecting the long term durability of composite materials are identified.

Dexter, H. B.↗

UIR-Net: Object Detection in Infrared Imaging of Thermomechanical Processes in Automotive Manufacturing

Thermomechanical processes (TMPs) such as resistance spot welding (RSW) and hot stamping are widely used in automotive manufacturing. Recent advancement in sensing technology has led to an increasing adoption of thermographic cameras to capture the infrared (IR) radiation of a metal part (or component of a part) during its thermomechanical processing or immediately after the process when the part is still hot. Detecting the object(s) of interest from raw IR images is an essential step in analyzing these data. Deep learning (DL) has been a recent success for object detection (OD), but the application of DL-based OD for industrial IR images in manufacturing is largely lagging behind. The major contribution of this work, which is also the distinction from previous OD studies, is the capability of building the OD model with unlabeled IR images, i.e., imaging data without accurate information indicating the object position. Here, the architecture of Unsupervised IR Image Net (UIR-Net) is designed to accommodate the unique characteristics of IR images from TMPs in manufacturing. This study presents a novel method for OD in unlabeled IR images from TMPs. The proposed method, called UIR-Net, consists of two components: label generation and DL model construction. Two case studies from automotive manufacturing, RSW and hot stamping, are reported to demonstrate the feasibility and effectiveness of the proposed method.

42 ENGINEERING↗

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↗

AMES: MS and MENG in Advanced Manufacturing for Energy at the University of Connecticut (Final Technical Report)

The objective of the project is to develop and implement an advanced degree program (MS and MENG in Advanced Manufacturing for Energy Systems, AMES) responding to the long-term workforce and technology requirements of the nation’s advanced energy products manufacturing industry. The program provided an industry relevant research experience by leveraging existing energy (e.g. fuels, power electronics, electrochemical power sources) and advanced manufacturing (e.g. additive manufacturing, composites, sensing) research at UConn funded by federal and state agencies, and industry, as well as through our industry partnerships. The trainees have joined research teams, advised by faculty with relevant research interests and expertise and were co-advised by industrial mentors. The AMES program have developed a truly interdisciplinary curriculum, first graduate degree program at UConn School (now College) of Engineering not housed in an academic department, with concentrations focusing on various challenges in advanced manufacturing for energy systems, e.g. advanced materials and processing. The project also developed new courses focusing on common technical and professional skills, and integrated various components for an industry relevant training. The program has admitted 29 Master of Science (MS) students since inception in January 2019. Twenty six of these students were AMES fellows, who have received partial funding from DoE through this project. The program far exceeded the goal of admitting at least five new MS (with thesis) students. All students were required to complete a thesis (M.S.) or a capstone (M.Eng.) project that are defined in collaboration with industry partners to ensure industrial relevancy, addressing a current industrial challenges. Industrial mentors also participated in advising the students in their research. AMES fellows, in addition were also required to complete an industrial internship for further industrial experience.

36 MATERIALS SCIENCE↗

Space Technology Mission Directorate: Game Changing Development Program: Rapid Analysis and Manufacturing Propulsion Technology (RAMPT)

Technology Overview: The RAMPT (Rapid Analysis and Manufacturing Propulsion Technology) project will develop and advance large scale light-weight multi-metallic freeform manufacturing and composite overwrap techniques and analysis capabilities required to implement them to reduce design and fabrication cycles for regeneratively-cooled liquid rocket engine components; RAMPT will reduce design, fabrication, assembly schedules while allowing for reduced parts, increased reliability, significant weight reduction and a healthy American supply chain. Four technology areas developed: 1) Freeform Blown Powder Nozzle; 2) Composite overwrap structural jacket; 3) Bimetallic radial deposition for manifolds; 4) Modeling and analysis tools for Additive and Regen design. Exploration & Science Impact: Addresses longest lead, highest cost and heaviest component in engine; Applicable to Lunar Lander Engine, Booster Engines, Upper Stage Engines, and NTP (Nuclear Thermal Propulsion) Technology; Public-private partnerships with specialty industry vendors, government partners, Commercial Crew, and infusion into commercial space companies and manufacturers; SSTIP (NASA's Strategic Space Technology Investment Plan) Core Investment Area - Launch Propulsion Systems (TA01 (NASA Technology Area 01); Lightweight Space Structures and Materials (TA12); Manufacturing (TA12).

