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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Fabrication of UN-Mo CERMET Nuclear Fuel Using Advanced Manufacturing Techniques

Ceramic-metallic nuclear fuels are a candidate fuel for nuclear thermal propulsion systems due to their high heat transport properties, which are necessary in very high-temperature environments. The conventional fabrication of uranium nitride–molybdenum fuel has been thoroughly studied in the past, but modern manufacturing techniques have presented a unique opportunity for further development within this field. This work demonstrates the use of advanced manufacturing techniques to produce nuclear fuel pellets composed of uranium nitride microspheres encased in a molybdenum matrix. Binder jetting is used to print molybdenum disks that are filled with uranium nitride microspheres and afterward sintered using spark plasma sintering. Two fuel pellets were fabricated to demonstrate the methodology and to provide a baseline analysis of the effects of temperature and pressure processing conditions. Characterization of the sintered fuel pellets includes detailed microstructural analysis and thermal conductivity measurements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Fabrication and testing of a newly designed slit system for depth-resolved X-ray diffraction measurements

A new system of slits called `spiderweb slits' have been developed for depth-resolved powder or polycrystalline X-ray diffraction measurements. The slits act on diffracted X-rays to select a particular gauge volume of sample, while absorbing diffracted X-rays from outside of this volume. Although the slit geometry is to some extent similar to that of previously developed conical slits or spiral slits, this new design has advantages over the previous ones in use for complex heterogeneous materials and in situ and operando diffraction measurements. For example, the slits can measure a majority of any diffraction cone for any polycrystalline material, over a continuous range of diffraction angles, and work for X-ray energies of tens to hundreds of kiloelectronvolts. The design is generated and optimized using ray-tracing simulations, and fabricated through laser micromachining. The first prototype was successfully tested at the X17A beamline at the National Synchrotron Light Source, and shows similar performance to simulations, demonstrating gauge volume selection for standard powders, for all diffraction peaks over angles of 2–10°. A similar, but improved, design will be implemented at the X-ray Powder Diffraction beamline at the National Synchrotron Light Source II.

depth-resolved↗
DOE OSTI2017

Field Quality and Fabrication Analysis of HQ02 Reconstructed Nb3Sn Coil Cross Sections

© 2017 IEEE. The U.S. LHC Accelerator Research Program (LARP) quadrupole HQ02 was designed and fully tested as part of the low-beta quad development for Hi-Lumi LHC. HQ02's design is well documented with full fabrication accounting along with full field analysis at low and high current. With this history, HQ02 is an excellent test bed for developing a methodology for measuring turn locations from magnet cross sections and comparing with CAD models and measured field. All four coils of HQ02 were cut in identical locations along the magnetic length corresponding to magnetic field measurement and coil metrology. A real-time camera and coordinate measuring equipment was used to plot turn corners. Measurements include systematic and random displacements of winding blocks and individual turns along the magnetic length. The range of cable shifts and the field harmonic range along the length are in agreement, although correlating turn locations and measured harmonics in each cross section is challenging.

Holik, Eddie Frank↗
DOE OSTI2023

Advanced Fuel Cycle Cost Basis Report: Module D1-4 and Module D1-5 Ceramic Pelletized Sodium-Cooled Fast Reactor (SFR) Fuel Fabrication Ceramic Vibrocompacted Fuel Fabrication

This is a cost module that is part of the Advanced Fuel Cycle -- Cost Basis Report. Module D1-4: Nature of this module update (Rev 1) from previous advanced fuel cycle cost basis reports (AFCCBRs): new life cycle cost data on U,Pu SFR mixed oxide (MOX) fuels is derived from the Nonproliferation Assessment Systems Analysis Program (NASAP) conducted in the late 1970s. Highassay low-enriched uranium (HALEU) ceramic fuel is also discussed in more detail compared to earlier AFC-CBRs, since some advanced SFR concepts currently under development will require this HALEU fuel type for startup. Module D1-5: Nature of this FY-21 module update from previous AFC-CBRs: this module includes a few new references and a somewhat expanded discussion of vibrocompaction fuel fabrication technology. The WIT values for VIPAC are pegged directly to those for conventional LWR and SFR pelletized U,Pu MOX (note that this module now includes VIPAC MOX fuel for LWRs in addition to SFRs). Based on information from Russia, where VIPAC has been studied extensively, the unit costs are expressed as a percentage of those in the new updated Module D1-2 (pelletized U,Pu MOX) and new updated Module D1-4 (pelletized U,Pu MOX) for large NOAK fabrication facilities of the same production capacity. Since both ceramic pelletized MOX Modules D1-2 and D1-4 benefitted from analysis of 1970s NASAP data, by extension this Module D1-5 also benefits.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Formation mechanisms of boron oxide films fabricated by large-area electron beam-induced deposition of trimethyl borate [Formation Mechanisms of Boron Oxide Fillms Fabricated by Large Area Electron Beam-Induced Deposition of Trimethyl Borate]

