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NASA NTRS2003

Liner-less Tanks for Space Application - Design and Manufacturing Considerations

Composite pressure vessels, used extensively for gas and fuel containment in space vehicles, are generally constructed with a metallic liner, while the fiber reinforcement carries the major portion of the pressure-induced load. The design is dominated by the liner s low strain at yield since the reinforcing fibers cannot operate at their potential load-bearing capability without resorting to pre-stressing (or autofrettaging). An ultra high-efficiency pressure vessel, which operates at the optimum strain capability of the fibers, can be potentially achieved with a liner-less construction. This paper discusses the design and manufacturing challenges to be overcome in the development of such a pressure vessel. These include: (1) gas/liquid containment and permeation, (2) design and structural analysis, and (3) manufacturing process development. The paper also presents the development and validation tests on a liner-less pressure vessel developed by Kaiser Compositek Inc. (KCI). It should be noted that KCI s liner-less tank exhibits a highly controlled leak-before-burst mode. This feature results in a structure having the highest level of safety.

Jones, Brian H.↗

NASA NTRS2011

A Radiation Hard Multi-Channel Digitizer ASIC for Operation in the Harsh Jovian Environment

In 1995, the Galileo spacecraft arrived at Jupiter to conduct follow-up experiments on pathfinder Pioneer and key Voyager discoveries especially at Io, Europa, Ganymede and Callisto. These new observations helped expand our scientific knowledge of the prominent Galilean satellites; studies revealed diversity with respect to their geology, internal structure, evolution and degree of past and present activity. Jupiter's diverse Galilean satellites, of which three are believed to harbor internal oceans, are central to understanding the habitability of icy worlds. Galileo provided for the first time compelling evidence of a near-surface global ocean on Europa. Furthermore, by understanding the Jupiter system and unraveling the history of its evolution from initial formation to the emergence of possible habitats and life, gives insight into how giant planets and their satellite systems form and evolve. Most important, new light is shed on the potential for the emergence and existence of life in icy satellite oceans. In 2009, NASA released a detailed Jupiter Europa Mission Study (EJSM) that proposed an ambitious Flagship Mission to understand more fully the satellites Europa and Ganymede within the context of the Jovian system. Key to EJSM is the NASA led Jupiter Europa Orbiter (JEO) and the ESA led Jupiter Ganymede Orbiter (JGO). JEO and JGO would execute a choreographed exploration of the Jovian system before settling into orbit around Europa and Ganymede, respectively. The National Academies Planetary Decadal Survey, 2011 has listed the NASA-led JEO as the second highest priority mission for the decade 2013-2022, and if chosen it would be launched in 2020 with arrival at Jupiter in 2025. If the JEO mission is not chosen it is anticipated that there will be opportunities in future decadal cycles. Jupiter Orbit Insertion (JOI) begins a 30-month Jovian system tour followed by nine months of science mapping after Europa Orbit Insertion (EOI) in July 2028. The orbiter will ultimately impact the surface of Europa after the mission is completed. The current JEO mission concept includes a range of instruments on the payload, to monitor dynamic phenomena (such as Io's volcanoes and Jupiters atmosphere), map the Jovian magnetosphere and its interactions with the Galilean satellites, and characterize water oceans beneath the ice shells of Europa and Ganymede. The payload includes a low mass (3.7 Kg) and low power (< 5 W) Thermal Instrument (TI) concept for measuring possible warm thermal anomalies on Europa s cold surface caused by recent (< 10,000 years) eruptive activity. Regions of anomalously high heat flow will be identified by thermal mapping using a nadir pointing, push-broom filter radiometer that provides far-IR imagery in two broad band spectral wavelength regions, 8-20 m and 20-100 m, for surface temperature measurements with better than a 2 K accuracy and a spatial resolution of 250 m/pixel obtained from a 100 Km orbit. The temperature accuracy permits a search for elevated temperatures when combined with albedo information. The spatial resolution is sufficient to resolve Europa's larger cracks and ridge axial valleys. In order to accomplish the thermal mapping, the TI uses sensitive thermopile arrays that are readout by a custom designed low-noise Multi-Channel Digitizer (MCD) ASIC that resides very close to the thermopile linear array outputs. Both the thermopile array and the MCD ASIC will need to show full functionality within the harsh Jovian radiation environment, operating at cryogenic temperatures, typically 150 K to 170 K. In the following, a radiation mitigation strategy together with a low risk Radiation-Hardened-By-Design (RHBD) methodology using commercial foundry processes is given for the design and manufacture of a MCD ASIC that will meet this challenge.

