Electron Beam Freeform Fabrication of Dissimilar Materials: Cracking in Inconel 625 on GRCop-84
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Additive manufacturing, electron beam, wire feed, ↗
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The Inhomogeneous Microstructure and Properties of Ti-6Al-4V Manufactured by NASA's Electron Beam Freeform Fabrication (EBF3)
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additive manufacturing, electron beam, titanium, m↗
Fabrication of freeform potassium dihydrogen phosphate crystals by belt-on-wheel polishing for spatially tailored polarization control in high-power lasers
Large-aperture (>30 cm) optical components that provide spatially tailored control of the properties of a laser beam, such as phase, polarization, and amplitude, have been the focus of much research and development in recent years. Such optics can improve energy throughput and target implosion efficiency in high-power laser systems conducting inertial confinement fusion research. Here, a method is demonstrated for fabricating freeform surface topographies into the birefringent crystalline material, potassium dihydrogen phosphate (KDP). Belt-on-wheel polishing with an oil-based fluid, developed to mitigate the deliquescent properties of KDP, is used to deterministically polish a freeform topography into KDP, enabling the fabrication of a wave plate with spatially arbitrary retardance. Testing of the laser-induced damage threshold of belt-on-wheel polished KDP was conducted at a wavelength of 351 nm and a pulse duration of 1 ns. The results revealed that the polished surfaces are highly resistant to laser-induced damage, making them suitable for large-aperture, high-power laser applications.
Urban, Nathaniel D. [Univ. of Rochester, NY (Unite↗
A Bootstrap Approach to Martian Manufacturing
In-Situ Resource Utilization (ISRU) is an essential element of any affordable strategy for a sustained human presence on Mars. Ideally, Martian habitats would be extremely massive to allow plenty of room to comfortably live and work, as well as to protect the occupants from the environment. Moreover, transportation and power generation systems would also require significant mass if affordable. For our approach to ISRU, we use the industrialization of the U.S. as a metaphor. The 19th century started with small blacksmith shops and ended with massive steel mills primarily accomplished by blacksmiths increasing their production capacity and product size to create larger shops, which produced small mills, which produced the large steel mills that industrialized the country. Most of the mass of a steel mill is comprised of steel in simple shapes, which are produced and repaired with few pieces of equipment also mostly made of steel in basic shapes. Due to this simplicity, we expect that the 19th century manufacturing growth can be repeated on Mars in the 21st century using robots as the primary labor force. We suggest a "bootstrap" approach to manufacturing on Mars that uses a "seed" manufacturing system that uses regolith to create major structural components and spare parts. The regolith would be melted, foamed, and sintered as needed to fabricate parts using casting and solid freeform fabrication techniques. Complex components, such as electronics, would be brought from Earth and integrated as needed. These parts would be assembled to create additional manufacturing systems, which can be both more capable and higher capacity. These subsequent manufacturing systems could refine vast amounts of raw materials to create large components, as well as assemble equipment, habitats, pressure vessels, cranes, pipelines, railways, trains, power generation stations, and other facilities needed to economically maintain a sustained human presence on Mars.
Dorais, Gregory A.↗
NASA Tech Briefs, July 2005
Thin-Film Resistance Heat-Flux Sensors Circuit Indicates that Voice-Recording Disks are Nearly Full Optical Sensing of Combustion Instabilities in Gas Turbines Topics include: Crane-Load Contact Sensor; Hexagonal and Pentagonal Fractal Multiband Antennas; Multifunctional Logic Gate Controlled by Temperature; Multifunctional Logic Gate Controlled by Supply Voltage; Power Divider for Waveforms Rich in Harmonics; SCB Quantum Computers Using iSWAP and 1-Qubit Rotations; CSAM Metrology Software Tool; Update on Rover Sequencing and Visualization Program; Selecting Data from a Star Catalog; Rotating Desk for Collaboration by Two Computer Programmers; Variable-Pressure Washer; Magnetically Attached Multifunction Maintenance Rover; Improvements in Fabrication of Sand/Binder Cores for Casting; Solid Freeform Fabrication of Composite-Material Objects; Efficient Computational Model of Hysteresis; Gauges for Highly Precise Metrology of a Compound Mirror; Improved Electrolytic Hydrogen Peroxide Generator; High-Power Fiber Lasers Using Photonic Band Gap Materials; Ontology-Driven Information Integration; Quantifying Traversability of Terrain for a Mobile Robot; More About Arc-Welding Process for Making Carbon Nanotubes; Controlling Laser Spot Size in Outer Space; or Software-Reconfigurable Processors for Spacecraft.
