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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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44 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Robotic Assisted Non-Destructive Testing (NDT)

Mission Statement: Concrete wall characterization for structural integrity evaluation of H-Canyon exhaust tunnel using a remote controlled robotic arm with a NDT Concrete Instrument. Challenges: Rough and Curved Surfaces, Remote location. The UR5 is a collaborative robotic arm capable of: Payload: 11 lbs (5 kg), Reach: 33.5 in (850 mm), Footprint: 5.87 in (149 mm) diameter, Weight: 45.4 Ibs (20.6 kg). The force torque sensor reacts to a set value inputted by the user that can be utilized for sensitive products. This allows the UR5 to react to surfaces using the built-in function to search for a wall and orient itself normal to that plane. The Proceq Pundit 250 array is a nondestructive device that the user applies against a concrete wall and scans using ultrasonic transducers. The back wall and other defects can be show through the touchscreen. A fixture to hold the Proceq Pundit 250 array onto the UR5 robotic arm was designed and 3D printed. It includes openings for easy access to the buttons from the Pundit array as well as a reinforced structural design. The scan from the Pundit array can show the back-wall, rebars, and other defects to assist in determining the structural integrity. In order to scan, a program was made to search for the wall first. 1. The UR5 robotic arm will go to the desired location away from the wall. 2. It will then search for the wall by moving towards it slowly. 3. After contact, the force applied will slowly but steadily increase to a preset value inputted by the user. 4. The force torque sensor will use those values and communicate with the UR5 by adjusting the arm to become normal to the wall. 5. The arm will then apply force to push back the transducers on the Pundit array to avoid gaps. 6. It will then prompt the user to collect data and wait until finished. The UR5 teach pendant allows the user to program the robot to perform automated and repeatable tasks. It includes a free drive mode which allows the user to move the arm to a desired position by hand. The user can also apply restricted planes which include either stopped or slower motion to ensure safety. The concrete sample being tested includes rebars and different grades of surface roughness to understand the readings from the Proceq Pundit 250 array. Desired concrete samples are currently being fabricated that will simulate the terrain being tested.

3D PRINTING↗
NASA NTRS2013

Faxing Structures to the Moon: Freeform Additive Construction System (FACS)

Using the highly articulated All-Terrain Hex-Limbed Extra-Terrestrial Explorer (ATHLETE) robotic mobility system as a precision positioning tool, a variety of print head technologies can be used to 3D print large-scale in-situ structures on planetary surfaces such as the moon or Mars. In effect, in the same way CAD models can be printed in a 3D printer, large-scale structures such as walls, vaults, domes, berms, paving, trench walls, and other insitu derived elements can be FAXed to the planetary surface and built in advance of the arrival of crews, supplementing equipment and materials brought from earth. This paper discusses the ATHLETE system as a mobility / positioning platform, and presents several options for large-scale additive print head technologies, including tunable microwave "sinterator" approaches and in-situ concrete deposition. The paper also discusses potential applications, such as sintered-in-place habitat shells, radiation shielding, road paving, modular bricks, and prefabricated construction components.

Apollo Lunar Module↗
DOE OSTI2021

3D printing of calcined clay-limestone-based cementitious materials

This paper aims to investigate the influences of high Portland cement substitutions (>60 wt%) by low-grade calcined clay (CC) and limestone (LF) on 3D concrete printability, stiffness evolution and early-age hydration. Results show that, with the same dosage of admixtures (superplasticizer and viscosity modifier), increasing LF and CC content reduced the slump, flowability and initial material flow rate, and significantly improved the buildability of fresh mixtures, which can be attributed to the reduced water film thickness (WFT). Furthermore, the stiffness evolution and SSA{sub total} development up to the first 3 h were accelerated by increasing CC content, which can also be linked to the change of WFT, and consumption of superplasticizer for the dispersion induced by hydration products. Additionally, the dilution effect on compressive strength and hydration caused by the high cement replacement was observed.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Zero Launch Mass Three Dimensional Print Head

NASA's strategic goal is to put humans on Mars in the 2030s. The NASA Human Spaceflight Architecture Team (HAT) and NASA Mars Design Reference Architecture (DRA) 5.0 has determined that in-situ resource utilization (ISRU) is an essential technology to accomplish this mission. Additive construction technology using in-situ materials from planetary surfaces will reduce launch mass, allow structures to be three dimensionally (3D) printed on demand, and will allow building designs to be transmitted digitally from Earth and printed in space. This will ultimately lead to elimination of reliance on structural materials launched from Earth (zero launch mass of construction consumables). The zero launch mass (ZLM) 3D print head project addressed this need by developing a system that 3D prints using a mixture of in-situ regolith and polymer as feedstock, determining the optimum mixture ratio and regolith particle size distribution, developing software to convert g-code into motion instructions for a FANUC robotic arm, printing test samples, performing materials testing, and printing a reduced scale habitable structure concept. This paper will focus on the ZLM 3D Print Head design, materials selection, software development, and lessons learned from operating the system in the NASA KSC Swamp Works Granular Mechanics & Regolith Operations (GMRO) Laboratory.

