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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Japan's technology and manufacturing infrastructure

The JTEC panel found that, after four decades of development in electronics and manufacturing technologies, Japanese electronics companies are leaders in the development, support, and management of complex, low-cost packaging and assembly technologies used in the production of a broad range of consumer electronics products. The electronics industry's suppliers provide basic materials and equipment required for electronic packaging applications. Panelists concluded that some Japanese firms could be leading U.S. competitors by as much as a decade in these areas. Japan's technology and manufacturing infrastructure is an integral part of its microelectronics industry's success.

Boulton, William R.↗
DOE OSTI2020

Material Developments for 3D/4D Additive Manufacturing (AM) Technologies

Additive Manufacturing (AM), or 3D printing, is a unique technology in which structurally complex objects can be easily manufactured. While AM allows for the creation of intricate 3D objects, these objects are inactive and motionless. With recent incorporation of a “pre-programmed functionality’’ to the 3D printed objects, a new concept has emerged, 4D printing. Specifically, the 4D printing technology enables a static 3D printed object to change its shape, functionality or property over time upon exposure to a specific stimulus such as heat, stress, light, pH, and moisture, etc. We designed and produced compact 3D/4D printable materials that can be used as (a) structural components of the unmanned aerial vehicles (UAVs), and (b) as hydrogen storage materials that supply hydrogen to a fuel cell to expand the operational reach, namely flight time, and endurance of the UA Vs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Material Developments for 3D/4D Additive Manufacturing (AM) Technologies

Additive Manufacturing (AM), or 3D printing, is a unique technology in which structurally complex objects can be easily manufactured. While AM allows for the creation of intricate 3D objects, these objects are inactive and motionless. With recent incorporation of a “pre-programmed functionality” to the 3D printed objects, a new concept has emerged, 4D printing. Specifically, the 4D printing technology enables a static 3D printed object to change its shape, functionality or property over time upon exposure to a specific stimulus such as heat, stress, light, pH, and moisture, etc. We designed and produced compact 3D/4D printable materials that can be used as (a) structural components of the unmanned aerial vehicles (UAVs), and (b) as hydrogen storage materials that supply hydrogen to a fuel cell to expand the operational reach, namely flight time, and endurance of the UAVs.

08 HYDROGEN↗
NASA NTRS2018

Space Technology Mission Directorate: Game Changing Development Program: Rapid Analysis and Manufacturing Propulsion Technology (RAMPT)

Technology Overview: The RAMPT (Rapid Analysis and Manufacturing Propulsion Technology) project will develop and advance large scale light-weight multi-metallic freeform manufacturing and composite overwrap techniques and analysis capabilities required to implement them to reduce design and fabrication cycles for regeneratively-cooled liquid rocket engine components; RAMPT will reduce design, fabrication, assembly schedules while allowing for reduced parts, increased reliability, significant weight reduction and a healthy American supply chain. Four technology areas developed: 1) Freeform Blown Powder Nozzle; 2) Composite overwrap structural jacket; 3) Bimetallic radial deposition for manifolds; 4) Modeling and analysis tools for Additive and Regen design. Exploration & Science Impact: Addresses longest lead, highest cost and heaviest component in engine; Applicable to Lunar Lander Engine, Booster Engines, Upper Stage Engines, and NTP (Nuclear Thermal Propulsion) Technology; Public-private partnerships with specialty industry vendors, government partners, Commercial Crew, and infusion into commercial space companies and manufacturers; SSTIP (NASA's Strategic Space Technology Investment Plan) Core Investment Area - Launch Propulsion Systems (TA01 (NASA Technology Area 01); Lightweight Space Structures and Materials (TA12); Manufacturing (TA12).

