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NASA NTRSDate not supplied

22 N HPGP Thruster Life Testing

In the ever-changing paradigm of efficient and capable spacecraft design, scientific missions continue pushing the envelope enabling spacecraft subsystems to deliver effective solutions to meet challenging new mission/spacecraft needs. From an in-space storable liquid chemical propulsion perspective, monopropellant hydrazine has been, and continues to be, a dependable propellant with considerable flight heritage, a variety of engine thrust classes available from multiple vendors, with repeatable and reliable performance. Additionally, the space propulsion industry has learned to successfully handle hydrazine, its regulations, the safety protocols, the personnel protective equipment, and the unique training standards–all requisite for loading spacecraft propulsion systems with toxic hypergolic hydrazine. The question now arises as to “what is next for in-space chemical propulsion?” Further, with the evolution and concrete advancements in innovative in-space green propellant technologies, capable of providing realizable benefits to scientific missions, concern over the reliability and availability of this higher performing and safer to handle class of propellants is waning. As science missions move forward with the potential flight in fusion of High Performance Green Propulsion (HPGP), NASA and its industry partners are working to address any gaps in system reliability, performance, or unique operational considerations. Propellant technology that offers both higher performance and significant reduction in personnel hazards compared to hydrazine presents an attractive propulsion subsystem design opportunity. Increased propulsion subsystem performance can result in lower spacecraft launch mass, larger scientific payloads, or extended on-orbit lifetimes. Mission trades using green propulsion technologies have been documented on multiple NASA Goddard Space Flight Center (GSFC) mission classes, examining various parameters and requirements to support mission architectures in Low Earth Orbit (LEO), High Earth Orbit (HEO), geostationary, lunar, planetary, and Quasi-halo orbit around Sun-Earth Lagrange point (L2). The results of these trade studies show promising, attainable benefits. The perceived programmatic risk of flying a newer propulsion technology has, unfortunately, not outweighed the benefits to date. To take advantage of the improved performance and mitigate programmatic risk, HPGP engines must demonstrate life testing at higher propellant throughputs than have currently been demonstrated. In an effort to proactively address the challenges with technology infusion into a risk-averse community, NASA and the Swedish National Space Agency (SNSA) outlined a collaborative Implementing Arrangement (IA) for the respective agencies to pursue increased HPGP technology maturation. This initial IA effort began in 2013, fresh off the heels of the successful PRISMA HPGP technology demonstration mission. The IA targeted objective is to reduce risk to potential future HPGP missions and fully characterize the LMP-103S propellant and associated engine performance. Over the past eight years, HPGP has flown in propulsion systems on twenty-five(25) spacecraft from seven(7) different Launch Ranges around the globe and on seven (7) different Launch Vehicles. Six(6) of these launches involved multiple loading operations for multiple spacecraft. For U.S. Range operations, nine (9) HPGP systems have been processed at Vandenberg Space Force Base(VSFB):six(6) in 2017, and three (3) in 2018. Six (6) more have been processed at Cape Canaveral Air Force Station (CCAFS)in May 2020, with three (3) systems launched in June 2020 and the remaining three (3) system were left loaded and ready until their launch in August of 2020. Three (3) more systems have been processed at Wallops Flight Facility(WFF)and launched in June 2021. In addition, these propulsion subsystems employed heritage propulsion subsystem component such as valves, filters, and pressure transducers, and have further demonstrated nominal functionality in both diaphragm and Propellant Management Device (PDM) propellant tanks. Based on these successes, HPGP technology continues to be considered for NASA Science Mission Directorate missions at GSFC. The work presented herein represents many years of development and collaborative efforts to successfully align higher performance, low toxicity hydrazine alternatives into scientific missions. NASA GSFC Propulsion Engineering, in collaboration with Bradford ECAPS, has developed mission specific thruster design and testing requirements to establish GSFC’s desired test conditions and firing sequences.In2017, the first flight-like 22N HPGP thruster Engineering Qualification Model (EQM-1)was designed and built by Bradford ECAPS to prove out the thruster design, materials, build process, and test campaign with respect to NASA GSFC critical component and mission requirements. This test program was developed to comprehensively test the thruster, the technology, and ultimately increase the 22N HPGP Technology Readiness Level(TRL). EQM-1was tested to environmental qualification levels prior to hot fire performance testing to represent the relevant end-to-end environment (launch to on-orbit operation)with required margin. This thruster demonstrated steady-state and pulse mode operational capability with propellant thruster throughput up to~53kg.At this throughput level, the EQM-1 engine began to present off-nominal performance and the test campaign was halted to allow for non-destructive testing and identify the root cause for the an omalous performance. Capitalizing on the successful elements of the EQM-1 campaign, an upgraded 22N HPGP EQM-2 has been manufactured by Bradford ECAPS to meet the complete GSFC requirements. The EQM-2 thruster’s test campaign has further demonstrated the robustness of the HPGP propulsion technology and increased the Technology Readiness Level (TRL) by undergoing a full acceptance test program, then proceeding into qualification, including environmental testing (vibration and shock to qualification levels),as well as hot-fire life testing, operating at steady-state and pulse modes with increased propellant thruster throughput to~150kg. The HPGP thruster performance testing enables effective HPGP thruster readiness evaluation to meet NASA candidate mission requirements in the future.