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Evaluation of an Al-Cu-Zn-Mg Alloy for Wire-Fed Additive Manufacturing
A collaborative research study was conducted to evaluate an experimental Al-Cu-Zn-Mg alloy, designated Al C380H, developed by Arconic Corporation for wire-fed additive manufacturing (AM) techniques such as NASA’s electron beam freeform fabrication (EBF 3 ) process and the wire arc additive manufacturing (WAAM) process. The goal of the study was to determine, based upon metallurgical properties, whether additively manufactured Al C380H represented a viable alternative for applications currently using wrought 7xxx series aluminum. Al 2319 and Al 7075 were also deposited as AM-compatible and non-AM-compatible baselines, respectively. Evaluation was based on tensile, fracture, and corrosion properties. The strength and ductility of Al C380H-T6 materials produced by EBF3 and WAAM were sufficiently lower than typical values for Al 7050-T7 to indicate that additively manufactured Al C380H is not a viable replacement for current parts fabricated with Al 7050, due largely to the significant losses in Zn and Mg and development of porosity during deposition. EBF 3 parameters that reduced porosity, such as increasing electron beam current, higher raster frequency, sharper beam focus, and slower travel speed, augmented de-alloying of fugitive solute. Further enhancement of Zn and Mg content in Al C380H feedstock wire combined with adjustments to deposition conditions to minimize porosity may enable production of Al C380H parts by EBF 3 or WAAM that are viable replacements for current Al 7050 wrought products.
electron beam freeform fabrication (EBF3)↗
Progress in Additively Manufactured Copper-Alloy GRCop-84, GRCop-42, and Bimetallic Combustion Chambers for Liquid Rocket Engines
Additive Manufacturing (AM) has significantly evolved over the last decade for use in the aerospace industry, particularly for liquid rocket engines. AM offers a considerable departure from traditional manufacturing to rapidly fabricate components with complex internal features. High performance liquid rocket engine combustion chambers that operate in a high heat flux environment are fabricated using a copper-alloy liner with a series of integral coolant channels. Copper-alloys provide the necessary conductivity and material strength for adequate design margins offering high performance without the need for film coolant. Copper-alloys present unique challenges to properly melt the powder in laser-based AM processes due to their high reflectivity and conductivity. Starting in 2014, NASA’s Marshall Space Flight Center (MSFC) and Glenn Research Center (GRC) have developed a process for AM of GRCop (Copper- Chrome-Niobium) alloys using Selective Laser Melting (SLM). GRCop, originally developed at GRC, is a high conductivity, high-strength, dispersion strengthened copper-alloy for use in high-temperature, high heat flux applications. NASA has completed significant material characterization and testing, along with hot-fire testing, to demonstrate that GRCop-42 and GRCop-84 alloys are suitable for use in combustion chambers. Additional development and testing has been completed on AM bimetallic chambers using GRCop-84 liners and superalloy jackets, fabricated using two Directed Energy Deposition (DED) processes: Electron Beam Freeform Fabrication (EBF³) and Blown Powder DED. NASA completed hot-fire testing on various AM chambers using GRCop-84, GRCop-42, and bimetallic chambers in Liquid Oxygen (LOX)/Hydrogen, LOX/Methane, and LOX/Kerosene propellants.
