Search NASA⌕ Search

SEARCH · Search NASA

Results for “AM Powder Characterization”

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 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Development of Fe-9Cr Alloy via High-Energy Ball Milling and Spark Plasma Sintering

Iron and chromium powders were mixed and mechanically alloyed via high-energy ball milling for different time durations (2–20 h) to produce an alloy powder with a nominal composition of Fe-9Cr (wt.%). The milled Fe-9Cr powders were analyzed using scanning electron microscopy (SEM), x-ray diffraction (XRD) and transmission electron microscopy (TEM) to understand the impact of ball milling (BM) time on the characteristics of the milled powder. The optimized milled powder samples were then consolidated via spark plasma sintering (SPS) for different dwell times and temperatures. The density of consolidated samples was found to reach a maximum of 98%. Microstructural characterization of the SPS samples were performed using XRD, SEM, TEM and electron backscatter diffraction. This study highlights the principles and importance of high-energy BM and SPS of Fe-9Cr model alloy for the future development of more complex oxide dispersion-strengthened alloys for various applications including advanced nuclear reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Catalysts Prepared from Atomically Dispersed Ce(III) on MgO Rival Bulk Ceria for CO Oxidation

Atomically dispersed cerium catalysts on an inert, crystalline MgO powder support were prepared by using both Ce(III) and Ce(IV) precursors. The materials were used as catalysts for CO oxidation in a once-through flow reactor and characterized by atomic-resolution scanning transmission electron microscopy, X-ray absorption near edge structure spectroscopy, X-ray photoelectron spectroscopy, and temperature-programmed reduction, among other techniques, before and after catalysis. The most active catalysts, formed from the precursor incorporating Ce(III), displayed a performance similar to that reported for bulk ceria under comparable conditions. The catalyst provided stable time-on-stream performance for as long as it was kept on stream, two days, increasing slightly in activity as the atomically dispersed cerium ions were transformed into ceria nanodomains represented as CeO x and having increased reducibility on the MgO support. Furthermore, the results suggest how highly dispersed supported ceria catalysts with low cerium loadings can be prepared and may pave the way to improved efficiencies of cerium utilization in oxidation catalysis.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Come for predictions, stay for complexity: synthesis and experimental probing of ionic conductivity in Li 9 B 19 S 33

Lithium thioborates, despite their potential cost-effectiveness and low density, have received considerably less attention as solid electrolytes compared to their thiophosphate counterparts. A primary obstacle to their widespread investigation has been the inherent challenge in synthesizing single-phase materials. Computational studies have predicted several lithium thioborate phases exhibiting high ionic conductivity, with Li 9 B 19 S 33 notably predicted to reach 80 mS cm −1 . However, experimental validation of these theoretical predictions remains absent. This work addresses this gap by detailing a successful synthesis of the previously elusive Li 9 B 19 S 33 phase, facilitated by in situ temperature dependent powder X-ray diffraction. Our findings reveal the peritectic nature of phase formation, necessitating an excess of boron sulfide in the reaction mixture. We further present a comprehensive structural characterization of Li 9 B 19 S 33 utilizing spectroscopic techniques like NMR, FT-IR, and diffuse reflectance and report on its ionic conductivity. Solid-state 6 Li NMR line narrowing experiments revealed an ion mobility activation energy of 0.26 eV whereas activation energies derived from impedance spectroscopy measurements were significantly higher, resulting in lower than theoretically predicted ionic conductivity.

Oppong, Richeal A. [Iowa State Univ., Ames, IA (Un↗
DOE OSTI2020

Measurement of Palladium Hydride and Palladium Deuteride Isotherms Between 130 K and 393 K

The data collected in the present work extend the measured phase diagram for palladium hydride and palladium deuteride to a region that has been sparsely reported in open literature. Absorption isotherms were measured using a 2.5-g bed of palladium powder at temperatures between 130 K and 393 K and pressures less than 1.3 x 10 5 Pa. Such low-pressure and low-temperature measurements are useful for characterizing palladium beds used for tritium pumping and storage. For tritium storage, pressures are kept below a few millibar for safety reasons. Low temperatures increase the tritium storage capacity of palladium. The measured absorption isotherms show the well-documented, two-phase behavior for this system: two solubility regions and a mixed, hydride-forming region. The isotherms show that an increased quantity of hydride is formed at lower temperatures, as marked by an increase in the hydride-forming region. This region exceeds hydrogen to metal ratios of 0.75 for T ≤ 273 K. Equilibrium pressures in the mixed region decrease with decreasing temperatures until a critical temperature is reached for each isotope. Below these critical temperatures, the rate of pressure decrease with decreasing temperature is significantly reduced. This change in trend suggests hydrogen isotopes are adsorbed onto the palladium surface, rather than forming a hydride. Using the equilibrium pressures recorded at temperatures between 236 K and 393 K for protium and between 211 K and 354 K for deuterium, the van’t Hoff constants were calculated to be A = –36 ± 1 kJ/mol and B = 88 ± 3 J/K for protium and A = -32 ± 2 kJ/mol and B = 88 ± 9 J/K for deuterium. As a result, these constants agree favorably with literature in the range where the temperatures of the measured isotherms overlap.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Selective Deposition and Fusion of AISI 316L: An Additive Manufacturing Process for Space Environments via Direct Ink Writing and Laser Processing