High↗

NASA NTRSDate not supplied

Spaceflight Maximum Allowable Concentrations for Ethyl Acetate

Ethyl acetate is a simple organic compound that occurs naturally and is used industrially as a solvent. It has been detected in the ISS atmosphere and is known to off-gas from building materials. As NASA astronauts have been and will be exposed to ethyl acetate during space missions, Spaceflight Maximum Allowable Concentrations (SMACs) were developed following an extensive review of the available literature.

E Spencer Williams↗

NASA NTRS2022

Embedding Climate Change in Urban Planning and Urban Design in New York City

Confronting the challenges of a rapidly urbanizing world threatened by climate change requires expanding the traditional influence and capabilities of urban planning and urban design, integrating climate science, natural systems and compact urban form to configure dynamic, desirable and healthy communities. Cost-effective planning and design measures that help mitigate emissions while bringing adaptive benefits should be prioritized. The chapter draws from the publication Climate Change and Cities (Cambridge University Press 2018) by the Urban Climate Change Research Network (UCCRN). The two-phase New York City case study by the Urban Design Climate Lab at the New York Institute of Technology and a team of international urban design climate experts illustrates how this emerging expertise can be replicated and implemented worldwide. Its focus on configuring people-centered public spaces that enhance energy efficiency and improve public health draws from four urban climate factors: improving efficiency of urban systems, both in energy and transportation; optimizing the form and layout of urban districts to enhance ventilation; promoting appropriate building materials with high reflectivity; and increasing green and blue urban infrastructure. The chapter highlights a set of tools and methods to measure success.

Resiliency↗

NASA NTRSDate not supplied

Wichita Climate II: Quantifying and Mapping Urban Heat to Inform Equitable and Sustainable Urban Planning Initiatives in Wichita, Kansas

Extreme heat is the deadliest weather-related event in the United States, as well as one of the least discussed. Climate change has raised the frequency, intensity, and duration of severe heat events. The built, urban environment is often hotter than neighboring rural areas due to a denser concentration of pavement, metal and other building materials absorbing and retaining heat, as well as a low amount of vegetation – creating a phenomenon commonly known as the urban heat island effect. This effect contributes to a wide range of public health issues, associated with heat strokes, dehydration, loss of work productivity, decreased learning, respiratory difficulties, and heat-related mortality. The average summer temperature in Wichita has increased 1.3 degrees (F) since 1970, and the number of days over 100 degrees (F) has historically increased, from 40 days in 1934 to 53 days in 2011.

Ritisha Ghosh↗

NASA NTRSDate not supplied

Geologic Maps for Civil Engineering and Infrastructure Planning

The Artemis Program mandate for sustainable, long-term presence on the Moon requires learning to "Live Off the Land". Geologic maps enable a paradigm shift to model the development and scaling of infrastructure for robotic and human exploration inside a bounded system on the lunar surface. Relying on geologic maps produced from orbital data and robotic precursor missions, in-situ resource utilization (ISRU) will be required to produce infrastructure, building materials and consumables. The ISRU value chain must be mapped to identify linkages of resources, producers, processes and equipment capabilities for transforming excavated regolith into usable feedstocks. Coordination will be required to balance supply and demand across the whole system of lunar infrastructure and operations, at each stage of development.

