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At least 343 records · Page 19

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DOE OSTI2022

A process optimization framework for laser direct energy deposition: Densification, microstructure, and mechanical properties of an Fe-Cr alloy

Laser Direct Energy Deposition (DED) is a metal additive manufacturing technique with the ability to fabricate large and complex parts through deposition of metal powders. However, achieving high-density parts and targeted build heights using DED can be challenging due to the large number of highly sensitive process variables. This work proposes a robust fabrication parameter optimization framework to generate process maps for primary parameters in DED, including laser power, scan speed, mass flow rate, hatch spacing, and layer height. Simple single-track experiments were utilized to map out the parameter space, and a combination of geometric criteria for hatch spacing and layer height were proposed to determine parameter sets that achieve both targeted build heights and mitigate porosity formation. Using this framework, specimens with >99 % density and consistent mechanical properties were successfully fabricated over a wide range of process parameters for an Fe-9wt.%Cr (Fe9Cr) alloy, a surrogate for radiation damage-resistant reduced activation ferritic/martensitic (RAFM) steels. Processing these materials using DED is of particular interest in the development of plasma facing components for nuclear fusion applications. The microstructure and mechanical properties of as-printed Fe9Cr were characterized using optical and electron microscopy, X-ray diffraction, and uniaxial tensile tests. As-printed Fe9Cr displayed ~25 % elongation and ultimate tensile strengths of up to 475 MPa which is comparable to similar wrought alloys. Finally, the proposed framework will allow for accelerated DED parameter optimization for novel alloy systems, as well as open the possibility for local microstructure control while simultaneously mitigating defect formation.

42 ENGINEERING↗

DOE OSTI2022

Detecting missing struts in metallic micro-lattices using high speed melt pool thermal monitoring

Metal lattices are an important class of cellular materials that offer great advantages by providing high-strength and lightweight structures as compared to bulk materials. Progress in additive manufacturing techniques has led to increased complexity in design and shape of produced objects and is greatly beneficial for the development of metallic lattice structures. However additive manufacturing of lattices suffers from unpredictable defect creation that can compromise its mechanical integrity. Although post-build inspection techniques can provide quality assurance of the process, accurate assessment can be technically challenging, time consuming and costly. In this work, we investigate the use of high-speed measurements of thermal emission from the melt pool to identify defective individual struts formed with a missing bottom half in an otherwise fully built lattice structure produced with laser powder bed fusion. Surprisingly, results indicate lower photodiode signal, suggesting colder melt pool surface temperature, when printing struts with missing bottom half as compared to nominal struts. Additional thermographic imaging and multi-physics simulations reveal that the low photodiode signal is accompanied by presence of hot spatters carrying heat away from detection and continuous avalanche of powder on the melt pool. Based on these observations, a method was developed to identify defective individual struts with missing bottom half in full built lattices. This prediction approach provides valuable insights about part quality which are important for process qualification and illustrates the utility of melt pool thermal emission monitoring for identifying specific defects introduced by laser powder bed fusion.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Embedding Sensors in 3D Printed Metal Structures

The Transformational Challenge Reactor (TCR) program is leveraging recent advances in modeling and simulation, materials, and additive manufacturing (AM) technologies to design a modern nuclear reactor. Some of the main TCR technologies include in situ monitoring and the integration of sensors during the manufacturing of quality-significant nuclear reactor components. This report describes the general procedure and process optimization for embedding sensors within generic stainless steel 316 (SS316) components using laser powder bed fusion (LPBF). A more detailed, quality-significant test plan and supporting procedures are available upon request (ORNL/TM-2021/2127). LPBF involves the use of a scanning laser to selectively melt regions of a powder bed, additively building a part layer by layer. This report describes the LPBF processing technique and discusses the effects of LPBF processing parameters on the success of the sensor embedding process. Experiments used machined cavities in the form of channels in an SS316 base for the sensors to lay in while material is additively built over the top, thereby embedding them in an SS316 matrix. A preliminary investigation involved using empty SS316 sheaths as surrogates to explore the effects of various LPBF processing parameters and the dimensional requirements of the machined channels. Microstructural investigations showed that a smaller channel width/depth combination closer to the sensor’s diameter was best for the embedding process. After the desired parameters were selected, Type-K thermocouples were embedded and evaluated post-embedding using nondestructive thermal testing, as well as destructive sectioning and microscopy. Post-build characterization showed that the thermocouples were well-bonded to the SS316 matrix and were fully functional after embedding. During thermal testing to temperatures up to 500 °C, the embedded thermocouples read consistently with one another and deviated only slightly from the readings of a nonembedded thermocouple located within the furnace. This slight discrepancy was most likely due to differences in the thermal time constants for a nonembedded thermocouple vs. a thermocouple embedded in a solid SS316 block. The results presented in this report will serve as the foundation for future work that will focus on embedding sensors in relevant TCR reactor components and eventually testing those components under neutron irradiation.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed: A Robotic Excavation and Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior to surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, 3-axis robotic positioning system, and regolith bin. For the REACT project, a pellet extruder, feed hopper, and heated 600mm x 600mm (23.6x23.6in) build plate have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

