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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 OSTI2021

Preparation of Smart Materials by Additive Manufacturing Technologies: A Review

Over the last few decades, advanced manufacturing and additive printing technologies have made incredible inroads into the fields of engineering, transportation, and healthcare. Among additive manufacturing technologies, 3D printing is gradually emerging as a powerful technique owing to a combination of attractive features, such as fast prototyping, fabrication of complex designs/structures, minimization of waste generation, and easy mass customization. Of late, 4D printing has also been initiated, which is the sophisticated version of the 3D printing. It has an extra advantageous feature: retaining shape memory and being able to provide instructions to the printed parts on how to move or adapt under some environmental conditions, such as, water, wind, light, temperature, or other environmental stimuli. This advanced printing utilizes the response of smart manufactured materials, which offer the capability of changing shapes postproduction over application of any forms of energy. The potential application of 4D printing in the biomedical field is huge. Here, the technology could be applied to tissue engineering, medicine, and configuration of smart biomedical devices. Various characteristics of next generation additive printings, namely 3D and 4D printings, and their use in enhancing the manufacturing domain, their development, and some of the applications have been discussed. Special materials with piezoelectric properties and shape-changing characteristics have also been discussed in comparison with conventional material options for additive printing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Investigation of Deformation Behavior of Additively Manufactured AISI 316L Stainless Steel with In Situ Micro-Compression Testing

Additive manufacturing techniques are being used more and more to perform the precise fabrication of engineering components with complex geometries. The heterogeneity of additively manufactured microstructures deteriorates the mechanical integrity of products. In this paper, we printed AISI 316L stainless steel using the additive manufacturing technique of laser metal deposition. Both single-phase and dual-phase substructures were formed in the grain interiors. Electron backscatter diffraction and energy-dispersive X-ray spectroscopy indicate that Si, Mo, S, Cr were enriched, while Fe was depleted along the substructure boundaries. In situ micro-compression testing was performed at room temperature along the [001] orientation. The dual-phase substructures exhibited lower yield strength and higher Young’s modulus compared with single-phase substructures. Our research provides a fundamental understanding of the relationship between the microstructure and mechanical properties of additively manufactured metallic materials. The results suggest that the uneven heat treatment in the printing process could have negative impacts on the mechanical properties due to elemental segregation.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Nano-Magnets and Additive Manufacturing for Electric Motors

High power density is required for application of electric motors in hybrid electric propulsion. Potential path to achieve high power density in electric motors include advanced materials, lightweight thermal management, lightweight structural concepts, high power density power electronics, and advanced manufacturing. This presentation will focus on two key technologies for achieving high power density, advanced magnets and additive manufacturing. The maximum energy product in current magnets is reaching their theoretical limits as a result of material and process improvements. Future improvements in the maximum energy product for magnets can be achieved through development of nanocomposite magnets combining the hard magnetic phase and soft magnetic phase at the nanoscale level. The presentation will provide an overview of the current state of development for nanocomposite magnets and the future path for doubling the maximum energy product. The other part of the presentation will focus on the role of additive manufacturing in fabrication of high power density electric motors. The presentation will highlight the potential opportunities for applying additive manufacturing to fabricate electric motors.

materials↗
NASA NTRS2017

The Role of Advanced Manufacturing in Our Journey to Mars

The National Additive Manufacturing Innovation Institute was launched in August 2012 as a result of President Obama's proposed need for a whole-of-government advanced manufacturing effort. Mission: To accelerate the adoption of additive manufacturing technologies to increase domestic manufacturing competitiveness. Funding: Five federal agencies - the Departments of Defense, Energy, and Commerce, the National Science Foundation, and NASA - jointly committed to invest $45 million.

Advanced Manufacturing Innovation↗
NASA NTRS2018

Additively Manufactured Oxidizer Turbopump

Additive Manufacturing, or 3D printing, is a key technology for enhancing rocket engine designs and making them more affordable for future exploration missions. The Oxidzer Turbopump (OTP) offers the ability to demonstrate additively manufactured rotating, vaned, and critical pressure vessel components in relevant oxygen turbopump environments. The additively manufactured components of the OTP include the main housings, impeller, and turbine components. A key technology development goal is to understand the benefits and limitations of additive manufacturing as it applies to the complex geometries needed for a rocket engine turbopump.