Geologic Mapping↗

NASA NTRSDate not supplied

Characterization of Fluorescence Signals in Synthetic Anorthite

In-situ resource utilization (ISRU) is a key capability to enable a long term presence on the Moon and other planetary bodies. For example, efforts have been underway to develop processes to utilize the lunar regolith to produce building materials and extract useful resources. In processes that utilize the regolith directly to produce construction materials, such as in various sintering methods, characterizing the composition of the regolith is important as the composition can affect the optimal process parame-ters. In processes that involve extracting resources such as iron, oxygen, hydrogen, etc., identifying areas with higher abundance of a particular resource will be critical since different regions of the Moon exhibit differing regolith composition. To this end, Ra-man is one technique that can rapidly characterize the mineralogy of rock samples. This technique has al-ready been deployed on Mars to detect various miner-als including olivine, carbonates, phosphates, etc. Besides characterizing the mineralogy, Raman spectra often contain unwanted fluorescence signals that can mask Raman peaks. In some cases, the fluorescence signals are narrow enough to aid in the identification of specific elements in soils. In this work, we explore fluorescence peaks in a synthetic anorthite sample, which are at the same position as Ruby fluorescence peaks attributed to chromium. These fluorescence peaks, as well as similar fluorescence peaks attributed to other elements, could have important implications for ISRU and the mining of critical resources as has been previously described.

Raman Spectroscopy↗

NASA NTRS2024

System Modeling of a Lunar Molten Regolith Electrolysis Plant

In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO 2 , MgO, Al 2 O 3 ) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The S ystem Engineering and Integration ( S E&I) I SRU M odeling and A nalysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant.

In-Situ Resource Utilization↗

NASA NTRSDate not supplied

System Modeling of a Lunar Molten Regolith Electrolysis Plant

Introduction: In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO2, MgO, Al2O3) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The System Engineering and Integration (SE&I) ISRU Modeling and Analysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) [1] as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant. System Model: Figure 1: MRE Plant Block Diagram The regolith excavation model determines the mass and power needed to excavate sufficient regolith. The preheating auger initiates the regolith heating process before regolith enters the MRE re-actor to reduce the energy required to turn the solid into a molten liquid. The MRE reactor is modeled in COMSOL Multiphysics and based on the research by Dominguez, Sibille, and Schreiner [2, 3, 4]. This preliminary reactor model provides an accurate calculation of thermal equilibrium during electrochemical operation of the reactor system to assess the optimal mass and power required to process the inlet flow of regolith. The model also computes the outlet flowrates of oxygen and molten products. For this analysis, the primary components of the metal alloy considered were iron and silicon. The oxygen is then purified using an Yttrium Stabilized Zirconia (YSZ) electrode, followed by liquefaction using a 90K cryocooler to be stored as liquid oxygen in insulated cylindrical tanks. In future iterations of the system model, the molten metal tapped from the MRE reactor will undergo additional processing or refinement. However, downstream handling of metals is currently a technology gap that is missing a high TRL subsystem model. Therefore, for this analysis, the accumulated metal alloy stream terminates after leaving the MRE reactor. Study Goals: This analysis investigates multiple input variables to the system to determine the sensitivity of a (near) complete plant at full-scale. This preliminary investigation ran parametric sweeps on the MRE reactor geometry, electrical current supply, layers of multi-layer insulation (MLI) on the reactor, size of the electrodes in the oxygen purification model, and regolith composition (based on landing site location). Three production targets of oxygen (1,000, 10,000, and 50,000 kg/yr) were investigated for this analysis. The parametric sweeps conducted in this analysis provide valuable insight into the expected impact of the various model inputs on plant size. This information can be used to identify the most critical components of the plant and guide future decisions on allocating funding for research and development, providing subsystem developers with appropriate interfaces with downstream and upstream processes, and assessing the overall feasibility of MRE when compared to other ISRU plants. References: [1] Carlson, A. et al. (2024) ICES, ICES-2024-53. [2] Dominguez, D.A., and Sibille, L. (2011) AIAA, AIAA-2011-700. [3] Schreiner, S.S. (2015) MIT, Dissertation. [4] Schreiner, S.S. et al. (2016) ASR, 57(7), pp.1585-1603.

