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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Pressure-based process monitoring of direct-ink write material extrusion additive manufacturing

As additive manufacturing (AM) has become a reliable method for creating complex and unique hardware rapidly, the quality assurance of printed parts remains a priority. In situ process monitoring offers an approach for performing quality control while simultaneously minimizing post-production inspection. For extrusion printing processes, direct linkages between extrusion pressure fluctuations and print defects can be established by integrating pressure sensors onto the print head. In this work, the sensitivity of process monitoring is tested using engineered spherical defects. Pressure and force sensors located near an ink reservoir and just before the nozzle are shown to assist in identification of air bubbles, changes in height between the print head and build surface, clogs, and particle aggregates with a detection threshold of 60–70% of the nozzle diameter. Visual evidence of printed bead distortion is quantified using optical image analysis and correlated to pressure measurements. Importantly, this methodology provides an ability to monitor the quality of AM parts produced by extrusion printing methods and can be accomplished using commonly available pressure-sensing equipment.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Material extrusion additive manufacturing of wood pulp-reinforced epoxy composites

Direct ink writing (DIW) is an extrusion-based form of 3D-printing that has gained popularity over the last decade. DIW uses thixotropic fluid extrusion to form a particular shape. In order to form stable structures, the rheology of the paste is important to allow for extrusion from the syringe, stability of the growing print, and prevention of unwanted seeping flow during jog moves. In this work, we use wood pulp as a bio-based filler that can provide shear thinning properties to the ink, which produces a stable ink for DIW processing. Additionally, the filler imparts improved mechanical and thermal performance compared to neat resin. The wood pulp provided the shear thinning behavior necessary for DIW printing, and pulp loadings greater than 6 wt%, provided sufficient yield stress so that the composite could self-support during printing. Nanoclay was utilized to further improve ink rheology and appearance to enable larger scale printing. Overall, this work showed successful DIW of an epoxy resin with a sustainable filler improving its stiffness and thermal properties and provides an avenue for further development of bio-based inks for DIW towards various applications.

Lamm, Meghan E. [Oak Ridge National Laboratory (OR↗
DOE OSTI2023

Low density syntactic foams via material extrusion additive manufacturing

An ink formulation for additive manufacturing of low density syntactic foams is described. The ink formulation can include a thermoset resin, a curing agent suitable for use with the thermoset resin, a plurality of hollow spheres, such as glass microballoons, one or more solvents, and one or more non-hollow, viscosity modifying filler. Also described are a method of preparing the ink formulation, a method of preparing three-dimensional objects comprising low density syntactic foams, and the three-dimensional objects prepared thereby.

Compton, Brett Gibson↗
DOE OSTI2023

Invertible neural networks for real-time control of extrusion additive manufacturing

Material extrusion additive manufacturing (AM) has enabled an elegant fabrication pathway for a vast material library. Nonetheless, each material requires optimization of printing parameters generally determined through significant trial-and-error testing. To eliminate arduous, iteration-based optimization approaches, many researchers have used machine learning (ML) algorithms which provide opportunities for automated process optimization. Here, in this work, we demonstrate the use of an ML-driven approach for real-time material extrusion print-parameter optimization through in-situ monitoring of printed line geometry. To do this, we use deep invertible neural networks (INNs) which can solve both forward and inverse, or optimization, problems using a single network. By combining in-situ computer vision and deep INNs, the printing parameters can be autonomously optimized to print a target line width in 1.2 s. Furthermore, defects that occur during printing can be rapidly identified and corrected autonomously. The methods developed and presented in this work eliminate user-intensive, time-consuming, and iterative parameter discovery approaches that currently limit accelerated implementation of extrusion-based AM processes. Furthermore, the presented approach can be generalized to provide real-time monitoring and optimization pathways for increasingly complex AM environments.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Machine learning informed control systems for extrusion printing processes

Systems and methods for controlling a material extrusion device to extrude a filament of an ink are provided. An extrusion printing control system collects from one or more sensors measurements representing an internal state of material extrusion processing during extrusion of the filament. In addition, the system collects an image of the filament as the filament is extruded. The system applies a classifier to the collected image to generate an image-derived state characterizing the filament. Based on the internal state and the image-derived state, the system estimates a derived state using a model. The system determines control parameters using the model to achieve a desired quality of the filament by minimizing a cost function based on the internal state, the image-derived state, the derived state, and constraints of the material extrusion device. Finally, the system provides the control parameters to a controller of the material extrusion device.

