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NASA NTRS2015

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

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

J K Watson↗

DOE OSTI2024

Colloidal Stability of PFSA-Ionomer Dispersions. Part I. Single-Ion Electrostatic Interaction Potential Energies

Charged colloidal particles neutralized by a single counterion are increasingly important for many emerging technologies. Attention here is paid specifically to hydrogen fuel cells and water electrolyzers whose catalyst layers are manufactured from a perfluorinated sulfonic acid polymer (PFSA) suspended in aqueous/alcohol solutions. Partially dissolved PFSA aggregates, known collectively as ionomers, are stabilized by the electrostatic repulsion of overlapping diffuse double layers consisting of only protons dissociated from the suspended polymer. We denote such double layers containing no added electrolyte as "single ion". Size-distribution predictions build upon interparticle interaction potential energies from the Derjaguin-Landau-Verwey-Overbeek (DLVO) formalism. However, when only a single counterion is present in solution, classical DLVO electrostatic potential energies no longer apply. Accordingly, here a new formulation is proposed to describe how single-counterion diffuse double layers interact in colloidal suspensions. Part II (Srivastav, H.; Weber, A. Z.; Radke, C. J. Langmuir 2024 DOI: 10.1021/acs.langmuir.3c03904) of this contribution uses the new single-ion interaction energies to predict aggregated size distributions and the resulting solution pH of PFSA in mixtures of n-propanol and water. A single-counterion diffuse layer cannot reach an electrically neutral concentration far from a charged particle. Consequently, nowhere in the dispersion is the solvent neutral, and the diffuse layer emanating from one particle always experiences the presence of other particles (or walls). Thus, in addition to an intervening interparticle repulsive force, a backside osmotic force is always present. With this new construction, we establish that single-ion repulsive pair interaction energies are much larger than those of classical DLVO electrostatic potentials. The proposed single-ion electrostatic pair potential governs dramatic new dispersion behavior, including dispersions that are stable at a low volume fraction but unstable at a high volume fraction and finite volume-fraction dispersions that are unstable with fine particles but stable with coarse particles. Finally, the proposed single-counterion electrostatic pair potential provides a general expression for predicting colloidal behavior for any charged particle dispersion in ionizing solvents with no added electrolyte.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1996

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

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

Louis, P.↗

NASA NTRS1992

Development of a contact lens quality monitoring system

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

Singh, Jag J.↗

DOE OSTI2020

Thermal, mechanical, and electrical properties of LSCo/mullite composite contact materials for solid oxide fuel cells

Lanthanum strontium cobaltite (LSCo) is considered as a good candidate cathode contact material for solid oxide fuel cells, due to high electrical conductivity. However, LSCo has a very large coefficient of thermal expansion (CTE) than the cells and metallic interconnects. As a result, poor mechanical stability is expected during thermal cycling. To minimize the CTE mismatch, we investigate a composite approach involving mixing LSCo with an inert material of low CTE, such as mullite at volume fractions from 0.1 to 0.4. Composite’s CTE shows a decreasing trend with increasing mullite volume fractions, and is consistent with model predictions. X-ray powder diffraction analysis of sintered LSCo/mullite composites exhibits no presence of other phases for samples aged for 500h at 800oC, indicating chemical compatibility. Electrical conductivity by a 4-pt method shows a decreasing trend with increasing mullite content. Contact strength of as-sintered and thermally cycled samples show that only the composite with 0.4 volume fraction has a measurable strength; the other composites have no strength. Overall, the composite approach is demonstrated in the LSCo/mullite system to lower the CTE and hence achieve thermal cycle stability. The addition of the inert phase to the LSCo matrix; however, also reduces the electrical conductivity.

Contact materials, LSCo, mullite, CTE, electrical ↗

DOE OSTI2024

A Spectacular Viscoelastic Model Calibration for 828/D230/Alox Generated from Legacy Sandia Data

The nonlinear viscoelastic Spectacular model is calibrated to the thermo-mechanical behavior of 828/D230/Alox with an alox volume fraction of 20 %. Legacy experimental data from Sandia’s polymer properties database (PPD) is used to calibrate the model. Based on known densities of the epoxy 828/D230 and the alox filler, the alox volume fractions listed on the PPD were likely reported incorrectly. The alox volume fractions are recalculated here. Using the recalculated alox volume fractions, the PPD contains experimental data for 828/D230/Alox with alox volume fractions of 16 %, 24 %, and 33 %, so the thermo-mechanical behavior at 20 % alox volume fraction is estimated by interpolating between the bounding cases of of 16 % and 24 %. Because the Spectacularmodel can be fairly challenging to calibrate, the calibration procedure is described in detail. Several of the calibration steps involve inverse parameter identification, where an experiment is simulated and parameters are iteratively updated until the model response matches the experimental data. As the PPD does not fully describe all experimental procedures, the experimental simulations use assumed thermal and mechanical loading rates that are typical for the viscoelastic characterization of epoxies. Spectacular uses four independent relaxation functions related to volumetric (ƒ 1 ), shear (ƒ 2 ), thermal strain (ƒ 3 ), and thermal relaxations (ƒ 4 ). The previous SPEC model form, also known as the universal_polymer model, uses two independent relaxation functions related to volumetric and thermal relaxation (ƒ ν = ƒ 1 = ƒ 3 = ƒ 4 ) and shear relaxation (ƒ s = ƒ 2 ). The two constitutive choices are briefly evaluated here, where it is found that the four relaxation function approach of Spectacular was better suited for fitting the coefficient of thermal expansion during both heating and cooling.