ISRU↗

NASA NTRS2003

The Building Blocks of Materials: Gathering Knowledge at the Molecular Level

Two start-up positions were created within SD46 to pursue developments in the rapidly expanding areas of biomineralization and nano-technology. As envisioned by Dr. Sandor Lehoczy, the new laboratories to be developed must have the capacity to investigate not only processes associated with the self-assembly of molecules but also the examination of self-assembled structures. For these purposes, laboratories capable of performing the intended function, particularly light scattering spectroscopy and atomic force microscopy were created. What follows then are recent advances arising from the development of these new laboratories. With the implementation of the Atomic Force Microscopy Facility, examples of investigations that determine a correlation between the molecular structure of materials and their macroscopic physical properties are provided. In addition, examples of investigations with particular emphasis on the physical properties of protein crystals, at the molecular level, and subsequent macroscopic characteristics are as provided. Finally, progress in fabrication of technology at the nano-scale levels at the developmental stage is also presented.

Source record↗

NASA NTRS2019

Design of an Automated Ultrasonic Scanning System for In-Situ Composite Cure Monitoring and Defect Detection

The preliminary design and development of an automated ultrasonic scanning system for in-situ composite cure monitoring and defect detection in the high temperature environment of an oven was completed. This preliminary design is a stepping stone to deployment in the high temperature and high pressure environment of an autoclave, the primary cure method of aerospace grade thermoset composites. Cure monitoring with real-time defect detection during the process could determine when defects form and how they move. In addition, real-time defect detection during cure could assist validating physics-based process models for predicting defects at all stages of the cure cycle. A physics-based process model for predicting porosity and fiber waviness originating during cure is currently under development by the NASA Advanced Composites Project (ACP). For the design, an ultrasonic contact scanner is enclosed in an insulating box that is placed inside an oven during cure. Throughout the cure cycle, the box is nitrogen-cooled to approximately room temperature to maintain a standard operating environment for the scanner. The composite part is mounted on the outside of the box in a vacuum bag on the build/tool plate. The build plate is attached to the bottom surface of the box. The scanner inspects the composite panel through the build plate, tracking the movement of defects introduced during layup and searching for new defects that may form during cure. The focus of this paper is the evaluation and selection of the build plate material and thickness. The selection was based on the required operating temperature of the scanner, the cure temperature of the composite material, thermal conductivity models of the candidate build plates, and a series of ultrasonic attenuation tests. This analysis led to the determination that a 63.5 mm thick build plate of borosilicate glass would be utilized for the system. The borosilicate glass plate was selected as the build plate material due to the low ultrasonic attenuation it demonstrated, its ability to efficiently insulate the scanner while supporting an elevated temperature on the part side of the plate, and the availability of a 63.5 mm thick plate without the need for lamination.

Hudson, Tyler B.↗

NASA NTRS2010

Project M: Scale Model of Lunar Landing Site of Apollo 17

The basis of the project was creating a scale model representation of the Apollo 17 lunar landing site. Vital components included surface slope characteristics, crater sizes and locations, prominent rocks, and lighting conditions. The model was made for Project M support when evaluating approach and terminal descent as well as when planning surface operations with respect to the terrain. The project had five main mi lestones during the length of the project. The first was examining the best method to use to re-create the Apollo 17 landing site and then reviewing research fmdings with Dr. Tim Crain and EO staff which occurred on June 25, 2010 at a meeting. The second step was formulating a construction plan, budget, and schedule and then presenting the plan for authority to proceed which occurred on July 6,2010. The third part was building a prototype to test materials and building processes which were completed by July 13, 2010. Next was assembling the landing site model and presenting a mid-term construction status report on July 29, 2010. The fifth and final milestone was demonstrating the model and presenting an exit pitch which happened on August 4, 2010. The project was very technical: it needed a lot of research about moon topography, lighting conditions and angles of the sun on the moon, Apollo 17, and Autonomous Landing and Hazard Avoidance Technology (ALHAT), before starting the actual building process. This required using Spreadsheets, searching internet sources and conducting personal meetings with project representatives. This information assisted the interns in deciding the scale of the model with respect to cracks, craters and rocks and their relative sizes as the objects mentioned could interfere with any of the Lunar Landers: Apollo, Project M and future Landers. The project concluded with the completion of a three dimensional scale model of the Apollo 17 Lunar landing site. This model assists Project M members because they can now visualize approach phase, terminal descent phase, and surface phase operations on the physical model. The project had an additional requirement that was also satisfied: the granite table the model was placed on must be returnable to its original condition if needed in the future.

