Additive Manufacturing at NASA/MSFC. Hybrid Manufacturing of Bi-Metallic Liquid Rocket Engine Igniter
No abstract available
Burlingame, Steven↗
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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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Additive Manufacturing @ NASA: A Summary of NASA's Efforts in the Development of Additively Manufactured Metallic Hardware
No abstract available
Wells, Douglas↗
1st International Conference on Advanced Manufacturing: NASA’s Advanced Composites Materials and Manufacturing Research for the Future
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composites↗
Advanced Manufacturing for Propulsion Systems: Additive Manufacturing, Optical Measurement, and Composites
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Paul Gradl↗
Sustainable Manufacturing of Aircraft (SUMAC): Exploring A Paradigm-Shift in Materials, Manufacturing Processes, Testing & Health Monitoring Focused on Sustainability
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Sustainability↗
NASA Game Changing Development Program Manufacturing Innovation Project
This presentation examines the new NASA Manufacturing Innovation Project. The project is a part of the Game Changing Development Program which is one element of the Space Technology Programs Managed by Office of the Chief Technologist. The project includes innovative technologies in model-based manufacturing, digital additive manufacturing, and other next generation manufacturing tools. The project is also coupled with the larger federal initiatives in this area including the National Digital Engineering and Manufacturing Initiative and the Advanced Manufacturing Partnership. In addition to NASA, other interagency partners include the Department of Defense, Department of Commerce, NIST, Department of Energy, and the National Science Foundation. The development of game-changing manufacturing technologies are critical for NASA s mission of exploration, strengthening America s manufacturing competitiveness, and are highly related to current challenges in defense manufacturing activities. There is strong consensus across industry, academia, and government that the future competitiveness of U.S. industry will be determined, in large part, by a technologically advanced manufacturing sector. This presentation highlights the prospectus of next generation manufacturing technologies to the challenges faced NASA and by the Department of Defense. The project focuses on maturing innovative/high payoff model-based manufacturing technologies that may lead to entirely new approaches for a broad array of future NASA missions and solutions to significant national needs. Digital manufacturing and computer-integrated manufacturing "virtually" guarantee advantages in quality, speed, and cost and offer many long-term benefits across the entire product lifecycle. This paper addresses key enablers and emerging strategies in areas such as: Current government initiatives, Model-based manufacturing, and Additive manufacturing.
Tolbert, Carol↗
Additive Component Manufacturing
State-of-the-art technology like additive manufacturing has not yet been thoroughly applied to fluid control valves. Many valve manufacturing issues such as flow passage machining, deep hole boring, and bi-metallic joining could successfully be addressed with this new technology. The goal of this project was to apply additive manufacturing technology specifically to the problems that fluid control valves present. In order to properly apply additive manufacturing processes to the design of control valves, the plan was to manufacture samples using metals compatible with low temperature, high pressure oxygen service and then tested. While vetting this project with manufacturers, it was determined that the materials chosen were not ideal for additive manufacturing due to their high reflectivity. Therefore, materials for this project were currently undergoing reevaluation and materials that are better suited for additive manufacturing may be substituted. During FY20, additional alloys were selected that would be both appropriate for high pressure oxygen environments as well appropriate for additive manufacturing processes. However, final bid for manufacturing was six times larger than the available funding for this project. Based on previous additive manufacturing projects, the scope and funding for this project were appropriate, but a suitable manufacturer willing to provide a reasonable proposal, was not found. Therefore, funds were de-obligated for this project, and then re-obligated to augment another FY20 CIF project.
Jonathan Dickey↗
Manufacturing Process Simulation of Large-Scale Cryotanks
NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA.s Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aide in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing simulation support. This paper highlights the accomplishments of this task agreement, while also introducing the capabilities of simulation software.