RAMPT↗

New technologies for UV detectors

Several technologies are currently being developed, leading to substantial improvements in the performance of UV detectors or significant reductions in power or weight. Four technologies discussed are (1) thin-film coatings to enhance the UV sensitivity of CCD's, (2) highly innovative magnet assemblies that dramatically reduce weight and result in virtually no external flux, (3) new techniques for curving microchannel plates (MCP's) so that single plates can be used to prevent ion feedback and present highly localized charge clouds to an anode structure, and (4) high-performance alternatives to glass-based MCP's. In item (2), for example, very robust magnets are made out of rare earth materials such as samarium cobalt, and cladding magnets are employed to prevent flux from escaping from the detector into the external environment. These new ultralight magnet assemblies are able to create strong, exceptionally uniform magnetic fields for image intensification and focusing of photoelectrons. The principle advantage of such detectors is the quantum efficiencies of 70-80 percent obtained throughout ultraviolet wavelengths (900-2000 A), the highest of any device. Despite the improvements achieved under item (3), high-performance alternatives to conventional glass-based MCP's potentially offer three distinct new advantages that include (1) a 30-100-fold improvement in dynamic range resulting in correspondingly higher signal-to-noise ratios, (2) the use of pure dielectric and semiconductor materials that will not outgas contaminants that eventually destroy photocathodes, and (3) channels that have constant spacing providing long-ranged order since the plates are made using photolithography techniques from the semiconductor industry. The manufacturers of these advanced-technology MCP's, however, are a couple of years away from actually producing a functioning image intensifier. In contrast to the use of CCD's for optical, ground based observations, there is no single detector technology in the ultraviolet that dominates or is as universally suitable for all applications. Thus, several technological problems, recent advances, and the impact that these new enabling technologies represent for UV applications are addressed.

Joseph, C. L.↗

2020 ETI Annual Summer School: Data Science and Engineering

The Consortium for Enabling Technologies & Innovation (ETI) was established in 2019 to address emerging technologies within the context of nuclear nonproliferation. ETI creates a research and education environment to support cross-cutting technologies across three core disciplines: 1) computer and engineering science research specifically in a form of machine learning and high performance computing (HPC), 2) advanced manufacturing, and 3) nuclear detection technologies. For outreach and development, ETI hosted the first of three summer schools from August 24-28, 2020 with the theme of “Data Science and Engineering”. The school was hosted in an on-line format and had over 200 participants. The recorded content is available on-line as a resource for students. The summer school had four modules: 1) Fundamentals of data Applications, 2) Computational Machine Learning, 3) Bayesian Modeling and Inference, and 4) Data Science for Safeguards. Modules contained both lectures as well as student exercises. Poll Everywhere was utilized in some modules as an on-line method to engage large groups of students. Upcoming ETI Summer Schools include Novel Instrumentation in 2021 and Advanced Manufacturing in 2022.

Biegalski, Steven R.↗

Hydrogen-based ore-to-part manufacturing of near-net-shape stainless steel

Decarbonizing iron and steelmaking, combined with global disruptions to raw material supply chains, necessitates novel approaches to iron and steel production. In this work, we demonstrate a direct ore-to-part manufacturing route using a mixture of ore-derived oxide powders of Fe 2 O 3 , Cr 2 O 3 , NiO, and MoO 3 as feedstock for additive manufacturing, combined with sintering under H 2 to produce a near-net-shape austenitic stainless-steel. Complete reduction of all constituent oxides, including MoO 3 and Cr 2 O 3 , is achieved in-situ at 1300 °C, resulting in dense, crack-free bulk alloy. The fabricated part retains geometric fidelity while undergoing substantial volumetric shrinkage inherent to redox and sintering. Thermodynamic calculations elucidate the co-reduction mechanisms and alloying pathways that enable complete metallization. This work is the first demonstration of net-shaping metal parts directly from ore derived oxides, and this ore-to-part approach can minimize the emissions and lead time for manufacturing associated with downstream processing such as rolling, forging, and machining.

