Search NASA⌕ Search

SEARCH · Search NASA

Results for “part”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

System and method for inspecting parts using dynamic response function

A system and method for the non-destructive testing of additively manufactured parts. An input mechanism excites with an excitation force (e.g., a vibration) an additive manufacturing build structure, which includes a part on a build platform, to induce a dynamic response in the part. An output mechanism (e.g., a non-contact transducer) senses the induced dynamic response in the part. A processor determines and examines the relationship between the response and excitation to identify an indication of a defect in the part, and communicates an alert if the indication is identified. The processor may compare the phase, magnitude, coherence, or time delay of the relationship to a reference relationship and/or may compare the modal frequency or the modal damping to a reference to identify a deviation greater than a pre-established threshold.

Hartwig, Troy Juan↗
DOE OSTI2022

Frequency domain assurance criterion for defect detection in additively manufactured parts

Additive manufacturing (AM) is a very desirable manufacturing method for industries such as aerospace and automotive due to its ability to create internal features and complex geometries, however, these characteristics also present challenges for nondestructive evaluation (NDE) and defect detection. Dynamic analysis and modal analysis have shown promise for NDE and identifying flaws in AM parts. Frequency Domain Assurance Criterion (FDAC) is a method of dynamic evaluation that represents the degree of correlation between two sets of operational deflection shapes (ODS) at each spectral line. Using colormaps to display the results allows for quick and easy interpretation of parts’ similarities and differences. This method appears to show promise in identifying parts with minor defects and can be used to differentiate nominal and defective parts. This paper explores the use of FDAC on various AM parts with and without intentional defects.

Deonarain, G↗
DOE OSTI2026

Oversizing and Part-Load Problems

Oversizing, the common engineering practice of specifying devices with capacity exceeding the actual load requirement, is a widespread practice across virtually all building technologies end-use categories, including HVAC, electrical systems, lighting, appliances, and plug loads. This practice, driven by factors like design uncertainty, institutional pressures, and risk aversion, results in wasted capital investment, control difficulties, and excessive energy consumption due to inefficient part-load operation. Part-load operation, where devices run below maximum capacity, is the dominant operating mode in most energy systems and presents a complex design challenge. Solutions to match output to load fall into three broad categories: constraining the output, adjusting the device’s internal behavior, and linking output to energy storage or other waste-heat reuse applications. The energy implications of part-load are critical, as efficiency often drops sharply as load decreases across a wide diversity of devices. To quantify the extent of this problem, we derive a dimensionless Part-Load Metric (PLM) based on device efficiency and its frequency distribution of operating hours at various output levels. The PLM quantifies the deviation of a device's actual efficiency from its maximum design efficiency. This metric also serves as a measure of "capital inefficiency," enabling engineers to compare the impact of different part-load solutions and providing a unified framework for evaluating performance across various devices and systems.

Meier, Alan↗
DOE OSTI2020

Evolution of AISI 304L stainless steel part properties due to powder recycling in laser powder-bed fusion

Selective laser melting (SLM) is a powder-bed fusion process in Additive Manufacturing (AM) that uses a laser beam to selectively fuse layers of powder into near net-shape components with little porosity. However, inconsistencies in the part properties due to the presence of defects in as-built components has hindered the widespread adoption of SLM for industrial applications forcing researchers to study the sources of variation for quality control purposes. A critical area suspected of creating variation in the part properties is the feedstock, where batch-to-batch differences as well as changes in the powder properties with reuse have the potential to affect performance. During processing, laser spatter and condensate eject from the melt pool and deposit into the powder-bed surrounding the parts. These particulates, more commonly known as ejecta, differ morphologically and chemically from the virgin powder compromising its reusability. In this study, 304L stainless steel powder was recycled for a total of 5 times through a systematic approach aimed at accelerating powder degradation to reveal the influence on both the tensile and impact toughness properties. Through analysis of variance (ANOVA), it was found that tensile properties did not change with reuse, while the impact toughness showed a steady decline illustrating the differences in static and dynamic part properties due to powder recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Process-structure-property relationships for droplet-on-demand liquid-metal-jetted parts