Howell, Brian↗
DOE OSTI2023

1. Introduction to Additive Manufacturing

Additive manufacturing (AM) is the process of constructing an object by adding layer upon layer of material in specific locations, to build the object into its final shape. There are many different AM processes that can be used to add layers of material, such as extrusion, material jetting, and sheet lamination. All of the AM processes are a form of digital fabrication because the object to be constructed must first be modeled with a computer. The modeled object must be converted into machine instructions that an AM system can use to construct the object. This chapter serves as an introduction to the many different AM processes. Subsequent chapters will explore the intricacies of creating machine instructions for the AM processes introduced here.

Macdonald, Eric↗
DOE OSTI2023

Extrusion parameter control optimization for DIW 3D printing using image analysis techniques

Material extrusion is a well-recognized facet of additive manufacturing that involves the fabrication of parts through the deposition of structural material from an extrusion head from a bulk supply. In the subdivision of Direct Ink Writing (DIW) additive manufacturing, challenges arise when the structural material is flowable, synchronous extrusion control and tool movement becomes critical for achieving high-quality parts with low defect populations. DIW techniques are most used in laboratory settings using expensive custom instruments and may require specialized 3D slicing software. Here, in this study, the fabrication of an inexpensive, consumer-friendly progressive cavity pump dispensing system is detailed, in which can create high-quality parts by executing G-code commands produced from a commercial slicing software. The precision and repeatability of the movement-synchronized material extrusion is demonstrated through a series of optimization schemes, entailing the alteration of various control parameters, which directly affect the extrusion properties demonstrated during a print. In situ diagnostics were implemented to evaluate the results of the established optimization experiment. Using a machine vision technique, images of the optimization prints are processed. Following this, a supervised machine learning model was trained to autonomously judge whether or not the extrusion parameters produced a passing or failing result. The machine learning scheme serves as a preliminary benchmark for future layer-by-layer evaluation of more complex DIW parts. The construction of the printer and development of in situ characterization capabilities demonstrates the ability for this printer to create high-fidelity DIW parts for a fraction of the price of other systems.

42 ENGINEERING↗
DOE OSTI2024

Methodology to determine printability criteria of highly concentrated pastes through rheological characterization

Material extrusion is an additive manufacturing technique that enables the creation of reproducible and complex hardware by depositing a viscous, shear-thinning ink onto a substrate in a custom-pattern via extrusion through a syringe. Here, the ability of an ink to be extruded onto a substrate in many layers, and maintain the desired shape is what defines the printability. Printability is often investigated by formulating, printing, and postmortem analysis of final parts in an iterative manner. Investigations of printability through rheological characterization have often been concerned with inks that straddle the line between printable and too thin, leaving out an entire class of inks that are highly-filled pastes, where extrudability is the limiting factor. Highly-filled pastes continue to pose issues for researchers as the effect of filler morphology, size, loading, and packing fraction on the ink rheology and corresponding printability is not understood. While traditional rheological characterizations may be useful for some inks, we show that protocols utilizing steady-shear, or large-amplitude oscillatory shear are difficult and unreliable for highly-filled pastes. Through transient rheology paired with real-time images we show that each traditional protocol produces inhomogeneous deformations that violate the assumptions that underly common rheological definitions. Instead, we demonstrate metrics measured with small-amplitude oscillatory shear that are correlated to the printability of various ink formulations ranging in loading. The rheological measures that accurately predict the printability of the inks are the axial stress measured at small amplitudes, and the critical stress amplitude above which rheological characterizations become impossible. In addition, we estimate the maximum packing fraction for each filler, based on the exponent common to hard sphere models, and show that the printability of each ink can be predicted by the ratio of the packing fraction to the theoretical maximum. We show how small-amplitude oscillatory shear allows users to develop printability criteria for any ink to enhance the workflow in the development of new inks, increase the performance of material extrusion printing, and improve the stability of printed parts, with less wasted time and materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Planar slicing for nonextrusion AM processes