regolith↗

DOE OSTI2026

Autonomous elemental characterization enabled by a low cost robotic platform built upon a generalized software architecture

Despite the rapidly growing applications of robots in industry, the use of robots to automate tasks in scientific laboratories is less prolific due to the lack of generalized methodologies and the high cost of hardware. This paper focuses on the automation of characterization tasks necessary for reducing cost while maintaining generalization and proposes a software architecture for building robotic systems in scientific laboratory environments. A dual-layer (Socket.IO and ROS) action server design is the basic building block, which facilitates the implementation of a web-based front end for user-friendly operation and the use of ROS Behavior Trees for convenient task planning and execution. A robotic platform for automating mineral and material sample characterization is built upon the architecture, with an open-source, low-cost three-axis computer numerical control gantry system serving as the main robot. A handheld laser induced breakdown spectroscopy (LIBS) analyzer is integrated with a 3D printed adapter, enabling (1) automated 2D chemical mapping and (2) autonomous sample measurement (with the support of an RGB-Depth camera). We demonstrate the utility of automated chemical mapping by scanning the surface of a spodumene-bearing pegmatite core sample with a 1071-point dense hyperspectral map acquired at a rate of 1520 bits per second. Furthermore, we showcase the autonomy of the platform in terms of perception, dynamic decision-making, and execution, through a case study of LIBS measurement of multiple mineral samples. The platform enables controlled and autonomous chemical quantification in the laboratory that complements field-based measurements acquired with the same handheld device, linking resource exploration and processing steps in the supply chain for lithium-based battery materials.

Cao, Xuan [Lawrence Berkeley National Laboratory (↗

DOE OSTI2022

Printed Strain Gauges for Anthropomorphic Test Dummies for Vehicle Crash Testing

In Phase 1 of the technical collaboration between Oak Ridge National Laboratory (ORNL) and Humanetics, additive manufacturing was studied as a method to produce high strain – strain gauges that are embedded in an additively manufactured (AM) anthropomorphic crash test dummy (ATD) to provide high fidelity data to significantly improve vehicle safety. In this study commercially available conductive filament was acquired and the mechanical properties were tested for use in this application. The design space of embedded printed strain gauges was explored with multiple configurations printed and tested for performance. The testing resulted in finding that commercially available filament materials were unable to meet the performance requirements. Finally, an extensive literature survey was performed on advanced manufacturing techniques and novel high strain conductive materials to manufacture strain gauges that can be embedded in to the AM ATD. Humanetics have taken the literature survey and have reached out to material suppliers such as Techmer to provide custom blends of materials for testing. Humanetics will continue to build off of the research that was performed and test custom materials for use in AM ATDs.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Improved Breathing Cartridge (IBC)

The Fire Cartridge (FC) is designed to work with the Emergency Mask (EM) to protect the crew by cleaning the inhaled air in a post fire environment. The Improved Breathing Cartridge (IBC) is designed as a next generation FC with the lessons learned from years of building and testing the FC design, as well as novel catalyst materials to improve the performance and robustness of the cartridge. The FC was designed with minimal margin to save on mass, while the IBC was sized to have over 100% excess catalyst to achieve the required conversion, and still reduce the production cost. Kinetic data taken from another project was used to size the catalyst bed from the standard plug flow reactor conversion equation. The cartridge has been 3D printed and will soon be filled with the required levels of media. Testing has not yet been performed to determine final performance.

