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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

3-D Printed Ultem 9085 Testing and Analysis

The purpose of this document is to analyze the mechanical properties of 3-D printed Ultem 9085. This document will focus on the capabilities, limitations, and complexities of 3D printing in general, and explain the methods by which this material is tested. Because 3-D printing is a relatively new process that offers an innovative means to produce hardware, it is important that the aerospace community understands its current advantages and limitations, so that future endeavors involving 3-D printing may be completely safe. This document encompasses three main sections: a Slosh damage assessment, a destructive test of 3-D printed Ultem 9085 samples, and a test to verify simulation for the 3-D printed SDP (SPHERES Docking Port). Described below, 'Slosh' and 'SDP' refer to two experiments that are built using Ultem 9085 for use with the SPHERES (Synchronized Position Hold, Engage, Reorient, Experimental Satellites) program onboard the International Space Station (ISS) [16]. The SPHERES Facility is managed out of the National Aeronautics and Space Administration (NASA) Ames Research Center in California.

Aguilar, Daniel↗
DOE OSTI2025

Solid State Additive Manufacturing of Oxide Dispersion Strengthened-FeCrAl Alloy Components for High-Temperature Supercritical CO2 Power Cycle Applications

In this research, material extrusion additive manufacturing (MEAM) has been explored as an SSAM method for fabrication of 3-D components using ODS-FeCrAl alloy. MEAM-printed 3-D parts go through a series of process steps, e.g., chemical treatment, thermal treatment etc. in order to create a high density fully metallic part. Final 3-D part quality is associated with various process steps, e.g., filament fabrication, print design, and thermal treatment optimization. In MEAM, a metal powder loaded filament is used for printing 3-D shapes. Composition of the filament is very important since it provides shape retention at low-to-medium temperature. There are a few commercially available metallic alloy filaments. However, FeCrAl alloy filaments are not commercially available. In this project, we came up with a method to fabricate high quality composite FeCrAl filaments that could be used for MEAM printing. Subsequently, we have optimized MEAM print methods to fabricate samples that are larger than 10 mm, by using a modular print design approach. Finally, we have been able to optimize the chemical and high temperature heat treatment steps to achieve very high density (>98%) in sintered MEAM-printed products.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of a Robust Reference Electrode in Aggressive Chemical and Radiation Environments in the Hanford Waste Tanks

The Hanford site stores more than 200 million liters of radioactive and chemically hazardous wastes from the production of weapons materials. The wastes are stored in 177 underground carbon-steel storage tanks, separated between 149 single shell tanks (SSTs) and 28 double shell tanks (DSTs). The DSTs provide critical retrieval and interim storage before the waste is vitrified in the Waste Treatment and Isolation Plant (WTP). The tanks will need to remain in-service far beyond the initial 40-year design life, and effective corrosion control practices must remain in force to extend the tanks’ lifespans. This effort includes direct measurements of corrosion rate (e.g., ultrasonic measurements and corrosion coupons) and electrochemical processes (e.g., linear polarization measurements and open circuit potential measurements). The Hanford site began monitoring the corrosion potential in select DSTs in 2008. Of the 45 reference electrodes that have been installed, 29 have failed and 6 others provided unreliable results. DOE-EM is supporting a 3-year program to develop a chemical and radiation resistant reference electrode for application in the Hanford tanks. The first year of the program focused on understanding the failure mechanism for the reference electrodes and identification of candidate construction materials that would mitigate degradation of the electrodes in the waste environment. During the second year of the program, the objectives were to: 1) test candidate materials under simulated waste conditions, 2) design components that will extend the service life of the electrode, 3) fabricate materials for prototype reference electrodes, and 4) assemble prototype reference electrodes for accelerated testing. The reference electrode is constructed of four principal parts: 1) junction, 2) casing, 3) inner chamber backfill materials, and 4) the sensing wire. Principally, improvements of the junction, casing, and inner chamber backfill materials are being pursued. The junction material at the interface between the waste and the inner chamber of the reference electrode was identified as a critical component in the failure of the reference electrodes. Nine candidate replacement junction materials were tested under simulated waste conditions to evaluate permeation rate. These materials included a variety of polymeric and ceramic materials, some of which were 3-D printed. Thus far, porous polyvinylidene fluoride materials have performed satisfactorily and are being considered for prototype development. The commercial electrode casing materials in general have performed well. Additionally, 3-D printing of chemically and mechanically stable materials is being investigated as a means for further improvement in fabrication consistency. SRNL has also investigated altering the reference electrode design to extend the service life. The new design of the interior of the reference electrode casing creates a longer, more tortuous path between the junction material and the electrode sensing wire. A finite element model was used to optimize the design without adversely impacting the circuit resistance of the electrode during the measurements, thus preserving the measurement accuracy while enhancing the service life. The inner chamber back fill materials are also critical to the performance of the reference electrode. Materials that are resistant to intruding tank waste and provide a conductive path to the sensing wire were investigated. Gel and powder materials that are interspersed with a conductive chloride bearing material were tested for their influence on diffusion and electrode resistance. All the investigated materials and components will be assembled, with collaboration from commercial vendors, to fabricate the initial prototypes. Accelerated testing of the prototypes will be initiated in Year 2 of the program and will be completed in Year 3. A recommendation on the materials of construction and the design of the new robust reference electrode will be presented to the Hanford tank farm facility.