Aslam, Shahid↗

NASA NTRS2018

How Public Private Partnerships Enable NASA Future Space Communication Needs

The NASA Space Communications and Navigation (SCaN) Program is responsible for providing communication and navigation services to scientific and human space exploration missions. SCaN's current Space Network provides radio frequency (RF) relay services to near Earth space missions via Tracking and Data Relay Satellites (TDRS). SCaN plans to offer a new generation of relay services beginning in 2025, including the addition of optical communications capabilities and enhanced RF capabilities. The primary drivers behind the development of these next generation relay network services are to enhance communication and navigation services with significantly reduced development and operational costs. Several approaches being considered for implementation of these services are through government owned capabilities, through commercial service providers, or a combination of the two. One approach receiving a great deal of attention is the use of Public-Private Partnerships (PPP) to develop and provide capabilities or services. Utilizing Public-Private Partnerships allows NASA and commercial entities to share the investment, standards, and risks of developing and testing new or enhanced capabilities which can benefit both NASA and the commercial space communication industry. The capabilities developed under the PPP can then be used to support the growth of the commercial satellite communications industry while simultaneously being introduced into NASA operations to provide service to future NASA missions as part of the NASA Next Generation Architecture. Partnerships formed for this purpose can also serve as the basis for further NASA acquisition activities where government and industry can continue to share the cost, risk, and benefits of space communications capability development and operations. This objective is consistent with the 2010 National Space Policy stated principles: "The United States is committed to encouraging and facilitating the growth of a U.S. commercial space sector that supports U.S. needs, is globally competitive, and advances U.S. leadership in the generation of new markets and innovation-driven entrepreneurship." [1]NASA has conducted several internal studies as well as externally funded studies with industry to define the next generation space communication architecture. NASA has approached the commercial industry through a Request for Information (RFI) to define further the next generation architecture and has conducted numerous internal and external studies. The results are promising and are shaping the approach to utilize Public Private Partnership to achieve NASA's objectives while reducing costs. The commercial satellite industry has begun to deploy high performance, high throughput global satellite constellations which have the potential to provide communication services to NASA Missions. Commercial satellite manufacturers have advanced their processes to rapidly design, build, and deliver, reliable communication satellites using minimum government oversight. In this paper, we will 1) describe the NASA Next Generation Architecture, Concept of Operations (ConOps), and salient characteristics; 2) Discuss the rational of Public-Private Partnerships to achieve NASA’s next generation communication architecture; and 3) Summarize the preliminary analysis performed to date and describe the path forward.

Stegeman, James↗

NASA NTRSDate not supplied

Moderator Considerations for Space Nuclear Power and Propulsion Systems

Nuclear reactors have the potential to provide high energy density to enable sustainable surface power and advanced propulsion methods needed for human exploration activities at the moon and mars. Current mission planning is surveying different reactor types for space power and propulsion application. Of these reactor types, the use of a moderator within the reactor can enable reduced enrichment, reduce overall fuel loadings, and minimize the critical size of the reactor compared to unmoderated reference systems. This proceeding summarizes some moderator materials identified for space reactor applications: zirconium hydride, yttrium hydride, beryllium, and beryllium oxide, and the unique design considerations inherent to surface power and nuclear thermal propulsion reactor designs. It was found that there are four key considerations during the moderator selection and design process: nuclear properties, thermophysical & mechanical properties, manufacture & readiness, and environmental compatibility. Surface power reactors can benefit from moderators which minimize overall system mass and are capable of surviving high temperature irradiation environments for years with little degradation. Nuclear thermal propulsion reactors can benefit from moderators which are capable of retaining structural integrity under multiple burns while being exposed to a wide temperature range (40 < T < 500+ K). Moderator materials which exhibit good stability under irradiation and high temperature operation, minimize fuel pitch, and are high readiness are desirable for near term implementation.

nuclear thermal propulsion↗

NASA NTRSDate not supplied

An Approach to Critical Ablative TPS Capabilities Sustainment for Future NASA Missions