RAMPT↗
DOE OSTI2020

Clean Energy Manufacturing: Renewable Energy Technology Benchmarks

The manufacturing of clean energy technologies has become a global enterprise. An analysis of four clean energy technology manufacturing processes—wind turbine components, crystalline silicon solar photovoltaic modules, light-duty vehicle lithium-ion battery cells, and light-emitting diodes—was conducted to provide a reference point for comparison over time as this sector evolves. The manufacturing supply chain analysis included processing of raw materials, making required subcomponents, and assembling final products, using benchmarks that crossed 12 economies: Brazil, Canada, China, Germany, India, Japan, Malaysia, Mexico, South Korea, Republic of China (Taiwan), the United Kingdom, and the United States. Larger economies, with extensive manufacturing supply chains and high prevailing wages, tend to retain more value added from clean energy manufacturing than small economies. Manufacturing of clean energy technologies drives extensive trade among economies to support the widely distributed supply chain links. Production of wind turbine components and photovoltaic modules is more centralized than production of light-emitting diodes and lithium-ion battery cells. Across the four clean energy technologies evaluated, there was generally an excess of manufacturing capacity relative to global supply.

benchmarks↗
NASA NTRS2019

Rapid Analysis and Manufacturing Propulsion Technology (RAMPT)

The RAMPT project is maturing novel design and manufacturing technologies to increase scale, significantly reduce cost, and improve performance for regeneratively-cooled thrust chamber assemblies, specifically the combustion chamber and nozzle for government and industry programs.

Fikes, John C.↗
NASA NTRS2020

Technology Advancements for Channel Wall Nozzle Manufacturing In Liquid Rocket Engines

A regeneratively-cooled or dump-cooled nozzle is a critical component for expansion of hot gases to enable high temperature and performance in liquid rocket engines systems. Regeneratively-cooled channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design can be challenging to fabricate which results in extended lead times and higher costs. Some of these challenges include: 1) Unique and high temperature materials, 2) Tight tolerances on large parts during manufacturing and assembly to contain high pressure propellants, 3) Thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and complex tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) and U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements under evaluation for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on laser powder bed fusion (L-PBF), but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle, and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication technique. This publication presents an overview of the various channel wall nozzle manufacturing processes and materials under evaluation including results from the hot-fire testing. Future development and technology focus areas is also discussed relative to channel wall nozzle manufacturing.

Additive manufacturing↗
NASA NTRS1997

Radiation Effects on Current Field Programmable Technologies

Manufacturers of field programmable gate arrays (FPGAS) take different technological and architectural approaches that directly affect radiation performance. Similar y technological and architectural features are used in related technologies such as programmable substrates and quick-turn application specific integrated circuits (ASICs). After analyzing current technologies and architectures and their radiation-effects implications, this paper includes extensive test data quantifying various devices total dose and single event susceptibilities, including performance degradation effects and temporary or permanent re-configuration faults. Test results will concentrate on recent technologies being used in space flight electronic systems and those being developed for use in the near term. This paper will provide the first extensive study of various configuration memories used in programmable devices. Radiation performance limits and their impacts will be discussed for each design. In addition, the interplay between device scaling, process, bias voltage, design, and architecture will be explored. Lastly, areas of ongoing research will be discussed.

Katz, R.↗
DOE OSTI2023

In-Situ Monitoring Assisted Large-Scale Additive Manufacturing of Mild Steel and 316L Alloys for Nuclear Application