Liquid metal jetting droplet-on-demand additive manufacturing is an attractive alternative to industry-standard, laser-based metal additive manufacturing techniques that use powder feedstocks and produce large heat affected zones. Liquid metal jetting provides a low feedstock footprint, minimal materials waste, less contamination and inclusions from feedstock, and is compatible with a large range of materials. However, little has been reported on the liquid metal jetting process-structure-property relationships that are crucial to understanding how to consistently print high quality metal parts. We investigate the effects of build plate temperature, infill pattern, and track raster rate on the macro- and microstructure, density, hardness, and tensile strength of metal parts created with our custom droplet-on-demand setup using pure tin feedstock as a surrogate for more relevant structural materials. We found that although the build plate temperature had the largest influence on the structure and properties, the infill pattern is an important factor for optimal structural integrity. It was observed that the track raster rate influenced track-to-track porosity and should be considered in toolpath development. Despite printing in ambient air, we could not identify oxide on the surface or in the bulk of the parts and saw no adverse effects on microstructure or tensile performance. The results and methods of this study will help guide future work in optimizing the liquid metal jetting process to reliably print parts using any liquid metal jetting system for a wide variety of metal feedstocks.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Part I: Predicting performance of Purolite A532E resins for remediation of comingled contaminants in groundwater

Ion exchange (IX) resins are used in pump-and-treat (P&T) facilities to remove soluble groundwater contaminants. However, natural anions present at concentrations orders of magnitude higher than contaminants can compete for IX sites and impact resin lifecycles. Here, the Hanford Site’s 200 West Area P&T facility (Washington State, USA) was selected as a case study because it currently uses two IX resins: Purolite® A532E (A532E) to remove pertechnetate (TcO 4 - ) and DOWEX 21K (DOWEX) to remove uranium from groundwater. Nitrate (NO 3 - ), sulfate (SO 4 2- ), chloride (Cl - ), and carbonate (CO 3 2- ) anions have been identified to potentially compete for A532E and DOWEX IX sites. Hanford-relevant anion groundwater concentrations were used to design a series of laboratory-scale batch experiments to evaluate the impact of competing anions on resin performance and potential kinetic effects. These data are then modeled to obtain Cl--normalized equilibrium exchange coefficients (K) needed to predict IX resin performance. The work is presented in two parts, with IX performance evaluated for A532E in Part I and DOWEX in Part II. Part I results demonstrate that TcO 4 - uptake is not impacted by NO 3 - , SO 4 2- , Cl - , CO 3 2- (as HCO 3 - ) and U(VI) carbonate anions, with K TcO4-/Cl- > 4,000, likely due to the high selectivity of A532E trihexylammonium sites for the large, weakly hydrated TcO 4 - anion. Other anion K values were K NO3-/Cl- = 20, K SO4--/Cl- = 0.2, K HCO3-/Cl- = 0.09, K U/Cl- = 370–1000. These K values provide conservative parameters for predicting A532E performance, and demonstrate that, under these test conditions, A532E will remove TcO 4 - from current and future influent streams to meet groundwater treatment objectives.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies

Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. Here, in the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Current challenges and potential directions towards precision microscale additive manufacturing – Part III: Energy induced deposition and hybrid electrochemical processes

The Part III of the four-part series of articles discusses the challenges and opportunities in microscale additive manufacturing processes, specifically focusing on energy-induced deposition and electrochemical processes. Compared to the direct ink write (DIW) and laser-based processes, the energy-induced deposition methods can fabricate high-resolution, high aspect ratio and complex parts, while the hybrid electrochemical process can be used to fabricate complex parts using a wide range of conductive and photoactive materials. However, the volumetric throughput of these processes is lower than their DIW and laser-based counterparts. The processes that have been explored in this process are Focused-ion Beam Induced Deposition (FIBID), Laser Chemical Vapor Deposition (LCVD), Menicus-confined Electrodeposition (MCED) and Laser-Enabled Electrochemical Printing (LECP). The range of processable materials, feature-size resolution, geometry and volumetric throughput are used as factors to evaluate the current state-of-the-art for these processes. Finally, novel approaches have been proposed in the article to address these challenges associated with microscale AM processes.

