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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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

System and method for simulation-assisted additive manufacturing involving estimating anisotropic deformation

A simulation-assisted additive manufacturing system and method for generating an anisotropic compensation to account for non-uniform deformation due to additive manufacturing and service loading. The predicted deformation may not be fully defined. The present disclosure provides a system and method for estimating the missing deformation data through regression analysis. The present disclosure also provides an integrated framework where the various simulated-assisted design modules are configured for two-way communication and sharing access to changes to the model.

Kim, Seokpum↗
DOE OSTI2016

Microstructural design and additive manufacturing and characterization of 3D orthogonal short carbon fiber/acrylonitrile-butadiene-styrene preform and composite

In contrast to conventional preforming techniques, additive manufacturing features direct and layer-by-layer fabrication, which provides viable new capabilities for the fabrication of reinforced composites. In this paper, we explore the microstructural design as well as additive manufacturing and characterization of 3D orthogonal, short carbon fiber/acrylonitrile-butadiene-styrene (ABS) preforms and composite. First, an array of 3D orthogonal preforms is designed based on topological consideration and validated by fused filament fabrication of pure ABS wire; high fidelity between models and preforms is accomplished. Then, short carbon fibers are introduced into the designed 3D orthogonal preforms as reinforcement, using a short carbon fiber/ABS wire. Lastly, the compressive behavior of a 3D orthogonal, short carbon fiber/ABS preform and that of its silicone infused composite are characterized. Finally, the preform design methodology developed in this research as well as the preliminary effort made in composite fabrication and characterization demonstrates the feasibility of additive manufacturing of 3D orthogonal preform based fiber composites.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additive Manufacturing of Molds for Fabrication of Insulated Concrete Block

Oak Ridge National Laboratory (ORNL) worked with concrete block manufacturer, NRG Insulated Block, to demonstrate additive manufacturing of a multi-component block mold for its line of insulated blocks. Solid models of the mold parts were constructed from existing two-dimensional drawings, and the parts were fabricated on a Stratasys Fortus 900 using ULTEM™ 9085. Block mold parts were delivered to NRG and installed on one of their fabrication lines. While form and fit were acceptable, the blocks made from the molds collapsed when extruded from the printed molds during NRG’s testing. However, the project demonstrated significant time and cost reductions and achieving proper functionality through the use of different additive manufacturing techniques.

42 ENGINEERING↗
DOE OSTI2020

Discrete Element Method Analysis for Metal Powders Used in Additive Manufacturing, and DEM Simulation Tutorial Using LIGGGHTS-PUBLIC [PowerPoint and paper]

Discrete Element Method (DEM) is a method of analysis to evaluate the dynamic interactions between granular particles. This method has been used in the pharmaceutical industry to improve the powder compaction process for tablet manufacturing. There are also applications in agriculture, food industry, and manufacturing. Direct energy deposition is an additive manufacturing technique which uses metallic powders fed through a nozzle, melted using a directed laser, and transformed into a solid object layer by layer. One way of feeding metal particles into the system involves the use of a vibrating hopper. Given a specified amplitude and frequency input, the hopper will enable the powder to travel up a path, and inject through the system with assistance from a stream of gas. The mechanical properties of a printed object can vary, depending on the characteristics of the powder flow and the particles’ as-received properties. Improved understanding of dynamic interactions of flowing powders could enable additive manufacturing components with 2D or 3D variations in mechanical properties, e.g., density. This work uses DEM simulation software to investigate the effects of particle cohesion, friction, and density on the quality of the flow by performing an angle of repose simulation, which is often used as a metric to evaluate the flowability of powders.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Additive manufacturing capabilities applied to inertial confinement confusion at Los Alamos National Laboratory

We describe the use at Los Alamos National Laboratory of additive manufacturing (AM) for a variety of jigs and coating, assembly, and radiography fixtures. Additive manufacturing has also been used to produce shipping containers of complex design that would be too costly to have fabricated using traditional techniques. The current goal for AM use in target fabrication is to increase target accuracy and rigidity. This has been realized by implementing AM into target stalk fabrication, allowing increased complexity to address target strength and the addition of features for alignment at facilities. As a result, we will describe the fabrication of these components and our plans to utilize AM in the future.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Experimental Investigation on Additively Manufactured Transpiration and Film Cooling Structures