We plan to present an approach for NASA to maintain critical ablative TPS capabilities through small, sus-tained, smart and targeted investment. Historically, we have been pound foolish and penny wise for decades and paid very little attention to sustainability of abla-tive TPS and as a result, spent couple of decades in learning what we lost and inventing newer technology solutions. NASA’s ablative TPS history has been one of in-vesting in new and unique capabilities in anticipation of needs, and once flight proven, letting the capability atrophy due to lack of subsequent near-term mission needs [1]. When the need arises, NASA has resorted to two options: (1) revive the capability at considerable cost impact, or (2) develop an alternate capability with considerable schedule impact. Both these options have had considerable mission impact. The third alternate is to maintain proven capabilities in a cost effective manner. A risk informed decision process in terms of maintaining ablative TPS capabilities is feasible with planning and sustained support. Assured TPS availa-bility will allow the science community to propose competed missions with confidence and at a lower risk for selection. We submitted a white paper to the cur-rent Decadal Survey [2] on the need for and im-portance of sustainability. Since then, we have been formulating an executable cost effective strategy. The intent of this presentation is to outline the develop-ments since the submission of the white paper. NASA and DoD have had a working group related to critical technologies to periodically assess and make recommendations on at-risk items from a national need perspective. This inter-agency working group typically focuses on raw materials availability. While we agree that at-risk raw materials are important, fo-cus solely on them is not sufficient. Instead, we advo-cate for a broader focus that includes not only raw material but also industrial manufacturing and processing, and NASA expertise in design, testing and flight hardware certification. In this proposed presentation, we will give a brief overview of NASA’s ablative TPS history along with recent examples of atrophy to highlight case studies related to the PICA and Carbon-Phenolic TPS. We will present the rationale for sustaining PICA, HEEET and 3MDCP for future NASA missions. We will present an approach for how targeted small investments could lead to maintaining mission critical capabilities over long periods.

E Venkatapathy↗

NASA NTRSDate not supplied

Evaluation of Variable-Depth Liners with Slotted Cores

An initial evaluation of variable-depth, slotted-core liners fabricated with conventional, flightworthy com-ponents is presented. Liners with two distinct chamber lengths provide significant broadband absorption and their impedances are, to first order, predictable with the NASA impedance prediction code. These liners employ film caps embedded in alternating chambers to provide a near-rigid boundary condition. This enables improved control of the liner design process. A number of additively-manufactured, bent-chamber liners are also investigated to explore the e˙ects of the bend on the liner impedance. The liner impedance is negligibly a˙ected by changes to the partition width, but is significantly a˙ected by changes to the slot height. This o˙ers an option for achieving low-frequency sound absorption with relatively thin liners.

acoustic↗

NASA NTRSDate not supplied

Evaluation of Variable-Depth Liners with Slotted Cores

An initial evaluation of variable-depth, slotted-core liners fabricated with conventional, flightworthy components is presented. Liners with two distinct chamber lengths provide significant broadband absorption and their impedances are, to first order, predictable with the NASA impedance prediction code. These liners employ film caps embedded in alternating chambers to provide a near-rigid boundary condition. This enables improved control of the liner design process. A number of additively-manufactured, bent-chamber liners are also investigated to explore the effects of the bend on the liner impedance. The liner impedance is negligibly affected by changes to the partition width, but is significantly affected by changes to the slot height. This offers an option for achieving low-frequency sound absorption with relatively thin liners.

acoustic↗

DOE OSTI2024

Novel Hot Gas Components for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

Additive Manufacturing (AM), also known as 3D printing, has emerged as a manufacturing method that enables new design freedom for gas turbine engine manufacturers. However, the material selection for AM processable high-temperature super alloys is currently limited. Additionally, the heat transfer performance of AM enabled micro-cooling architectures is not yet well understood. Accordingly, in support of advanced manufacturing and engine performance development, Oak Ridge National Laboratory (ORNL)and Solar Turbines (Solar) conducted a multidisciplinary project to generate both AM super alloy material properties data and micro-channel performance data for two AM super alloys. The data supported the design and analysis of an internally cooled turbine hot section AM tip shoe component. This data was used to analytically predict the reduction in operating temperature of a gas turbine tip shoe. The work concluded that the cooling flow required to cool the tip shoe can be tuned to suit the efficiency improvements desired in an industrial gas turbine.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Printing thermoelectric inks toward next-generation energy and thermal devices

