Search NASA⌕ Search

SEARCH · Search NASA

Results for “Metallization process”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Magnesium production by molten salt electrolysis with liquid tin cathode and multiple effect distillation

Low-cost clean primary production of magnesium metal is important for its use in many applications, from light-weight structural components to energy technologies. This work describes new experiments and cost and emissions analysis for a magnesium metal production process. The process combines molten salt electrolysis of MgO using MgF₂-CaF₂ electrolyte and a reactive liquid tin cathode, with gravity-driven multiple effect thermal system (G-METS) distillation to separate out the magnesium product, and re-use of the tin. Electrolysis experiments with carbon anodes showed current yield above 90%, while a yttria-stabilized zirconia solid oxide membrane (SOM) anode experiment showed 84% current yield. G-METS distillation is an important component of the envisioned process. It can potentially lower costs and energy use considerably compared with conventional magnesium distillation. Techno-economic analysis including detailed mass and energy balances shows that this electrolyte composition could lower costs by utilizing CaO, which is the primary impurity in MgO, as the Hall-Héroult process uses the sodium impurity in alumina. Analysis options include: raw material types (magnesite rock vs. brine or seawater), drying and calcining using electricity vs. natural gas, and carbon vs. SOM anode type. Using SOM inert anodes results in a cost premium around 10%–15%, mostly due to higher electrical energy usage resulting from membrane resistance, and reduces GHG emissions by approximately 1 kg CO₂/kg Mg product. Capital and operating cost estimates, and cradle to gate greenhouse gas (GHG) emissions analysis under several raw material and process technology scenarios, show comparable costs and emissions to those of aluminum production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Neutron Imaging of Al6061 Prepared by Solid-State Friction Stir Additive Manufacturing

Solid-state Friction Stir Additive Manufacturing has recently gained attention as a result of its capacity to fabricate large-scale parts while preserving the mechanical properties of the feedstock material. However, the correlation between the quality of layer-by-layer bonding of the deposited metal and processing parameters has remained unknown. Neutron imaging techniques, with 90% total transmission per cm, are employed for Al6061 parts fabricated by MELD ® Technology as a non-destructive evaluation approach for the first time to investigate the layer-by-layer structure of a stadium-shaped ingot in different sections. The post-processed results show the fabricated parts with an optimized set of processing parameters are void-free. However, the hydrocarbon-based feedstock lubricant segregates between the layers, which consequently may lead to non-uniform weaker mechanical properties along the build direction and stimulate crack initiation during mechanical loading. The tensile test results show 14% lower strain-to-failure values in alleged contaminated areas in transmission imaging results. Additionally, layer bonding is significantly impacted by hot-on-hot and hot-on-cold layer deposition schemes, especially for larger layer thicknesses.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Raptor

Raptor is an efficient Python-based tool for predicting the formation and morphology of stochastic lack of fusion defects in metal AM processes. A major obstacle for the qualification and certification of additively manufactured parts in critical applications continues to be performance variability caused in part by porosity-related defects. High-fidelity process models that could predict these defect features are currently too computationally expensive for component-level analysis. To address this, Raptor employs a high-performance geometric method to model the dynamic melt pool rather than relying on computationally intensive thermal fluid dynamics. This allows Raptor to rapidly identify regions of unmelted material that correspond to lack of fusion pores. The efficiency of this approach significantly reduces the time and resources needed for generating 3D defect predictions, which enables users to conduct large-scale parameter studies and evaluate how process variations affect part quality. The framework offers operational flexibility; users can execute simulations through a simple command line interface or integrate core functions as a library within larger computational workflows. Simulation outputs include 3D porosity maps for visualization and tools for quantitative morphological analysis. These results are suitable for direct comparison with experimental characterization data from methods such as X-ray computed tomography and can be used for statistical process optimization.

Subraveti, Vamsi [Vanderbilt Univ., Nashville, TN ↗
NASA NTRS1973

Thermal static bending of deployable interlocked booms

Metal ribbons processed with a heat-forming treatment are enabled to form tubelike structures when deployed from a roll. Deployable booms of this have been utilized for gravity-gradient stabilization on the RAE, ATS, and Nimbus D satellites. An experimental thermal-mechanics test apparatus was developed to measure the thermal static bending and twist of booms up to 3 meters long. The apparatus was calibrated by using the correlation between calculated and observed thermal bending of a seamless tube. Thermal static bending values of 16 interlocked deployable booms were observed to be within a factor of 2.5 of the values calculated from seamless-tube theory. Out-of-Sun-plane thermal bending was caused by complex heat transfer across the interlocked seam. Significant thermal static twisting was not observed.

Staugaitis, C. L.↗
NASA NTRS1974

Rotational bursting of interplanetary dust particles

Solar radiation pressure is discussed as a cause of rotational bursting, and of eventual elimination of asymmetric dust particles from the solar system, by a windmill effect. The predicted life span with this process for metallic particles with radii of 0.00001 to 0.01 cm ranges from 10 to 10,000 years. The effects of magnetic spin damping were considered. This depletion mechanism works faster than the traditional Poynting-Robertson effect by approximately one order of magnitude for metallic particles and about two orders of magnitude for nonmetallic particles.