The last 50 years has witnessed significant improvement in film cooling technologies while transpiration cooling is still not implemented in turbine airfoil cooling. Although transpiration cooling could provide higher cooling efficiency with less coolant consumption compared to film cooling, the fine pore structure and high porosity in transpiration cooling metal media always raised difficulties in conventional manufacturing. Recently, the rapid development of additive manufacturing (AM) has provided a new perspective to address such challenge. With the capability of the innovative powder bed selective laser metal sintering (SLMS) AM technology, the complex geometries of transpiration cooling part could be precisely fabricated and endued with improved mechanical strength. This study utilized the SLMS AM technology to fabricate the transpiration cooling and film cooling structures with Inconel 718 superalloy. Five different types of porous media including two perforated plates with different hole pitches, metal sphere packing, metal wire mesh, and blood vessel shaped passages for transpiration cooling were fabricated by EOS M290 system. One laidback fan-shaped film cooling coupon was also fabricated with the same printing process as the control group. Heat transfer tests under three different coolant mass flow rates and four different mainstream temperatures were conducted to evaluate the cooling performance of the printed coupons. The effects of geometry parameters including porosity, surface outlet area ratio, and internal solid–fluid interface area ratio were investigated as well. The results showed that the transpiration cooling structures generally had higher cooling effectiveness than film cooling structure. The overall average cooling effectiveness of blood vessel-shaped transpiration cooling reached 0.35, 0.5, and 0.57, respectively, with low (1.2%), medium (2.4%), and high (3.6%) coolant injection ratios. The morphological parameters analysis showed the major factor that affected the cooling effectiveness most was the internal solid–fluid interface area ratio for transpiration cooling. This study showed that additive manufactured transpiration cooling could be a promising alternative method for turbine blade cooling and worthwhile for further investigations.

Engineering↗
DOE OSTI2020

A Digital Twin Approach to Study Additive Manufacturing Processing Using Embedded Optical Fiber Sensors and Numerical Modeling

One of the major challenges for metal-powder-based additive manufacturing is measuring and mitigating residual strain induced during the manufacturing processes. This article reports distributed fiber optic sensors embedded in Inconel alloy components as experimental means to validate numerical models of additive manufacturing process. Electroplating was used to deposit a metal protective jacket onto standard telecom single-mode fibers for strain measurements, Fiber sensors were embedded in an Inconel alloy substrate using the laser engineered net shaping (LENS) process. Here by using a Rayleigh-scattering optical frequency domain reflectometer (OFDR), temperature changes, and residual strain in the metal substrate were monitored with 5 mm spatial resolution during the LENS process. Using finite element analysis, temperature and strain profiles induced by the LENS deposition processes were also numerically studied. Discrepancies between the simulated temperature and strain profiles and those measured directly were less than 10%. Results presented in this article demonstrates a digital twin approach to fuse modeling results with distributed fiber sensor measurement data to study additive manufacturing process toward design and fabrication process optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Experimental Validation of an Additively Manufactured Stiffness-Optimized Short-Fiber Reinforced Composite Clevis Joint

This effort describes experiments for the validation of the response of an additively manufactured stiffness-optimized short-fiber reinforced composite. A Direct Ink Write (DIW) method is used to additively manufacture a clevis joint plate which was designed such that its compliance would be minimized (i.e., stiffness maximized) for far-field axial loading. A unique aspect of the optimization scheme is that it accounts for manufacturing constraints, such as tool turn radius and tool path spacing. Along with the optimized clevis joint plate, additively manufactured 0°–90° and ± 45° composite plates of the same number of layers, as well as a control 0°–90° sample of resin only, were also studied. In addition to far-field load-displacement, near-field strain was monitored using digital image correlation (DIC). The results showed that the optimized plate did indeed exhibit the largest stiffness, based on far-field measurements. DIC-measured strains showed that locally the axial strain component, which is the largest, was also minimized for the optimized specimen, although the other strain components followed different trends. Furthermore, in the experiments it was seen that the optimized design exhibited a nonlinear/hysteretic behavior which is believed to be a consequence of its internal gap/cell structure. This internal structure, which results by optimized placement of material, although explicitly not accounted for in the optimization, may affect global response. Lastly, although not a part of the optimization study itself, the failure load for the optimized joint plate was also seen to be the largest of all the cases studied.

