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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Zero to Integration in Eight Months, the Dawn Ground Data System Engineering Challenge

The Dawn Project has presented the Ground Data System (GDS) with technical challenges driven by cost and schedule constraints commonly associated with National Aeronautics and Space Administration (NASA) Discovery Projects. The Dawn mission consists of a new and exciting Deep Space partnership among: the Jet Propulsion Laboratory (JPL), manages the project and is responsible for flight operation; Orbital Sciences Corporation (OSC), is the spacecraft builder and is responsible for flight system test and integration; and the University of California, at Los Angeles (UCLA), is responsible for science planning and operations. As a cost-capped mission, one of Dawn's implementation strategies is to leverage from both flight and ground heritage. OSC's ground data system is used for flight system test and integration as part of the flight heritage strategy. Mission operations, however, are to be conducted with JPL's ground system. The system engineering challenge of dealing with two heterogeneous ground systems emerged immediately. During the first technical interchange meeting between the JPL's GDS Team and OSC's Flight Software Team, August 2003, the need to integrate the ground system with the flight software was brought to the table. This need was driven by the project's commitment to enable instrument engineering model integration in a spacecraft simulator environment, for both demonstration and risk mitigation purposes, by April 2004. This paper will describe the system engineering approach that was undertaken by JPL's GDS Team in order to meet the technical challenge within a non-negotiable eight-month schedule. Key to the success was adherence to fundamental systems engineering practices: decomposition of the project request into manageable requirements; integration of multiple ground disciplines and experts into a focused team effort; definition of a structured yet flexible development process; definition of an in-process risk reduction plan; and aggregation of the intermediate products to an integrated final product. In addition, this paper will highlight the role of lessons learned from the integration experience. The lessons learned from an early GDS deployment have served as the foundation for the design and implementation of the Dawn Ground Data System.

Ground Data System (GDS)↗
NASA NTRS2002

A geostatistical analysis of small-scale spatial variability in bacterial abundance and community structure in salt marsh creek bank sediments

Small-scale variations in bacterial abundance and community structure were examined in salt marsh sediments from Virginia's eastern shore. Samples were collected at 5 cm intervals (horizontally) along a 50 cm elevation gradient, over a 215 cm horizontal transect. For each sample, bacterial abundance was determined using acridine orange direct counts and community structure was analyzed using randomly amplified polymorphic DNA fingerprinting of whole-community DNA extracts. A geostatistical analysis was used to determine the degree of spatial autocorrelation among the samples, for each variable and each direction (horizontal and vertical). The proportion of variance in bacterial abundance that could be accounted for by the spatial model was quite high (vertical: 60%, horizontal: 73%); significant autocorrelation was found among samples separated by 25 cm in the vertical direction and up to 115 cm horizontally. In contrast, most of the variability in community structure was not accounted for by simply considering the spatial separation of samples (vertical: 11%, horizontal: 22%), and must reflect variability from other parameters (e.g., variation at other spatial scales, experimental error, or environmental heterogeneity). Microbial community patch size based upon overall similarity in community structure varied between 17 cm (vertical) and 35 cm (horizontal). Overall, variability due to horizontal position (distance from the creek bank) was much smaller than that due to vertical position (elevation) for both community properties assayed. This suggests that processes more correlated with elevation (e.g., drainage and redox potential) vary at a smaller scale (therefore producing smaller patch sizes) than processes controlled by distance from the creek bank. c2002 Federation of European Microbiological Societies. Published by Elsevier Science B.V. All rights reserved.

Non-NASA Center↗
NASA NTRSDate not supplied

Tradeoffs When Considering Deep Reinforcement Learning for Contingency Management in Advanced Air Mobility

Air transportation is undergoing a rapid evolution globally with the introduction of Advanced Air Mobility (AAM) and with it comes novel challenges and opportunities for transforming aviation. As AAM operations introduce increasing heterogeneity in vehicle capabilities and density, increased levels of automation are likely necessary to achieve operational safety and efficiency goals. This paper focuses on one example where increased automation has been suggested. Autonomous operations will need contingency management systems that can monitor evolving risk across a span of interrelated (or interdependent) hazards and, if necessary, execute appropriate control interventions via supervised or automated decision making. Accommodating this complex environment may require automated functions (autonomy) that apply artificial intelligence (AI) techniques that can adapt and respond to a quickly changing environment. This paper explores the use of Deep Reinforcement Learning (DRL) which has shown promising performance in complex and high-dimensional environments where the objective can be constructed as a sequential decision-making problem. An extension of a prior formulation of the contingency management problem as a Markov Decision Process (MDP) is presented and uses a DRL framework to train agents that mitigate hazards present in the simulation environment. A comparison of these learning-based agents and classical techniques is presented in terms of their performance, verification difficulties, and development process.