Regolith↗
DOE OSTI2023

Studies of time resolution, light yield, and crosstalk using SiPM-on-tile calorimetry for the future Electron-Ion Collider

We recently proposed a high-granularity calorimeter insert for the Electron-Ion Collider (EIC) that is based on plastic scintillator tiles readout with silicon photomultipliers. In this work, we concretize its design by characterizing its building blocks with measurements of light yield, optical crosstalk, and timing resolutions using cosmic-rays, an LED, and a beta source. We also compared two approaches for the optical isolation of cells: "megatiles" with grooved boundaries between cells, and a 3D-printed plastic frame hosting individual cells. Further, we found that the latter suppresses optical crosstalk to negligible levels while providing an easier assembly method. Overall, these performance studies can help inform calorimeter design and realistic simulations of 5D showers (time, energy, position) for the EIC and other experiments.

47 OTHER INSTRUMENTATION↗
NASA NTRS2017

Hypervelocity Impact Testing of Materials for Additive Construction: Applications on Earth, the Moon, and Mars

Additive Construction is the process of building infrastructure such as habitats, garages, roads, berms, etcetera layer by layer (3D printing). The National Aeronautics and Space Administration (NASA) and the United States Army Corps of Engineers (USACE) are pursuing additive construction to build structures using resources available in-situ. Using materials available in-situ reduces the cost of planetary missions and operations in theater. The NASA team is investigating multiple binders that can be produced on planetary surfaces, including the magnesium oxide-based Sorel cement; the components required to make Ordinary Portland Cement (OPC), the common cement used on Earth, have been found on Mars. The availability of OPC-based concrete on Earth drove the USACE to pursue additive construction for base housing and barriers for military operations. Planetary and military base structures must be capable of resisting micrometeoroid impacts with velocities ranging from 11 to 72km/s for particle sizes 200 micrometers or more (depending on protection requirements) as well as bullets and shrapnel with a velocity of 1.036km/s with projectiles 5.66mm diameter and 57.40mm in length, respectively.

Hypervelocity Impact↗
DOE OSTI2021

Rheological characterization of 3D printable geopolymers

This study demonstrates a two-step approach that enables quantification of concrete printability through dynamics mode rheological measurements; I) modeling shearing history during extrusion; II) monitoring the hardening evolution of deposited material by applying a strain smaller than the critical strain. It is shown that the shearing history of the material is removed by imposing a pre-shearing above the critical strain, and zero value yield stress is measured for all specimens. At step II, a linear extrapolation of the green strength development can quantify the static yield stress at the origin, which we used to quantify the material printability. As far as this yield stress surpasses the stress level that exists in the printed structure, the material retains its shape stability. We show the performance of the model on a series of geopolymer mortars with a wide range of rheological properties as a function of material composition, aging, and pre-shearing consequences.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Defect and satellite characteristics of additive manufacturing metal powders

Metal additive manufacturing (AM) requires high-quality metal powders to three-dimensionally (3D) print metallic components with complex and customizable geometries. The lack of quantification of AM metal powders creates quality control challenges for 3D printed components, increases the uncertainty of printing reliability and net cost of inspected and certified printed components, and reduces the recyclability of used powders. However, critical characteristics of AM metal powders that are decisive factors for the 3D printing process, such as internal porosity, contamination, and satellite feature, remain ambiguous. In this work, we developed a novel approach to 3D quantify key characteristics of AM metal powders down to individual particles by using high-resolution synchrotron x-ray computed tomography. Empowered by the penetrative capability of high-energy x-ray, internal porosity and contamination within as-atomized metal powders from high-entropy alloys to nickel-based superalloys were evaluated. Additionally, the newly-developed dispersion method enables the homogeneous separation of individual particles, and consequently, results in the implementation of 3D particle shape analysis. To resolve a major challenge of identification and quantification of satellite-feature particles in as-atomized AM metal powders, the satellite features were quantitated by modeling and analyzing the shape parameter of local thickness variance. Furthermore, the 3D analytical methods of particle assessment in this study can be applied to other materials systems like rock, food, and pharmaceutical particles, and provide insights for process optimization across powder metallurgy, concrete, food and pharmaceutical manufacturing, and AM industries.

36 MATERIALS SCIENCE↗