36 MATERIALS SCIENCE↗

NASA NTRS1982

On determination of fibre fraction in continuous fibre composite materials

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

Whittenberger, J. D.↗

NASA NTRS1992

Thermal and ultrasonic evaluation of porosity in composite laminates

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

Johnston, Patrick H.↗

NASA NTRS1997

Laser-Induced Incandescence Measurements in Low Gravity

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

VanderWal, R. L.↗

NASA NTRS1996

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

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

Ku, Jerry C.↗

DOE OSTI2024

Shape effects on the local dynamics of suspensions of spheroidal particles

The effect of shape on the dynamics of suspensions of non-spherical heavy particles is examined by fully resolved numerical simulations of oblate and prolate spheroids, as well as spheres, for a density ratio of ten, volume fractions ranging from 0.5% to 5%, and Reynolds numbers between 20 and 30. The dynamics is determined both by the interactions of the particles with the fluid as well as by collisions, with the number and importance of collisions increasing with volume fractions. A single isolated oblate or prolate spheroid falling under gravity generally falls broadside on, for the governing parameters examined here, and at low-volume fractions, the majority of particles in a suspension fall that way. At higher-volume fractions, the orientation is more random. The slip velocity decreases as the volume fraction increases for all shapes, as expected, but the effect of the shape is much less than seen for a single particle. Furthermore, this seems to be due to two effects. For all volume fractions, the most deformed particles cluster more than spheres and less deformed particles, which increases their slip velocity. As the concentration increases, the increased particle interactions also causes more particles to fall short side-on, which reduces the frontal area and the resulting drag, increasing the slip velocity. This second effect is, of course, absent for spherical particles.

42 ENGINEERING↗

NASA NTRS1999

Evolution of Local Microstructures: Spatial Instabilities of Coarsening Clusters

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

Frazier, Donald O.↗

DOE OSTI2025

A Geometric Volume of Fluid-Based Multiphase Flow Solver Extension to the Reacting Flow Solver, PeleLM

A new algorithm is presented to simulate multiphase flows with surface tension in a pathway for spray combustion simulation. The algorithm combines capabilities from two open-source packages, including the interface reconstruction library (IRL), a library of computational geometry routines to enable the volume of fluid (VOF) method, and PeleLM, a solver for the reacting Navier-Stokes equations. Additionally, surface tension is implemented using the continuum surface force (CSF) model with an improved height function technique in the volume fraction field. Spurious errors in volume fraction arising from our combined strategy are corrected through a topology-based method that improves both numerical stability and accuracy. Multiple validation simulations are conducted, including (i) translations and rotations of Zalesak's disk, (ii) a stationary circular droplet with surface tension, (iii) an oscillating elliptical droplet, and (iv) three-dimensional deformation of a spherical droplet. Results indicate that the combined scheme retains the favorable properties of each of the component algorithms.

42 ENGINEERING↗

DOE OSTI2024

On the Flow of a Cement Suspension: The Effects of Nano-Silica and Fly Ash Particles

Additives such as nano-silica and fly ash are widely used in cement and concrete materials to improve the rheology of fresh cement and concrete and the performance of hardened materials and increase the sustainability of the cement and concrete industry by reducing the usage of Portland cement. Therefore, it is important to study the effect of these additives on the rheological behavior of fresh cement. In this paper, we study the pulsating Poiseuille flow of fresh cement in a horizontal pipe by considering two different additives and when they are combined (nano-silica, fly ash, combined nano-silica, and fly ash). To model the fresh cement suspension, we used a modified form of the power-law model to demonstrate the dependency of the cement viscosity on the shear rate and volume fraction of cement and the additive particles. The convection–diffusion equation was used to solve for the volume fraction. After solving the equations in the dimensionless forms, we conducted a parametric study to analyze the effects of nano-silica, fly ash, and combined nano-silica and fly ash additives on the velocity and volume fraction profiles of the cement suspension. According to the parametric study presented here, larger nano-silica content results in lower centerline velocity of the cement suspension and larger non-uniformity of the volume fraction. Compared to nano-silica, fly ash exhibits an opposite effect on the velocity. Larger fly ash content results in higher centerline velocity, while the effect of the fly ash on the volume fraction is not obvious. For cement suspension containing combined nano-silica and fly ash additives, nano-silica plays a dominant role in the flow behavior of the suspension. The findings of the study can help the design and operation of the pulsating flow of fresh cement mortars and concrete in the 3D printing industry.

36 MATERIALS SCIENCE↗

NASA NTRS2000

The Burning of Large N-Heptane Droplets in Microgravity

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

Manzello, Samuel L.↗

NASA NTRS1992

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

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

Ellis, David L.↗

NASA NTRS1993

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

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

Hammond, Vincent H.↗

NASA NTRS1997

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

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

VanderWal, Randall L.↗