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NASA NTRS2015

A Decision-Support Model for Selecting Additive Manufacturing Versus Subtractive Manufacturing Based on Energy Consumption

This paper presents a simple computational model for determining whether additive manufacturing or subtractive manufacturing is more energy efficient for production of a given metallic part. The key discriminating variable is the fraction of the bounding envelope that contains material – i.e. the volume fraction of solid material. For both the additive process and the subtractive process, the total energy associated with the production of a part is defined in terms of the volume fraction of that part. The critical volume fraction is that for which the energy consumed by subtractive manufacturing equals the energy consumed by additive manufacturing. For volume fractions less than the critical value, additive manufacturing is more energy efficient. For volume fractions greater than the critical value, subtractive manufacturing is more efficient. The model considers the entire manufacturing lifecycle – from production and transport of feedstock material through processing to return of post-production scrap for recycling. Energy consumed by processing equipment while idle is also accounted for in the model. Although the individual energy components in the model are identified and accounted for in the expressions for additive and subtractive manufacturing, values for many of these components may not be currently available. Energy values for some materials’ production and subtractive and additive manufacturing processes can be found in the literature. However, since many of these data are reported for a very specific application, it may be difficult, if not impossible, to reliably apply these data to new process-material manufacturing scenarios since, very often, insufficient information is provided to enable extrapolation to broader use. Consequently, this paper also highlights the need to develop improved knowledge of the energy embodied in each phase of the manufacturing process. To be most valuable, users of the model should determine the energy consumed by their manufacturing process equipment on the basis of energy-per-unit-volume of production for each material of interest – considering both alloy composition and form. Energy consumed during machine idle per unit time should also be determined by the user then scaled to specific processing scenarios. Energy required to generate feedstock material (billet, plate, bar, wire, powder) must be obtained from suppliers.

J K Watson↗

NASA NTRS1996

Computer Simulation of Spatial Arrangement and Connectivity of Particles in Three-Dimensional Microstructure: Application to Model Electrical Conductivity of Polymer Matrix Composite

Computer simulation is a powerful tool for analyzing the geometry of three-dimensional microstructure. A computer simulation model is developed to represent the three-dimensional microstructure of a two-phase particulate composite where particles may be in contact with one another but do not overlap significantly. The model is used to quantify the "connectedness" of the particulate phase of a polymer matrix composite containing hollow carbon particles in a dielectric polymer resin matrix. The simulations are utilized to estimate the morphological percolation volume fraction for electrical conduction, and the effective volume fraction of the particles that actually take part in the electrical conduction. The calculated values of the effective volume fraction are used as an input for a self-consistent physical model for electrical conductivity. The predicted values of electrical conductivity are in very good agreement with the corresponding experimental data on a series of specimens having different particulate volume fraction.

Louis, P.↗

NASA NTRS1992

Development of a contact lens quality monitoring system

The quality of contact lens samples depends strongly on their free volume fractions. It is expected that the free volume fraction of the test samples will also impact their attenuation coefficients for soft x rays. Samples with larger free volume fractions should have lower linear attenuation coefficients. Linear attenuation coefficients for Cd-109/Ag-109 x rays have been measured in five contact lens samples. It has been shown that the difference in the linear attenuation coefficients of discs from any given sample are entirely due to the difference in their respective volume fractions. It is therefore concluded that an x ray attenuation measurement system can serve as a quality monitor for contact lens polymers.

Singh, Jag J.↗

NASA NTRS1982

On determination of fibre fraction in continuous fibre composite materials

It is pointed out that the fiber volume fraction is probably the most important parameter influencing the properties of fibrous composite materials. The present investigation is concerned with questions regarding the accurate determination of this parameter. It is found that an estimate of the fiber volume fraction based on determinations from several coupons taken from different regions of a laminate is not accurate. At present fiber volume fractions are not directly measured but rather are calculated from the fiber weight fraction and densities of the composite and fiber. Image analysis techniques can and should be applied to determine fiber volume fraction. However, several factors have to be considered in this connection. It is necessary to make many measurements of the local fiber area fractions, and the preparation of representative planar cross sections parallel to the fiber axis may be difficult.

Whittenberger, J. D.↗

NASA NTRS1992

Thermal and ultrasonic evaluation of porosity in composite laminates

The effects of porosity on damage incurred by low-velocity impact are investigated. Specimens of graphite/epoxy composite were fabricated with various volume fractions of voids. The void fraction was independently determined using optical examination and acid resin digestion methods. Thermal diffusivity and ultrasonic attenuation were measured, and these results were related to the void volume fraction. The relationship between diffusivity and fiber volume fraction was also considered. The slope of the ultrasonic attenuation coefficient was found to increase linearly with void content, and the diffusivity decreased linearly with void volume fraction, after compensation for an approximately linear dependence on the fiber volume fraction.