42 ENGINEERING↗
DOE OSTI2025

srlife : a software tool for estimating the life of high temperature concentrating solar receivers. Part I – metallic receivers

Here, this paper introduces srlife, a tool for estimating the structural service life of concentrating solar power (CSP) receivers operating at high temperatures. Supporting both metallic and ceramic receiver designs, srlife is available as open-source software at https://github.com/applied-material-modeling/srlife and can be installed via the PyPi package manager (https://pypi.org). Given basic receiver geometry and incident heat flux, the tool performs thermohydraulic and structural analysis and estimates the life of a receiver. Designed for easy integration into a software stack, including solar field and levelized cost analysis, the tool can be utilized for optimizing receiver designs to meet service life and economic targets. This paper is Part I in a two-part series. Part I discusses the analysis process used to estimate the life of metallic receivers, along with a description of the required input data. Additionally, several heuristics applied within srlife can reduce analysis time significantly while maintaining accurate life estimations for metallic receivers when compared to full analyses. Several examples demonstrating the utility of srlife in receiver design are also discussed. Part II focuses on the life estimation of ceramic receivers, using time-dependent reliability analysis and various ceramic failure models implemented in srlife.

Creep-fatigue analysis↗
DOE OSTI2026

Hydrogen-based ore-to-part manufacturing of near-net-shape stainless steel

Decarbonizing iron and steelmaking, combined with global disruptions to raw material supply chains, necessitates novel approaches to iron and steel production. In this work, we demonstrate a direct ore-to-part manufacturing route using a mixture of ore-derived oxide powders of Fe 2 O 3 , Cr 2 O 3 , NiO, and MoO 3 as feedstock for additive manufacturing, combined with sintering under H 2 to produce a near-net-shape austenitic stainless-steel. Complete reduction of all constituent oxides, including MoO 3 and Cr 2 O 3 , is achieved in-situ at 1300 °C, resulting in dense, crack-free bulk alloy. The fabricated part retains geometric fidelity while undergoing substantial volumetric shrinkage inherent to redox and sintering. Thermodynamic calculations elucidate the co-reduction mechanisms and alloying pathways that enable complete metallization. This work is the first demonstration of net-shaping metal parts directly from ore derived oxides, and this ore-to-part approach can minimize the emissions and lead time for manufacturing associated with downstream processing such as rolling, forging, and machining.

Yang, Mingzhang [Univ. of Waterloo, ON (Canada); F↗
DOE OSTI2022

Developing solid-surface plasma facing components for pilot plants and reactors with replenishable wall claddings and continuous surface conditioning. Part B: required research in present tokamaks

Abstract The companion part A paper (Stangeby et al 2022) reports a number of independent estimates indicating that high-duty-cycle DT tokamaks starting with pilot plants will likely experience rates of net erosion and deposition of solid PFC, plasma facing component, material in the range of 10 3 to 10 4 kg yr −1 , regardless of the material used. The subsequent redeposition of such large quantities of material has the potential for major interference with tokamak operation. Similar levels and issues will be involved if ∼continuous low-Z powder dropping is used for surface conditioning of DT tokamaks, independent of the material used for the PFC armor. In Stangeby et al (2022) (part A) it is proposed that for high-duty-cycle DT tokamaks, non-metallic low-Z refractory materials such as ceramics (graphite, SiC, etc) used as in situ replenishable, relatively thin—of order mm—claddings on a substrate which is resistant to neutron damage could provide a potential solution for protecting the main walls, while reducing the risk of degrading the confined plasma. Assessment of whether such an approach is viable will require information, much of which is not available today. Section 6 of part A identifies a partial list of major physics questions that will need to be answered in order to make an informed assessment. This part B report describes R&D needed to be done in present tokamaks in order to answer many of these questions. Most of the required R&D is to establish better understanding of low-Z slag generation and to identify means to safely manage it. Powder droppers provide a unique opportunity to carry out controlled studies on the management of low-Z slag in current tokamaks, independent of whether their protection tiles use low-Z or high-Z material.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

2.5D Super-Resolution Approaches for X-Ray Computed Tomography-Based Inspection of Additively Manufactured Parts