The Advanced Materials and Manufacturing Technologies (AMMT) Program is aimed at developing cross-cutting technologies in support of a broad range of nuclear reactor parts, and to maintain U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of the AMMT program is to accelerate the development, qualification, demonstration and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. One of its three goals is to target big challenges and game-changing technologies, to realize the mission and vision of AMMT program. Based on this context, this multi-year work package focuses on understanding the current state of large-scale additive manufacturing (AM) technology for the deposition of 316L stainless steel materials for final components and mild steel for use in nuclear manufacturing processes. The targeted AM modality is directed energy deposition (DED), capable of fabricating components on the size scale of meters including valves, pumps, impellers. etc. that are challenging or difficult to source, especially when developing new systems or replacing obsolete components. Accordingly, the current writeup aims at providing a baseline literature survey on structure-property relationships in mild steel and 316L alloys. Also, information on preliminary trials to date involving these two alloys show tremendous potential of printing parts having complex geometry and thin- walled structures, such as nuclear valve and Hot isostatic Press (HIP) can, using wire based (Wire Arc Additive Manufacturing and Hybrid Additive Manufacturing) as well as blown powder DED machines. All of this is aimed towards (i) demonstrating the ability to fabricate large components for pressure boundary applications relevant to the nuclear community and nuclear manufacturing technology, and (ii) understanding the effect of different manufacturing technology on AM can production and post HIPed material for nuclear applications. Another target of this writeup is to compile various in-situ monitoring tools that have been incorporated for different DED AM modalities, in order to understand process variability during the entire fabrication process. This can be correlated with processing-structure-property response surfaces and would add confidence around process quality verification and ultimately component certification for nuclear applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Initial Results of PostProcess NDE Using Advanced Techniques

The U.S. Department of Energy, Office of Nuclear Energy Advanced Materials and Manufacturing Technologies Program is developing advanced materials and manufacturing technologies that will enable the safe and economical operation of both the current fleet and the next generation of advanced nuclear reactors. Post-process nondestructive evaluation capabilities are a key enabling technology that will be required to qualify and verify the condition of components produced using advanced materials and manufacturing technologies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Preliminary Characterization and Evaluation on FFF Manufactured 316H and ODS Steels

The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Solid-state advanced manufacturing techniques can overcome some of the challenges in liquid-based additive manufacturing (AM) processes and should therefore be considered in material design and manufacturing as well. The work presented in this report forms part of a study on solid-state AM techniques of 316 stainless steels (SS) and oxide dispersion strengthened (ODS) steel components and supports the vision and goals of the AMMT program relevant to accelerate the development and deployment of advanced manufacturing processes. Achieving this can provide a safety improvement through larger safety margins, economic benefit for higher efficiency during operation, and a cost reduction through more effective manufacturing processes and less waste. This study provides preliminary information on development of the fused-filament fabrication (FFF) process using different powder types to demonstrate the sensitivity, and therefore the characterization of these sample components. The full solid-state manufacturing feasibility study will be completed and reported in a final feasibility evaluation during 2025. The study investigation used two 14YWT ODS powder batches, which provided information and the effect of different powder morphologies on manufacturability. The two 316SS powders demonstrated the effect of powder size on the manufacturability using FFF. Two product forms, namely a honeycomb structure and flat samples, were manufactured to demonstrate the flexibility of product form.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Preliminary Characterization and Evaluation on ShAPE Manufactured 316H and ODS Steels

This study provides the first- of- a- kind results of direct tube formation through shear assisted processing and extrusion (ShAPE) for oxide dispersion strengthened (ODS) steel material; previously only bar was successfully made. The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Solid-state advanced manufacturing techniques can overcome some of the challenges in liquid-based additive manufacturing processes and should therefore be considered in material design and manufacturing as well. The work presented in this report forms part of a study on solid-state additive manufacturing techniques of 316 stainless steels and ODS steel components and supports the vision and goals of the AMMT program relevant to accelerate the development and deployment of advanced manufacturing processes. Achieving this can provide a safety improvement through larger safety margins, economic benefit for higher efficiency during operation, and a cost reduction through more effective manufacturing processes and less waste.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Compliant heat exchangers, heat pipes and methods for making same

A method for fabricating heat exchangers using additive manufacturing technologies. Additive manufacturing enables the manufacture of heat exchangers with complex geometries and/or with internal and external integral surface features. Additive manufacture also facilitates the manufacture of heat exchangers with regional variations, such as changes in size, shape and surface features. In one embodiment, the present invention provides a heat exchanger with a helicoidal shape that provides axial elastic compliance. In one embodiment, the internal channel of the heat exchanger varies along its length. The internal channel may have a cross-sectional area that increases progressively from one end to the other. In one embodiment, the external shape of the tubular structure may be non-circular to optimize heat transfer with an external heat transfer fluid. In one embodiment, the present invention provides a heat pipe with an internal wicking structure formed as an integral part of the additive manufacturing process.