Johnston, Patrick H.↗

NASA NTRS1997

Laser-Induced Incandescence Measurements in Low Gravity

A low-gravity environment offers advantages to investigations concerned with soot growth or flame radiation by eliminating of buoyancy-induced convection. Basic to each type of study is knowledge of spatially resolved soot volume fraction, (f(sub v). Laser-induced incandescence (LII) has emerged as a diagnostic for soot volume fraction determination because it possesses high temporal and spatial resolution, geometric versatility and high sensitivity. Implementation and system characterization of LII in a drop tower that provides 2.2 sec of low-gravity (micro)g) at the NASA Lewis Research Center are described here. Validation of LII for soot volume fraction determination in (micro)g is performed by comparison between soot volume fraction measurements obtained by light extinction [20] and LII in low-gravity for a 50/50 mixture (by volume) of 0 acetylene/nitrogen issuing into quiescent air. Quantitative soot volume fraction measurements within other laminar flames of ethane and propane and a turbulent diffusion flame in (micro)g via LII are also demonstrated. An analysis of LII images of a turbulent acetylene diffusion flame in 1-g and (micro)g is presented.

VanderWal, R. L.↗

NASA NTRS1996

Measurements and Modeling of Soot Formation and Radiation in Microgravity Jet Diffusion Flames

This is a computational and experimental study for soot formation and radiative heat transfer in jet diffusion flames under normal gravity (1-g) and microgravity (0-g) conditions. Instantaneous soot volume fraction maps are measured using a full-field imaging absorption technique developed by the authors. A compact, self-contained drop rig is used for microgravity experiments in the 2.2-second drop tower facility at NASA Lewis Research Center. On modeling, we have coupled flame structure and soot formation models with detailed radiation transfer calculations. Favre-averaged boundary layer equations with a k-e-g turbulence model are used to predict the flow field, and a conserved scalar approach with an assumed Beta-pdf are used to predict gaseous species mole fraction. Scalar transport equations are used to describe soot volume fraction and number density distributions, with formation and oxidation terms modeled by one-step rate equations and thermophoretic effects included. An energy equation is included to couple flame structure and radiation analyses through iterations, neglecting turbulence-radiation interactions. The YIX solution for a finite cylindrical enclosure is used for radiative heat transfer calculations. The spectral absorption coefficient for soot aggregates is calculated from the Rayleigh solution using complex refractive index data from a Drude- Lorentz model. The exponential-wide-band model is used to calculate the spectral absorption coefficient for H20 and C02. It is shown that when compared to results from true spectral integration, the Rosseland mean absorption coefficient can provide reasonably accurate predictions for the type of flames studied. The soot formation model proposed by Moss, Syed, and Stewart seems to produce better fits to experimental data and more physically sound than the simpler model by Khan et al. Predicted soot volume fraction and temperature results agree well with published data for a normal gravity co-flow laminar flames and turbulent jet flames. Predicted soot volume fraction results also agree with our data for 1-g and 0-g laminar jet names as well as 1-g turbulent jet flames.

Ku, Jerry C.↗

NASA NTRS1999

Evolution of Local Microstructures: Spatial Instabilities of Coarsening Clusters

This work examines the diffusional growth of discrete phase particles dispersed within a matrix. Engineering materials are microstructurally heterogeneous, and the details of the microstructure determine how well that material performs in a given application. Critical to the development of designing multiphase microstructures with long-term stability is the process of Ostwald ripening. Ripening, or phase coarsening, is a diffusion-limited process which arises in polydisperse multiphase materials. Growth and dissolution occur because fluxes of solute, driven by chemical potential gradients at the interfaces of the dispersed phase material, depend on particle size. The kinetics of these processes are "competitive," dictating that larger particles grow at the expense of smaller ones, overall leading to an increase of the average particle size. The classical treatment of phase coarsening was done by Todes, Lifshitz, and Slyozov, (TLS) in the limit of zero volume fraction, V(sub v), of the dispersed phase. Since the publication of TLS theory there have been numerous investigations, many of which sought to describe the kinetic scaling behavior over a 0 range of volume fractions. Some studies in the literature report that the relative increase in coarsening rate at low (but not zero) volume fractions compared to that predicted by TLS is proportional to v(sub v)(exp 1/2), whereas others suggcest V(sub v)(exp 1/3). This issue has been resolved recently by simulation studies at low volume fractions in three dimensions by members of the Rensselaer/MSFC team. Our studies of ripening behavior using large-scale numerical simulations suggest that although there are different circumstances which can lead to either scaling law, the most important length scale at low volume fractions is the diffusional analog of the Debye screening length. The numerical simulations we employed exploit the use of a recently developed "snapshot" technique, and identifies the nature of the coarsening dynamics at various volume fractions. Preliminary results of numerical and experimental investigations, focused on the growth of finite particle clusters, provide important insight into the nature of the transition between the two scaling regimes. The companion microgravity experiment centers on the growth within finite particle clusters, and follows the temporal dynamics driving microstructural evolution, using holography.