X-ray computed tomography (XCT) is a key tool in non-destructive evaluation of additively manufactured (AM) parts, allowing for internal inspection and defect detection. Despite its widespread use, obtaining high-resolution CT scans can be extremely time consuming. This issue can be mitigated by performing scans at lower resolutions; however, reducing the resolution compromises spatial detail, limiting the accuracy of defect detection. Super-resolution algorithms offer a promising solution for overcoming resolution limitations in XCT reconstructions of AM parts, enabling more accurate detection of defects. While 2D super-resolution methods have demonstrated state-of-the-art performance on natural images, they tend to under-perform when directly applied to XCT slices. On the other hand, 3D super-resolution methods are computationally expensive, making them infeasible for large-scale applications. To address these challenges, we propose a 2.5D super-resolution approach tailored for XCT of AM parts. Our method enhances the resolution of individual slices by leveraging multi-slice information from neighboring 2D slices without the significant computational overhead of full 3D methods. Specifically, we use neighboring low-resolution slices to super-resolve the center slice, exploiting inter-slice spatial context while maintaining computational efficiency. This approach bridges the gap between 2D and 3D methods, offering a practical solution for high-throughput defect detection in AM parts.

Sullivan, Haley↗
DOE OSTI2023

Rethinking the Price Formation Problem–Part 2: Rewarding Flexibility and Managing Price Risk

In this study, part 1 of this two-part paper describes the impact that uncertainty has on the design and analysis of price formation policies in the non-convex auctions conducted by U.S. wholesale electricity market operators. Using first a toy model and then a large-scale test system, Part 2 demonstrates the difference in prices under the idealized benchmark of ex ante convex hull pricing defined in Part 1 versus existing methods, in particular documenting the potential for suppression of volatility and therefore under-compensation of flexibility by existing methods. The examples highlight that inefficient spot price formation can induce inefficient forward commitments of generators, necessitating out-of-market intervention to restore a reliable and efficient operating plan.Given the potential side effects of existing policies for investment and operation, we suggest two elements in a reoriented approach to the price formation problem: first ensuring that prices exhibit full-strength volatility, and second ensuring that risk-averse market participants have sufficient ability to manage this volatility.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

A Variational Method for Analyzing Vortex Flows in Radar-Scanned Tornadic Mesocyclones. Part III: Sensitivities to Vortex Center Location Errors

Abstract When the vortex center location is estimated from a radar-scanned tornadic mesocyclone, the estimated location is not error-free. This raises an important issue concerning the sensitivities of analyzed vortex flow (VF) fields by the VF-Var (formulated in Part I of this paper series and tested in Part II) to vortex center location errors, denoted by Δ x c . Numerical experiments are performed to address this issue with the following findings: The increase of |Δ x c | from zero to a half of vortex core radius causes large analysis error increases in the vortex core but the increased analysis errors decrease rapidly away from the vortex core especially for dual-Doppler analyses. The increased horizontal-velocity errors in the vortex core are mainly in the Δ x c -normal component, because this component varies much more rapidly than the other component along the Δ x c direction in the vortex core. The vertical variations of Δ x c distort the vertical correlation structure of Δ x c -dislocated VF-dependent background error covariance, which can increase the analysis errors in the vortex core. The dual-Doppler analyses have adequate accuracies outside the vortex core even when |Δ x c | increases to a half of vortex core radius, while single-Doppler analyses can also have adequate accuracies outside the vortex core mainly for the single-Doppler-observed velocity component. The sensitivities to Δ x c are largely unaffected by the vortex slanting. The above findings are important and useful for assessing the accuracies of analyzed VFs for real radar-observed tornadic mesocyclones. Significance Statement When the vortex center location is estimated from a radar-scanned tornadic mesocyclone, the estimated location is not error-free. This raises an issue concerning the sensitivity of analyzed vortex flow (VF) by the VF-Var (formulated in Part I of this paper series and tested with simulated radar observations in Part II) to vortex center location error. This issue and its required investigations are very important for the VF-Var to be applied to real radar-observed tornadic mesocyclones, especially in an operational setting with the WSR-88Ds. Numerical experiments are performed to address this issue. The findings from these experiments are important and useful for assessing the accuracies of VF-Var analyzed VF fields for real radar-observed tornadic mesocyclones.