Babai, Majid↗
Comparison Made of Operating Characteristics of Spiral Bevel Gears Manufactured Using Different Methods
Spiral bevel gears are important components on all current rotorcraft drive systems. These components are required to operate at high speeds, high loads, and for an extremely large number of load cycles. In this application, spiral bevel gears are used to redirect the shaft from the horizontal gas turbine engine to the vertical rotor. Because of the high expense of manufacturing these gears, methods that can achieve the same level of performance at reduced cost are highly desirable to aerospace gear manufacturers. Gears manufactured for aerospace applications use high-quality materials and are manufactured to tight tolerances. Special manufacturing machine tools and computer numerically controlled coordinate measurement systems have enabled rotorcraft drive system manufacturers to produce extremely high-quality gears during their normal production. Because of low production rates for rotorcraft, these gears are manufactured in small batches, and thus are unable to benefit from the economics of high production numbers as in other industries. In this investigation, two different manufacturing methods, face-milled and face-hobbed, were used to fabricate spiral bevel gears. For face-milled spiral bevel gears, grinding of the contacting surfaces is the final manufacturing step. At least two different specialty machines are needed to generate the teeth for face-milled spiral bevel gears. For face-hobbed gears, hard cutting is the final manufacturing process. The same machine is used to rough cut and finish cut the gears. This study compared the operational behavior of face-milled spiral bevel gears with that of face-hobbed spiral bevel gears. Test hardware was manufactured to fit within NASA Glenn Research Center's Spiral Bevel Test Facility and to aerospace quality standards. Tests were conducted for stress, vibration, and noise. A comparison of the results attained indicated that the face-hobbed gears had a lower alternating stress level with a more even distribution of loading across the teeth, and slightly reduced levels of vibration and noise. Results of this study show that the face-hobbed method is a viable and lower-cost alternative for producing aerospace-quality spiral-bevel gears.
Handschuh, Robert F.↗
Manufacturing Process Simulation of Large-Scale Cryotanks
NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA's Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aid in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI.
Babai, Majid↗
Fracture Control for Additively Manufactured Spacecraft Structures
This paper describes how the intent of current NASA fracture control requirements may be applied to “fracture critical” additively manufactured spacecraft hardware. Fracture control is a multi-discipline design and certification methodology that is applied in order to mitigate catastrophic failure of structures resulting from growth of an undetected crack-like defect. The methodology is defined in existing NASA standards and is required on all human-rated space structures. As legacy spacecraft structures have been built using primarily metallic and composite materials manufactured using well established methods, guidance for application of fracture control to parts composed of these material types has been established and is documented in several NASA requirements. Additive manufactured structures offer advantages in design flexibility and manufacturing efficiency and as a result are expected to continue to be used more and more in the future. Recently, relevant guidance has been published by NASA to define materials and processes requirements for certain additive manufactured hardware, but procedures for fracture control are not addressed yet in any requirements or guidance document. While use of additive manufactured parts in non-critical scenarios may be of relatively low concern in current structural certification processes, there is a need for new fracture control guidance in order to use and certify additively manufacture hardware that is “fracture critical” where failure of the part may result in loss of life or loss of vehicle. Assurance of damage tolerance, i.e., that as-built flaws in a given part either do not exist or will not grow to become catastrophic, is of particular interest to the fracture control community. This poses a challenge due to the fact that damage tolerance behavior is not well understood in additive manufactured parts compared to legacy material types and manufacturing techniques. The discussion contained herein is necessary at this time as new guidance in this area should be founded collaboratively by the technical community at large. Different hardware types (e.g., pressure vessel, structural member) are described to highlight specific challenges and solutions for each. The discussion concludes with considering specific disciplines within fracture control (non-destructive evaluation, materials & processes, fracture mechanics, and structural certification) in a proposed extension of existing fracture control requirements to additive manufactured parts.
McElroy, Mark↗
Fracture Control for Additive Manufactured Spacecraft Structures
This paper describes how the intent of current NASA fracture control requirements may be applied to “fracture critical” additively manufactured spacecraft hardware. Fracture control is a multi-discipline design and certification methodology that is applied in order to mitigate catastrophic failure of structures resulting from growth of an undetected crack-like defect. The methodology is defined in existing NASA standards and is required on all human-rated space structures. As legacy spacecraft structures have been built using primarily metallic and composite materials manufactured using well established methods, guidance for application of fracture control to parts composed of these material types has been established and is documented in several NASA requirements. Additive manufactured structures offer advantages in design flexibility and manufacturing efficiency and as a result are expected to continue to be used more and more in the future. Recently, relevant guidance has been published by NASA to define materials and processes requirements for certain additive manufactured hardware, but procedures for fracture control are not addressed yet in any requirements or guidance document. While use of additive manufactured parts in non-critical scenarios may be of relatively low concern in current structural certification processes, there is a need for new fracture control guidance in order to use and certify additively manufacture hardware that is “fracture critical” where failure of the part may result in loss of life or loss of vehicle. Assurance of damage tolerance, i.e., that as-built flaws in a given part either do not exist or will not grow to become catastrophic, is of particular interest to the fracture control community. This poses a challenge due to the fact that damage tolerance behavior is not well understood in additive manufactured parts compared to legacy material types and manufacturing techniques. The discussion contained herein is necessary at this time as new guidance in this area should be founded collaboratively by the technical community at large. Different hardware types (e.g., pressure vessel, structural member) are described to highlight specific challenges and solutions for each. The discussion concludes with considering specific disciplines within fracture control (non-destructive evaluation, materials & processes, fracture mechanics, and structural certification) in a proposed extension of existing fracture control requirements to additive manufactured parts.