Extrusion-based AM processes, including material extrusion and directed energy deposition, construct objects by continuously depositing a relatively small amount of molten feedstock to a specific location. Nonextrusion AM processes, on the other hand, tend to form each layer by linearly or areally projecting either energy onto a vat of photocurable liquid or a binding agent into a bed of loose powder. Such systems vary significantly from extrusion-based AM processes but do share similarities. The general approach to path planning is the same, but nonextrusion processes typically favor the use of bitmap representations, instead of polygons, for pathing computation and do not use a g-code file to command the printer. In this chapter, a high-level discussion of these differences will be covered.

Macdonald, Eric↗
DOE OSTI2022

Sealability Qualification of Material Extruded Zytel Gaskets at Extreme Temperatures

In this work, an in-depth qualification of additively manufactured Zytel for gasketing proton exchange membrane fuel cells (PEMFC’s) subject to extreme temperature conditions. The temperature cycling of the PEMFC from 55°C to 100°C accelerates the deterioration of these gaskets compared to that of conventional operation. The additive manufacturing process employed to print these gaskets is material extrusion using Zytel filament. In order to see the effects of the temperature of interest on the printed specimen, each specimen was thermally soaked and then charactered and tested according to ASTM standard F37B. ASTM F37B tests a materials ability to seal and maintain it while bearing both a compressive load and internal pressure load to simulate being in static operation. This process of thermally soaking and sealability testing is shown to show the validity of both this material and additive manufactured components for other applications as well. It is observed that soaking the gaskets at 100°C corrects some of the defects that are present after printing such as missing layers and small voids on the surface of the samples. This allowed for the hot soaked materials to perform better than the samples at room temperature and cold soaked.

Sealability↗
DOE OSTI2023

Using Large-Scale Additive Manufacturing for Wind Turbine Blade Core Structures

This report describes the techno-economic potential of using additive manufacturing technologies to design large wind turbine blade structures. After considering all additive technologies, the authors identified large-scale, polymer-based, material extrusion as the three-dimensional (3D) printing technology best suited to meet modern wind turbine blade manufacturing costs, cycle times, and geometric scale. Due to the lower structural performance requirements and the opportunity to reduce resin uptake mass penalties within the blade, the core material within the sandwich composite sections of the wind turbine blade is established as a logical entry point into advanced wind turbine blade manufacturing.

17 WIND ENERGY↗
DOE OSTI2023

Correlating viscosity and die swell in 3D printing of polyphenylsulfone: A thermo-mechanical optimization modus operandi

Additive manufacturing (AM) of polyphenylsulfone (PPSU), an amorphous high-performance polymer (HPP), has shown promise in exhibiting structural integrity for many applications. With thermoplastic material extrusion 3D printing, parts consisting of layered melts exhibited voids, where the adhesion quality and void size depend on the processing parameters implemented during printing. However, the structure-process-property (SPP) relationships between the thermal properties and rheological and mechanical behavior of AM PPSU are poorly understood. Here, in this study, a comprehensive analysis of the thermal, thermo-mechanical, and layer-by-layer build-up of PPSU is investigated and correlated with viscosity and extrudate die swell behavior with void fraction volume as confirmed by high-resolution x-ray computed tomography (XCT). Gas chromatography–mass spectrometry (GC–MS) pyrolysis confirmed PPSU composition and degradation at 480 °C, consistent with thermo-gravimetric analysis TGA. A 141% difference in viscosity was observed when processing temperatures increased from 350 °C to 400 °C. Likewise, extrudate die swell decreased with increasing temperatures, resulting in a 17% difference. Tensile and compressive properties confirmed that higher extruding temperatures resulted in lower porosity and higher mechanical strength. In general, higher extruding temperatures lower the viscosity to allow for stronger cohesion between layers; however, increasing the temperature too high results in a below unity extrudate die swell, reducing mechanical properties. Therefore, to optimize the mechanical integrity of 3D printed amorphous PPSU parts, an increase in the viscosity, near unity of the extrudate die swell, and tempered extrusion temperature are needed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Selective Deposition and Fusion of AISI 316L: An Additive Manufacturing Process for Space Environments via Direct Ink Writing and Laser Processing