Frazier, Donald O.↗

NASA NTRS2000

The Burning of Large N-Heptane Droplets in Microgravity

Experimental results are presented on the burning and sooting behavior of large n-heptane droplets in air at atmospheric pressure under microgravity conditions. The experiments were performed at the Japanese Microgravity Center (JAMIC) 10 sec dropshaft in Hokkaido, Japan. Soot volume fraction, burning rate, flame standoff and luminosity were measured for droplets of 2.6 mm and 2.9 mm in initial diameter. These are the largest droplets for which soot volume fraction measurements have ever been performed. Previous measurements of soot volume fractions for n-heptane droplets, confined to smaller droplet sizes of less than 1.8 mm, indicated that maximum soot volume fraction increased monotonically with initial droplet size. The new results demonstrate for the first time that sooting tendency is reduced for large droplets as it has been speculated previously but never confirmed experimentally. The lower soot volume fractions for the larger droplets were also accompanied by higher burning rates. The observed phenomenon is believed to be caused by the dimensional influence on radiative heat losses from the flame. Numerical calculations confirm that soot radiation affects the droplet burning behavior.

Manzello, Samuel L.↗

NASA NTRS1992

Properties of Graphite Fiber Reinforced Copper Matrix Composites for Space Power Applications

The thermal and mechanical properties of pitch-based graphite fiber reinforced copper matrix (Gr/Cu) composites usable for space applications such as radiator fins were investigated. Thermal conductivity was measured as a function of fiber volume fraction and architecture. Results showed for unidirectional P-100 Gr/Cu composites, the longitudinal thermal conductivity was nearly independent of fiber volume fraction. Transverse thermal conductivities (perpendicular to the fibers) were strongly affected by the fiber volume fraction with higher volume fractions resulting in lower thermal conductivities. The effect of architecture on thermal conductivity followed the cosine squared law for simple architectures. Insufficient data are available currently to model more complex architectures, but adding fibers in the direction of the heat flow increases the thermal conductivity as low conductivity plies are supplemented by high conductivity plies. Thermal expansion tests were conducted on the Gr fibers and Gr/Cu composites. The results show a considerable thermal expansion mismatch between the fibers and the Cu matrix. The longitudinal thermal expansion showed a strong dependence on the architecture of the Gr/Cu composites. The composites also show a thermal expansion hysteresis. The hysteresis was eliminated by an engineered interface. Mechanical testing concentrated on the dynamic modulus and strength of the composites. The dynamic modulus of the Gr/Cu composites was 305 GPa up to 400 C, a value equivalent to Be. The strengths of the composites were less than expected, but this is attributed to the poor bond across the interface between the Gr fibers and Cu matrix. Testing of composites with an engineered interface is expected to yield strengths nearer the values predicted by the rule of mixtures.

Ellis, David L.↗

NASA NTRS1993

Verification of a two-dimensional infiltration model for the resin transfer molding process