Manufacturing↗
NASA NTRS2019

Additive Manufacturing for Human Space Exploration

NASA’s In Space Manufacturing Initiative (ISM): The Case for ISM - Why; ISM Path to Exploration; In Space Robotic Manufacturing and Assembly (IRMA). Additive Manufacturing (AM) Development For Liquid Rocket Engine Space Flight Hardware. MSFC (Marshall Space Flight Center) Standard and Specification For Additively Manufactured Space Flight Hardware.

Additive Manufacturing Exploration↗
NASA NTRSDate not supplied

Developing Radiation Protection Garments with Additive Manufacturing

The RadWorks Wearable Technology team is dedicated to developing protective garments to ameliorate the effects of radiation caused by Solar Particle Events (SPEs). This work requires that we remain open to new avenues for processing hydrogen-rich materials that may be useful in the development of these protective garments. The purpose of this research was to identify new ways of processing polyolefin polymers (polypropylene, more specifically) with additive manufacturing techniques. First, we conducted a literature review to identify known problems with processing polypropylene using additive manufacturing. Then, we looked toward finding ways to manage these difficulties within the additive manufacturing process. The primary goal was to develop techniques for processing polypropylene in a way that would generate a product amenable to inclusion in a worn garment (e.g., flexible, strong, and with ample radiation protection). In the end, we were able to generate designs which addressed polypropylene’s high coefficient of thermal expansion and lack of material adhesion, while meeting the requirements set forth by the use-case for wearable technology. This research offers novel avenues for processing one of the most common plastics in the world, which could contribute to the development of protective garments, as well as new avenues to explore for additive manufacturing in low-gravity environments.

Additive Manufacturing, 3D Printing, Polypropylene↗
NASA NTRSDate not supplied

Assured Performance of Additively Manufactured and Composite Parts through Embedded Sensing and Life Cycle Monitoring: An Enabler for in-Space Use

Lightweight composites have a range of applications in aerospace where operational costs and mission (payload) capabilities depend significantly on component weight. Additive manufacturing of the composite components expands the design and production space allowing for complex part geometries. A limiting factor to the utilization of the composites in high value applications, such as aerospace generally, and particularly for in-space applications, is the ability to determine the part quality both at the time of production as well as through the lifetime of the component. Work on monitoring the performance of additively manufactured and autoclaved composites that encompasses the design and manufacturing as well as use in operational environments will be discussed. Optimization of the component design for manufacturability, the use of process monitoring sensors during the component build as well as embedding of carbon nanotube yarn based structural sensors will be described.

Additive Manufacturing↗
NASA NTRSDate not supplied

Additively Manufactured Wind Tunnel Balances for Propulsive Force Measurement

Propulsive forces and moments during powered descent are not understood well enough to design an entry, decent, and landing vehicle with high confidence using solely computational fluid dynamics modelling (CFD). Therefore, wind tunnel testing is required to quantify uncertainties in computational modeling and simulation. Wind tunnel balances are structural, high-precision, multi-axis force transducers that provide direct measurement of these aerodynamic forces and moments, however their complex designs make them costly and time consuming to produce and approaches used to manufacture them have not changed significantly since the 1960s. This work demonstrates that additive manufacturing (AM) can be used to manufacture wind tunnel balances with significantly reduced fabrication time and expense. Moreover, the design flexibility afforded by the additive manufacturing process has the potential to enable new capabilities with respect to measuring propulsion forces during entry, decent, and landing testing. Here we present two novel balance designs enabled by AM. One will provide direct measurement of aerodynamic interference forces and moments on powered descent models (retropropulsion forces) to support CFD validation and further development of Mars human landing vehicle concepts. The second design will be used to characterize a reaction control system during entry descent and landing testing over a wide Mach number range.

Wind tunnel balance↗
NASA NTRSDate not supplied

Additively Manufactured Balances for Propulsive Force Measurement

Propulsive forces and moments during powered descent are not understood well enough to design an entry, decent, and landing vehicle with high confidence using solely computational fluid dynamics modelling (CFD). Therefore, wind tunnel testing is required to quantify uncertainties in computational modeling and simulation. Wind tunnel balances are structural, high-precision, multi-axis force transducers that provide direct measurement of these aerodynamic forces and moments, however their complex designs make them costly and time consuming to produce and approaches used to manufacture them have not changed significantly since the 1960s. This work demonstrates that additive manufacturing (AM) can be used to manufacture wind tunnel balances with significantly reduced fabrication time and expense. Moreover, the design flexibility afforded by the additive manufacturing process has the potential to enable new capabilities with respect to measuring propulsion forces during entry, decent, and landing testing. Here we present two novel balance designs enabled by AM. One will provide direct measurement of aerodynamic interference forces and moments on powered descent models (retropropulsion forces) to support CFD validation and further development of Mars human landing vehicle concepts. The second design will be used to characterize a reaction control system during entry decent and landing testing over a wide Mach number range.