O'Brien, Hollie↗

NASA NTRS2015

Biomaterials Out of Thin Air: in Situ, On-Demand Printing of Advanced Biocomposites

Upmass is the single most significant limitation of our current space mission capability. Although biomaterials and biocomposites have mass, strength, flexibility, and self-healing properties that could significantly reduce upmass, their use is limited by the following drawbacks: Expensive, specific production. Many biomaterials can only be produced as part of significant support ecosystem; Inaccessible functional customization. The grain of wood, the porosity of bone, and so on are an integral part of the materials' desired mechanical properties, but are not deterministic when the material is naturally grown; Limited compositions. Most biomaterials (unlike metal, plastic, etc.) cannot be easily combined or modified to produce new materials. This project builds on recent advances in: Synthetic biology. Libraries of standardized genetic parts which can be used for controlled cellular material production, delivery, and binding; 3D printing. Commercial off-the-shelf components which can be used to make of a pico- to nanoliter cell deposition system; Tissue engineering. Proven cell-compatible support hydrogels and scaffolds can be modified to bind the deposited biomaterials of interest. Objectives: Feasibility and benefit analysis. Two mission contexts span the concept's scope (see below); Proof-of-concept demonstration. A simple grid of two proteins, fluorescent for easy detection, to validate the core technology concept; Proposed implementations for follow-on work. Avenues for future work on each core component (host cell, production control, material delivery, material binding, etc.); Complementary studies exploration. A survey of other emerging areas (in situ resource utilization, protein engineering, etc.) with the potential to multiply our technology's impact. Potential Impacts: This application could dramatically expand manufacturing capabilities on Earth and in space: In situ resource utilization. A far greater range of materials and products will be available from the limited palette offered by in situ resource extraction techniques; Reduced equipment and material upmass for off-Earth habitats. Ready- to-use highly specialized construction materials (radiation hardened, compressive/tensile, light or dense) from an extremely low starting mass; Structured biomaterial production. New ready-to-use macro, micro, and molecular manufacturing techniques for traditional biomaterials such as wood, bone and shell; New and novel biocomposite creation. The ability to create completely novel material composites from any base material that cells can be engineered to produce. Suggested Mission Contexts: ISS part manufacturing. A 'minimal working example' making a finished biomaterial part aboard the International Space Station; A long-term Mars habitat. 'Cradle-to-grave' use at a hypothetical Mars habitat, covering everything from tools to construction materials. Alternate Abstract: Imagine being able to print anything from tools and composite building materials to food and human tissues. Imagine being on Mars with the ability to replace any broken part, whether it's a part of your spacesuit, your habitat, or your own body. We propose a technique that would allow just that. By printing 3D arrays of cells engineered to secrete the necessary materials, the abundant in situ resources of atmosphere and regolith become organic, inorganic, or organic-inorganic composite materials. Such materials include novel, biologically derived materials not previously possible to fabricate.

habitats↗

NASA NTRS2015

Biomaterials Out of Thin Air: in Situ, On-demand Printing of Advanced Biocomposites

habitats↗

NASA NTRS1997

Emergency Operations Center at Johnson Space Center

In June 1966, at the start of the Gulf Coast hurricane season, the Johnson Space Center (JSC) celebrated the opening of its new 4,000-square foot, state-of-the-art Emergency Operations Center (EOC). The new EOC has been upgraded and enhanced to support a wide spectrum of emergencies affecting JSC and neighboring communities. One of the main features of the EOC is its premier computerized dispatch center. The new system unites many of JSC's critical emergency functions into one integrated network. It automatically monitors fire alarms, security entrances, and external cameras. It contains the JSC inventory of hazardous materials, by building and room, and can call up Material Safety Data Sheets for most of the generic hazardous materials used on-site. The EOC is available for community use during area emergencies such as hurricanes and is a welcome addition to the Clear Lake/Galveston Bay Area communities' emergency response resources.