machine learningautonomous systems; flight simulat↗
NASA NTRSDate not supplied

Tradeoffs When Considering Deep Reinforcement Learning for Contingency Management in Advanced Air Mobility

Air transportation is undergoing a rapid evolution globally with the introduction of Advanced Air Mobility (AAM) and with it comes novel challenges and opportunities for transforming aviation. As AAM operations introduce increasing heterogeneity in vehicle capabilities and density, increased levels of automation are likely necessary to achieve operational safety and efficiency goals. This paper focuses on one example where increased automation has been suggested. Autonomous operations will need contingency management systems that can monitor evolving risk across a span of interrelated (or interdependent) hazards and, if necessary, execute appropriate control interventions via supervised or automated decision making. Accommodating this complex environment may require automated functions (autonomy) that apply artificial intelligence (AI) techniques that can adapt and respond to a quickly changing environment. This paper explores the use of Deep Reinforcement Learning (DRL) which has shown promising performance in complex and high-dimensional environments where the objective can be constructed as a sequential decision-making problem. An extension of a prior formulation of the contingency management problem as a Markov Decision Process (MDP) is presented and uses a DRL framework to train agents that mitigate hazards present in the simulation environment. A comparison of these learning-based agents and classical techniques is presented in terms of their performance, verification difficulties, and development process.

machine learning↗
DOE OSTI2025

A distinct subpopulation of membrane vesicles in Pseudomonas putida is enriched in enzymes for lignin catabolism

Bacterial membrane vesicles (MVs) mediate diverse microbial processes and are emerging as powerful biomedical tools, but MV population heterogeneity remains an open question. Here, we separate, enumerate, and characterize two MV populations from the soil bacterium Pseudomonas putida during growth with or without lignin-derived carbon, a major carbon source from plant cells in the rhizosphere. Small MVs (MV-S, diameter ~100 nm) were produced from all cultures, whereas large MVs (MV-L, diameter ~300 nm) were observed during the late stationary phase of lignin cultivations. MV-S contained selectively packaged proteins with diverse physiological functions, whereas the MV-L proteome was smaller and largely enriched in outer membrane proteins. Interestingly, enzymes known to mediate the catabolism of lignin-derived aromatic compounds were enriched in MV-S. Overall, this study highlights the need for careful consideration of MV populations in microbial systems.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS1983

Isotopic composition of carbonaceous-chondrite kerogen Evidence for an interstellar origin of organic matter in meteorites

Stepwise combustion has revealed systematic patterns of isotopic heterogeneity for C, H and N in the insoluble organic fraction (m-kerogen) from the Orgueil and Murray carbonaceous chondrites. Those patterns are essentially identical for both meteorites, indicating a common source of m-kerogen. The data cannot be reconciled with a single mass-fractionation process acting upon a single precursor composition. This indicates either a multi-path history of mass-dependent processing or a significant nucleogenetic contribution, or both. If mass-fractionation were the dominant process, the magnitude of the observed isotopic variability strongly suggests that ion-molecule reactions at very low temperatures, probably in interstellar clouds, were responsible. In any case, an interstellar, rather than solar nebular, origin for at least some of the meteoritic organic matter is indicated. This has interesting implications for the origin of prebiotic molecules, temperatures in the early solar system, and the isotopic compositions of volatiles accreted by the terrestrial planets.