Wind tunnel balance↗
NASA NTRSDate not supplied

Component Applications using Metal Additive Manufacturing Techniques and Materials for Rocket Propulsion

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED) and arc-based deposition. A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. Additional information will be provided on the development of multi-metallic additive manufacturing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗
NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

Additive Manufacturing↗
NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

DED↗
NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Additive Manufacturing↗
NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

pragmatic method↗
NASA NTRSDate not supplied

Manufacture of Hybrid Standard-Ply/Thin-Ply Carbon/Epoxy Panels for Notched Test Specimens

Weight is a critical metric for aerospace structures, and one possible way to reduce weight is to improve performance using hybrid standard-ply/thin-ply laminates from a single material system. Previous studies showed benefits for stiffness, strength, reduced damage after impact, and increased compression-after-impact strength for these hybrid laminates. Another study suggested that performance of compression-loaded notched hybrid laminate specimens performed better than standard-ply laminates under compression, but the standard-ply laminates performed better under tension loading. However, analysis predicted the failure load and mode better for the hybrid laminates. An analytical study determined several hybrid laminate designs to use in a follow-on testing regiment that is planned to further study the notched hybrid composite performance under compression and tension load. Described herein is a manufacturing method to efficiently manufacture hybrid laminates using automated fiber placement using a 16-tow head where 8 tows are standard-ply and 8 tows are thin-ply. The method saves time in that it eliminates the need to change spools of material when switching from standard-ply to thin-ply lamina, and reduces the waste associated with changing of spools. The method is ideal for small manufacturing operations or research facilities that have only a single head, and the method was successfully applied at the NASA Langley Research Center (LaRC) Integrated Structural Assembly of Advanced Composites (ISAAC) facility to manufacture nine panels that will be used for the follow-on notched specimen testing of hybrid and standard laminates.

composite↗
NASA NTRSDate not supplied

Manufacture of Hybrid Standard-Ply/Thin-Ply Carbon/Epoxy Panels for Notched Test Specimens

Weight is a critical metric for aerospace structures, and one possible way to reduce weight is to improve performance using hybrid standard-ply/thin-ply laminates from a single material system. Previous studies showed benefits for stiffness, strength, reduced damage after impact, and increased compression-after-impact strength for these hybrid laminates. Another study suggested that performance of compression-loaded notched hybrid laminate specimens performed better than standard-ply laminates under compression, but the standard-ply laminates performed better under tension loading. However, analysis predicted the failure load and mode better for the hybrid laminates. An analytical study determined several hybrid laminate designs to use in a follow-on testing regiment that is planned to further study the notched hybrid composite performance under compression and tension load. Described herein is a manufacturing method to efficiently manufacture hybrid laminates using automated fiber placement using a 16-tow head where 8 tows are standard-ply and 8 tows are thin-ply. The method saves time in that it eliminates the need to change spools of material when switching from standard-ply to thin-ply lamina, and reduces the waste associated with changing of spools. The method is ideal for small manufacturing operations or research facilities that have only a single head, and the method was successfully applied at the NASA Langley Research Center (LaRC) Integrated Structural Assembly of Advanced Composites (ISAAC) facility to manufacture nine panels that will be used for the follow-on notched specimen testing of hybrid and standard laminates.

composite↗
NASA NTRS2017

Development of NASA Standards for Enabling Certification of Additively Manufactured Parts

There are currently no NASA standards providing specific design and construction requirements for certification of additively manufactured parts. Several international standards organizations are developing standards for additive manufacturing; however, NASA mission schedules preclude the Agency from relying on these organizations to develop standards that are both timely and applicable. NASA and its partners in human spaceflight (Commercial Crew, Space Launch System, and Orion Multi-Purpose Crew Vehicle Programs) are actively developing additively manufactured parts for flight as early as 2018. To bridge this gap, NASA Marshall Space Flight Center (MSFC) is authoring a Center-level standard (MSFC-STD-3716) 1 to establish standard practices for the Laser Powder Bed Fusion (L-PBF) process. In its draft form, the MSFC standard has been used as a basis for L-PBF process implementation for each of the human spaceflight programs. The development of an Agency-level standard is proposed, based upon the principles of MSFC-STD-3716, which would have application to multiple additive manufacturing processes and be readily adaptable to all NASA programs.

NASA Standards↗