Gradl, Paul R.↗
Height Control and Deposition Measurement for the Electron Beam Free Form Fabrication (EBF3) Process
A method of controlling a height of an electron beam gun and wire feeder during an electron freeform fabrication process includes utilizing a camera to generate an image of the molten pool of material. The image generated by the camera is utilized to determine a measured height of the electron beam gun relative to the surface of the molten pool. The method further includes ensuring that the measured height is within the range of acceptable heights of the electron beam gun relative to the surface of the molten pool. The present invention also provides for measuring a height of a solid metal deposit formed upon cooling of a molten pool. The height of a single point can be measured, or a plurality of points can be measured to provide 2D or 3D surface height measurements.
Seufzer, William J.↗
Volumetric Additive Manufacturing of Dicyclopentadiene by Solid‐State Photopolymerization
Polymerization in the solid state is generally infeasible due to restrictions on mobility. However, in this work, the solid-state photopolymerization of crystalline dicyclopentadiene is demonstrated via photoinitiated ring-opening metathesis polymerization. The source of mobility in the solid state is attributed to the plastic crystal nature of dicyclopentadiene, which yields local short-range mobility due to orientational degrees of freedom. Polymerization in the solid state enables photopatterning, volumetric additive manufacturing of free-standing structures, and fabrication with embedded components. Solid-state photopolymerization of dicyclopentadiene offers a new paradigm for advanced and freeform fabrication of high-performance thermosets.
additive manufacturing↗
Laser gain media fabricated via direct ink writing (DIW) and ceramic processing
A transparent ceramic optic includes: a lasing region comprising at least one lasing species dopant; and a transparent region transparent to light generated by the lasing species. At least the transparent region is doped with at least one other dopant species such that the lasing region and the transparent region are characterized by a difference in refractive index between the two regions in an amount of about 1.0×10−4 or less. Inventive formulations of inks suitable for fabricating transparent ceramic optics having desirable compositional characteristics such as concentration gradients in desired spatial arrangements, e.g. using additive manufacturing techniques such as direct ink writing and/or extrusion freeform fabrication are also disclosed, along with suitable techniques for forming the transparent ceramic optics from such inks.
Payne, Stephen A.↗
Additively Manufactured Low Cost Upper Stage Combustion Chamber
Over the past two years NASA's Low Cost Upper Stage Propulsion (LCUSP) project has developed Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. High pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design fabrication to be costly and time consuming due to the number of individual steps and different processes required. Under LCUSP, AM technologies in Sintered Laser Melting (SLM) GRCop-84 and Electron Beam Freeform Fabrication (EBF3) Inconel 625 have been significantly advanced, allowing the team to successfully fabricate a 25k-class regenerative chamber. Estimates of the costs and schedule of future builds indicate cost reductions and significant schedule reductions will be enabled by this technology. Characterization of the microstructural and mechanical properties of the SLM-produced GRCop-84, EBF3 Inconel 625 and the interface layer between the two has been performed and indicates the properties will meet the design requirements. The LCUSP chamber is to be tested with a previously demonstrated SLM injector in order to advance the Technology Readiness Level (TRL) and demonstrate the capability of the application of these processes. NASA is advancing these technologies to reduce cost and schedule for future engine applications and commercial needs.
Protz, Christopher↗
High Tensile Strength Amalgams for In-Space Fabrication and Repair
Amalgams are well known for their use in dental practice as a tooth filling material. They have a number of useful attributes that include room temperature fabrication, corrosion resistance, dimensional stability, and very good compressive strength. These properties well serve dental needs but, unfortunately, amalgams have extremely poor tensile strength, a feature that severely limits other potential applications. Improved material properties (strength and temperature) of amalgams may have application to the freeform fabrication of repairs or parts that might be necessary during an extended space mission. Advantages would include, but are not limited to: the ability to produce complex parts, a minimum number of processing steps, minimum crew interaction, high yield - minimum wasted material, reduced gravity compatibility, minimum final finishing, safety, and minimum power consumption. The work presented here shows how the properties of amalgams can be improved by changing particle geometries in conjunction with novel engineering metals.
