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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 OSTI2024

Effect of laminae count and manufacturing methods on mechanical properties of thin‐ply woven composites

Abstract Thin‐ply woven composites exhibit exceptional mechanical performance by delaying the onset of damage, making them suitable for high‐performance structural applications. This study outlines the impact of manufacturing techniques (vacuum bagging and hot pressing), ply count, and fiber waviness on the mechanical properties of aromatic thermosetting copolyester/carbon‐fiber (ATSP/CF) composites. The analysis encompasses several different ply counts, evaluating their effects on the in‐plane elastic modulus (0°–90°) and tensile strength. Results demonstrate that reducing the waviness (or crimp) ratio significantly enhances the in‐plane elastic modulus, with improvements up to 188%, highlighting the importance of fiber alignment. Vacuum bagging produced ply thicknesses from 128 to 58 μm for 1–36 plies, with in‐plane elastic moduli from 30.3 to 87.2 GPa, and 4‐ and 8‐ply samples showed approximately 40% higher stiffness than those made by hot pressing. ATSP resin with high thermal stability (up to 400°C) and recyclability was used. Furthermore, this study highlights the microstructural enhancements achieved through vacuum bagging, as revealed by scanning electron and optical microscopy, and micro‐computed tomography imaging. This paper provides insights into damage mitigation and achieving enhanced mechanical properties by controlling fiber waviness using vacuum bagging and higher ply count in thin‐ply ATSP/CF composites. Highlights Crimp ratio reduction enhances elastic in‐plane elastic modulus up to 188%. Vacuum bagging increases modulus over the hot pressing manufacturing method by 40%. Lowering thickness‐per‐ply increases failure strain from 0.8% to 1.2%. Explored the performance of a novel ATSP matrix with high recyclability and thermal stability.

Kushwaha, Shashank [The Grainger College of Engine↗
DOE OSTI2024

The Influence of Residual Stress on Fatigue Crack Growth Rates in Stainless Steel Processed by Different Additive Manufacturing Methods

The properties and microstructure of Type 304L stainless steel produced by two additive manufacturing (AM) methods—directed energy deposition (DED) and powder bed fusion (PBF)—are evaluated and compared. Localized heating and steep temperature gradients of AM processes lead to significant residual stress and distinctive microstructures, which may be process-specific and influence mechanical behavior. Test data show that materials produced by DED and PDF have small differences in tensile strengths but clear differences in residual stress and microstructural features. Measured fatigue crack growth rates (FCGRs) for cracks propagating parallel to and perpendicular to the build directions differ between the two AM materials. To separate the influences of residual stress and microstructure, K-control test procedures with decreasing and constant stress intensity factor ranges are used to measure FCGRs in the near-threshold regime (crack growth rates ≤ 1 × 10 −8 m/cycle). Residual stress is quantified by the residual stress intensity factor, K res , measured by the online crack compliance method. Correcting the FCGR data for differences in K res brings results for specimens of the two AM materials into agreement with each other and with results for wrought specimens, when the latter are corrected for crack closure. Differences in microstructure and tensile strength have an insignificant influence on FCGRs in these tests.

additive manufacturing↗
DOE OSTI2024

Sintering-based Metal Additive Manufacturing Methods for Magnetic Materials

In this chapter, we review the relationship between solid-state sintering and additive manufacturing (AM) methods for fabricating soft and hard magnetic materials. Heat treatment as a post-processing method has been done in conjunction with AM as a method to improve density and/or mechanical properties. In binder jetting (BJT) of metal powders, sintering is a crucial post-processing step and is necessary for obtaining the final product. This is because the parts are only in the “green” state when they leave the BJT printer, with poor mechanical properties and high porosity. Sintering densifies and strengthens the green part into the final product. A potential industrial application for sintering-based AM is the fabrication of magnetic materials. The motivation for doing so, the process and properties of the AM magnets, and the potential applications of post-sintered AM magnets are explored.

Wang, Haobo↗
DOE OSTI2022

Additive manufacturing method and assembly

Methods and assemblies for additive manufacturing portions of components with enhanced strength are provided. The assemblies comprise a first deposition head and an apparatus for causing one or more reinforcement fibers to extend more than two layers within previously-deposited layers of build material. The first deposition head is configured to deposit a plurality of layers of a filament comprising a reinforcement fiber and thermoplastic material. The apparatus may comprise a needle point configured to be inserted into the plurality of layers to displace the reinforcement fiber so that it extends two or more of the plurality of layers. The apparatus may additionally or alternatively comprise a second deposition head having a needle tip configured to be inserted into the plurality of layers to inject a length of a second filament comprising thermoplastic material and a reinforcement fiber so that the reinforcement fiber of the second filament extends two or more layers of the plurality of layers of the first filament.

Barr, Christian G.↗
DOE OSTI2022

Turbine nozzle and method of manufacture

Methods of fabricating a turbomachine component and turbomachine components are provided. The method includes irradiating a layer of powder in a powder bed to form a fused region. The powder is disposed on a build plate. The method further includes a step of providing a subsequent layer of powder over the powder bed by passing a recoater arm over the powder bed from a first side of the powder bed. The method further includes repeating the irradiating and providing steps until a turbine nozzle assembly is formed on the build plate. The turbine nozzle assembly includes the turbine nozzle and a plurality of heat fins disposed within the turbine nozzle. The plurality of heat fins transfer heat away from a thermally sensitive portion of the turbine nozzle.

Griffis, Clay Thomas↗
DOE OSTI2023

Multimaterial powder bed patterning for additive manufacturing method

The present disclosure relates to an additive manufacturing system. In one embodiment the system makes use of a reservoir for holding a granular material feedstock. A nozzle is in communication with the reservoir for releasing the granular material feedstock in a controlled fashion from the reservoir to form at least one layer of a part. An excitation source is included for applying a signal which induces a controlled release of the granular material feedstock from the nozzle as needed, to pattern the granular material feedstock as necessary to form a layer of the part.