McElroy, Mark↗
AIAA Ascend 2021 Conference On Demand Manufacturing of Electronics Panel Abstract
1. Session Proposal o Session Title NASA’s In Space Manufacturing and the On Demand Manufacturing of Electronics o Session Topic Primary -- Space Logistics, Autonomy, and Robotics; Secondary – Transformative Research and Technologies o Session Format: Panel Discussion. o Requested Session Duration: 60 minutes o Short Session Description: The goal of NASA’s On Demand Manufacturing of Electronics project is to develop and demonstrate the feasibility of a low-gravity, on-demand manufacturing system for flexible hybrid electronic devices on the International Space Station. This panel will feature several key collaborators and team members from the commercial sector, academia, and internal to NASA, each of which are contributing an unique and vital role to the design and implementation of this new technology system. o Extended Session Description (Please describe in detail the activity proposed, including how you intend to use the requested session duration. This session description will be provided to the reviewers for consideration and will not be displayed in the online agenda.): The session will be moderated by Curtis Hill, the Project Lead for the On Demand Manufacturing of Electronics (ODME), and he will start by giving a brief introduction to the ODME project which is working to produce a demo system for the manufacturing of electronic devices on the International Space Station. Panelists consisting of collaborators and team members to the ODME project will then give a brief (~5 min) introduction highlighting their contributions to the project, followed by time for Q&A from the audience. The panel will consist of: 1. Kenneth Church, nScrypt. nScrypt is a leader in multi-material printing with a modular system that incorporates a direct write thick film print head, a polymer fused filament fabrication print head, a laser sintering attachment, a drill head attachment for milling, and a pick and place. The system can print a layer and scan for accuracy of prints. The combination of multiple print heads and scanning allows for the on-demand production of intricate electronic components. 2. Andy Kurk, TechShot, Inc. Techshot, Inc. has collaborated extensively with NASA on the in space manufacturing of both printed electronics and fused metal materials. They are currently working to develop and integrate a test system for printed electronics, and a flight demonstration on the International Space Station is anticipated in 2024. 3. Ed Hendricks, NextFlex. NextFlex has the goal of advancing the manufacture of flexible hybrid electronics in the U.S. They are working with ODME on the development of AstroSense, an additively manufactured, wireless, flexible, and wearable health sensor. 4. Dr. Pradeep Lall, Auburn University. Professor Lall is the MacFarlane Endowed Distinguished Professor in the Department of Mechanical Engineering with a Courtesy Joint Appointment in the Department of Electrical and Computer Engineering and a Courtesy Joint Appointment in the Department of Finance. He is collaborating with NASA’s ODME project to develop multilayer printable devices and to develop techniques to test the quality of a printed electronic device. 5. Dr. Wei Gao, California Institute of Technology. Professor Gao is an Assistant Professor of Medical Engineering. His group is developing fully printed, flexible, and wearable biosensors for crew health monitoring in collaboration with NASA’s ODME project. In addition, they are working on using sweat to power biofuel cells for wearable, self-powered electronic devices. 6. Beth Paquette, NASA Goddard. The ODME branch at NASA Goddard is spearheading a sounding rocket flight demo to prove the capability of a printed electronic device with multiple sensors. In addition, they focus on thin film and flexible energy storage evaluations. o Session Goal(s)/Outcome(s): Please list the learning objectives and/or tangible outcomes (technical paper or other publication). The goal of this session is to highlight the internal and collaborative efforts of NASA’s On Demand Manufacturing of Electronics project to develop a system for printing electronics that will be tested on the International Space Station in 2024. In addition, the session with facilitate discussion with the community on the state of the art of printable electronics, current challenges, and new avenues for collaboration.