Fire Response↗

DOE OSTI2021

Tailored Fiber Placement for Complex Preforms

Tailored Fiber Placement (TFP) offers a novel approach to optimize fiber architecture for the fabrication of complex, structural parts not traditionally suitable for advanced composites. This technology not only offers new routes for weight reduction via metal substitution, it also offers cost reduction through minimization of material scrap and reduced labor. This reduction in component weight leads to increased fuel efficiency, and reduced production energy consumption, thereby, helping to achieve the stated IACMI technical goals. This technology leverages centuries of manufacturing development in support of the textile and embroidery industry. One major drawback to this technology is the lack of commercial or non- proprietary structural performance data and robust analytical tools used to optimize fiber architecture and predict performance. This project was structured to utilize common sub-element features to validate analytical performance tools, generate performance data, and gather cost and performance data on components of interest. This project was designed to give industry sponsors the confidence and ability to take full advantage of TFP to fabricate primary, highly loaded structure and integrate features such as metallic fasteners. The project focused principally on the use of high strength carbon fiber, such as T700, and the use of aerospace epoxy resin matrix to primarily support development of new composite applications in vehicle, aerospace, and industrial markets. This project applied previously developed analytical tools to predict the performance of TFP produced parts. This work focused on developing the pipeline to characterize material in order to accurately predict component performance when modifying the TFP print paths and stitch density. This focused on experimental characterization via standardized ASTM testing, alongside experimental testing of more representative service components by testing curved beam strength, beam shear performance, a large scale TFP lug, and ultimately designing a fully TFP clip bracket that reduced weight and cost compared to a traditional metallic component. The new knowledge gained from this program included: 1) development and demonstration of novel analytical tools applied to analysis of TFP preforms; 2) development and demonstration of a building block approach using coupons and sub-elements to optimize the design of a more complex component; 3) demonstration that optimized fiber orientation using TFP can exceed performance of conventional textile composite materials and can open new applications currently limited to metallic components; 4) Demonstration of performance and cost benefits of the TFP process as compared to metallic and conventional textile composites. Recommendations for follow-on work include development of design allowables to assess the impact of high temperature/moisture exposure or saturation during loading, tracking the impact of stitching needle wear on the performance of parts and ability to stitch thicker preforms, using TFP preforms as local reinforcement at areas of bearing or complex loading, and topology optimization of components by tow steering. The expertise developed during the course of this project can be leveraged to provide commercial engineering design and fabrication services using TFP. UDRI is in the process of formalizing their partnership with Spintech, who will serve as the commercialization partner for this technology and provide molding services and deliver finished components to the end user. UDRI will continue to produce the preforms until the economics allow Spintech to procure its own TFP equipment or lease UDRI equipment, at which point UDRI will step away from manufacture and serve as the engineering and design lead on product development.

36 MATERIALS SCIENCE↗

NASA NTRS1994

Tactile display device using an electrorheological fluid

A tactile display device utilizes an electrorheological fluid to activate a plurality of tactile dots. A voltage is selectively produced uniformly across an electrorheological fluid flowing between a common ground electrode and a plurality of conductive dot electrodes, thereby producing an increase in the fluid's viscosity to the extent that fluid flow between the two electrodes is restricted. The flow restriction produces a build-up of electrorheological fluid in a corresponding dot actuator chamber. The resulting pressure increase in the chamber displaces an elastic diaphragm fixed to a display surface to form a lump which can be perceived by the reader as one dot in a Braille character cell. A flow regulation system provides a continually pressurized flow system and provides for free flow of the electrorheological fluid through the plurality of dot actuator chambers when they are not activated. The device is adaptable to printed circuit techniques and can simultaneously display tactile dots representative of a full page of Braille characters stored on a medium such as a tape cassette or to display tactile dots representative of non-Braille data appearing on a computer monitor or contained on another data storage medium. In an alternate embodiment, the elastic diaphragm drives a plurality of spring-loaded pins provided with positive stops to maintain consistent displacements of the pins in both their actuated and nonactuated positions.

Garner, H. Douglas↗

NASA NTRS1996

Method and device for producing a tactile display using an electrorheological fluid

Garner, H. Douglas↗

NASA NTRS2000

Development of a Two Dimensional Synthetic Aperture Radiometer at L-Band

A radiometer that uses aperture synthesis in two dimensions is being built as part of research under NASA's Instrument Incubator Program. The instrument development team consists of engineers at the Goddard Space Flight Center, the University of Massachusetts and Quadrant Engineering. This will be an aircraft instrument operating at L-band which builds on the heritage of Electronically Steered Thinned Array Radiometer (ESTAR). This instrument is a next step in the development of aperture synthesis (STAR technology) to meet the goal of a future mission to monitor soil moisture globally from space. The instrument will be designed to fly on the NASA P-3 aircraft in a nadir pointing mode, although other options are possible. The antenna will consist of an array of modules in a rectangular grid. Each module will be comprised of a printed circuit dual-polarized patch and integrated receiver. The distribution of modules within the rectangular array will be adjustable so that several different imaging configurations (e.g. '+', 'Y', 'T') can be employed. The integrated receiver will provide amplification and conversion to infrared (IF). The IF signal will be routed to a processor where the required correlations performed. The I and Q channels will be created digitally and the correlations will be done digitally in this processor. The digitization will be done with sufficient bits to study the effects of quantization on radiometer performance. A computer/controller will store the data for conversion to an image and will also perform temperature control and other data interfacing and housekeeping tasks. The design of critical components has been completed and hardware is being assembled to test the individual elements. It is expected that a complete two-channel correlator will be tested by the end of 2000 and that the complete instrument will be ready for flight tests the following summer (2001).