Kerridge, J. F.↗
NASA NTRS2021

Chemical Reactivity of In-Situ Lunar Dust for Biotoxicity Assessment

How does the chemical reactivity of in-situ lunar dust compare to Apollo samples currently stored in curation facilities here on Earth? Essential investigations of this question will help us to further mitigate exploration risks for future human explorers on the Moon and will also provide critical information for astrobiologists and space biologists using the Moon for scientific inquiry. Apollo 14 dust biotoxicity studies, carried out by the NASA Lunar Airborne Dust Toxicity Assessment Group (LADTAG), included numerous cellular and animal experiments. Intratracheal instillation and inhalation studies in rats both showed Apollo 14 dust to be intermediate in toxicity compared to low-tox titanium dusts and high-tox quartz dusts of similar particle sizes. The collective results were used in models to establish a safe exposure limit for astronauts. Although LADTAG took extensive steps to preserve what chemical reactivity may still have existed in the samples, it is simply unknown if they possessed true in-situ chemical reactivity or if that reactivity has decayed. Initial gas loss on collection and other alterations, and even intermittent exposure to Earth-normal conditions during subsequent decades of handling, obscure a forensic reconstruction of the initial state. Because a mineral dust’s chemical reactivity influences its biotoxicity, researchers have developed methods to “activate” lunar dust and simulants. Past studies that modeled impact processes and radiation in the lunar environment suggest that in-situ lunar dust is likely to be more chemically reactive than Earth-exposed samples. Because of these results, in-situ measurements are warranted. Since the lunar surface is heterogeneous, dust biotoxicity is expected to vary from site to site due to particle size, mineralogy, physical characteristics, degree of space weathering, and chemical reactivity. This circumstance dictates dust assessments at a suite of lunar sites enabled by CLPS opportunities. Dose, location, and duration of particle exposure will also affect biological responses. In-situ chemical reactivity measurements can inform cross-cutting collaborative research campaigns such as astrobiology studies examining regolith interactions with organisms and its ability to preserve chemical and structural biomarkers, as well as space biology investigations that examine regolith-microbe interactions relating to life support systems, plant growth, biomining, and development of regolith biocomposites.

Jon C Rask↗
DOE OSTI2024

A Review of Coupled Geochemical–Geomechanical Impacts in Subsurface CO 2 , H 2 , and Air Storage Systems

Increased demand for decarbonization and renewable energy has led to increasing interest in engineered subsurface storage systems for large-scale carbon reduction and energy storage. In these applications, a working fluid (CO 2 , H 2 , air, etc.) is injected into a deep formation for permanent sequestration or seasonal energy storage. The heterogeneous nature of the porous formation and the fluid–rock interactions introduce complexity and uncertainty in the fate of the injected component and host formations in these applications. Interactions between the working gas, native brine, and formation mineralogy must be adequately assessed to evaluate the efficiency, risk, and viability of a particular storage site and operational regime. This study reviews the current state of knowledge about coupled geochemical–geomechanical impacts in geologic carbon sequestration (GCS), underground hydrogen storage (UHS), and compressed air energy storage (CAES) systems involving the injection of CO 2 , H 2 , and air. Specific review topics include (1) existing injection induced geochemical reactions in these systems; (2) the impact of these reactions on the porosity and permeability of host formation; (3) the impact of these reactions on the mechanical properties of host formation; and (4) the investigation of geochemical-geomechanical process in pilot scale GCS. This study helps to facilitate an understanding of the potential geochemical–geomechanical risks involved in different subsurface energy storage systems and highlights future research needs.

08 HYDROGEN↗
DOE OSTI2025

Application of a temporal multiscale method for efficient simulation of degradation in PEM Water Electrolysis under dynamic operating conditions

Hydrogen is emerging as a vital energy carrier, driven by the need to reduce carbon emissions. Proton Electrolyte Membrane Water Electrolysis (PEMWE) enables hydrogen production under fluctuating renewable power conditions but requires improved understanding and stability of the anode catalyst layer under dynamic operating conditions, especially with low noble metal loadings. Long-term degradation experiments are both time-consuming and costly; therefore, a systematic, model-aided approach is essential. In the present work, a temporal multiscale method is applied to reduce the computational effort of simulating long-term degradation processes in PEMWE, with an exemplary focus on catalyst dissolution. A mechanistic model incorporating the oxygen evolution reaction, catalyst dissolution, and hydrogen permeation from the cathode to the anode was hypothesized and implemented. In this way, the local periodicity of transport and reaction processes in dynamic PEMWE operation, which influence the gradual degradation of the catalyst layer, is captured. The temporal multiscale method significantly reduces the computational effort of simulation, decreasing processing time from hours to mere minutes. This efficiency gain is attributed to the limited evolution of Slow-Scale variables during each period of time P of the Fast-Scale variables. Consequently, simulation is required only until local periodicity is achieved within each Slow-Scale time step. Hence, the fully resolved dynamic problem is decoupled into these two scales, employing a heterogeneous multiscale technique. The developed approach effectively accelerates parameter estimation and predictive simulations, supporting systematic modeling of PEMWE degradation under dynamic conditions.