Jennifer McInnis Jones↗
Advanced Lightweight Metallic Fuselage Project Manufacturing Trade Study
Recent advances in large-scale flow forming of integrally stiffened cylinders (ISCs) have motivated evaluation of available technologies for rapid manufacturing of metallic fuselages. The current state-of-the-art in flow forming of ISCs produces 10-ft. diameter, 5-ft. long barrels with integral longitudinal blade stiffeners, and these single-piece ISCs are produced in approximately 1.5 hours. While other manufacturing processes are required to incorporate additional structural elements (ASE) such as circumferential ring frames, reinforcements around window and door cut-outs, and floors to the ISCs to complete the fuselage structure, flow forming technology may assist the aerospace industry in meeting manufacturing rate demands. In order to evaluate this technology, a fuselage manufacturing demonstration article (MDA) fabricated from two ISCs is scheduled for fabrication and delivery to NASA Langley Research Center (LaRC) by the end of 2022. In this study, eight manufacturing technologies were assessed to downselect candidate manufacturing processes for adding ASE to complete the MDA. A literature review and evaluation of contractor-produced panels covering a spectrum of welding and additive manufacturing (AM) processes were conducted at NASA LaRC. The analytical hierarchy process (AHP) was used to evaluate figures of merit (FOMs) for selecting manufacturing process(es) to integrate ASE with the ISCs to form a fuselage MDA. The AHP results revealed that scalability, structural performance, and distortion control were the most valued criteria for downselecting the manufacturing process to construct the internal stiffening structures. Based on the FOMs, this study concluded that a welding process is best suited for integrating the majority of the ASE, namely the circumferential ring frames. All of the welding processes received higher scores than AM processes due to higher maturity, higher structural performance, fewer post-processing requirements in machining and heat treating, and faster deposition rates. Among the welding processes, cold metal transfer (CMT) welding was ranked the most favorable process for assembling the MDA, with the other welding processes (laser welding (LW), friction stir welding (FSW), and refill friction stir spot welding (RFSSW)) scoring slightly lower. This was a consequence of the perceived maturity of the CMT welding process and its relatively high structural performance and low distortion resulting from the low heat input. Among the AM processes, CMT AM showed the greatest promise due to benefits derived from its scalability, lower 1st order process complexity, and low distortion. The AM processes may have potential for select applications, such as adding structural reinforcements around window and door cut-outs, but are not considered optimal for integrating the entire MDA.
Manufacturing↗
Manufacturing Trials of Integrally Stiffened Composite Panels Using Automated Fiber Placement
Commercial aircraft structures are frequently manufactured from carbon-epoxy materials because of their weight and stiffness advantages compared to metallic materials. Wing cover panels are regularly manufactured using an automated fiber placement (AFP) process, but current design and manufacturing methodologies do not fully take advantage of the opportunities afforded by AFP. Design and manufacturing studies were undertaken at the NASA Langley Research Center at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to quantify manufacturing benefits and limitations associated with AFP to create structurally efficient integral stiffeners as an alternative to bonded or mechanically fastened stiffeners. This methodology could save weight and remove failure mechanisms by reducing the need for rivets and bonding materials since the stiffener plies are interleaved within the skin plies. The use of AFP with integral stiffeners can open the design space, but a fundamental, systematic evaluation of manufacturing limitations is necessary. Manufacturing trials are described herein, where considered manufacturing variables included stiffener location, stiffener course staggering, stiffener widths, stiffener intersections, and material thicknesses for both the skin and stiffener plies. The manufacturing process and lessons learned from each trial are described, including the most successful current design which contains staggered stiffeners, non-traditional laminate angles, and a combination of multiple material thicknesses within the same laminate.
Composite manufacturing↗
Establishing and Maintaining the Digital Thread of Additively Manufactured Materials and Applications
Additive Manufacturing (AM) and Integrated Computational Materials Engineering (ICME) are complementary enabling technologies for design and manufacturing of “fit-for-purpose” materials. Both technologies will impact rapid material design, reduction in cost- and time-to-market for new applications, and discovery and implementation of new materials. An ICME approach to design, however, requires experimentally validated material models at multiple length and time scales, an integrated framework that can connect analysis tools with one another to ensure the digital thread of an application is maintained, and the manufacturing (e.g., AM) capability to leverage processing-structure-property-performance (PSPP) relationships to achieve spatially varying material properties where desired. AM enables the implementation of the design of an optimized, spatially varying microstructure through careful selection of the processing parameters used during an additively manufactured build. In order to establish these PSPP relations, a large amount of data is necessary, and that data must be properly captured, analyzed and maintained in an information management system that can establish the required traceability between various aspects of the design process to ensure an application’s digital thread is maintained (from design to end of life). Such an information management system must be able to capture feedstock material pedigree, resulting microstructure from various build parameters, subsequent mechanical properties derived from testing, developed material models, and enable spatial variations in material assignment in an engineering application. Furthermore, the information management system should be easily integrated with traditionally engineered materials in a single, centralized platform to enable an ICME optimization tool to explore both types of manufacturing processes. At NASA GRC, a robust, 21st century materials information management system has been previously developed with a focus towards enabling ICME. In this work, GRC’s ICME schema is extended to accommodate additively manufactured materials, enabling storage of both traditionally and additively manufactured materials in the same construct. The methodology for properly capturing additively manufactured materials across the entire material lifecycle is presented, following the previously established database best practices, as a potential framework for establishing PSPP relationships for additively manufactured materials and applying them to engineering applications.
Data management↗