Unlocking the potential of additive manufacturing (AM) for space exploration hinges on overcoming key challenges, notably the ability to manufacture or repair parts on-site during exploration missions with consideration of quality, feedstock utilization, and challenges involved in microgravity environments. While there are multiple efforts to investigate the use of existing metal AM processes such as powder bed fusion (PBF), directed energy deposition (DED), and filament-based material extrusion, each process comes with a different set of challenges in space environments. Here, in this work, we introduce a new AM method that integrates the benefits of direct ink writing (DIW) to selectively deposit metallic pastes with laser-based processing to locally debind and subsequently melt and fuse metal powder, layer by layer, enabling the manufacturing of AISI 316L samples with densities exceeding 99.0%. The impact of process parameters on single-track dimensions, surface morphology, and porosity was characterized. The efficacy of laser debinding was assessed via secondary-ion mass spectrometry, permitting the carbon content to be estimated at 0.0152%, which is safely below the acceptable limit (0.03 wt%) for AISI 316L.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Updated ASME design correlations and qualification plan for powder bed fusion 316H stainless steel

This report provides an update on the Advanced Materials and Manufacturing Technologies (AMMT) program effort to qualify Laser-Powder Bed Fusion (L-PBF) 316H stainless steel for use with the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules. The report summarizes progress in testing and characterizing L-PBF material at elevated temperatures by providing preliminary design data for L-PBF 316H and by comparing the elevated temperature performance of the L-PBF material to wrought and conventional fusion welded 316H. The report then updates the initial AMMT qualification plan for L-PBF 316H, originally developed in 2023, to update the accelerated qualification strategy adopted in that plan to account for the new high temperature test data. The report also explores a few methods for further accelerating the qualification process using machine learning techniques to supplement the more conventional, empirical analysis methods typically used by ASME to correlate and extrapolate time-dependent material test data.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Development of PNNL’s Plutonium Metallography Capability

The goal of this project was to develop plutonium metallography capabilities and establish workflows for characterization at PNNL’s Radiological Processing Facility (RPL). Developing and expanding on this capability opens more opportunities for PNNL to better support science through collaborations with other labs, plants, and sites withing the Department of Energy Complex and through programs within the National Nuclear Security Administration. This project established metallography equipment in an air glovebox, polishing protocols, as well as radiological and facility controls and procedures so that gram quantities of plutonium metal could be analyzed on multiple characterization tools. Data was collected and analyzed on two different delta phase plutonium - Gallium samples and a calciothermically reduced alpha plutonium metal using a combination of optical and electron microscopy, powder X-ray diffraction, and atom probe tomography. This report highlights the metallography capabilities, some preliminary data collections, and plans at PNNL to support plutonium material science.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Preliminary Report on U-Th-Pb Isotope Systematics of the Olivine-Phyric Shergottite Tissint

Geochemical studies of shergottites suggest that their parental magmas reflect mixtures between at least two distinct geochemical source reservoirs, producing correlations between radiogenic isotope compositions, and trace element abundances.. These correlations have been interpreted as indicating the presence of a reduced, incompatible-element- depleted reservoir and an oxidized, incompatible-element-rich reservoir. The former is clearly a depleted mantle source, but there has been a long debate regarding the origin of the enriched reservoir. Two contrasting models have been proposed regarding the location and mixing process of the two geochemical source reservoirs: (1) assimilation of oxidized crust by mantle derived, reduced magmas, or (2) mixing of two distinct mantle reservoirs during melting. The former clearly requires the ancient martian crust to be the enriched source (crustal assimilation), whereas the latter requires a long-lived enriched mantle domain that probably originated from residual melts formed during solidification of a magma ocean (heterogeneous mantle model). This study conducts Pb isotope and U-Th-Pb concentration analyses of the olivine-phyric shergottite Tissint because U-Th-Pb isotope systematics have been intensively used as a powerful radiogenic tracer to characterize old crust/sediment components in mantle- derived, terrestrial oceanic island basalts. The U-Th-Pb analyses are applied to sequential acid leaching fractions obtained from Tissint whole-rock powder in order to search for Pb isotopic source components in Tissint magma. Here we report preliminary results of the U-Th-Pb analyses of acid leachates and a residue, and propose the possibility that Tissint would have experienced minor assimilation of old martian crust.