08 HYDROGEN↗
DOE OSTI2026

iDDS: intelligent distributed dispatch and scheduling for workflow orchestration

The intelligent distributed dispatch and scheduling (iDDS) service is a versatile workflow orchestration system designed for large-scale, distributed scientific computing. iDDS extends traditional workload and data management by integrating data-aware execution, conditional logic, and programmable workflows, enabling automation of complex and dynamic processing pipelines. Originally developed for the ATLAS experiment at the large hadron collider, iDDS has evolved into an experiment-agnostic platform that supports both template-driven workflows and a Function-as-a-Task model for Python-based orchestration. This paper presents the architecture and core components of iDDS, highlighting its scalability, modular message-driven design, and integration with systems such as PanDA and Rucio. We demonstrate its versatility through real-world use cases: fine-grained tape resource optimization for ATLAS, orchestration of large Directed Acyclic Graph (DAG) workflows for the Rubin Observatory, distributed hyperparameter optimization for machine learning applications, active learning for physics analyses, and AI-assisted detector design at the electron–ion collider. By unifying workload scheduling, data movement, and adaptive decision-making, iDDS reduces operational overhead and enables reproducible, high-throughput workflows across heterogeneous infrastructures. We conclude with current challenges and future directions, including interactive, cloud-native, and serverless workflow support.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2015

A Principled Approach to the Specification of System Architectures for Space Missions

Modern space systems are increasing in complexity and scale at an unprecedented pace. Consequently, innovative methods, processes, and tools are needed to cope with the increasing complexity of architecting these systems. A key systems challenge in practice is the ability to scale processes, methods, and tools used to architect complex space systems. Traditionally, the process for specifying space system architectures has largely relied on capturing the system architecture in informal descriptions that are often embedded within loosely coupled design documents and domain expertise. Such informal descriptions often lead to misunderstandings between design teams, ambiguous specifications, difficulty in maintaining consistency as the architecture evolves throughout the system development life cycle, and costly design iterations. Therefore, traditional methods are becoming increasingly inefficient to cope with ever-increasing system complexity. We apply the principles of component-based design and platform-based design to the development of the system architecture for a practical space system to demonstrate feasibility of our approach using SysML. Our results show that we are able to apply a systematic design method to manage system complexity, thus enabling effective data management, semantic coherence and traceability across different levels of abstraction in the design chain. Just as important, our approach enables interoperability among heterogeneous tools in a concurrent engineering model based design environment.

platform-based design↗
DOE OSTI2025

Ion Traps and Packaging for Heterogenous Integration - Chimera

Microfabricated surface ion traps and silicon-based photonics are critical technologies for scaling quantum systems. Current ion trap architectures face scalability and integration challenges due to limitations in optical access, fabrication techniques, and material compatibility. State-of-the-art quantum computers and atomic clocks are investigating monolithic integration, which necessitates custom traps for each ion species and has not overcome the integration hurdles presented by merging these technologies. The Chimera (Ion Traps and Packaging for Heterogeneous Integration) project proposes a novel approach utilizing heterogeneous integration (HI) of ion traps and photonic circuits. This separation of components allows for flexibility in ion trap design and reduces fabrication compromises. The Chimera project specifically designed an ion trap to interface vertically with a separately fabricated waveguide chip and demonstrates the first steps to integrating them at the packaging level. The ion trap features a large area of removed silicon, allowing the photonics chip outputs closer to the ion trap, improving alignment and packaging processes. The alignment must be accurate to < 1 µm to ensure that the light from the waveguide can overlap with the trapping region. This fine alignment must also be maintained through an ultra-high vacuum bake, a critical step in preparing an ion trap experiment. By combining separate chips, we demonstrate a new path for scaling trapped ion technology that is less reliant on monolithic integration. We successfully fabricated a trap with a large area of oxide removed, resulting in a region thinned to about 40 µm, a key milestone toward successful integration.