LeVine, D. M.↗

DOE OSTI2024

Formation of functionally graded steel by laser powder bed fusion via in-situ carbon doping

Additive Manufacturing (AM) enables functional integration by combining multiple components into a single part to shorten assembly time, reduce weight, and improve performance. Laser Powder Bed Fusion (LPBF) is an important AM method due to excellent spatial resolution, surface finish, and material properties without the need for extensive post-processing. Functional integration could be enhanced by spatial tuning of properties, but LPBF cannot readily vary material composition. Here, this paper addresses a method to add spatial composition control by printing small quantities of dopants via liquid carrier prior to laser fusion. The impact of carbon black suspension added to select regions of a Stainless Steel 316 L powder bed on melt pool dimension, hardness, and porosity is reported. The distribution of the carbon between the doped and plain layers and the resulting spatial variation in hardness is measured. Optical microscopy and composition analysis show that the carbon dispersed uniformly within the layer of deposition and diffused as little as 50 μm in the build direction. Keyhole conditions dramatically increase the inter-layer transport of the dopant. The added carbon increased hardness by >50 %. Porosity increased in doped regions but remained below 1.5 % for the best processing parameters. These results demonstrate that the composition of LPBF parts could be controlled in 3-dimensions using a dopant that is soluble in the melt pool. Additional work will be required to evaluate different dopant materials and optimize processing conditions for full density, but microalloying with soluble dopants appears to be a plausible solution to enhance functional integration with LPBF.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Accelerating massively parallel hemodynamic models of coarctation of the aorta using neural networks

Comorbidities such as anemia or hypertension and physiological factors related to exertion can influence a patient’s hemodynamics and increase the severity of many cardiovascular diseases. Observing and quantifying associations between these factors and hemodynamics can be difficult due to the multitude of co-existing conditions and blood flow parameters in real patient data. Machine learning-driven, physics-based simulations provide a means to understand how potentially correlated conditions may affect a particular patient. Here, we use a combination of machine learning and massively parallel computing to predict the effects of physiological factors on hemodynamics in patients with coarctation of the aorta. We first validated blood flow simulations against in vitro measurements in 3D-printed phantoms representing the patient’s vasculature. We then investigated the effects of varying the degree of stenosis, blood flow rate, and viscosity on two diagnostic metrics – pressure gradient across the stenosis (ΔP) and wall shear stress (WSS) - by performing the largest simulation study to date of coarctation of the aorta (over 70 million compute hours). Using machine learning models trained on data from the simulations and validated on two independent datasets, we developed a framework to identify the minimal training set required to build a predictive model on a per-patient basis. We then used this model to accurately predict ΔP (mean absolute error within 1.18 mmHg) and WSS (mean absolute error within 0.99 Pa) for patients with this disease.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1999

Conformal, Transparent Printed Antenna Developed for Communication and Navigation Systems

Conformal, transparent printed antennas have advantages over conventional antennas in terms of space reuse and aesthetics. Because of their compactness and thin profile, these antennas can be mounted on video displays for efficient integration in communication systems such as palmtop computers, digital telephones, and flat-panel television displays. As an array of multiple elements, the antenna subsystem may save weight by reusing space (via vertical stacking) on photovoltaic arrays or on Earth-facing sensors. Also, the antenna could go unnoticed on automobile windshields or building windows, enabling satellite uplinks and downlinks or other emerging high-frequency communications.

Lee, Richard Q.↗

DOE OSTI2023

Self-Driving Laboratory for Polymer Electronics

Owing to the chemical pluripotency and viscoelastic nature of electronic polymers, polymer electronics have shown unique advances in many emerging applications such as skin-like electronics, large-area printed energy devices, and neuromorphic computing devices, but their development period is years-long. Recent advancements in automation, robotics, and learning algorithms have led to a growing number of self-driving (autonomous) laboratories that have begun to revolutionize the development and accelerated discovery of materials. In this perspective, we first introduce the current state of autonomous laboratories. Then we analyze why it is challenging to conduct polymer electronics research by an autonomous laboratory and highlight the needs. Here, we further discuss our efforts in building an autonomous laboratory, namely Polybot, for the automated synthesis and characterization of electronic polymers and their processing and fabrication into electronic devices. Finally, we share our vision in using a self-driving laboratory for different types of polymer electronics research.