Moriwaki, R.↗
NASA NTRSDate not supplied

Additive Manufacturing (AM) for Propulsion Component and System Applications

NASA MSFC is developing several areas of additive manufacturing (AM) for propulsion component and system applications. These developments include new AM process and material development, large-scale AM pathfinder component fabrication and hot-fire testing, AM-centric design methodology, modeling and simulation, post-processing advancements, and new design applications of AM in aerospace. Some specific areas NASA has focused is the development and commercial infusion of AM supply chain for materials such as copper-alloy GRCop (Cu-Cr-Nb), Hydrogen-resistant alloys (NASA HR-1, JBK-75), refractory-based alloys (C-103, W, Mo, new formulations), and bimetallic and multi-metallic AM processes. Additional efforts have been focused on large scale AM demonstrating complex thin-wall structures up to 60” diameter using directed energy deposition. Material characterization, properties and component hot-fire testing has been completed using many of these newly developed AM alloys/processes. NASA has also focused on improvements to post-processing including powder removal, surface enhancements, and support removal to further realize cost and schedule benefits to the overall supply chain. These developments are part of the NASA Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Low Cost Upper Stage Propulsion (LCUSP) and Long Life Additive Manufacturing (LLAMA) projects, in addition to internal IRAD, and external collaborations.

Additive Manufacturing↗
DOE OSTI2021

The onset of alloying in Cu-Ni powders under high-shear consolidation

Friction consolidation (FC) is a solid phase processing methodology that densifies a material through high-shear deformation and pressure at elevated temperature. The method has garnered interest in the scientific community because of its ability to produce extremely refined and homogeneous microstructures, off-axis texture development, and improved material properties. This manuscript presents an investigation of Cu and Ni material mixing via evaluation of morphological evolution, grain boundary characterization, and compositional analysis to provide insights on the operational alloying mechanisms occurring under high shear and elevated temperature. Using correlative microscopy techniques, we show alloying progresses via a combination of grain boundary diffusion and interfacial roughening at heterophane boundaries. Evidence supporting Cu infiltration along Ni-Ni grain boundaries along with asymmetric diffusion of Cu into Ni grains is highlighted. The resultant, consolidated microstructure was produced directly from a powder compact in ~30 s and exhibited a submicron, equiaxed grain size.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cation Adaptive Structures Based on Manganese Cyanide Prussian Blue Analogues: Application of Powder Diffraction Data to Solve Complex, Unprecedented Stoichiometries and New Structure Types

Abstract A Mn(II) salt and A + CN − under anaerobic conditions react to form 2‐D and 3‐D extended structured compounds of A m Mn II n (CN) m+2n stoichiometry. Here, the creation and characterization of this large family of compounds, for example AMn II 3 (CN) 7 , A 2 Mn II 3 (CN) 8 , A 2 Mn II 5 (CN) 12 , A 3 Mn II 5 (CN) 13 , and A 2 Mn II [Mn II (CN) 6 ], where A represents alkali and tetraalkylammonium cations, is reviewed. Cs 2 Mn II [Mn II (CN) 6 ] has the typical Prussian blue face centered cubic unit cell. However, the other alkali salts are monoclinic or rhombohedral. This is in accord with smaller alkali cation radii creating void space that is minimized by increasing the van der Waals stabilization energy by reducing ∠Mn−N≡C, which, strengthens the magnetic coupling and increases the magnetic ordering temperatures. This is attributed to the non‐rigidity of the framework structure due the significant ionic character associated with the high‐spin Mn II sites. For larger tetraalkylammonium cations, the high‐spin Mn sites lack sufficient electrostatic A + ⋅⋅⋅NC stabilization and form unexpected 4‐ and 5‐coordinated Mn sites within a flexible, extended framework around the cation; hence, the size, shape, and charge of the cation dictate the unprecedented stoichio‐metry and unpredictable cation adaptive structures. Antiferromagnetic coupling between adjacent Mn II sites leads to ferrimagnetic ordering, but in some cases antiferromagnetic coupling of ferrimagnetic layers are compensated and synthetic antiferromagnets are observed. The magnetic ordering temperatures for ferrimagnetic A 2 Mn II [Mn II (CN) 6 ] with both octahedral high‐ and low‐spin Mn II sites increase with decreasing ∠Mn−N≡C. The crystal structures for all of the extended structured materials were obtained by powder diffraction.