42 ENGINEERING↗
DOE OSTI2025

The variety and origin of materials accreted by Bennu’s parent asteroid

The first bodies to form in the Solar System acquired their materials from stars, the presolar molecular cloud and the protoplanetary disk. Asteroids that have not undergone planetary differentiation retain evidence of these primary accreted materials. However, geologic processes such as hydrothermal alteration can dramatically change their bulk mineralogy, isotopic compositions and chemistry. Here we analyse the elemental and isotopic compositions of samples from asteroid Bennu to uncover the sources and types of material accreted by its parent body. We show that some primary accreted materials escaped the extensive aqueous alteration that occurred on the parent asteroid, including presolar grains from ancient stars, organic matter from the outer Solar System or molecular cloud, refractory solids that formed close to the Sun, and dust enriched in neutron-rich Ti isotopes. We find Bennu to be richer in isotopically anomalous organic matter, anhydrous silicates, and light isotopes of K and Zn than its closest compositional counterparts, asteroid Ryugu and Ivuna-type (CI) carbonaceous chondrite meteorites. We propose that the parent bodies of Bennu, Ryugu and CI chondrites formed from a common but spatially and/or temporally heterogeneous reservoir of materials in the outer protoplanetary disk.

Kuiper belt↗
NASA NTRS2000

Controlling Microbial Byproducts using Model-Based Substrate Monitoring and Control Strategies

We have developed a computer-controlled bioreactor system to study various aspects of microbially-mediated nitrogen cycling. The system has been used to investigate methods for controlling microbial denitrification (the dissimilatory reduction of nitrate to N2O and N2) in hydroponic plant growth chambers. Such chambers are key elements of advanced life support systems being designed for use on long duration space missions, but nitrogen use efficiency in them is reduced by denitrification. Control software architecture was designed which permits the heterogeneous control of system hardware using traditional feedback control, and quantitative and qualitative models of various system features. Model-based feed forward control entails prediction of future systems in states and automated regulation of system parameters to achieve desired and avoid undesirable system states. A bacterial growth rate model based on the classic Monod model of saturation kinetics was used to evaluate the response of several individual denitrifying species to varying environmental conditions. The system and models are now being applied to mixed microbial communities harvested from the root zone of a hydroponic growth chamber. The use of a modified Monod organism interaction model was evaluated as a means of achieving more accurate description of the dynamic behavior of the communities. A minimum variance parameter estimation routine was also' used to calibrate the constant parameters in the model by iterative evaluation of substrate (nitrate) uptake and growth kinetics. This representation of processes and interactions aids in the formulation of control laws. The feed forward control strategy being developed will increase system autonomy, reduce crew intervention and limit the accumulation of undesirable waste products (NOx).

Smernoff, David T.↗
NASA NTRS2026

Molecular Inventory and Comparative Organic Profiling of A Homogenized Aggregate Sample From Asteroid (101955) Bennu

Evaluating the distribution and diversity of solvent-soluble organic molecules in extraterrestrial materials provide information about the physicochemical environments where prebiotic chemistry occurred and is essential for assessing the inventory of prebiotic compounds available to the early Earth. In this work, we conducted a comprehensive molecular characterization of solvent-soluble organic compounds in a homogenized aggregate sample (ID: OREX-800107-128) of unsorted regolith from asteroid (101955) Bennu returned by NASA’s OSIRIS-REx mission. Using two-dimensional gas chromatography coupled with high-resolution time-of-flight mass spectrometry (GC×GC-HRMS), we identified 87 organic compounds across several molecular classes, including alkanes, polycyclic aromatic hydrocarbons, and nitrogen-, oxygen-, and sulfur-bearing species. Comparison with the organic inventory of CI (Orgueil), C2-ungrouped (Tagish Lake and Tarda), and CM2 (Murchison) carbonaceous chondrites revealed that Bennu sample OREX-800107-128 is most similar to Tagish Lake and Tarda yet compositionally distinct from all of these meteorites. This Bennu sample exhibits a relatively high abundance of low-molecular-weight aromatics (e.g., toluene), pyridine derivatives, and sulfur species such as dimethyl sulfite, consistent with episodic low-temperature aqueous alteration. The presence of these organic compounds suggests that this material experienced chemically diverse processes in the parent body conducive to complex organic synthesis, including aldol condensation reactions responsible for N- and O-bearing compounds. We also compared the molecular distributions of this Bennu sample and previously analyzed samples from (162173) Ryugu to assess potential common origins between these two carbonaceous asteroids. Bennu shows more chemically diverse and nitrogen-rich organic materials than Ryugu. While both asteroids share broadly similar primitive compositions, the observed chemical differences indicate distinct evolutionary histories within a likely common formation environment though whether Bennu and Ryugu derive from a single compositionally heterogeneous parent body or from multiple closely related progenitors remains unresolved. Further detailed comparative analyses of material from Bennu, Ryugu, and specific carbonaceous meteorites (e.g., Tagish Lake and Tarda) will provide new insights into how the N-rich molecular profile observed in Bennu samples was formed and evolved in the outer Solar System.

