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DOE OSTI2023

A novel approach for adaptive skeleton toolpath generation

Industry 4.0 is revolutionizing manufacturing through the integration of automation and real-time data sharing in cyber-physical systems. At the forefront of this revolution is large-format additive manufacturing. In large-format printing, parts are often designed to be an even number of beads wide to produce a completely dense part. However, voids can still arise. This is often due to the part not being an even number of bead widths wide in some areas, or in geometry containing acute angles, as the process of generating closed contours cannot completely fill the space. Voids can be tolerated in smaller models, but in large-format additive manufacturing they may cause mechanical defects. To fill these voids, open loop paths called skeletons are often used, but they are typically limited by the physical constraints defined in the slicing software. To address this, researchers at Oak Ridge National Laboratory have extended skeleton toolpaths via an adaptive methodology. These adaptive skeletons were found to better fill void spaces through manipulation of physical parameters of the build process and were calculated as part of the slicing process.

42 ENGINEERING↗

DOE OSTI2021

Embodied carbon in the U.S. manufacturing and trade

On average, one quarter of the global carbon footprint is embodied in traded goods. These emissions are a growing issue for global efforts to decarbonize the world economy. Embodied emissions in trade are not accounted for by existing greenhouse gas accounting systems. For example, countries only report their domestic carbon emissions (also known as production-based or territorial accounting) to the Intergovernmental Panel on Climate Change (IPCC). If the embodied carbon in trade were accounted for and reported, the promising climate trends depicted by many countries would be negated or reversed. For example, many achievements of reducing emissions by developed countries under the Kyoto Protocol would actually appear as emissions outsourced to developing countries. Like many other developed countries, the United States is a net importer of embodied greenhouse gas (GHG) emissions in trade. The goal of this study was to calculate the carbon footprint of various sectors of the U.S. economy using the latest available data and based on that, estimate the embodied carbon in certain manufacturing sector products imported and exported by the U.S. First, we conducted an input-output analysis to calculate the carbon footprint of 401 aggregate level sectors of the U.S. economy. After that, for a selected number of manufacturing subsectors /products(hereafter referred to as products),we collected their trade(import/export) data and combined that with their computed carbon footprint to estimate the embodied carbon in import and export of these products for the U.S. While we conducted the carbon footprint analysis for sectors covering the entire U.S. economy (401 sectors), we only conducted the embodied carbon in trade analysis for a few products within specific aggregate level manufacturing sectors,such as computer and electronic product manufacturing (NAICS 334), transport equipment manufacturing (NAICS 336), machinery manufacturing (NAICS 333), and chemical manufacturing (NAICS 325). It is possible to do the detailed embodied carbon analysis for all other products within the various aggregate level manufacturing sectors of the U.S. economy, but given the scope of this study and space constraint of this report, we only present the results for a few products. The results of our analysis for the selected products show the embodied carbon in trade for each product by country and also show the rankings of countries in terms of top importers and exporters of embodied carbon in trade with the U.S. Our results show that in majority of cases, the U.S. is a net importer of embodied carbon in trade. Unless consumption-based accounting is used, the U.S. and other net embodied carbon importing countries may continue to outsource their emissions to meet their climate change mitigation targets under the Paris Agreement, as observed previously with the Kyoto Protocol. Some countries reported reductions that exceeded their Kyoto targets, however, the changes in emissions embodied in imports were comparable to or larger than changes in domestic emissions. Traded emissions undermined emissions reductions in the Kyoto Protocol, and threaten to continue to do so for the Paris Agreement. New climate policies such as California’s Buy Clean act, EU’s proposed border carbon tax adjustment, as well as efforts in the private sector can help address the embodied carbon in traded products.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Basic Research Needs for Transformative Manufacturing (Brochure)

Manufacturing is central to the nation’s prosperity and security. Manufacturing currently represents about 12% of the gross domestic product, provides nearly 13 million jobs, and accounts for about 25% of energy use. The nation’s economy relies heavily on wide-ranging manufacturing sectors - all of which share common challenges including data issues, lack of physics and chemistry-based models across scales, and resource constraints in a global environment. Furthermore, there are many hurdles that must be overcome to move basic science innovations to market. Addressing broad-ranging challenges demands a basic-science strategy that underpins applied research activities. This strategy would accelerate innovation and transform manufacturing. A Basic Research Needs workshop for Transformative Manufacturing was held in March 2020. The focus of the workshop was to identify the basic science research priorities that could accelerate innovation to transform manufacturing in the future. This was the first workshop of its kind to examine how basic energy science can drive manufacturing forward and innovate new ways to manufacture goods. Five Priority Research Directions were identified that address these science challenges: (1) innovative synthetic approaches to enable scalable assembly of matter, (2) computational methods and theoretical models to transform how manufacturing processes are controlled, (3) new characterization tools that can handle the necessary complexity, scales, and processing speeds to meet manufacturing needs, (4) new science to address opportunities relevant to sustainable and energy-efficient manufacturing, and (5) foundational approaches to co-design of materials, process, and products.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1992