Xu, Qin↗
DOE OSTI2020

Commercial Electronic Part Class Definitions

Electronic parts used in Nuclear Security Enterprise (NSE) applications have varying pedigrees. Understanding the differences among these "part classes" will better enable Kansas City National Security Campus (KCNSC) and Sandia National Laboratories (SNL, or Sandia) to effectively manage factors such as risk, effort, cost, etc. across all functional areas which have a shared interest in the definition and acquisition process. Regardless of the pedigree and complexity, all parts are expected to meet necessary quality and reliability requirements. This activity has been conducted as part of the COTS Transformation Initiative (CTI).

42 ENGINEERING↗
DOE OSTI2020

Computational Analysis of Water Film Thickness During Rain Events for Assessing Hydroplaning Risk Part 2: Rough Road Surfaces

Hydroplaning occurs when a water film forms on a road during a rain event and vehicles are traveling at a speed that does not provide sufficient time for the tires to push the water film out of the tire path. Under these conditions, the tire loses contact with the road and the driver may lose control over the vehicle. The present study is a part of a multiyear research effort aimed at gaining a better understanding of the factors that contribute to hydroplaning risk in order to minimize the occurrence of hydroplaning accidents. Three-dimensional computational fluid dynamics (CFD) analysis was used to investigate the water film thickness on multilane roads, one of the key parameters in evaluating hydroplaning risk. In the first part of the study, water films forming on wide roadways, i.e. multilane highways with 2, 4, and 6 lanes per side, were analyzed, with varying cross slope, longitudinal slope, and rainfall rate. Roadways with and without curbs and drainage were included in the analysis. The analysis in the first part was limited to nearly smooth asphalt or concrete surfaces because the maximum roughness height that can be specified in a CFD model using wall functions to determine shear stress at the road surface boundary is one half the thickness of computational cell layer adjacent to the boundary and the need to resolve the vertical velocity distribution in a thin water film requires cell layers that are a fraction of a millimeter thick. In this part of the study, the analysis was extended to consider the influence of pavement roughness over a range extending up 3.6 mm on the development of water film thickness. Various methods of modeling roughness were investigated and are presented: the roughness height model, a meshed-out geometry of the macrotexture of the pavement, and a porous region model. The computational results were analyzed and compared with experimental measurements performed by Gallaway et al.

42 ENGINEERING↗
DOE OSTI2020

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower (CRADA NFE-18-07280 Final Report)

ORNL worked with Cadens, LLC, to explore the use of additive manufacturing (AM) to produce low-cost parts for low-head hydropower systems. Cadens develops design optimization software that leverages the flexible, low-cost, high-strength benefits of AM and composite materials. Cadens also operates a micro-hydro lab to test AM components in controlled environments. Until now, Cadens’ tests have been limited to components of a size that they can cost-effectively manufacture using local commercial systems. This project provided an opportunity for Cadens to scale up their modular AM hydropower parts using the capabilities of Big Area Additive Manufacturing (BAAM). This project was a success and resulted in the design and fabrication of several end-use parts of a hydropower system, using a Big Area Additive Manufacturing (BAAM) system. The fabricated parts include a draft tube, thimble, runner housing mold, PVC end fitting and two PVC pipe supports. In addition, a runner system was fabricated using fused deposition modeling on a 3D Platform Workbench 400 Series System.

13 HYDRO ENERGY↗
DOE OSTI2024

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower

ORNL worked with Cadens, LLC to explore the use of additive manufacturing (AM) for the production of low-cost parts for low-head hydropower systems. Cadens develops design optimization software that leverages the flexible, low-cost, high-strength benefits of AM and composite materials, and operates a micro-hydro lab to test AM components in controlled environments. Until now Cadens’ tests have been limited in size to components that they can cost-effectively manufacture using local commercial systems. This project provided an opportunity for Cadens to scale up their modular AM hydropower parts using the capabilities of Big Area Additive Manufacturing (BAAM). This project was a success and resulted in the design and fabrication of several end use parts of a hydropower system using a Big Area Additive Manufacturing (BAAM) system. The fabricated parts include draft tube, thimble, runner housing mold, PVC end fitting and two PVC pipe supports. The components have been in use for more than three years without a 3D printed component failing.

13 HYDRO ENERGY↗