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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Performance Evaluation of an Additively Manufactured ultra-High Operating Temperature SiC Solar-Thermal Air Receiver (HOTSSTAR) Test Module

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal and solar power systems. GE Aerospace Research in collaboration with Heliogen Inc and Sandia National Laboratories (SNL) is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. HOTSSTAR goal is to demonstrate SiC receiver with air exit temperatures up to 1100oC. We discuss fabrication and on-sun test results of a prototype 50kWth test module. The receiver architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around central absorber. These components were fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the thermo-mechanical reliability of SiC test articles in thermal gradient/ shock environment of the application, the components were laminated with GE’s MI SiC CMC. A dedicated test facility was constructed at SNL Solar Tower to evaluate the operational performance of HOTSSTAR module under solar fluxes >200 W/cm2. We report on our final 50kW test module fabrication, integration at the test facility at Sandia, and discuss on-sun test results. We compare the performance of HOTSSTAR module relative to our model predictions.

14 SOLAR ENERGY↗
DOE OSTI2020

Additive Manufacturing of Tool Steels

This article provides a brief overview of additive manufacturing (AM) of tool steels via various AM technologies such as laser powder bed fusion, electron powder bed fusion, blown powder directed energy deposition, and binder jet AM. The discussion includes process overview and covers the mechanism, advantages, and applications of each of these techniques.

Nandwana, Peeyush↗
DOE OSTI2023

Freeform Hybrid Manufacturing: Binderjet, Structured Light Scanning, Confocal Microscopy, and CNC Machining

This paper describes a hybrid manufacturing approach for silicon carbide (SiC) freeform surfaces using binder jet additive manufacturing (BJAM) to print the preform and machining to obtain the design geometry. Although additive manufacturing (AM) techniques such as BJAM allow for the fabrication of complex geometries, additional machining or grinding is often required to achieve the desired surface finish and shape. Hybrid manufacturing has been shown to provide an effective solution. However, hybrid manufacturing also has its own challenges, depending on the combination of processes. For example, when the subtractive and additive manufacturing steps are performed sequentially on separate systems, it is necessary to define a common coordinate system for part transfer. This can be difficult because AM preforms do not inherently contain features that can serve as datums. Additionally, it is important to confirm that the intended final geometry is contained within the AM preform. The approach described here addresses these challenges by using structured light scanning to create a stock model for machining. Results show that a freeform surface was machined with approximately 70 µm of maximum deviation from that which was planned.

Dvorak, Jake (ORCID:0000000260989944)↗
DOE OSTI2025

Experiments in 3D Printing Electric Motors

This paper catalogues a series of experiments we conducted to explore how to 3D print a DC electric motor. The individual parts of the electric motor were 3D printed but assembled by hand. First, we focused on a rotor with soft magnetic properties, for which we adopted ProtoPasta TM , which is a commercial off-the-shelf PLA filament incorporating iron particles. Second, we focused on the stator permanent magnets, which were 3D printed through binder jetting. Third, we focused on the wire coils, for which we adopted a form of laminated object manufacture of copper wire. The chief challenge was in 3D printing the coils, because the winding density is crucial to the performance of the motor. We have demonstrated that DC electric motors can be 3D printed and assembled into a functional system. Although the performance was poor due to the wiring problem, we showed that the other 3D printing processes were consistent with high performance. Nevertheless, we demonstrated the principle of 3D printing electric motors.

3D printed motor↗
DOE OSTI2023

Heat Transfer of an Integrated Counterflow Ceramic Heat Exchanger

The ceramic-based heat exchanger is one of the leading contenders for high-efficiency concentrating solar power plants using a molten salt heat transfer fluid and a supercritical carbon dioxide Brayton power cycle operating at temperatures above 700 °C due to the excellent resistance of ceramics to corrosion, oxidation, erosion, creep, and fouling. In the present study, the thermal performance of a ceramic silicon carbide prototype heat exchanger, with semi-elliptical heat transfer channels, integrated header channels, and a counterflow configuration fabricated by using binder jetting additive manufacturing, was experimentally investigated. Experimental heat transfer tests of the prototype were conducted at high temperatures and under various test fluid flow rates and inlet temperatures. The experimental heat transfer rates compared favorably with simulation predictions.