42 ENGINEERING↗
DOE OSTI2026

A time-parallel method for scalable heat transfer simulations of additive manufacturing

Here, a major challenge in simulating the thermal behavior in additive manufacturing processes is the disparate length and time scales between transport phenomena occurring in the melt pool and the component. A common simulation approach relies on spatial decomposition for parallel computing, but due to the nature of heat transfer in AM, where most of the computational expenditure is localized near the melt pool, the computational speedup from spatial parallelization saturates quickly. Therefore, additional parallelism by means of time-domain decomposition is needed to fully take advantage of high-performance computing (HPC) resources. This work introduces a time-parallel method to improve the computational scalability of additive manufacturing simulations on HPC systems, while maintaining high temporal resolution of heat transfer near the melt pool. The method, inspired by the nonlinear paraexp formalism, performs an iterative superposition of nonlinear solutions to the initial value problem, integrating the heat equation across overlapping time-parallel intervals. For a single layer of the NIST AMB2018–01 L7 benchmark problem, the method achieves a 38.51x speedup in wall-clock time with a maximum error in the global temperature solution of 0.99%. This reduces the total solution time from 196.72 min to 5.11 min on 128 nodes of the ORNL Frontier supercomputer. The tradeoff between accuracy and total wall-clock time is investigated and recommendations for time-parallel deployment for AM problems are made.

Additive manufacturing↗
DOE OSTI2015

Additive manufacturing method for SRF components of various geometries

An additive manufacturing method for forming nearly monolithic SRF niobium cavities and end group components of arbitrary shape with features such as optimized wall thickness and integral stiffeners, greatly reducing the cost and technical variability of conventional cavity construction. The additive manufacturing method for forming an SRF cavity, includes atomizing niobium to form a niobium powder, feeding the niobium powder into an electron beam melter under a vacuum, melting the niobium powder under a vacuum in the electron beam melter to form an SRF cavity; and polishing the inside surface of the SRF cavity.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Impacts of the Additive Manufacturing Process on the Roughness of Engine Scale Vanes and Cooling Channels

Abstract By leveraging the additive manufacturing (AM) platform, development time and costs for turbine component testing can be reduced relative to traditional investment casting. Surface roughness is a key characteristic of the additive manufacturing process that can impact flow, heat transfer, and mechanical integrity of printed components. There are multiple design and build considerations that result in variability in surface roughness, especially when additively fabricating complicated three-dimensional vanes and internal cooling passages. This study characterizes the surface roughness of internal cooling passages, vanes, and flat external surface samples made using additive manufacturing, specifically the direct metal laser sintering process. The samples were manufactured with various wall thicknesses, layer thicknesses, build locations, build directions, and on different AM machines. A combination of computed tomography scanning and optical profilometry was used to evaluate surface roughness levels. The data indicate that the dominant factors in roughness for a given layer thickness are a function of wall thickness, build location, and build direction.

Engineering↗
DOE OSTI2020

Structural integrity of additively manufactured stainless steel with cold sprayed barrier coating under combined cyclic loading