High-temperature strain measurement techniques: Current developments and challenges

Since 1987, a very substantial amount of R&D has been conducted in an attempt to develop reliable strain sensors for the measurements of structural strains during ground testing and hypersonic flight, at temperatures up to at least 2000 deg F. Much of the effort has been focused on requirements of the NASP Program. This presentation is limited to the current sensor development work and characterization studies carried out within that program. It is basically an assessment as to where we are now and what remains to be done in the way of technical accomplishments to meet the technical challenges posed by the requirements and constraints established for the NASP Program. The approach for meeting those requirements and constraints has been multi-disciplinary in nature. It was recognized early on that no one sensor could meet all these requirements and constraints, largely because of the large temperature range (cryogenic to at least 2000 deg F) and many other factors, including the most challenging requirement that the sensor system be capable of obtaining valid 'first cycle data'. Present candidate alloys for resistance-type strain gages include Fe-Cr-Al and Pd-Cr. Although they have superior properties regarding withstanding very high temperatures, they exhibit large apparent strains that must either be accounted for or cancelled out by various techniques, including the use of a dual-element, half-bridge dummy gage, or electrical compensation networks. A significant effort is being devoted to developing, refining, and evaluating the effectiveness of those techniques over a broad range in temperature and time. In the quest to obtain first-cycle data, ways must be found to eliminate the need to prestabilize or precondition the strain gage, before it is attached to the test article. It should be noted that present NASP constraints do not permit prestabilization of the sensor, in situ. Gages are currently being 'heat treated' during manufacture in both the wire- and foil-type resistance strain gages, and evaluation is in progress. In addition, the 'gage-on-shim' concept is being revisited. That concept will permit heat treatment of the gage during manufacture, before attachment on the test article. Also, it may permit the individual calibration of each gage regarding gage factor and apparent strain. Candidate alloys for the NASP include titanium metal-matrix and carbon-carbon composites. Although those materials have very attractive properties at elevated temperatures in terms of strength and weight, they pose significant attachment problems. Methods for making reliable strain gage and thermocouple attachments to them are currently under development. Experience to date indicates that Rokide attachment of the sensor directly to the protective coating is easier than to the base material itself. However, interpreting strain data from gages attached in this way may prove difficult because of possible cracks in the coating that form 'islands' and the mobility of those 'islands'. It is concluded, therefore, that major technical challenges lie ahead as we proceed to meet the stringent strain sensor requirements and constraints of the NASP Program.

Lemcoe, M. M.↗

NASA NTRS1973

Residual stress alleviation of aircraft metal structures reinforced with filamentary composites

Methods to eliminate or reduce residual stresses in aircraft metal structures reinforced by filamentary composites are discussed. Residual stress level reductions were achieved by modifying the manufacturing procedures used during adhesive bonding. The residual stress alleviation techniques involved various forms of mechanical constraint which were applied to the components during bonding. Nine methods were evaluated, covering a wide range in complexity. All methods investigated during the program affected the residual stress level. In general, residual stresses were reduced by 70 percent or more from the stress level produced by conventional adhesive bonding procedures.

Kelly, J. B.↗

DOE OSTI2026

Domestic Manufacturing & Supply Summary for Transmission Components [Slides]

The purpose of this presentation is to describe how the input assumptions for transmission grid supply constraints were developed. These assumptions will be used in a subsequent paper to evaluate the ability of transmission supply chains to meet anticipated transmission development needs.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2019

Evaluation of Cyclo Olefin Polymer as Sabot Material for High-Density Projectiles

Assuring the integrity of spacecraft and its occupants are a priority in the field of space exploration. Micrometeoroids and orbital debris are one of the primary threats that affect spacecraft materials due to the high kinetic energies involved with hypervelocity impacts. Improvement of projectile launching capabilities prompts the investigation of adequate materials for the manufacturing of sabots able to carry high-density projectiles without catastrophic failure. Polycarbonate has been the chosen material by the Hypervelocity Team at White Sands Test Facility for sabots on the 0.50 caliber launcher; however, there is a material constraint when the projectile becomes significantly dense and the inertial stresses surpass the yield strength of the sabot material. This research proposes a new polymer material for manufacturing sabots, known as cyclo olefin polymer (COP) with the purpose of successfully shooting the intended high-density projectiles. In this investigation, both polycarbonate and COP were analyzed using tensile and impact testing to observe the differences in their mechanical properties. The experimental details along with the detailed characterization of the materials are presented.