Grugel, Richard N.↗
High Tensile Strength Amalgams for In-Space Repair and Fabrication
Amalgams are defined as an alloy of mercury with one or more other metals. These, along with those based on gallium (also liquid at near room temperature), are widely used in dental practice as a tooth filling material. Amalgams have a number of useful attributes that indude room temperature compounding. corrosion resistance, dimensional stability, and good compressive strength. These properties well serve dental needs but, unfortunately, amalgams have extremely poor tensile strength, a feature that severely limits their applications. The work presented here demonstrates how, by modifying particle geometry, the tensile strength of amalgams can be increased and thus extending the range of potential applications. This is relevant to, for example, the freeform fabrication of replacement parts that might be necessary during an extended space mission. Advantages, i.e. Figures-of-Merit. include the ability to produce complex parts, minimum crew interaction, high yield - minimum wasted material, reduced gravity compatibility, minimum final finishing, safety, and minimum power consumption.
Grugel, R. N.↗
NASA Tech Briefs, April 2012
Topics include: Computational Ghost Imaging for Remote Sensing; Digital Architecture for a Trace Gas Sensor Platform; Dispersed Fringe Sensing Analysis - DFSA; Indium Tin Oxide Resistor-Based Nitric Oxide Microsensors; Gas Composition Sensing Using Carbon Nanotube Arrays; Sensor for Boundary Shear Stress in Fluid Flow; Model-Based Method for Sensor Validation; Qualification of Engineering Camera for Long-Duration Deep Space Missions; Remotely Powered Reconfigurable Receiver for Extreme Environment Sensing Platforms; Bump Bonding Using Metal-Coated Carbon Nanotubes; In Situ Mosaic Brightness Correction; Simplex GPS and InSAR Inversion Software; Virtual Machine Language 2.1; Multi-Scale Three-Dimensional Variational Data Assimilation System for Coastal Ocean Prediction; Pandora Operation and Analysis Software; Fabrication of a Cryogenic Bias Filter for Ultrasensitive Focal Plane; Processing of Nanosensors Using a Sacrificial Template Approach; High-Temperature Shape Memory Polymers; Modular Flooring System; Non-Toxic, Low-Freezing, Drop-In Replacement Heat Transfer Fluids; Materials That Enhance Efficiency and Radiation Resistance of Solar Cells; Low-Cost, Rugged High-Vacuum System; Static Gas-Charging Plug; Floating Oil-Spill Containment Device; Stemless Ball Valve; Improving Balance Function Using Low Levels of Electrical Stimulation of the Balance Organs; Oxygen-Methane Thruster; Lunar Navigation Determination System - LaNDS; Launch Method for Kites in Low-Wind or No-Wind Conditions; Supercritical CO2 Cleaning System for Planetary Protection and Contamination Control Applications; Design and Performance of a Wideband Radio Telescope; Finite Element Models for Electron Beam Freeform Fabrication Process Autonomous Information Unit for Fine-Grain Data Access Control and Information Protection in a Net-Centric System; Vehicle Detection for RCTA/ANS (Autonomous Navigation System); Image Mapping and Visual Attention on the Sensory Ego-Sphere; HyDE Framework for Stochastic and Hybrid Model-Based Diagnosis; and IMAGESEER - IMAGEs for Education and Research.
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Advanced Design and 3D Printing Strategies With Alginate‐Nanoclay Nanocomposites: From Microstructure to Bioprinting
Nanocomposites made from alginate and nanoclay are extensively applied for diverse biomedical applications. However, the lack of a clear understanding of the interactions between alginate and nanoclay makes it difficult to rationally design the nanocomposites for different material extrusion-based 3D bioprinting strategies. Here, a combined analytical model is proposed to accurately predict the interaction mechanisms between alginate and nanoclay through small-angle neutron scattering. These mechanisms are summarized into a phase diagram that can guide the design of alginate-nanoclay nanocomposites for different bioprinting applications. The rheological properties of various nanocomposites are measured to validate the proposed interaction mechanisms at the macroscale. Accordingly, three representative extrusion-based bioprinting strategies are linked with the nanocomposite design and applied to freeform fabricate complex structures. In conclusion, a roadmap is summarized to bridge the gap between biomaterial design and bioprinting processes, enabling the rapid and rational selection of biomaterial formula based on available 3D printing methods, and vice versa.