Integration of metal additive manufacturing (AM) and cold spray (CS) technologies provide an unprecedented opportunity to manufacture coated material systems with complex geometrical features. The application of these material systems in functionally critical components requires adequate structural integrity, particularly in the presence of cyclic loading. This article researches the multiaxial fatigue (axial-torsional cyclic loading) behavior of a coated material system consisting of 15Cr-5Ni precipitation-hardening stainless steel (15-5 PH SS) substrate additively manufactured by direct metal laser sintering with a layer of chromium carbide nickel (CrC-Ni) barrier coating deposited by CS. The influence of AM and CS-induced residual stresses on fatigue performance of test specimens was thoroughly studied. Additionally, the effect of surface roughness and processes induced defects were considered to explain the crack growth mechanism. Stresses assessed by synchrotron X-ray diffraction indicated a substantial accumulation of residual stresses, particularly in the outer surface of the as-fabricated 155 PH SS specimens. The state of residual stress was changed notably following the deposition of CrC-Ni coating in the axial, hoop, and radial directions of the fatigue test specimen. Also, CS deposition of CrC-Ni coating caused significant improvement in the surface quality of the additively manufactured components. Fatigue test results indicated, CS deposition of CrC-Ni substantially enhances the fatigue life of the AM-produced 15-5 PH SS substrate in all loading conditions, particularly in the high cycle fatigue regime. The improvement in the fatigue life of the specimens with coating was associated with a reduction in equivalent residual stress at the substrate surface and improvement in the specimens' surface condition (i.e., reduced surface roughness). The fractographic analysis of the specimen indicated the cracks tend to initiate in the surface of both as-fabricated and cold-sprayed specimens. However, the mechanism of crack growth changed notably following the deposition of CrC-Ni coating. The cracks tended to propagate in the planes parallel or with a small deviation from the build layers of the AM-produced specimens. On the other hand, deposition of CrC-Ni coating increased the deviation of crack growth plane from the build layers of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Living additive manufacturing: Transformation of parent gels into diversely functionalized daughter gels made possible by visible light photoredox catalysis

Light-initiated additive manufacturing techniques typically rely on layer-by-layer addition or continuous extraction of polymers formed via nonliving, free radical polymerization methods that render the final materials “dead” toward further monomer insertion; the polymer chains within the materials cannot be reactivated to induce chain extension. An alternative “living additive manufacturing” strategy would involve the use of photocontrolled living radical polymerization to spatiotemporally insert monomers into dormant “parent” materials to generate more complex and diversely functionalized “daughter” materials. Here, we demonstrate a proof-of-concept study of living additive manufacturing using end-linked polymer gels embedded with trithiocarbonate iniferters that can be activated by photoinduced single-electron transfer from an organic photoredox catalyst in solution. This system enables the synthesis of a wide range of chemically and mechanically differentiated daughter gels from a single type of parent gel via light-controlled modification of the parent’s average composition, strand length, and/or cross-linking density. Furthermore, daughter gels that are softer than their parent, stiffer than their parent, larger but with the same modulus as their parent, thermally responsive, polarity responsive, healable, and weldable are all realized.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Characterizing material transitions in large-scale Additive Manufacturing

Integrating Multiple Materials (MM) into large-scale Additive Manufacturing (AM) is a key for various industrial applications wishing to incorporate site-specific properties into geometrically complex designs that are difficult to manufacture with traditional techniques. Printing with multiple materials is typically accomplished by using layers as natural material boundaries, but having the capability to switch between materials within a single layer without pausing would further expand MM possibilities. This study used Cincinnati Incorporated’s Big Area Additive Manufacturing (BAAM) system to explore material transitions with a novel dual-hopper that enables in-situ material blending of a pelletized feedstock. Constructing MM and functionally graded material (FGM) structures requires depositing a specific material composition at a specific geometric location to achieve a desired performance. Furthermore, accurately implementing this with the BAAM’s blended extrusion system requires a thorough understanding of the transition between distinct material compositions. This study characterizes a step-change transition between neat acrylonitrile butadiene styrene (ABS) and carbon fiber-reinforced ABS. Three distinct techniques were compared for analyzing the fiber content, and the transition zone between materials was characterized as a function of transition direction. The transition process was consistent to within 0.7 wt% carbon fiber variation between different layers and prints. The transition between materials was found to be directionally dependent, with ABS to CF/ABS having a transition length of 3.5 m compared to 3.2 m for CF/ABS to ABS. Furthermore, the transition from Material A to Material B was found to be repeatable with a possible variance in transition length of 0.3 m.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Large-scale additive manufacturing of self-heating molds