Yu, Wenhua (ORCID:0000000219457014)↗
NASA NTRS2014

A Fully Non-metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

manufacturing↗
NASA NTRS2015

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute, represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies to fabricate polymer matrix composite and ceramic matrix composite turbine engine components. The benefits include: 50 weight reduction compared to metallic parts, reduced manufacturing costs, reduced part count and rapid design iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature polymer filaments. The CMC effort uses a binder jet process to fabricate silicon carbide test coupons and demonstration articles. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The research project includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

Ceramics↗
NASA NTRS2015

Additive Manufacturing of SiC Based Ceramics and Ceramic Matrix Composites

Silicon carbide (SiC) ceramics and SiC fiber reinforcedSiC ceramic matrix composites (SiCSiC CMCs) offer high payoff as replacements for metals in turbine engine applications due to their lighter weight, higher temperature capability, and lower cooling requirements. Additive manufacturing approaches can offer game changing technologies for the quick and low cost fabrication of parts with much greater design freedom and geometric complexity. Four approaches for developing these materials are presented. The first two utilize low cost 3D printers. The first uses pre-ceramic pastes developed as feed materials which are converted to SiC after firing. The second uses wood containing filament to print a carbonaceous preform which is infiltrated with a pre-ceramic polymer and converted to SiC. The other two approaches pursue the AM of CMCs. The first is binder jet SiC powder processing in collaboration with rp+m (Rapid Prototyping+Manufacturing). Processing optimization was pursued through SiC powder blending, infiltration with and without SiC nano powder loading, and integration of nanofibers into the powder bed. The second approach was laminated object manufacturing (LOM) in which fiber prepregs and laminates are cut to shape by a laser and stacked to form the desired part. Scanning electron microscopy was conducted on materials from all approaches with select approaches also characterized with XRD, TGA, and bend testing.

3-D printing↗
NASA NTRS2019

Advanced CMCs, Additive Manufacturing, and Joining/Integration Technologies

An overview of ceramic matrix composite (CMC) and additive manufacturing capabilities at GRC is provided. The additive manufacturing methods include laminated object manufacturing (LOM), binder jetting, 3-D printing, extrusion, direct writing and multi-materials additive manufacturing. Examples are given of GRC's extensive experience in the development and implementation of CMCs in various aerospace systems. Additive manufacturing offers significant advantages in fabricating preforms, ceramics, and CMCs. They will have to be selectively applied to "traditional" components but can also enable new applications. Additive manufacturing of lightweight and multifunctional polymer composites can provide wide ranging properties. Multi-material printing approaches could provide new opportunities to explore and expand the design envelope. Joining and Integration technologies, gaskets and sealants, as well as repair and refurbishment are also keys for Hypersonic applications.

Grady, Joseph E.↗
NASA NTRS2019

Additive Manufacturing Technologies for Aerospace Applications

An overview will be provided on NASA GRC activities in additive manufacturing (AM) technology development for advanced high performance, propulsion component designs in electric motors and turbine engine systems in future electrified aircraft. AM offers significant benefits over conventional manufacturing to fabricate components that are more compact, lighter weight, geometrically complex, innovatively cooled, integrated, multi-material, and multifunctional. For turbine engine applications, silicon carbide (SiC) based composites are being pursued using binder jetting. For electric motor applications, additive processes are being applied toward optimized component designs to include the housing, rotor, and stators with 3-D printing and wire imbedded coils and with direct printed 3-phase coils. The will be an emphasis on capabilities in additive manufacturing.

Halbig, Michael C.↗
NASA NTRS2019

Enabling Additive Manufacturing Technologies for Advanced Aero Propulsion Materials & Components

Additive manufacturing (AM) technologies are enabling for advanced high performance, propulsion component designs in electric motors1-2 and turbine engine systems in future electrified aircraft. AM offers significant benefits over conventional manufacturing to fabricate components that are more compact, lighter weight, geometrically complex, innovatively cooled, integrated, multi-material, and multifunctional. For turbine engine applications, silicon carbide (SiC) based composites are being pursued using binder jetting and laminated object manufacturing (LOM) for components such as shrouds, vanes, and recuperators. For electric motor applications, additive processes are being applied toward optimized component designs to include the housing, rotor, and stators with 3-D printing and wire imbedded coils and with direct printed 3-phase coils. The electrical conductivity of silver conductor coils optimized by evaluating alternate sintering methods and additions of graphene and carbon nanostructures will be presented. Potential benefits of new electric motor components in improving temperature capability, efficiency, and power density for reductions in energy consumption and emissions will be discussed.