Tarango, Estebanne↗

DOE OSTI2026

Physicochemical properties of digital light processing 3D-Printed alumina and mullite ceramics

Alumina ceramics fabricated using conventional techniques such as uniaxial pressing or injection molding are popular due to their low density, excellent insulation, and mechanical properties. However, these methods often limit the fabrication of complex geometries with high dimensional accuracy due to tooling constraints and limited design freedom. To overcome these limitations, this study employed Digital Light Processing (DLP) additive manufacturing (AM), which enables the production of precise structures. In addition, the optimization of sintering parameters to enhance the densification and performance of alumina and mullite ceramics was investigated, with a specific focus on how varying sintering temperatures and hold times affect part shrinkage, geometric accuracy, and material integrity. Flexural strength of both alumina and mullite specimens was clearly influenced by the way the layers was stacked. When layers were arranged across the direction of the applied load (Z = 4; XZ), the strength was higher than when they were stacked along the same direction as the load (Z = 3; XY). Weibull analysis based on these results showed high modulus values across all samples, indicating good reliability in the flexural strength measurements. This reliability, combined with the clear influence of sintering parameters, highlights how processing conditions effect the material properties and mechanical performance of parts produced through DLP additive manufacturing. In conclusion, these findings open new avenues for ceramic AM across various applications, enhancing the potential for innovation in fields such as aerospace, biomedical engineering, and energy.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Digital redesign of the control system for the Robotics Research Corporation model K-1607 robot

The analog control system for positioning each link of the Robotics Research Corporation Model K-1607 robot manipulator was redesigned for computer control. In order to accomplish the redesign, a linearized model of the dynamic behavior of the robot was developed. The parameters of the model were determined by examination of the input-output data collected in closed-loop operation of the analog control system. The robot manipulator possesses seven degrees of freedom in its motion. The analog control system installed by the manufacturer of the robot attempts to control the positioning of each link without feedback from other links. Constraints on the design of a digital control system include: the robot cannot be disassembled for measurement of parameters; the digital control system must not include filtering operations if possible, because of lack of computer capability; and criteria of goodness of control system performing is lacking. The resulting design employs sampled-data position and velocity feedback. The criteria of the design permits the control system gain margin and phase margin, measured at the same frequencies, to be the same as that provided by the analog control system.

Carroll, Robert L.↗

NASA NTRS2021

ED1: Design and Prototype of a 3D Printed Wind Tunnel Model with Integrated Force Measurement

Wind tunnel testing using conventionally manufactured force measurement systems (balances) is able to yield precise and accurate results. These balances are delicate, complex instruments. Due to the nature of this high-precision complexity, balances are expensive and time-consuming to produce. These factors can limit the design potential of the model because using conventionally manufactured balances generally means that the model is designed to accommodate balances that already exist. Ideally, engineers would be able to design a measurement system that is tailored to fit the needs of the model, rather than the other way around. The goal of this research project was to determine if it is possible to overcome these drawbacks by designing a wind tunnel model with a modifiable integrated force measurement system that leverages additive manufacturing. This was undertaken by utilizing the existing UT-63 wind tunnel balance (measurement system), integrating it with a model based on the existing AGARD-B model, and performing stress analysis to optimize the design. Due to time constraints, the result of this endeavor is currently incomplete. Continued analysis and optimization are required to have a thorough understanding of the success or failure of the attempted design. As additive manufacturing technology evolves, the ability for it to become the primary method of fabrication for sensitive measurement systems increases. This project contributes to this by providing one method for design, a framework for optimizing existing balances for additive manufacturing, and resources for performing necessary stress analysis.

Callie Ellsworth↗

DOE OSTI2023

And manufacture of generalized flow profile-producing devices

The present invention provides a process for making a flow conditioning device that transforms an input flow into a desired output flow. The process includes the steps of inputting into a computer program a set of design constraints representative of the input flow and the output flow. The computer program generates a design representative of a flow-conditioning device that transforms the input flow into the output flow. The process then provides the output design to an additive manufacturing or other suitable production system adapted to form a solid representation of the flow-conditioning device.