36 MATERIALS SCIENCE↗
Technology Assessment of Laser-Assisted Materials Processing in Space
Lasers are useful for performing operations such as joining, machining, built-up freeform fabrication, shock processing, and surface treatments. These attributes are attractive for the supportability of longer-term missions in space due to the multi-functionality of a single tool and the variety of materials that can be processed. However, current laser technology also has drawbacks for space-based applications, specifically size, power efficiency, lack of robustness, and problems processing highly reflective materials. A review of recent laser developments will be used to show how these issues may be reduced and indicate where further improvement is necessary to realize a laser-based materials processing capability in space. The broad utility of laser beams in synthesizing various classes of engineering materials will be illustrated using state-of-the art processing maps for select lightweight alloys typically found on spacecraft. With the advent of recent breakthroughs in diode-pumped solid-state lasers and fiber optic technologies, the potential to perform multiple processing techniques is increasing significantly. Lasers with suitable wavelengths and beam properties have tremendous potential for supporting future space missions to the moon, Mars and beyond.
Nagarathnam, Karthik↗
Laser Materials Processing for NASA's Aerospace Structural Materials
Lasers are useful for performing operations such as joining, machining, built-up freeform fabrication, and surface treatment. Due to the multifunctional nature of a single tool and the variety of materials that can be processed, these attributes are attractive in order to support long-term missions in space. However, current laser technology also has drawbacks for space-based applications. Specifically, size, power efficiency, lack of robustness, and problems processing highly reflective materials are all concerns. With the advent of recent breakthroughs in solidstate laser (e.g., diode-pumped lasers) and fiber optic technologies, the potential to perform multiple processing techniques in space has increased significantly. A review of the historical development of lasers from their infancy to the present will be used to show how these issues may be addressed. The review will also indicate where further development is necessary to realize a laser-based materials processing capability in space. The broad utility of laser beams in synthesizing various classes of engineering materials will be illustrated using state-of-the art processing maps for select lightweight alloys typically found on spacecraft. Both short- and long-term space missions will benefit from the development of a universal laser-based tool with low power consumption, improved process flexibility, compactness (e.g., miniaturization), robustness, and automation for maximum utility with a minimum of human interaction. The potential advantages of using lasers with suitable wavelength and beam properties for future space missions to the moon, Mars and beyond will be discussed. The laser processing experiments in the present report were performed using a diode pumped, pulsed/continuous wave Nd:YAG laser (50 W max average laser power), with a 1064 nm wavelength. The processed materials included Ti-6AI-4V, Al-2219 and Al-2090. For Phase I of this project, the laser process conditions were varied and optimized to see the effects on melt-quenching, cladding/alloying (using the pre-placed powder technique), and cutting. Key parameters such laser power, pulse repetition frequency, process speed, and shield gas flow and the observed process characteristics such as plasma formation during laser/material interaction, have been reported for all experimental runs. Preliminary materials characterization of select samples was carried out using various microscopy, diffraction, spectroscopy and microhardness test methods, and reported. Select nitridation results of Ti-6AI-4V using nitrogen assist gas indicated the successful formation of hard titanium nitrides with much higher hardness (2180 kg/sq mm). A cost-effective and simple powder delivery system has been successfully fabricated for the further experimentation in Phase H.
Nagarathnam, Karthik↗
Prototyping the Future
Advanced Ceramics Research (ACR) of Tucson, Arizona, researches transforming scientific concepts into technological achievement. Through the SBIR (Small Business Innovative Research) program, ACR developed a high pressure and temperature fused deposition system, a prototyping system that is known as extrusion freeform fabrication. This system is useful in manufacturing prosthetics. ACR also developed a three-dimensional rapid prototyping process in which physical models are quickly created directly from computer generated models. Marshall Space Flight Center also contracted ACR to fabricate a set of ceramic engines to be appraised for a solar thermal rocket engine test program.
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