Yang, Mingzhang [Univ. of Waterloo, ON (Canada); F↗

Measuring the density, viscosity, and surface tension of molten titanates using electrostatic levitation in microgravity

Rare earth and barium titanates are useful as ferroelectric, dielectric, and optical materials. Measurements of their thermophysical properties in the liquid state can help guide melt processing technologies for their manufacture and advance understanding of fragile liquids' behavior and glass formation. Here, we report the density, thermal expansion, viscosity, and surface tension of molten BaTi 2 O 5 , BaTi 4 O 9 , and 83TiO 2 -17RE 2 O 3 (RE = La or Nd). Measurements were made using electrostatic levitation and droplet oscillation techniques in microgravity, which provide access to quiescent liquid droplets and deep supercooling of 510–815 K below the equilibrium melting points. Densities were measured over 900–2400 K. Viscosities were similar for all four compositions, increasing from ~10 mPa s near 2100 K to ~30 mPa s near 1750 K. Surface tensions were 450–490 dyn cm -1 for the rare earth titanates and 383–395 dyn cm -1 for the barium titanates; surface tensions of all compositions had small or negligible temperature dependence over 1700–2200 K. In conclusion, for solids recovered after melt quenching, x-ray microtomography revealed the fracture mechanics in crystalline products and minimal internal porosity in glass products, likely arising from entrapped gas bubbles. Internal microstructures were generally similar for products processed either in microgravity or in a terrestrial aerodynamic levitator.

42 ENGINEERING↗

Hydrogen: Targeting $1/kg in 1 Decade

The societal energy system is evolving rapidly as the impacts of our existing energy system are better appreciated and technological advances have dramatically decreased the cost of renewable resources. Simultaneously, the importance of energy transfer across timeframes and the difficulty of decarbonizing the industrial loads and transportation demands using electricity are being recognized. At the center of this need is achieving low-cost clean hydrogen. The U.S. Department of Energy launched the Hydrogen Energy EarthShot which seeks to reduce the cost of clean hydrogen to $1 per 1 kilogram in one decade. Reaching the $1/kg goal is dependent on the evolution of the electrical energy system to increase renewable energy deployment and low electricity costs; advances in electrolysis technology and manufacturing readiness; and infrastructure build-out and hydrogen market establishment that results in the ability to make, move, store, and use clean hydrogen economically while spurring job creation.

08 HYDROGEN↗

Material development for laminar flow control wing panels

The absence of suitable porous materials or techniques for the economic perforation of surface materials has previously restricted the design of laminar flow control (LFC) wing panels to a consideration of mechanically slotted LFC surfaces. A description is presented of a program which has been conducted to exploit recent advances in materials and manufacturing technology for the fabrication of reliable porous or perforated LFC surface panels compatible with the requirements of subsonic transport aircraft. Attention is given to LFC design criteria, surface materials, surface concepts, the use of microporous composites, perforated composites, and perforated metal. The described program was successful in that fabrication processes were developed for producing predictable perforated panels both of composite and of metal.

Meade, L. E.↗

Ceramic component processing development for advanced gas-turbine engines

A review of ceramic component advancements directed at developing manufacturing technologies for rotors, stators, vane-seat platforms and scrolls is presented. The first three components are being produced from HIPed Si3N4, while scrolls were prepared from a series of siliconized silicon-carbide materials. Developmental work has been conducted on all aspects of the fabrication process utilizing Taguchi experimental design methods. An assessment of material properties for various components from each process and material are made.

Mcentire, B. J.↗