Boron-containing materials are increasingly drawing interest for the use in electronics, optics, laser targets, neutron absorbers, and high-temperature and chemically resistant ceramics. In this article, the first investigation into the deposition of boron-based material via electron beam-induced deposition (EBID) is reported. Thin films were deposited using a novel, large-area EBID system that is shown to deposit material at rates comparable to conventional techniques such as laser-induced chemical vapor deposition. The deposition rate and stoichiometry of boron oxide fabricated by EBID using trimethyl borate (TMB) as precursor is found to be critically dependent on the substrate temperature. By comparing the deposition mechanisms of TMB to the conventional, alkoxide-based precursor tetraethyl orthosilicate it is revealed that ligand chemistry does not precisely predict the pathways leading to deposition of material via EBID. Lastly, the results demonstrate the first boron-containing material deposited by the EBID process and the potential for EBID as a scalable fabrication technique that could have a transformative effect on the athermal deposition of materials.

36 MATERIALS SCIENCE↗
NASA NTRS1995

Fabrication of the Advanced X-ray Astrophysics Facility (AXAF) Optics: A Deterministic, Precision Engineering Approach to Optical Fabrication

The mirror assembly of the AXAF observatory consists of four concentric, confocal, Wolter type 1 telescopes. Each telescope includes two conical grazing incidence mirrors, a paraboloid followed by a hyperboloid. Fabrication of these state-or-the-art optics is now complete, with predicted performance that surpasses the goals of the program. The fabrication of these optics, whose size and requirements exceed those of any previous x-ray mirrors, presented a challenging task requiring the use of precision engineering in many different forms. Virtually all of the equipment used for this effort required precision engineering. Accurate metrology required deterministic support of the mirrors in order to model the gravity distortions which will not be present on orbit. The primary axial instrument, known as the Precision Metrology Station (PMS), was a unique scanning Fizeau interferometer. After metrology was complete, the optics were placed in specially designed Glass Support Fixtures (GSF's) for installation on the Automated Cylindrical Grinder/Polishers (ACG/P's). The GSF's were custom molded for each mirror element to match the shape of the outer surface to minimize distortions of the inner surface. The final performance of the telescope is expected to far exceed the original goals and expectations of the program.

Gordon, T. E.↗
NASA NTRS2002

Hoop Tensile Characterization Of SiC/SiC Cylinders Fabricated From 2D Fabric

Tensile stress-strain properties in the hoop direction were obtained for 100-mm diameter SiC/SiC cylinders using ring specimens machined from the cylinder ends. The cylinders were fabricated from 2D balanced fabric with several material variants, including wall thickness (6, 8, and 12 plies), Sic fiber type (Sylramic, Sylramic-iBN, Hi-Nicalon, and Hi-Nicalon S), fiber sizing type, and matrix type (full CVI Sic, and partial CVI plus melt-infiltrated SiC-Si). Fiber ply splices existed in the all the hoops. Tensile hoop measurements were made at room temperature and 1200 C using hydrostatic ring test facilities. The hoop results are compared with in-plane data measured on flat panels using same material variants, but containing no splices.

Verrilli, Michael J.↗
NASA NTRS2008

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗
NASA NTRS2009

Tensile Properties and Microstructure of Inconel 718 Fabricated with Electron Beam Freeform Fabrication (EBF(sup 3))

Electron beam freeform fabrication (EBF3) direct metal deposition processing was used to fabricate two Inconel 718 single-bead-width wall builds and one multiple-bead-width block build. Specimens were machined to evaluate microstructure and room temperature tensile properties. The tensile strength and yield strength of the as-deposited material from the wall and block builds were greater than those for conventional Inconel 718 castings but were less than those for conventional cold-rolled sheet. Ductility levels for the EBF3 material were similar to those for conventionally-processed sheet and castings. An unexpected result was that the modulus of the EBF3-deposited Inconel 718 was significantly lower than that of the conventional material. This low modulus may be associated with a preferred crystallographic orientation resultant from the deposition and rapid solidification process. A heat treatment with a high solution treatment temperature resulted in a recrystallized microstructure and an increased modulus. However, the modulus was not increased to the level that is expected for Inconel 718.