36 MATERIALS SCIENCE↗

NASA NTRS2016

NH11B-1726: FrankenRaven: A New Platform for Remote Sensing

Small, modular aircraft are an emerging technology with a goal to maximize flexibility and enable multi-mission support. This reports the progress of an unmanned aerial system (UAS) project conducted at the NASA Ames Research Center (ARC) in 2016. This interdisciplinary effort builds upon the success of the 2014 FrankenEye project to apply rapid prototyping techniques to UAS, to develop a variety of platforms to host remote sensing instruments. In 2016, ARC received AeroVironment RQ-11A and RQ-11B Raven UAS from the US Department of the Interior, Office of Aviation Services. These aircraft have electric propulsion, a wingspan of roughly 1.3m, and have demonstrated reliability in challenging environments. The Raven airframe is an ideal foundation to construct more complex aircraft, and student interns using 3D printing were able to graft multiple Raven wings and fuselages into FrankenRaven aircraft. Aeronautical analysis shows that the new configuration has enhanced flight time, payload capacity, and distance compared to the original Raven. The FrankenRaven avionics architecture replaces the mil-spec avionics with COTS technology based upon the 3DR Pixhawk PX4 autopilot with a safety multiplexer for failsafe handoff to 2.4 GHz RC control and 915 MHz telemetry. This project demonstrates how design reuse, rapid prototyping, and modular subcomponents can be leveraged into flexible airborne platforms that can host a variety of remote sensing payloads and even multiple payloads. Modularity advances a new paradigm: mass-customization of aircraft around given payload(s). Multi-fuselage designs are currently under development to host a wide variety of payloads including a zenith-pointing spectrometer, a magnetometer, a multi-spectral camera, and a RGB camera. After airworthiness certification, flight readiness review, and test flights are performed at Crows Landing airfield in central California, field data will be taken at Kilauea volcano in Hawaii and other locations.

remote sensing↗

DOE OSTI2023

Residual Strains in an Additively Processed Ni-based Superalloy Transpiration-Cooled Aerodynamic Leading Edge Structure using Neutron Diffraction

Selective Laser Melting (SLM) is a well-known additive manufacturing method based on a layer-by-layer building process that is capable of fabricating gas turbine Ni-based superalloy parts with complex and integrated cooling geometries that are typically not achievable using conventional casting methods. However, the impact of residual stress concentration on SLM component life is a concern. In this work, residual strains present at room temperature in an SLM Inconel 718 generic aerodynamic leading edge segment with transpiration cooling were investigated using neutron diffraction at Oak Ridge National Laboratory. This study reveals that areas of the part where complex cooling holes were printed exhibit residual tensile strains that can be detrimental to its integrity. The study paves the way for future studies of the design of cooling hole geometries and manufacturing parameters that achieve improved cooling while minimizing stress concentration effects.

Fouliard, Quentin↗

NASA NTRS2023

Hot Cracking Behavior and Beam-Induced Grain Refinement in Electron Beam Freeform Fabricated Al 7075

Electron beam freeform fabrication (EBF 3 ) is a high deposition rate, wire-based directed energy deposition (DED) additive manufacturing (AM) process used to print metallic parts in a vacuum environment. While high specific strength 7xxx-series Al alloys are of interest in the aerospace and automotive industries, these alloys suffer from hot cracking issues during fusion welding and AM. In this work, linear deposits of Al 7075 were fabricated with EBF 3 to study the effects of baseplate thickness, preheat temperature, and beam focus on hot cracking behavior. Solidification cracks were observed in the first deposition layer, and by the third layer coalesced into large “macrocracks” running vertically through the build height. Fine, intergranular liquation “microcracks” appeared between macrocracks below the root of the final deposit layer fusion zone. Increasing the substrate preheat temperature from 165°C to 320°C deepened the partially melted zone and resulted in a more than twofold increase in the liquation microcrack density. Analysis of Scheil solidification diagrams revealed that fugitive losses of Zn and Mg during deposition increased the susceptibility to solidification cracking and promoted substrate liquation cracking. Focused electron beam (EB) conditions combined with a high aspect ratio elliptical raster pattern resulted in bands of refined, equiaxed grains. The refined microstructure suppressed solidification macrocracking and caused a nearly fivefold reduction in liquation crack density, demonstrating that beam-induced grain refinement may be a promising low-cost method for reducing hot cracking during AM.

aluminum↗