Lara-Curzio, Edgar↗
DOE OSTI2023

Qualification Framework Evaluations, Status Quo, and Recommendations

The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. The acceleration of qualification processes is one of the key aspects and qualification processes for the nuclear industry is not necessarily equivalent or benchmarked against other industries.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Survey Corrosion Testing Methodologies for Additively Manufactured Materials – PNNL

The Advanced Materials and Manufacturing Technology (AMMT) Program intends to develop cross-cutting technologies in support of a broad range of nuclear reactor technologies, and to maintain U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of the AMMT Program is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy.

36 MATERIALS SCIENCE↗
NASA NTRS1993

A new technology for manufacturing scheduling derived from space system operations

A new technology for producing finite capacity schedules has been developed in response to complex requirements for operating space systems such as the Space Shuttle, the Space Station, and the Deep Space Network for telecommunications. This technology has proven its effectiveness in manufacturing environments where popular scheduling techniques associated with Materials Resources Planning (MRPII) and with factory simulation are not adequate for shop-floor work planning and control. The technology has three components. The first is a set of data structures that accommodate an extremely general description of a factory's resources, its manufacturing activities, and the constraints imposed by the environment. The second component is a language and set of software utilities that enable a rapid synthesis of functional capabilities. The third component is an algorithmic architecture called the Five Ruleset Model which accommodates the unique needs of each factory. Using the new technology, systems can model activities that generate, consume, and/or obligate resources. This allows work-in-process (WIP) to be generated and used; it permits constraints to be imposed or intermediate as well as finished goods inventories. It is also possible to match as closely as possible both the current factory state and future conditions such as promise dates. Schedule revisions can be accommodated without impacting the entire production schedule. Applications have been successful in both discrete and process manufacturing environments. The availability of a high-quality finite capacity production planning capability enhances the data management capabilities of MRP II systems. These schedules can be integrated with shop-floor data collection systems and accounting systems. Using the new technology, semi-custom systems can be developed at costs that are comparable to products that do not have equivalent functional capabilities and/or extensibility.

Hornstein, R. S.↗
DOE OSTI2022

Scalability Testing Approach for Internet of Things for Manufacturing SQL and NoSQL Database Latency and Throughput

The proliferation of low-cost sensors and industrial data solutions has continued to push the frontier of manufacturing technology. Machine learning and other advanced statistical techniques stand to provide tremendous advantages in production capabilities, optimization, monitoring, and efficiency. The tremendous volume of data gathered continues to grow, and the methods for storing the data are critical underpinnings for advancing manufacturing technology. This work aims to investigate the ramifications and design tradeoffs within a decoupled architecture of two prominent database management systems (DBMS): sql and NoSQL. A representative comparison is carried out with Amazon Web Services (AWS) DynamoDB and AWS Aurora MySQL. The technologies and accompanying design constraints are investigated, and a side-by-side comparison is carried out through high-fidelity industrial data simulated load tests using metrics from a major US manufacturer. The results support the use of simulated client load testing for comparing the latency of database management systems as a system scales up from the prototype stage into production. As a result of complex query support, MySQL is favored for higher-order insights, while NoSQL can reduce system latency for known access patterns at the expense of integrated query flexibility. Here, by reviewing this work, a manufacturer can observe that the use of high-fidelity load testing can reveal tradeoffs in IoTfM write/ingestion performance in terms of latency that are not observable through prototype-scale testing of commercially available cloud DB solutions.

AWS↗