A two-dimensional finite element model for the infiltration of a dry textile preform by an injected resin was verified. The model, which is based on the finite element/control volume technique, determines the total infiltration time and the pressure increase at the mold inlet associated with the RTM process. Important input data for the model are the compaction and permeability behavior of the preform along with the kinetic and rheological behavior of the resin. The compaction behavior for several textile preforms was determined by experimental methods. A power law regression model was used to relate fiber volume fraction to the applied compaction pressure. Results showed a large increase in fiber volume fraction with the initial application of pressure. However, as the maximum fiber volume fraction was approached, the amount of compaction pressure required to decrease the porosity of the preform rapidly increased. Similarly, a power law regression model was used to relate permeability to the fiber volume fraction of the preform. Two methods were used to measure the permeability of the textile preform. The first, known as the steady state method, measures the permeability of a saturated preform under constant flow rate conditions. The second, denoted the advancing front method, determines the permeability of a dry preform to an infiltrating fluid. Water, corn oil, and an epoxy resin, Epon 815, were used to determine the effect of fluid type and viscosity on the steady state permeability behavior of the preform. Permeability values measured with the different fluids showed that fluid viscosity had no influence on the permeability behavior of 162 E-glass and TTI IM7/8HS preforms. Permeabilities measured from steady state and advancing front experiments for the warp direction of 162 E-glass fabric were similar. This behavior was noticed for tests conducted with corn oil and Epon 815. Comparable behavior was observed for the warp direction of the TTI IM7/8HS preform and corn oil. Mold filling and flow visualization experiments were performed to verify the analytical computer model. Frequency dependent electromagnetic sensors were used to monitor the resin flow front as a function of time. For the flow visualization tests, a video camera and high resolution tape recorder were used to record the experimental flow fronts. Comparisons between experimental and model predicted flow fronts agreed well for all tests. For the mold filling tests conducted at constant flow rate injection, the model was able to accurately predict the pressure increase at the mold inlet during the infiltration process. A kinetics model developed to predict the degree of cure as a function of time for the injected resin accurately calculated the increase in the degree of cure during the subsequent cure cycle.

Hammond, Vincent H.↗

NASA NTRS1997

Characterization and Demonstrations of Laser-Induced Incandescence in both Normal and Low-Gravity

Knowledge of soot volume fraction is important to a wide range of combustion studies in microgravity. Laser-induced incandescence (LII) offers high sensitivity, high temporal and spatial resolution in addition to geometric versatility for real-time determination of soot volume fraction. Implementation of LII into the 2.2 see drop tower at The NASA-Lewis Research Center along with system characterization is described. Absolute soot volume fraction measurements are presented for laminar and turbulent gas-jet flames in microgravity to illustrate the capabilities of LII in microgravity. Comparison between LII radial intensity profiles with soot volume fraction profiles determined through a full-field light extinction technique are also reported validating the accuracy of LII for soot volume fraction measurements in a microgravity environment.

VanderWal, Randall L.↗

NASA NTRS2007

An Experimental Investigation of the Laminar Flamelet Concept for Soot Properties

The soot properties of round, nonbuoyant, laminar jet diffusion flames are described, based on experiments at microgravity carried out on orbit during three flights of the Space Shuttle Columbia, (Flights STS-83, 94 and 107). Experimental conditions included ethylene- and propane-fueled flames burning in still air at an ambient temperature of 300 K and ambient pressures of 35-100 kPa. Measurements included soot volume fraction distributions using deconvoluted laser extinction imaging, and soot temperature distributions using deconvoluted multiline emission imaging. Flowfield modeling based on the work of Spalding is presented. The present work explores whether soot properties of these flames are universal functions of mixture fraction, i.e., whether they satisfy soot state relationships. Measurements are presented, including radiative emissions and distributions of soot temperature and soot volume fraction. It is shown that most of the volume of these flames is bounded by the dividing streamline and thus should follow residence time state relationships. Most streamlines from the fuel supply to the surroundings are found to exhibit nearly the same maximum soot volume fraction and temperature. The radiation intensity along internal streamlines also is found to have relatively uniform values. Finally, soot state relationships were observed, i.e., soot volume fraction was found to correlate with estimated mixture fraction for each fuel/pressure selection. These results support the existence of soot property state relationships for steady nonbuoyant laminar diffusion flames, and thus in a large class of practical turbulent diffusion flames through the application of the laminar flamelet concept.

Diez, F. J.↗

NASA NTRS1993

Development of an Atomization Methodology for Spray Combustion

In liquid rocket propulsion, the knowledge and the understanding of liquid-gas interfacial phenomena are very important. This is important for predicting the onset of cavitation occurring in swirl injection elements used in STME, as well as atomization processes in shear-induced injectors (co-axial) and impinging injector elements. From the fact that all the physical processes including droplet size distribution, droplet dispersion, mixing and combustion are controlled by atomization processes, it is expected that the successful incorporation of the volume of fraction (VOF) will greatly enhance the analytical capability of predicting spray combustion processes in liquid-fueled engines. In this paper, a methodology is developed to define and track interfaces between two fluids in non-orthogonal, body-fitted grids using a single fractional volume of fluid (VOF) variable to describe the distribution of the liquid phase in a gas-liquid flow field. This method was implemented in a mature CFD code MAST (Multiphase All-Speed Transient) utilizing the general PISO-C algorithm. For the preliminary study on the analysis of spray combustion and tracking of the interface between two phases, we will report on the progress of the simulation of the instability on the liquid column; the surface wave instability and the droplet breakup from the liquid surface.