Sykes, Kiana [Savannah River National Laboratory (↗
DOE OSTI2025

High-pressure high-temperature melting and recrystallization of nanolamellar high-entropy alloys

Additively manufactured (AM) High Entropy Alloys (HEAs) are notable for their exceptional high-yield strength and large tensile ductility. The nanolamellar Eutectic HEA (EHEA) AlCoCrFeNi 2.1 was fabricated by laser powder bed fusion (L-PBF) in the as-printed form (EHEA1) and subsequently annealed at 1000oC (EHEA2) and 600oC (EHEA3) to achieve a broad range of mechanical properties. EHEA2 and EHEA3 samples were studied using Scanning transmission electron microscopy (STEM), energy dispersive X-ray diffraction (EDXRD) at high-pressures and high temperatures, nanoindentation hardness and modulus measurements. According to EDXRD EHEA2 and EHEA3 are composed of B2 and L1 2 phases. High-pressure high-temperature EDXRD studies show melting for EHEA2 at 1698 ± 25 K at a pressure of 6.5 GPa and melting for EHEA3 at 1598 ± 25 K at a pressure of 5.8 GPa. Post-melt and recrystallized samples were recovered at ambient conditions, and XRD analysis showed retention of B2 and L1 2 phases, although a new σ phase appeared for both EHEA2 and EHEA3 samples due to high-pressure and high-temperature melting and recrystallization experiment. SEM analysis also demonstrated the preservation of the nanolamellar morphology. Nanoindentation studies revealed that recrystallized EHEAs retain their original mechanical property hierarchy, with EHEA3 being 47% harder than EHEA2, largely related to higher content of B2-phase and retention of nanolamellar morphology. We also present Pressure-Volume-Temperature (P-V-T) data for 3-D printed and annealed eutectic high entropy alloys and extract mechanical and thermal properties data.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Understanding and promoting the reaction kinetics of photothermally driven Diels–Alder reaction with minimized side reactions

The thermoreversible Diels–Alder (DA) reaction involving furan and maleimide precursors has been extensively exploited to develop reversible thermosets for circular economy and additive manufacturing. Recently, applications of photothermal nanoparticles, which can absorb light and generate nanoscale heat, have gained significant attention in driving the Diels–Alder (DA) reaction more efficiently. This approach can be utilized by various applications, for example, solar light-enhanced recycling, self-healing at targeted area, and photothermal 3-D printing. Here, in this work, we address an important fundamental question on the photothermal approach: how does the reaction kinetics of the photothermally driven DA reaction compared to that of the conventional heat driven one? We found that the forward DA reaction kinetics varies dramatically depending on a type of heat sources, i.e., light-induced photothermal heat or conventional heat, despite of a similar bulk temperature. We observed that the light-induced photothermal heat significantly enhances the DA reaction rate in comparison to the bulk heating in an inert environment. On the contrary, the photothermally driven forward DA reaction is significantly slower than that of the heat driven reaction in the presence of oxygen. This is attributed to the photoexcited electrons in photothermal nanoparticles that can generate singlet oxygen ( 1 O 2 ) in the presence of visible light. This singlet oxygen may facilitate an endoperoxide side reaction on the furan group, ultimately, retard the DA reaction from the furan group. These results reveal the effectiveness of photothermal nanoparticles in accelerating DA reaction while underscoring the need to minimize oxygen exposure to prevent unfavorable side reactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Miniaturized Millimeter-Wave Multilayer Filter Design Using Additive Manufacturing