Bird, R. Keith↗
NASA NTRS2010

Effect of Orientation on Tensile Properties of Inconel 718 Block Fabricated with Electron Beam Freeform Fabrication (EBF3)

Electron beam freeform fabrication (EBF3) direct metal deposition processing was used to fabricate an Inconel 718 bulk block deposit. Room temperature tensile properties were measured as a function of orientation and location within the block build. This study is a follow-on activity to previous work on Inconel 718 EBF3 deposits that were too narrow to allow properties to be measured in more than one orientation

Bird, R. Keith↗
DOE OSTI2018

USHPRR FUEL FABRICATION PILLAR: FABRICATION STATUS, PROCESS OPTIMIZATIONS, AND FUTURE PLANS

The Fuel Fabrication (FF) Pillar, a project within the U.S. High Performance Research Reactor Conversion program of the National Nuclear Security Administration’s Office of Material Management and Minimization, is tasked with the scale-up and commercialization of high-density monolithic U-Mo fuel for the conversion of appropriate research reactors to use of low-enriched fuel. The FF Pillar has made significant steps to demonstrate and optimize the baseline co-rolling process using commercial-scale equipment at both the Y-12 National Security Complex (Y-12) and BWX Technologies (BWXT). These demonstrations include the fabrication of the next irradiation experiment, Mini-Plate 1 (MP-1), and casting optimizations at Y-12. The FF Pillar uses a detailed process flow diagram to identify potential gaps in processing knowledge or demonstration, which helps direct the strategic research agenda of the FF Pillar. This paper describes the significant progress made toward understanding the fuel characteristics, and models developed to make informed decisions, increase process yield, and decrease lifecycle waste and costs.

Wight, Jared M.↗
DOE OSTI2025

Friction-based recycling: an evaluation of friction extrusion for fabricating Ti-6Al-4 V wire fabricated from machining chip feedstock

Abstract Titanium and its alloys are used in aviation and automobile industries due to their remarkable strength to weight ratio, but machining loss commonly is high with ~ 80 wt% of the material being converted to scrap. Recycling post-consumer Ti scrap directly into solid bulk products is a potential solution for repurposing valuable material. Further, eliminating fresh Ti sponge during recycling might lead to lower energy and greenhouse gas emissions. In this study, a solid-phase process known as friction extrusion was utilized to recycle Ti-6Al-4 V machining chips into solid wires which could be used as feedstock in additive manufacturing. The friction consolidation technique was first used to convert chips with varying degrees of oxygen content into solid billets for its use as feedstock material in subsequent friction extrusion. The extrudates were fabricated above the beta transition temperature, which was achieved by selecting the rotation rate and feed rate, to process the billets near 1000 °C using a tungsten-lanthana extrusion die. This work presents the first occurrence of friction extruded titanium alloy wires. The effect of friction extrusion on microstructural features, tensile properties, and texture are reported. Overall, the friction extrusion method is capable of directly recycling Ti-6Al-4 V scrap into extruded wire.

Friction Extrusion↗
DOE OSTI2017

Fabrication of oxide dispersion strengthened bond coats with low Al 2 O 3 content [Fabrication of ODS bond coats with low Al 2 O 3 content]

Here, nanoscale oxide dispersions have long been used to increase the oxidation and wear resistance of alloys used as bond coatings in thermal barrier coatings. Their manufacturing via mechanical alloying is often accompanied by difficulties regarding their particle size, homogeneous distribution of the oxide dispersions inside the powder, involving considerable costs, due to cold welding of the powder during milling. A significant improvement in this process can be achieved by the use of process control agent (PCA) to achieve the critical balance between cold welding and fracturing, thereby enhancing the process efficiency. In this investigation, the influence of the organic additive stearic acid on the manufacturing process of Al 2 O 3 -doped CoNiCrAlY powder was investigated. Powders were fabricated via mechanical alloying at different milling times and PCA concentrations. The results showed a decrease in particle size, without hindering the homogeneous incorporation of the oxide dispersions. Two powders manufactured with 0.5 and 1.0 wt.% PCA were deposited by high velocity oxygen fuel (HVOF) spraying. Results showed that a higher content of elongated particles in the powder with the higher PCA content led to increased surface roughness, porosity and decreased coating thickness, with areas without embedded oxide particles.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fabrication of highly dense isotropic Nd-Fe-B nylon bonded magnets via extrusion-based additive manufacturing [Fabrication of highly dense isotropic Nd-Fe-B bonded magnets via extrusion-based additive manufacturing]

Magnetically isotropic bonded magnets with a high loading fraction of 70 vol.% Nd-Fe-B are fabricated via an extrusion-based additive manufacturing, or 3D printing system that enables rapid production of large parts. The density of the printed magnet is ~5.2 g/cm 3 . The room temperature magnetic properties are: intrinsic coercivity H ci = 8.9 kOe (708.2 kA/m), remanence B r = 5.8 kG (0.58 T), and energy product (BH)max = 7.3 MGOe (58.1 kJ/m 3 ). The as-printed magnets are then coated with two types of polymers, both of which improve the thermal stability as revealed by flux aging loss measurements. Tensile tests performed at 25 °C and 100 °C show that the ultimate tensile stress (UTS) increases with increasing loading fraction of the magnet powder, and decreases with increasing temperature. AC magnetic susceptibility and resistivity measurements show that the 3D printed Nd-Fe-B bonded magnets exhibit extremely low eddy current loss and high resistivity. Lastly, we demonstrate the performance of the 3D printed magnets in a DC motor configuration via back electromotive force measurements.

36 MATERIALS SCIENCE↗