Caylor, Gary C.↗

NASA NTRSDate not supplied

Updates to the Predictive Materials Modeling Software Tools

Updates on NASA's efforts to build predictive material models from the micro-scale to the macro-scale are presented. To complement the mission design cycle process and reduce the need for extensive testing, NASA is developing modeling and simulation tools that enable characterizing material properties and response to hot plasma experienced during atmospheric entry. The PuMA (microstructure analysis), PATO (macroscale material response), SPARTA (direct simulation Monte Carlo) and ARCHeS (arc heater modeling) codes are described. A range of applications, encompassing calculating effective material properties, study of high shear boundary layer flow over woven materials, new model of silicone-based coatings, new model of mechanical erosion, as well as approach to loose multi-physics coupling, are presented.

material modeling↗

NASA NTRS1986

Building a Lunar Base

This video looks at the testing of lunar materials as a possible building material for lunar bases.

Source record↗

NASA NTRSDate not supplied

3D Construction of Biologically Derived Materials

System for the 3D Construction of Biologically Derived Materials, Structures, and Parts NASA has developed a novel approach for macroscale biomaterial production by combining synthetic biology with 3D printing. Cells are biologically engineered to deposit desired materials, such as proteins or metals, derived from locally available resources. The bioengineered cells build different materials in a specified 3D pattern to produce novel microstructures with precise molecular composition, thickness, print pattern, and shape. Scaffolds and reagents can be used for further control over material product. This innovation provides modern design and fabrication techniques for custom-designed organic or organic-inorganic composite biomaterials produced from limited resources. Benefits Conserves resources. Few raw or bulk starting materials needed Enables custom design of diverse materials Fast, portable, macroscale, on-demand manufacturing High-fidelity microstructures Uses commercially available parts Applications Biomaterials, biotechnology Organic-inorganic composite materials On-demand manufacturing In situ resource utilization Space stations Military Infrastructure materials The Technology Once genes for a desired material type, delivery mode, control method and affinity have been chosen, assembling the genetic components and creating the cell lines can be done with well-established synthetic biology techniques. A 3D microdeposition system is used to make a 3D array of these cells in a precise, microstructure pattern and shape. The engineered cells are suspended in a printable 'ink'. The 3D microdeposition system deposits minute droplets of the cells onto a substrates surface in a designed print pattern. Additional printer passes thicken the material. The cell array is fed nutrients and reagents to activate the engineered genes within the cells to create and deposit the desired molecules. These molecules form the designed new material. If desired, the cells may be removed by flushing. The end product is thus a 3D composite microstructure comprising the novel material. This innovation provides a fast, controlled production of natural, synthetic, and novel biomaterials with minimum resource overhead and reduced pre- and post-processing requirements.

3D↗

NASA NTRS2024

Effects of Oxide Dispersion on Failure Modes in an Additively Manufactured Superalloy

Additive manufacturing opens new paths for introducing oxide particles into superalloys, to potentially provide oxide dispersion strengthening (ODS) at high temperatures. This provides opportunities to study how such dispersions can influence failure modes for a given superalloy, after nearly identical material processing paths. The objective of this study was to compare monotonic failure modes for additively manufactured superalloys with versus without an introduced oxide dispersion. The superalloy for each case was produced by laser powder bed fusion additive manufacturing. Specimens were subsequently given consistent thermal treatment paths and then tested in tensile and creep tests at varied temperatures. Failure modes were then compared. Additively manufactured NiCrAl without ODS had randomly oriented equiaxed grains while this alloy with 0.25 wt% Y 2 O 3 ODS additions had elongated [001] oriented grains in the build direction. Material made without ODS (“No-ODS”) was nearly completely single phase gamma, while ODS additions resulted in gamma, chromium carbide, and Y-Al-Cr oxide phases, with carbide and oxide phases contents estimated at no more than 13 and 1 vol%, respectively. Compared to No-ODS, material made with ODS had higher tensile strengths at room, 760 and 1093 °C. The elongation of ODS material was lower than No-ODS at room temperature, but higher at 760 °C. At 1093 °C ODS material had higher elongation than No-ODS when tested in the build direction, however elongation was lower for ODS material in the transverse direction at 1093 °C. Creep rupture strain, life, and area reduction at 760 and 1093 °C were all much higher for ODS material compared to No-ODS; 760 °C rupture life was nearly 100 times longer for ODS material. The presence of Y in the ODS material significantly improved oxidation resistance.

supperalloys↗