Here, this article presents an innovative, fully additive manufactured approach to millimeter-wave multilayer circuits. An aerosol jet printer is used to fabricate a multilayer stepped-impedance low-pass filter. By leveraging the second layer for miniaturization, we achieve a more compact design. By precisely controlling conductor separation and utilizing 3-D printing technology, we were able to optimize the width of the high- and low-impedance segments for optimal filter performance. Two filter types were successfully fabricated: a low-pass microstrip filter and a low-pass stripline filter, both with a cutoff frequency near 29 GHz and exhibiting acceptable stopband attenuation. The stripline configuration allows for a 36% decrease in the stripline waveguide conductor area while achieving a great passband insertion loss of just 0.62 dB, enabled by aerosol jet printing (AJP). The line loss of both designs was characterized using a microstrip through line and a stripline through line. Both designs demonstrated low overall loss, with the microstrip line exhibiting a loss of 0.26 dB/mm and the stripline having a loss of 0.37 dB/mm at 29 GHz. This work demonstrates a multilayer integration solution and offers an advantage in reducing the size of RF circuits such as filter banks for next-generation integrated RF front ends.

additive manufacturing↗
NASA NTRS2013

Neutron Characterization for Additive Manufacturing

Oak Ridge National Laboratory (ORNL) is leveraging decades of experience in neutron characterization of advanced materials together with resources such as the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) shown in Fig. 1 to solve challenging problems in additive manufacturing (AM). Additive manufacturing, or three-dimensional (3-D) printing, is a rapidly maturing technology wherein components are built by selectively adding feedstock material at locations specified by a computer model. The majority of these technologies use thermally driven phase change mechanisms to convert the feedstock into functioning material. As the molten material cools and solidifies, the component is subjected to significant thermal gradients, generating significant internal stresses throughout the part (Fig. 2). As layers are added, inherent residual stresses cause warping and distortions that lead to geometrical differences between the final part and the original computer generated design. This effect also limits geometries that can be fabricated using AM, such as thin-walled, high-aspect- ratio, and overhanging structures. Distortion may be minimized by intelligent toolpath planning or strategic placement of support structures, but these approaches are not well understood and often "Edisonian" in nature. Residual stresses can also impact component performance during operation. For example, in a thermally cycled environment such as a high-pressure turbine engine, residual stresses can cause components to distort unpredictably. Different thermal treatments on as-fabricated AM components have been used to minimize residual stress, but components still retain a nonhomogeneous stress state and/or demonstrate a relaxation-derived geometric distortion. Industry, federal laboratory, and university collaboration is needed to address these challenges and enable the U.S. to compete in the global market. Work is currently being conducted on AM technologies at the ORNL Manufacturing Demonstration Facility (MDF) sponsored by the DOE's Advanced Manufacturing Office. The MDF is focusing on R&D of both metal and polymer AM pertaining to in-situ process monitoring and closed-loop controls; implementation of advanced materials in AM technologies; and demonstration, characterization, and optimization of next-generation technologies. ORNL is working directly with industry partners to leverage world-leading facilities in fields such as high performance computing, advanced materials characterization, and neutron sciences to solve fundamental challenges in advanced manufacturing. Specifically, MDF is leveraging two of the world's most advanced neutron facilities, the HFIR and SNS, to characterize additive manufactured components.