The ability of thermoelectric (TE) materials to convert thermal energy to electricity and vice versa highlights them as a promising candidate for sustainable energy applications. Despite considerable increases in the figure of merit zT of thermoelectric materials in the past two decades, there is still a prominent need to develop scalable synthesis and flexible manufacturing processes to convert high-efficiency materials into high-performance devices. Scalable printing techniques provide a versatile solution to not only fabricate both inorganic and organic TE materials with fine control over the compositions and microstructures, but also manufacture thermoelectric devices with optimized geometric and structural designs that lead to improved efficiency and system-level performances. In this review, we aim to provide a comprehensive framework of printing thermoelectric materials and devices by including recent breakthroughs and relevant discussions on TE materials chemistry, ink formulation, flexible or conformable device design, and processing strategies, with an emphasis on additive manufacturing techniques. Additionally, we review recent innovations in the flexible, conformal, and stretchable device architectures and highlight state-of-the-art applications of these TE devices in energy harvesting and thermal management. Perspectives of emerging research opportunities and future directions are also discussed. While this review centers on thermoelectrics, the fundamental ink chemistry and printing processes possess the potential for applications to a broad range of energy, thermal and electronic devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1992

A senior manufacturing laboratory for determining injection molding process capability

The following is a laboratory experiment designed to further understanding of materials science. This subject material is directed at an upper level undergraduate/graduate student in an Engineering or Engineering Technology program. It is assumed that the student has a thorough understanding of the process and quality control. The format of this laboratory does not follow that which is normally recommended because of the nature of process capability and that of the injection molding equipment and tooling. This laboratory is instead developed to be used as a point of departure for determining process capability for any process in either a quality control laboratory or a manufacturing environment where control charts, process capability, and experimental or product design are considered important topics.

Wickman, Jerry L.↗

DOE OSTI2022

Design of Production PIP-II SSR1 Cavities

The testing and manufacturing process of the PIP-II Single Spoke Resonators Type 1 (SSR1) prototype jacketed cavity presented opportunities for refinement of the production series. Experience from the prototype cavity and the design of other cavities at Fermilab were used. The mechanical design of the production jacketed cavity has been modified from the prototype design to allow for improvements in overall performance, structural behavior, and manufacturability of the weld joints.

43 PARTICLE ACCELERATORS↗

DOE OSTI2026

Microchannel-based Membrane-less Extraction of Li from Unconventional Lithium Sources & the Separation of REE