Paddack, S. J.↗
NASA NTRS1975

Heavy element affinities in Apollo 17 samples

Pb-204, Bi, Tl, and Zn in samples from the Apollo 17 site exhibit relationships not found in samples from other sites. Pb-204, Tl, and Zn in residues remaining after dilute acid leaching are correlated with one another. Orange soil 74220, which is enriched in Pb-204, Tl, and Zn, is included in these relationships. In addition, the submicron metallic phase generally associated with agglutinate formation is correlated with all three of these elements; this relationship has already been reported for Pb-204 in other samples. Thus, orange soil and agglutinates appear to be involved in concentrating heavy volatile metals. A process other than mixing is required to account for this. As a consequence of the isolation of the landing site by the surrounding massifs, local supply and recycling of volatile trace elements in soils may account for some of the interelement relations.

Allen, R. O., Jr.↗
NASA NTRS1975

Rotational bursting of interplanetary dust particles

Solar radiation pressure can cause rotational bursting and eventual elimination from the solar system of asymmetric dust particles by a windmill effect. The life span against this process for metallic particles with radii of 0.00001-0.01 cm ranges from 10 to 10,000 years. The effects of magnetic spin damping have been considered in this estimate. This depletion mechanism works faster than the traditional Poynting-Robertson effect by approximately one order of magnitude for metallic particles and about two-orders of magnitude for nonmetallic particles.

Paddack, S. J.↗
NASA NTRS1976

Polymer adhesives for hybrid circuits

Report discusses number of tests used in comparing polymer adhesives with metal bonding processes and includes charts and photographs to illustrate test results. Findings suggest reduced quality control costs when epoxies are used in fabrication of microcircuits.

Caruso, S. V.↗
NASA NTRS1977

Attaching strain gages by ultrasonic plastic welding

Technique employs application of pressure and ultrasound to effect welding of encapsulated strain gates to metallic surfaces. Process requires no heat or adhesives. Technique might also be used to simplify curing of epoxy adhesives and for attachment problems like bonding cryogenic temperature sensors to structural parts.

Sheppard, A. T.↗
NASA NTRS1977

Homogeneous eutectic of Pb-Sb

Dendrite free eutectic mixture of Pb-Sb is expected to be superelastic material that can be used in formation of shaped charge liners for industrial explosive metal-forming processes and other applications.

Winter, J. M., Jr.↗
NASA NTRS1977

The interaction of bubbles with solidification interfaces

The behavior of bubbles at a dendritic solidification interface was studied during the coasting phase of a sounding rocket flight. Sequential photographs of the gradient freeze experiment showed nucleation, growth and coalescence of bubbles at the moving interface during both the low-gravity and one-gravity tests. In the one-gravity test the bubbles were observed to detach from the interface and float to the top of the melt. However, in the low-gravity tests no bubble detachment from the interface or steady state bubble motion occurred and large voids were grown into the crystal. These observations are discussed in terms of the current theory of thermal migration of bubbles and in terms of their implications on the space processing of metals.

Papazian, J. M.↗
NASA NTRS1977

Preliminary Solar Sail Design and Fabrication Assessment: Spinning Sail Blade, Square Sail Sheet

Blade design aspects most affecting producibility and means of measurement and control of length, scallop, fullness and straightness requirements and tolerances were extensively considered. Alternate designs of the panel seams and edge reinforcing members are believed to offer advantages of seam integrity, producibility, reliability, cost and weight. Approaches to and requirements for highly specialized metalizing methods, processes and equipment were studied and identified. Alternate methods of sail blade fabrication and related special machinery, tooling, fixtures and trade offs were examined. A preferred and recommended approach is also described. Quality control plans, inspection procedures, flow charts and special test equipment associated with the preferred manufacturing method were analyzed and are discussed.

Daniels, J. B.↗
NASA NTRS1980

Double metalization for VLSI

Postsintering process increases yield of double-layer metal conductors to almost 100 percent. When wafers containing double-metalized chips are sintered, metal layers react with oxide film remaining in insulation layer holes, breaking it up so that it no longer impedes electric current. Cooling also mechanically disrupts oxide film.

Trotter, J. D.↗
NASA NTRS1980

Theory of positronium formation and positron emission at metal surfaces

The range of metallic surface processes available to the implanted positron is examined with a view to bare positron escape, positron surface state trapping, surface state detrapping, and positronium atom conversion. The stopping distance and its rms deviation are calculated. The effect of the elastic positron-ion core scattering, and the finite temperature corrections in the positron-phonon scattering are included. Overall conversion and emission efficiencies are calculated by solving an appropriate diffusion equation with boundary conditions set by the branching ratios for the surface processes. The temperature and incident energy dependence of the results for positronium atom conversion and positron emission efficiency are compared to experimental data.

Nieminen, R. M.↗
NASA NTRS1982

Analysis of solidification interface shape resulting from applied sinusoidal heating

Maintaining a flat solidification interface is important for forming desired crystal structures in certain types of metal casting processes. This has application in new manufacturing techniques for naturally strengthened composite components such as turbine blades. The solidification interface shape will adjust to be compatible with the spatial distribution of energy being transferred to it. The interface shape must be found that satisfies conditions of simultaneously being at the fusion temperature and having an imposed spatially varying heat flux. Specific results are obtained for the heat transfer from the liquid phase varying along the interface in a cosine fashion. Interface shapes are found as a function of the amplitude and wavelength of the imposed heat transfer variations, and the sensitivity of the interface shape to these variations is examined.

Siegel, R.↗
NASA NTRS1980

Extraterrestrial materials processing and construction

Three different chemical processing schemes were identified for separating lunar soils into the major oxides and elements. Feedstock production for space industry; an HF acid leach process; electrorefining processes for lunar free metal and metal derived from chemical processing of lunar soils; production and use of silanes and spectrally selective materials; glass, ceramics, and electrochemistry workshops; and an econometric model of bootstrapping space industry are discussed.

Criswell, D. R.↗