Chemistry↗
DOE OSTI2019

Embedded Sensor Development in Metallic Structures for the Transformational Challenge Reactor

The ability to make minimally intrusive measurements of process conditions has tremendous potential for improving system performance and control in applications such as nuclear power generation. Towards this end, emerging and evolving advanced manufacturing methods, such as additive manufacturing, present new opportunities for more seamlessly integrating sensing with structure. This technical report summarizes the progress of work performed to assess the feasibility of embedding commercial off-the-shelf (COTS) sensors in a metallic reactor core using advanced manufacturing methods. The progress of four research and development tasks are documented: 1) A survey of COTS sensors for nuclear applications that are candidates for embedded fabrication, 2) Development of a conceptual framework for investigating the feasibility of sensor embedment, 3) Definition of structural geometries and other characteristics that will represent compelling proof-of-concept, and 4) Preliminary prototyping of embedded sensors. For the purposes of this initial study, nuclear grade K-type thermocouples were selected for investigation of embedment methodologies. This sensor was selected as an initial candidate because it represents one of the simplest sensor configurations that can provide useful process information. A selective laser melting (SLM) additive manufacturing process was used to fabricate structures with complexity representative of the core design of the transformational challenge reactor (TCR) and methods were developed to embed a thermocouple with a complex two-dimensional routing path. There are many challenges associated with embedding sensors during the additive manufacturing process including securing the sensor in the structure, relocating the part in the additive machine if using a “pick and place” sensor placement method, mitigating the potential for powder contamination, optimizing energy deposition parameters to build as closely as possible around the sensor path and improve structural integrity of the part, and tuning energy deposition to mitigate thermally induced warpage of the sensor and part as well as potential for damaging the sensing device. Preliminary results indicate that it is feasible to integrate the sensor while minimally compromising the structural integrity of the part and preserving sensor performance. This first phase of this work focused on developing a workflow for embedding sensors and controlling energy deposition during the additive manufacturing process to better understand the build characteristics around the sensor. Future work will perform more in-depth characterization of prototype parts using X-ray computed tomography and scanning electron microscopy to better understand fabricated structures, performance testing of embedded sensors in high temperature environments, adding new embedded measurement modalities, embedding devices with dissimilar materials in contact with additive powders, and the development of methods for embedding sensors with three-dimensional routing paths.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Growth and characterization of detector-grade CdMnTe by the vertical Bridgman Technique

Here, we grew Cd1-xMnxTe crystals with a nominal Mn concentration of 5% by the vertical Bridgman growth technique. The compositional variation along the length of the grown ingot was studied by powder X-ray diffraction. The composition was found to be uniform along the growth direction. The achieved resistivity was 1-2.5 x10 10 ohm-cm with a mobility-lifetime (μτ) product value for electrons of ~1.7x10 -3 cm 2 /V. An energy resolution of ~7.5% at 662 keV was achieved or a 9-mm long Frisch grid detector fabricated from an ingot grown using as-received starting materials.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Deposition and characterization of ZnS/Si heterojunctions produced by vacuum evaporation

Isotype heterojunctions of ZnS (lattice constant 5.41 A) were grown on silicon (lattice constant 5.43 A) p-n junctions to form a minority-carrier mirror. The deposition process was vacuum evaporation from a ZnS powder source onto a heated (450 C) substrate. Both planar (100) and textured (111) surfaces were used. A reduction of the minority-carrier recombination at the surface was seen from increased short-wavelength quantum response and increased illuminated open-circuit voltage. The minority-carrier diffusion length was not degraded by the process.

Landis, Geoffrey A.↗
NASA NTRS1991

Development, preparation, and characterization of high-performance superconducting materials for space applications

The preparation of high-temperature superconducting ceramics in bulk form is a major challenge in materials science. The current status of both partial melting and melt quenching techniques, with or without an intermediate powder processing stage, is described in detail, and the problems associated with each of the methods are discussed. Results of studies performed on melt-processed materials are reported and discussed. The discussion places emphasis on magnetization and on other physical properties associated with it, such as critical current density, levitation force, and flux creep. The nature of structural features which give rise to flux pinning, including both small and large defects, is discussed with reference to theoretical considerations. The rates of flux creep and the factors involved in attempting to retard the decay of the magnetization are surveyed.

Thorpe, Arthur N.↗
NASA NTRSDate not supplied

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗
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↗