This final report provides an overview of the Project's entire duration, covering July 1, 2021 to December 31, 2023. It primarily focuses on the achievements, technological developments, and unique challenges the team faced while working on separating and extracting Lithium from produced waters. The project's primary aim was to create an integrated, high-throughput, membrane-less, and modular microfluidic platform that could extract Lithium from unconventional sources. We have successfully met all goals and milestones envisioned in the SOPO document. The most critical primary milestones, including the Go-No-Go milestone (refer to the Gantt chart in the Appendices), were successfully accomplished. We demonstrated phase separation (>90%) and extraction (>85%) performance in the MPSE using synthetic, and representative produced water composition feed at 50 ml/min total flow through MPSE 36. We have also performed a parametric study of the MPSE operations, beyond the scope of SOPO, exploring operating conditions of current and broader interest. The extended investigation of operational parameters is concurrent with our efforts to seek further development of the MPSE technology beyond the scope of the Project. Along these lines of development, we have made efforts to be responsive to DOE calls for technological developments of other types of resources (beyond PW) for the recovery of Critical Materials and higher TRL development (beyond TRL 4). During the work on this Project, we developed and implemented three innovative technical approaches that emerged from our efforts to successfully meet the Project milestones. The innovative & original technical approaches developed and implemented in this Project are now the contributions to process engineering that could be clearly credited to the Project. First, Convergent Design Approach is a comprehensive feedforward & feedback loop of four design phases: i) design for functionality, ii) design for manufacturing, iii) design for sustainability, and iv) design for market. Next was Process Intensification. A major aim of this Project was to create an innovative phase separation & extraction microscale-based technology for Li separation – thus the words microchannel-based in the Project title. A microscale-based technology is intrinsically in the center of the Process Intensification domain as defined by its unique principles. Therefore, Process Intensification was implicitly envisioned in the Project’s SOPO. Lastly, Time Scale Analysis is a novel tool for discovering the needs and directions of Process Intensification implementations in any process technology. This Project is fully credited for developing and implementing the three novel technical approaches mentioned above. These are general contributions to process engineering that emerged from this Project. Beyond the original SOPO scope, the OSU-U.Pitt research group utilized a Convergent Design methodology, integrating first-principles mathematical modeling with experimental validation on the Minimum Development Vehicle. By creating these Digital Twins, the team rapidly assessed manufacturing iterations to support TEA analysis. This framework further enabled the development of advanced Surface Modification Techniques, where hydrophobic and oleophobic coating strategies were optimized via Digital Twin tools and validated through rigorous 100-hour longevity testing. TEA Analysis: The closing efforts of this Project were focused on the TEA analysis. TEA analysis had two primary functions: i) enabling critical assessments of design variations withing 10 the Concurrent Design Approach, thus enabling evolution of the MPSE design to reach faster- better-cheaper alternatives; and ii) to create a bridge between the accomplishments of this Project and future projects of higher TRL, beyond TRL 6 level. It is important to note that the TEA model created in the Project stirred the technological solutions for the recovery of critical materials toward a vision of a very profitable modular plant that has unique zero-waste water discharge signature. More importantly, thanks to our experimental performance data and conservative assumptions, the TEA model predicts minimal technological and investment risks. Low cost of a modular unit of a nominal capacity of [1000 tons of Li 2 CO 3 /year] positions the MPSE based technology within the reach of community investors, thus offering a paradigm shift in the development of critical technologies. The project successfully navigated two primary challenges: solvent selection and manufacturing adaptation. Restricted by the SOPO to existing literature for lithium recovery, the team identified a critical need for a "material excellence program" to develop next-generation solvents, eventually concluding with a preliminary investigation into promising Ionic Liquids (ILs). Simultaneously, COVID-19 supply chain disruptions forced a pivot from traditional manufacturing to advanced additive methods at ATAMI-OSU. By transitioning from stainless steel to 3D-printed polymer substrates, the team achieved a transformative three-order-of- magnitude reduction in manufacturing costs and compressed prototyping timelines from several months to just two days. The MPSE technology offers significant energy, environmental, and economic advantages by overcoming the traditional bottlenecks of phase-separation hardware and contactor size. Unlike conventional mixer-settlers or membrane-based systems, MPSE operates without moving parts or fouling-prone membranes, achieving robust performance even with challenging, viscous, or particulate-heavy feeds. Key performance metrics include an energy intensity reduction of 5–50x (3–40 kJ/m 3 ) compared to incumbent technologies and a dramatic reduction of processing time to under 60 seconds, which drastically reduces the physical plant footprint. These technical efficiencies translate into superior economic outcomes; for a 100 t/year Li 2 CO 3 facility, implementing MPSE is projected to nearly halve contactor CAPEX (from $\$$6.08M to $\$$3.01M) and significantly increase the project's Net Present Value (NPV), derisking new investment and enabling distributed critical-mineral processing configurations. The commercialization of MPSE technology is being spearheaded by Vigsur Dynamics Inc., which has adopted a structured, parallel approach to technical and business development since its formation in January 2026. Following extensive customer discovery and engagement with the Oregon State University accelerator, Vigsur Dynamics is working to establish a business model that transitions from pilot demonstrations to modular hardware sales, ultimately aiming for a "build-own-operate" service strategy. Current technical milestones—including 100 hours of continuous operation, superior energy efficiency, and successful 6-unit modular scale-up— provide a foundation for this transition. Backed by ongoing IP licensing and a growing network of industrial and venture advisors, the company is actively de-risking the platform to replace conventional mixer-settler systems in the critical minerals market.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1972

Manufacture and quality control of interconnecting wire hardnesses, Volume 1

A standard is presented for manufacture, installation, and quality control of eight types of interconnecting wire harnesses. The processes, process controls, and inspection and test requirements reflected are based on acknowledgment of harness design requirements, acknowledgment of harness installation requirements, identification of the various parts, materials, etc., utilized in harness manufacture, and formulation of a typical manufacturing flow diagram for identification of each manufacturing and quality control process, operation, inspection, and test. The document covers interconnecting wire harnesses defined in the design standard, including type 1, enclosed in fluorocarbon elastomer convolute, tubing; type 2, enclosed in TFE convolute tubing lines with fiberglass braid; type 3, enclosed in TFE convolute tubing; and type 5, combination of types 3 and 4. Knowledge gained through experience on the Saturn 5 program coupled with recent advances in techniques, materials, and processes was incorporated.