Halbig, Michael C.↗
DOE OSTI2022

Indirect additive manufacturing process using amine-containing adhesive polymers

A method for binder jetting additive manufacturing of an object, the method comprising: (i) separately feeding a powder from which said object is to be manufactured and a solution comprising an adhesive polymer dissolved in a solvent into an additive manufacturing device, wherein said adhesive polymer is an amine-containing polymer having a molecular weight of at least 200 g/mole and is present in said solution in a concentration of 1-30 wt % to result in said solution having a viscosity of 2-25 mPa·s and a surface tension of 25-45 mN/m at room temperature; and (ii) dispensing selectively positioned droplets of said adhesive polymer, from a printhead of said additive manufacturing device, into a bed of said powder to bind particles of said powder with said adhesive polymer to produce a preform having a shape of the object to be manufactured.

Saito, Tomonori↗
DOE OSTI2024

Design optimization of lightweight automotive seatback through additive manufacturing compression overmolding of metal polymer composites

With the growing demand for enhanced automotive fuel efficiency and environmental sustainability, there is a need for lightweighting automotive components through innovative design and manufacturing processes. Here, this study leverages a combination of numerical iterative design optimization and hybrid additive manufacturing–compression molding (AM-CM) technique for metal polymer composites to lightweight an automotive seatback. The AM-CM process enables robust mechanical interlocking between metals and composites, boasting high stiffness and strength with low overall density. Replacing metallic components with such metal polymer composites allows for comparable mechanical performance while significantly reducing the overall weight. First, the automotive seatback design space is reduced to critical load carrying regions using topology optimization and high stress concentration areas are identified using finite element analysis. Next, a lightweight metal polymer subcomponent is designed for a high stress concentration region. The full seatback frame with spatially heterogeneous material-specific design is then iteratively optimized to enable enhanced stiffness with minimal weight. Overall, the automotive seatback frame designed with location-specific metal, polymer, and metal polymer composite materials weighs 20% less than the metal-only design while exhibiting similar stiffness.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Impact of melt viscosity on filler dispersion in elastomeric nanocomposites

Compounding of commercial nanocomposites usually involves the addition of viscosity enhancers such as binder resins in ink jet inks, and paints. Contrary to this, plasticizers such as process oils are added to reduce the melt viscosity and ease processability of reinforced elastomers. Nanofillers such as silica and carbon black are typically added to reinforce rubber and enhance performance of automotive tire treads. Filler dispersion has traditionally been qualitatively (indirectly) assessed by measuring the properties of reinforced elastomers. While dispersion can be quantified by examining filler agglomeration through surface roughness measurements and microscopy, the size-scale dependence for these hierarchical fillers has usually been ignored. Here, we have recently devised a method to quantify nano-scale dispersion of fillers using Ultra small-angle X-ray scattering (USAXS) techniques. This method is advantageous since it directly links the controllable processing/compounding parameters such as the mixing speed, mixer geometry, residence time (or mixing duration), melt density, flow gap distance, and melt viscosity to nano-scale dispersion. While our previous studies have explored the impact of different processing parameters, this study specifically investigates the impact of melt viscosity on nano-scale filler dispersion in elastomer compounds. Commercially available polybutadienes with different Mooney viscosities were used in conjunction with different grades and amounts of process oils to modify the melt viscosity.

Carbon black↗
NASA NTRS1966

Fibers of newly developed refractory ceramics produced by improved process

Rods of refractory ceramic material and glasses having relatively high fusion temperatures and tensile strengths are converted to fiber by subjecting these rods to alternate fusion and gas-jet bursts. The refractory, high tensile strength fibers produced are combined with suitable binder to produce heat-resistant fabrics and rigid structures.

Source record↗