Ferrar, Anthony M.↗

DOE OSTI2024

Design of Modular Test Facility for Particle/sCO2 Heat Exchanger Evaluation

Heliogen has designed a 1.3 MW particle and supercritical carbon dioxide (sCO2) test loop to retire technical and manufacturing risks. The data from this facility will be used to validate near commercial-scale particle heat exchanger modules. The heat exchanger is scaled to capture all features of the full-scale modules. Testing will be conducted with CARBOBEAD HSP 16/30, a larger particle size than other recent testing. The system was designed to ASME codes with the constraint that sCO2 piping and other major components are stainless steels.

14 SOLAR ENERGY↗

DOE OSTI2022

Design optimization of integrated cooling inserts in modular Fischer-Tropsch reactors

Sustainable production of liquid fuels and feedstocks from atmospheric CO 2 through carbon recycling technologies is necessary to broaden decarbonization efforts and further reduce global emissions. Fischer–Tropsch (FT) reactors can address this challenge by providing storable, high-value liquid hydrocarbon fuels and feedstocks from syngas generated through reductive CO 2 utilization. FT technology, however, is most cost effective at large-scale, fixed-site plants and does not effectively address the smaller, globally distributed CO 2 point sources. Alternatively, smaller, modular reactors can be composed together to the specific scale of the emission source, yielding a flexible solution that enables more widespread deployment. In these modular reactors, thermal management using a finned cooling insert embedded within the catalyst matrix is critical to maintaining the performance and viability. Thus, in this work, topology optimization is used to determine the cooling insert geometry that maximizes reactor productivity while preventing auto-thermal runaway. Optimal designs are generated for varying number of constituent fins and over a range of maximum operating temperatures. Constraints including minimum feature length-scales and prescribed cooling insert material are imposed on the designs to enhance manufacturability. The impact of design features such as insert tapering and increased length scale hierarchy is automatically revealed by the systematic design framework employed. Here, this approach thus generates novel optimal geometries while automating, accelerating, and enhancing the design process compared to traditional heuristic approaches for cooling insert design in modular FT reactors.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS1989

SSME component assembly and life management expert system

The space shuttle utilizes several rocket engine systems, all of which must function with a high degree of reliability for successful mission completion. The space shuttle main engine (SSME) is by far the most complex of the rocket engine systems and is designed to be reusable. The reusability of spacecraft systems introduces many problems related to testing, reliability, and logistics. Components must be assembled from parts inventories in a manner which will most effectively utilize the available parts. Assembly must be scheduled to efficiently utilize available assembly benches while still maintaining flight schedules. Assembled components must be assigned to as many contiguous flights as possible, to minimize component changes. Each component must undergo a rigorous testing program prior to flight. In addition, testing and assembly of flight engines and components must be done in conjunction with the assembly and testing of developmental engines and components. The development, testing, manufacture, and flight assignments of the engine fleet involves the satisfaction of many logistical and operational requirements, subject to many constraints. The purpose of the SSME Component Assembly and Life Management Expert System (CALMES) is to assist the engine assembly and scheduling process, and to insure that these activities utilize available resources as efficiently as possible.

Ali, M.↗

NASA NTRS2002

A System for Planning Ahead

A software system that uses artificial intelligence techniques to help with complex Space Shuttle scheduling at Kennedy Space Center is commercially available. Stottler Henke Associates, Inc.(SHAI), is marketing its automatic scheduling system, the Automated Manifest Planner (AMP), to industries that must plan and project changes many different times before the tasks are executed. The system creates optimal schedules while reducing manpower costs. Using information entered into the system by expert planners, the system automatically makes scheduling decisions based upon resource limitations and other constraints. It provides a constraint authoring system for adding other constraints to the scheduling process as needed. AMP is adaptable to assist with a variety of complex scheduling problems in manufacturing, transportation, business, architecture, and construction. AMP can benefit vehicle assembly plants, batch processing plants, semiconductor manufacturing, printing and textiles, surface and underground mining operations, and maintenance shops. For most of SHAI's commercial sales, the company obtains a service contract to customize AMP to a specific domain and then issues the customer a user license.