Dudukovic, Nikola↗
DOE OSTI2025

Mesoscale fractal whey protein particles derived from microscale linear-shaped protein assemblies (Part 1): Manufacturing method and particle characteristics

Whey protein isolates (WPI) are widely used in processed foods for their versatile functional properties. Modifying the structural properties of proteins by assembling them into mesoscale or microscale particles may improve their functionality and broaden their applications. This study aims to manufacture and characterize mesoscale whey protein particles (WPP) derived from WPI. Two types of WPP, WPP1 (0.05 mL/min) and WPP2 (0.25 mL/min), were prepared through a multistep approach involving liquid antisolvent (LAS) precipitation, heat treatment, and microfluidization. Liquid antisolvent precipitation was performed by injecting a 20% (wt/vol) WPI dispersion (pH 7) into an ethanol-glycerol mixture (75:25, vol/vol) under laminar flow, followed by heat treatment at 80°C for 20 min as a particle hardening step. This process produced stable fiber- and ribbon-shaped whey protein assemblies (WPA), which served as precursors to WPP. Subsequent microfluidization (150 MPa, 6 passages) reduced the size of WPA, yielding mesoscale WPP with irregular morphologies and a more uniform size distribution, as revealed by microscopy and dynamic light scattering. ζ-Potential and fluorescence labeling indicated higher surface charge and surface hydrophobicity of WPP compared with untreated WPI. The WPP showed internal mass fractal and surface fractal structures at larger length scales, analyzed using small-angle X-ray scattering. Fourier transform infrared spectroscopy demonstrated an increased fraction of intermolecular β-sheets in WPP, suggesting that hydrogen bonding contributed to their formation. Gel electrophoresis confirmed that disulfide bonds served as the primary cross-links stabilizing the WPP structure. Furthermore, turbidity measurements showed that WPP exhibited superior colloidal phase stability compared with untreated WPI and maintained high colloidal stability under both acidic and neutral pH conditions.

Antisolvent precipitation↗
NASA NTRS2018

Needs and Opportunities in the Development of Advanced Materials and Manufacturing Methods for Future Long-Duration Human Space Exploration

Weight, functionality, and sustainability are all critical concerns for future, long-duration, human exploration of space. Exploration missions will be mass-limited, since the amount of supplies and instruments that future astronauts will be able to take with them will be limited by launch vehicle and spacecraft mass and efficiency. Astronauts will need to have the capability to repair or replace worn-out or broke hardware and produce new components to be able to function for long periods at locations far-removed from Earth. Ultra-lightweight, multifunctional materials will be required to enable significant reductions in launch vehicle, spacecraft, and habitat mass in order to maximize payload. "Mass-less Exploration" concepts must be developed that will recycle materials and waste and convert available planetary materials into new feedstock materials and utilize in-space additive manufacturing to use these materials to produce the

composites↗
NASA NTRS1993

Manufacturing methods for machining spring ends parallel at loaded length

A first end surface of a coiled compression spring at its relaxed length is machined to a plane transverse to the spring axis. The spring is then placed in a press structure having first and second opposed planar support surfaces, with the machined spring end surface bearing against the first support surface, the unmachined spring end surface bearing against a planar first surface of a lateral force compensation member, and an opposite, generally spherically curved surface of the compensation member bearing against the second press structure support surface. The spring is then compressed generally to its loaded length, and a circumferentially spaced series of marks, lying in a plane parallel to the second press structure support surface, are formed on the spring coil on which the second spring end surface lies. The spring is then removed from the press structure, and the second spring end surface is machined to the mark plane. When the spring is subsequently compressed to its loaded length the precisely parallel relationship between the machined spring end surfaces substantially eliminates undesirable lateral deflection of the spring.

Hinke, Patrick Thomas↗
NASA NTRS1995

Manufacturing methods for machining spring ends parallel at loaded length

A first end surface of a coiled compression spring at its relaxed length is machined to a plane transverse to the spring axis. The spring is then placed in a press structure having first and second opposed planar support surfaces, with the machined spring end surface bearing against the first support surface, the unmachined spring end surface bearing against a planar first surface of a lateral force compensation member, and an opposite, generally spherically curved surface of the compensation member bearing against the second press structure support surface. The spring is then compressed generally to its loaded length, and a circumferentially spaced series of marks, lying in a plane parallel to the second press structure support surface, are formed on the spring coil on which the second spring end surface lies. The spring is then removed from the press structure, and the second spring end surface is machined to the mark plane. When the spring is subsequently compressed to its loaded length the precisely parallel relationship between the machined spring end surfaces substantially eliminates undesirable lateral deflection of the spring.

Hinke, Patrick Thomas↗
NASA NTRS2018

All-Elastomer 3-Axis Contact Resistive Tactile Sensor Arrays and Micromilled Manufacturing Methods Thereof

At least one tactile sensor includes an insulating layer and a conductive layer formed on the surface of the insulating layer. The conductive layer defines at least one group of flexible projections extending orthogonally from the surface of the insulating layer. The flexible projections include a major projection extending a distance orthogonally from the surface and at least one minor projection that is adjacent to and separate from the major projection wherein the major projection extends a distance orthogonally that is greater than the distance that the minor projection extends orthogonally. Upon a compressive force normal to, or a shear force parallel to, the surface, the major projection and the minor projection flex such that an electrical contact resistance is formed between the major projection and the minor projection. A capacitive tactile sensor is also disclosed that responds to the normal and shear forces.

Charalambides, Alexandros↗