Large-scale material extrusion additive manufacturing technology is becoming the new mainstream technology for scaled-up composite mold and die applications. This paradigm shift in composite processing technology is primarily driven by out-of-autoclave tooling applications, in which fiber reinforced composite molds with scaled-up sizes and embedded heating elements are attractive. The present research describes the design, manufacturing, and testing of self-heating composite molds fabricated via a large-scale pellet extrusion 3D printing machine with an integrated wire co-extrusion tool. Polycarbonate (PC) composites reinforced with carbon fiber (PC/CF; 20 wt.%) and glass fiber (PC/GF; 20 wt.%) were used to fabricate mold parts. Joule heating thermal test results showed that uniform temperatures (~100 °C) were achieved for both PC/CF and PC/GF mold surfaces, using a custom-made feedback control power supply and infrared thermography. Mechanical characterizations, including tensile and flexural testing were performed on the wire-embedded and un-wired PC/CF and PC/GF base specimens to investigate the impact of the fiber reinforcement as well as the embedded wires. In the direction of extrusion, the ultimate tensile stress of PC/CF was 105 MPa, and that of PC/GF was 73 MPa, while the neat PC value was 64 MPa. Inner-bead voids and interfacial gaps were observed and characterized via optical and scanning electron microscopy. The embedded wires and inner bead impacted the mechanical properties of the composites. Furthermore, the stiffness of the wire-embedded mold was still satisfactory, proving that the technology can be used to fabricate additively manufactured out-of-oven/autoclave molds.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additive Manufacturing for Highly Efficient Window Inserts

ORNL partnered with the Mackinac Technology Company to demonstrate how additive manufacturing can be used to create highly energy efficient window inserts for retrofit in pre-existing buildings. Many early iterations of the window inserts were fabricated using carbon fiber reinforced thermoplastics and polycarbonate films as a stand in for the low-e coated films produced by the Mackinac Technology Company. After demonstration of the proof of concept, i.e. custom window inserts with tensioned film, the materials used for the manufacture of the frames was more closely examined. Hollow particle-filled syntactic foam and low-density polymer composites formed by expandable microspheres were explored as the materials used to additively manufacture the frames of the inserts. It was concluded that low-cost retrofit window inserts in custom sizes could be easily fabricated using large scale additive manufacturing. Furthermore, the syntactic and expanded foams developed and tested satisfy the mechanical performance requirements for the application.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Engineering mechanical and thermomechanical performance in additive manufacturing–Compression molded composites through multiplexed extrusion

Traditional extrusion-based additive manufacturing is limited to single material systems, restricting the multifunctional properties of composites. For this work to overcome this limitation, multiplexed additive manufacturing–compression molding (AM-CM) was employed to fabricate multi-material thermoplastic composites with spatially tailored architectures. Neat acrylonitrile butadiene styrene (ABS) and 20 wt% carbon-fiber reinforced ABS (CF-ABS) were co-extruded through a core–sheath nozzle to produce hybrid composites with neat ABS as sheath (30-50 wt%) and CF-ABS as core (50 – 70 wt%). The results show that the hybrid composites have balance of mechanical and thermomechanical performance. The tensile strength and modulus of hybrid composites exhibited a 61–95% and 173–473% increase compared to neat ABS with increases in CF-ABS content whereas the impact resistance improved by 41% compared to CF-ABS at 50 wt% ABS. Additionally, hybrid composites showed significant reduction (54 - 70%) in creep strain at 100 °C compared to neat ABS. These findings demonstrate that multiplexed AM-CM enables tunable structure–property relationships, reducing CF-ABS usage up to 50 wt% while maintaining balanced stiffness, toughness, and creep resistance.

Additive manufacturing↗
DOE OSTI2019

Infiltration studies of additive manufacture of WC with Co using binder jetting and pressureless melt method

Additive manufacturing (AM) of tungsten carbide-cobalt (WC-Co) is explored starting with WC preforms shaped with binder jet additive manufacturing (BJAM) followed by melt infiltration of Co. The research objective is to demonstrate the ability to net-shape WC-Co composites through BJAM of a WC preform followed by backfilling with cobalt via pressureless infiltration. This method also has the potential to minimize shrinkage and grain growth compared to other AM techniques. The effects of sintering, Co content, and infiltration time on the net shaping and properties of processed composites are shown. The best shaped material had an average grain size of 5.1 μm, 32 vol.% Co, density of 98.54% theoretical, fracture toughness of 23.2 MPa m 1/2 , and hardness of 9.0 GPa. Data presented illustrates that the proposed approach results in favorable ceramic-metal (cermet) properties and is viable for fabricating cermets of other material combinations. Furthermore successful AM of cermets provides complex geometries, high throughout, and low costs.

36 MATERIALS SCIENCE↗