Source record↗

NASA NTRSDate not supplied

Hardware Autonomy for Space Infrastructure

NASA prioritizes autonomous systems development with the expectation that it will continue to drive significant improvements in human and science exploration capability. Crew operations benefit from a spectrum of machine assistance to complete replacement of dangerous or highly repetitive tasks. Many science operations have a teleoperation component, and similarly benefit from a range of autonomy implementations that make long distance applications feasible. As we consider longer duration deep space missions, we also consider higher levels of autonomy in order meet emergent safety, maintenance, and logistics needs. One of the challenges within this scope is installation and maintenance of infrastructure, such as large scale instrumentation and communications equipment, crew habitats, and operational facilities. We describe how a programmable meta-material architecture may shift the paradigm of how we design, build, and operate future space infrastructure and assets. A primary objective of this strategy is to free the design space from launch vehicle constraints and fundamentally shift how a mission is designed and conducted. This integrates advances in materials (mechanical meta-materials), manufacturing (cooperative mobile robotics), and autonomy (multi-agent planning algorithms). Engineering systems that utilize a modular and reconfiguration building block approach, such as digital communication and computation systems, currently lead in terms of size and complexity scalability. NASA is extending the benefits and flexibility of digital systems to hardware systems, to optimize materials life-cycle management and expand our space exploration mission capabilities to meet long duration and deep space infrastructure needs, in accordance with long term NASA goals of "in-space reliance" and "mass-less exploration."

In space assembly↗

NASA NTRS2018

The Second European Service Module (ESM-2) Evolutions, Production and Challenges

This paper presents an overview of the Second European Service Module (ESM-2), the second in a series of European Service Modules produced as part of the Barter agreement between NASA and ESA for the Orion Program. The European Industrial consortium is led by the ESA prime contractor Airbus Defence and Space in Bremen. ESA and Airbus signed the ESM-2 contract on 16 February 2017, for this key element of the Orion Exploration Mission 2 (EM-2). EM-2 is the first crewed mission for Orion and will take astronauts farther into the solar system than humanity has ever travelled. EM-2 will also be a historic mission for Europe, as the ESM-2 will be the first European spacecraft to be part of a human transportation system carrying humans beyond low Earth orbit. ESM-2 is mainly a recurring production following ESM-1. Nevertheless, there are a number of important changes being implemented, for example, to incorporate upgrades to further enhance safety and reliability. The challenging delivery schedule for ESM-2 has driven the need to commence manufacturing prior to completion of the qualification on ESM-1. In addition, some requirement deviations and non-compliances approved for ESM-1 have resulted in modifications for ESM-2. In order to manage the competing constraints effectively, the ESM-2 Team has put in place a number of novel approaches to manage schedule, risk, and technical changes. Airbus has set up multi-functional teams according to an approach known as "Major Spacecraft Deliveries" consisting of quality assurance, engineering and procurement. The risk of starting manufacturing prior to qualification is managed through a special risk share agreement. This agreement necessitates rigorous risk reviews across the board for all manufacturing, assembly, integration and test milestones. The ESM-2 changes are managed by Configuration Management, but Airbus has also introduced the Technical Baseline Matrix to provide a transparent top-level overview of the changes from ESM-1 to ESM-2. The tool provides the basis for ESM-2 design and development needs, decisions, as well as the input for the Orion EM-2 Critical Design Review (CDR). The main technical evolutions, status of the production and the novel management approaches for ESM-2 are presented and discussed in the paper.

Orion European Service Module Programme↗

DOE OSTI2025

DESIGN ISSUES AND QUALIFICATION OF HYDROFORMED DOUBLE WALLED EXPANSION JOINTS IN VACUUM SERVICE

The Vacuum Auxiliary System for ITER is devoted to pumping out, venting, and purging the vacuum volumes of the tokamak. Over 5000 clients including the cryostat and vacuum vessel, at 8500 m3 and 1400 m3 respectively, are serviced by approximately 150 pumping stations through 6 km of pipework. The piping and functions provided to the clients include component operation, routing of potentially tritiated gases, and timely leak localization. Expansion joints are used to reduce loadings on pumps and piping stresses but also to qualify in-line components having low allowable design loads. The ITER project utilizes vacuum valves that are not designed to withstand typical piping system loadings and require detailed design and evaluation. Loading scenarios prescribed by governing system specifications must be considered. To maintain allowable design loads for components and to keep piping stresses below code requirements, double walled hydroformed expansion joints have been employed in the design. These are not standard items and require custom fabrication. Installation space constraints and adjacent pipe support attachment location availability at ITER limit standard expansion joint installation guidelines provided by the Expasion Joint Manufacturers Association (EJMA). Careful consideration must be given to the analysis model to ensure proper function and life expectancy of the component. These considerations include accurate accounting of thrust forces, thermal movements, seismic accelerations, equipment and building differential displacements. In addition to displacements, the process internal, external, and interspace pressures affect the qualification and selection of the double walled expansion joints. The calculation results shall confirm that deflections, forces, and moments are reasonable for the size and type required for the system’s demands as evaluated against the manufacturer’s design.

Clark, Forrest [ORNL] (ORCID:0009000678106843)↗