sample return↗
DOE OSTI2025

Accelerated and heterogeneous corrosion of Cr-doped uranium nitride fuel pellets

The steam oxidation of Cr-doped UN fuel pellets is analyzed during sequential isothermal holds up to 720 °C. In situ neutron diffraction results show how Cr is accommodated in a secondary U 2 CrN 3 phase, leading to the formation of a duplex UN/U 2 CrN 3 microstructure. Under corrosion, the oxidation of the two phases begins at 400 °C for UN and 430 °C for U 2 CrN 3 , respectively. Because the UN phase is preferentially oxidized in the presence of U 2 CrN 3 , addition of Cr in UN based nuclear fuel is found to accelerate the corrosion rate. At 430 °C the oxidation of UN in the UN/U 2 CrN 3 microstructure is ~ 5 times faster than pure UN, increasing to ~19 times faster at 460 °C. The oxidation of U 2 CrN 3 produces UO 2 via the formation of two transient intermediate phases. In situ neutron diffraction enables oxidation processes of UN and U 2 CrN 3 components to be followed separately within the two-phase system.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1991

Development of a portable multispectral thermal infrared camera

The purpose of this research and development effort was to design and build a prototype instrument designated the 'Thermal Infrared Multispectral Camera' (TIRC). The Phase 2 effort was a continuation of the Phase 1 feasibility study and preliminary design for such an instrument. The completed instrument designated AA465 has application in the field of geologic remote sensing and exploration. The AA465 Thermal Infrared Camera (TIRC) System is a field-portable multispectral thermal infrared camera operating over the 8.0 - 13.0 micron wavelength range. Its primary function is to acquire two-dimensional thermal infrared images of user-selected scenes. Thermal infrared energy emitted by the scene is collected, dispersed into ten 0.5 micron wide channels, and then measured and recorded by the AA465 System. This multispectral information is presented in real time on a color display to be used by the operator to identify spectral and spatial variations in the scenes emissivity and/or irradiance. This fundamental instrument capability has a wide variety of commercial and research applications. While ideally suited for two-man operation in the field, the AA465 System can be transported and operated effectively by a single user. Functionally, the instrument operates as if it were a single exposure camera. System measurement sensitivity requirements dictate relatively long (several minutes) instrument exposure times. As such, the instrument is not suited for recording time-variant information. The AA465 was fabricated, assembled, tested, and documented during this Phase 2 work period. The detailed design and fabrication of the instrument was performed during the period of June 1989 to July 1990. The software development effort and instrument integration/test extended from July 1990 to February 1991. Software development included an operator interface/menu structure, instrument internal control functions, DSP image processing code, and a display algorithm coding program. The instrument was delivered to NASA in March 1991. Potential commercial and research uses for this instrument are in its primary application as a field geologists exploration tool. Other applications have been suggested but not investigated in depth. These are measurements of process control in commercial materials processing and quality control functions which require information on surface heterogeneity.

Osterwisch, Frederick G.↗
DOE OSTI2025

Characterization of Build Parameters and Microstructure in Low Heat Input WAAM of Ni-Based Superalloy Haynes 282

Ni-based superalloy Haynes® 282® is being targeted for various applications in advanced power generation systems for its superior fabricability, weldability, and excellent high temperature creep and corrosion performance. This process optimization study aims to use a low heat-input, high deposition rate, controlled Gas Metal Arc Welding (GMAW) process, Cold Metal Transfer (CMT) by Fronius, attempting to achieve fully dense fabrication and possibly avoid the need for HIP. Twenty-one multilayer blocks (~25x100x40 mm3) were deposited to explore a large set of build parameters variations that focused on varying the travel speed from 14 to 42 inches per minute (ipm) and wire feed speed from 150 to 450 ipm. A strong correlation has been observed between arc energy – controlled primarily by travel and wire feed speed. Initial visual inspection, internal microstructural examination, and computed tomography (CT) have been used to determine the effects of built parameters on evolution of internal porosity and defects. Scanning electron microscopy techniques enabled structural and compositional imaging of heterogeneity and changes in microstructural properties.

additive manufacturing↗