Seung, S. P.↗

NASA NTRS2002

Self-Consistent Physical Properties of Carbon Nanotubes in Composite Materials

A set of relationships is developed for selected physical properties of single-walled carbon nanotubes (SWCN) and their hexagonal arrays as a function of nanotube size in terms of the chiral vector integer pair, (n,m). Properties include density, principal Young's modulus, and specific Young's modulus. Relationships between weight fraction and volume fraction of SWCN and their arrays are developed for polymeric mixtures.

Pipes, R. B.↗

NASA NTRS1999

Novel Method Used to Inspect Curved and Tubular Structural Materials

At the NASA Lewis Research Center, a technique for the ultrasonic characterization of plates has been extended to tubes and to curved structures in general. In this technique, one performs measurements that yield a thickness-independent value of the local through-the-thickness speed of sound in a specimen. From such measurements at numerous locations across the specimen, one can construct a map of velocity as a function of location. The gradients of velocity indicated by such a map indicate local through-the-thickness-averaged microstructural parameters that affect the speed of sound. Such parameters include the pore volume fraction, mass density, fiber volume fraction (in the case of a composite material), and chemical composition. Apparatus was designed to apply the technique to tubular and other curved specimens.

Roth, Don J.↗

NASA NTRS2003

Evolution of Local Microstructures: Spatial Instabilities in Coarsening Clusters

Diffusion-limited capillarity-driven coarsening of precipitates is an important and intensively studied phenomenon. The classic coarsening theory developed by Lifshitz and Syozov and Wagner (LSW theory) is limited to infinitesimally small volume fractions, V(sub nu), therefore neglects all direct interparticle interactions. This work uses modeling and holographic imaging to compare coarsening rates in "high" volume fraction versus low volume fraction microstructures by observing mixed-dimensional droplets (spherical caps on a surface coarsening by two-dimensional diffusion) during ground-based investigations. The method involves filling a cell with selected homogeneous parent phase, and cooling below the consolute temperature to the isopycnic temperature in the two-phase region of a monotectic system. A microgravity holographic experiment is required for three-dimensional observations to minimize sedimentation during long-term coarsening. Determination of sizes and positions of the many droplets in the holographic images requires automation. We have developed software for automated data analysis, and demonstrated good agreement between regenerated maps and scaled photographs of the original holograms for mixed dimensional coarsening. The results of these experiments were presented in a formal microgravity Science Concept Review (SCR) on December 18, 2000.

Source record↗

NASA NTRS1997

Colloids and Nucleation

The objectives of the work funded under this grant were to develop a microphotographic technique and use it to monitor the nucleation and growth of crystals of hard colloidal spheres. Special attention is given to the possible need for microgravity studies in future experiments. A number of persons have been involved in this work. A masters student, Keith Davis, began the project and developed a sheet illumination apparatus and an image processing system for detection and analysis. His work on a segmentation program for image processing was sufficient for his master's research and has been published. A post doctoral student Bernie Olivier and a graduate student Yueming He, who originally suggested the sheet illumination, were funded by another source but along with Keith made photographic series of several samples (that had been made by Keith Davis). Data extraction has been done by Keith, Bernie, Yueming and two undergraduates employed on the grant. Results are published in Langmuir. These results describe the sheet lighting technique as one which illuminates not only the Bragg scattering crystal, but all the crystals. Thus, accurate crystal counts can be made for nucleation rate measurements. The strange crystal length scale reduction, observed in small angle light scattering (SALS) studies, following the initial nucleation and growth period, has been observed directly. The Bragg scattering (and dark) crystal size decreases in the crossover region. This could be an effect due to gravitational forces or due to over- compression of the crystal during growth. Direct observations indicate a complex morphology for the resulting hard sphere crystals. The crystal edges are fairly sharp but the crystals have a large degree of internal structure. This structure is a result of (unstable) growth and not aggregation. As yet unpublished work compares growth exponents data with data obtained by SALS. The nucleation rate density is determined over a broad volume fraction range (0.505 to 0.575) and compared to classical nucleation rate calculations. The experimental nucleation rate density varies with volume fraction more slowly than expected theoretically. Gravity may influence nucleation because crystal nuclei are more dense than the surrounding fluid and may be gravitationally convected. The largest observed crystal size was near volume fraction 0.52. Near the freezing point, crystals should grow to large size because nuclei are sparse and there is plenty of room to grow without contacting other crystals. Near melting the opposite is true, with crystals growing into one another shortly after nucleation. The maximum crystal size seen near 0.52 volume fraction suggests that gravitational stresses are limiting crystal growth near freezing.

Ackerson, Bruce↗