Source record↗

NASA NTRSDate not supplied

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗

NASA NTRSDate not supplied

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

Additive Manufacturing↗

NASA NTRS2003

Capabilities of the Materials Contamination Team at Marshall Space Flight Center

The Materials Contamination Team of the Environmental Effects Group, Materials, Processes, and Manufacturing Department, has been recognized for its contribution to space flight, including space transportation, space science and flight projects, such as the reusable solid rocket motor, Chandra X-Ray Observatory, and the International Space Station. The Materials Contamination Team s realm of responsibility encompasses all phases of hardware development including design, manufacturing, assembly, test, transportation, launch-site processing, on-orbit exposure, return, and refurbishment if required. Contamination is a concern in the Space Shuttle with sensitivity bondlines and reactive fluid (liquid oxygen) compatibility as well as for sensitive optics, particularly spacecraft such as Hubble Space Telescope and Chandra X-Ray Observatory. The Materials Contamination Team has a variety of facilities and instrumentation capable of contaminant detection identification, and monitoring. The team addresses material applications dealing with environments, including production facilities, clean rooms, and on-orbit exposure. The team of engineers and technicians also develop and evaluates new surface cleanliness inspection technologies. Databases are maintained by the team for proces! materials as well as outgassing and optical compatibility test results for specific environments.

Burns, H. D.↗

DOE OSTI2025

Assessment of Microstructure Prediction Capabilities for Powder Bed Fusion Stainless Steel 316

The Advanced Materials and Manufacturing Technologies program aims to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. However, the characteristic process-structure-property relationships of additive manufacturing (AM) materials pose challenges for the qualification and certification of AM nuclear components. In particular, component-scale variations in microstructure and properties can be driven by localized changes in melt pool dynamics due to how process parameters interact with different part geometries. Computational modeling tools can play a crucial role in predicting and controlling this variability. This report presents final results on process modeling tools designed to predict microstructure variability in additively manufactured stainless steel 316 parts. It details the software packages and physical modeling approaches employed to simulate an AM component within an automated process modeling workflow. Results are demonstrated through comparisons between predicted microstructures and experimental measurements across various representative processing conditions. The report concludes by discussing identified challenges and future opportunities for connecting the developed simulation workflow with mechanics simulations for prediction of part performance.

36 MATERIALS SCIENCE↗

NASA NTRS2008

Metrology - Beyond the Calibration Lab

We rely on data from measurements every day; a gas-pump, a speedometer, and a supermarket weight scale are just three examples of measurements we use to make decisions. We generally accept the data from these measurements as "valid." One reason we can accept the data is the "legal metrology" requirements established and regulated by the government in matters of commerce. The measurement data used by NASA, other government agencies, and industry can be critical to decisions which affect everything from economic viability, to mission success, to the security of the nation. Measurement data can even affect life and death decisions. Metrology requirements must adequately provide for risks associated with these decisions. To do this, metrology must be integrated into all aspects of an industry including research, design, testing, and product acceptance. Metrology, the science of measurement, has traditionally focused on the calibration of instruments, and although instrument calibration is vital, it is only a part of the process that assures quality in measurement data. For example, measurements made in research can influence the fundamental premises that establish the design parameters, which then flow down to the manufacturing processes, and eventually impact the final product. Because a breakdown can occur anywhere within this cycle, measurement quality assurance has to be integrated into every part of the life-cycle process starting with the basic research and ending with the final product inspection process. The purpose of this paper is to discuss the role of metrology in the various phases of a product's life-cycle. For simplicity, the cycle will be divided in four broad phases, with discussions centering on metrology within NASA. .

Mimbs, Scott M.↗