Unlocking the potential of additive manufacturing (AM) for space exploration hinges on overcoming key challenges, notably the ability to manufacture or repair parts on-site during exploration missions with consideration of quality, feedstock utilization, and challenges involved in microgravity environments. While there are multiple efforts to investigate the use of existing metal AM processes such as powder bed fusion (PBF), directed energy deposition (DED), and filament-based material extrusion, each process comes with a different set of challenges in space environments. Here, in this work, we introduce a new AM method that integrates the benefits of direct ink writing (DIW) to selectively deposit metallic pastes with laser-based processing to locally debind and subsequently melt and fuse metal powder, layer by layer, enabling the manufacturing of AISI 316L samples with densities exceeding 99.0%. The impact of process parameters on single-track dimensions, surface morphology, and porosity was characterized. The efficacy of laser debinding was assessed via secondary-ion mass spectrometry, permitting the carbon content to be estimated at 0.0152%, which is safely below the acceptable limit (0.03 wt%) for AISI 316L.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Large-scale additive manufacturing tooling for extrusion-compression molds

Carbon fiber reinforced polymer composites (CFPC) have been used in additive manufacturing (AM) due to both the high-strength-to-weight and superior-stiffness-to-weight ratios. CF AM is being considered for tooling applications. In AM, CFPCs are usually aligned along the deposition direction; however, it results in anisotropic thermal properties which affect the heat transfer and warpage of the final part. In this study, three male molds with different infill patterns were produced via the material extrusion additive manufacturing (EDF-AM) process. These include (a) 0°: infill pattern along the printing direction; (b) 90°: infill pattern perpendicular to the printing direction; and (c) 0°/90°: alternate layers along and perpendicular directions. The effect of the infill pattern on thermal conductivity was analyzed and observed that 0° infill (surface temperature: 79.2°C) had the highest conductivity; and 90° infill (surface temperature: 66.4°C) had the least.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The Qualification of Sealability and Creep Relaxation of Additively Manufactured Zytel Gaskets for PEM Fuel Cells

The purpose of this thesis is to study the feasibility of low-cost additive manufacturing of gaskets for proton exchange membrane fuel cells exposed to extreme temperature conditions ranging from -55°C to 100°C. With the growing popularity and decreasing costs of additive manufacturing technologies, specifically Material Extrusion (ME), research is being conducted to determine the feasibility of ME components. Thermally cycled PEMFCs may exhibit accelerated gasket deterioration, therefore, the mechanical stability of material extruded gaskets following a harsh thermal cycle must be assessed. The feasibility of the material extruded gaskets will be proven by manufacturing optimization and mechanical testing. The target material for this study is Zytel by DuPont Chemical. The mechanical stability will be assessed via sealability and creep relaxation testing according to ASTM F37B and ASTM F38B respectively. Because the capabilities to conduct sealability testing at temperature were not available, each specimen was thermally soaked and allowed to return to room temperature prior to testing. As a result of sealability experiments, the 100°C-soaked specimens resulted in lower leak rates with a higher precision when compared to specimens soaked at -55°C and 22°C at across all compressive loads. It was observed from results from creep relaxation testing that there is thermal contraction and expansion occurring at 55°C and 100°C respectively, which can be observed by the resultant graphs. The recoverability of thermally cycled specimens are better than those that just experienced a high temperature hold. After the seven-day thermal cycle, the samples stabilized and maintained their structure.

Lazarin, Robert↗