Watkins, Thomas↗
NASA NTRS2014

Capillary Flows Along Open Channel Conduits: The Open-Star Section

Capillary rise in tubes, channels, and grooves has received significant attention in the literature for over 100 years. In yet another incremental extension of such work, a transient capillary rise problem is solved for spontaneous flow along an interconnected array of open channels forming what is referred to as an 'open-star' section. This geometry possesses several attractive characteristics including passive phase separations and high diffusive gas transport. Despite the complex geometry, novel and convenient approximations for capillary pressure and viscous resistance enable closed form predictions of the flow. As part of the solution, a combined scaling approach is applied that identifies unsteady-inertial-capillary, convective-inertial-capillary, and visco-capillary transient regimes in a single parameter. Drop tower experiments are performed employing 3-D printed conduits to corroborate all findings.

Weislogel, Mark↗
NASA NTRS2014

Nondestructive Evaluation of Additive Manufacturing State-of-the-Discipline Report

This report summarizes the National Aeronautics and Space Administrations (NASA) state of the art of nondestructive evaluation (NDE) for additive manufacturing (AM), or "3-D printed", hardware. NASA's unique need for highly customized spacecraft and instrumentation is suited for AM, which offers a compelling alternative to traditional subtractive manufacturing approaches. The Agency has an opportunity to push the envelope on how this technology is used in zero gravity, an enable in-space manufacturing of flight spares and replacement hardware crucial for long-duration, manned missions to Mars. The Agency is leveraging AM technology developed internally and by industry, academia, and other government agencies for its unique needs. Recent technical interchange meetings and workshops attended by NASA have identified NDE as a universal need for all aspects of additive manufacturing. The impact of NDE on AM is cross cutting and spans materials, processing quality assurance, testing and modeling disciplines. Appropriate NDE methods are needed before, during, and after the AM production process.

Waller, Jess M.↗
NASA NTRS2015

Development and Testing of a Post-Installable Deepwater Monitoring System Using Fiber-Optic Sensors

This paper addresses the design and development of a fiber-optic monitoring system that can be deployed on existing deepwater risers and flowlines; and provides a summary of test article fabrication and the subsequent laboratory testing performed at the National Aeronautics and Space Administration-Johnson Space Center (NASA-JSC). A major challenge of a post-installed instrumentation system is to ensure adequate coupling between the instruments and the riser or flowline of interest. This work investigates the sensor coupling for pipelines that are suspended in a water column (from topside platform to seabed) using a fiber-optic sensor clamp and subsea bonding adhesive. The study involved the design, fabrication, and test of several prototype clamps that contained fiber-optic sensors. A mold was produced by NASA using 3-D printing methods that allowed the casting of polyurethane clamp test articles to accommodate 4-inch and 8-inch diameter pipes. The prototype clamps were installed with a subsea adhesive in a "wet" environment and then tested in the NASA Structures Test Laboratory (STL). The tension, compression, and bending test data showed that the prototype sensor clamps achieved good structural coupling, and could provide high quality strain measurement for active monitoring.

Seaman, Calvin H.↗
NASA NTRS2015

Low Cost Upper Stage-Class Propulsion (LCUSP)

NASA is making space exploration more affordable and viable by developing and utilizing innovative manufacturing technologies. Technology development efforts at NASA in propulsion are committed to continuous innovation of design and manufacturing technologies for rocket engines in order to reduce the cost of NASA's journey to Mars. The Low Cost Upper Stage-Class Propulsion (LCUSP) effort will develop and utilize emerging Additive Manufacturing (AM) to significantly reduce the development time and cost for complex rocket propulsion hardware. Benefit of Additive Manufacturing (3-D Printing) Current rocket propulsion manufacturing techniques are costly and have lengthy development times. In order to fabricate rocket engines, numerous complex parts made of different materials are assembled in a way that allow the propellant to collect heat at the right places to drive the turbopump and simultaneously keep the thrust chamber from melting. The heat conditioned fuel and oxidizer come together and burn inside the combustion chamber to provide thrust. The efforts to make multiple parts precisely fit together and not leak after experiencing cryogenic temperatures on one-side and combustion temperatures on the other is quite challenging. Additive manufacturing has the potential to significantly reduce the time and cost of making rocket parts like the copper liner and Nickel-alloy jackets found in rocket combustion chambers where super-cold cryogenic propellants are heated and mixed to the extreme temperatures needed to propel rockets in space. The Selective Laser Melting (SLM) machine fuses 8,255 layers of copper powder to make a section of the chamber in 10 days. Machining an equivalent part and assembling it with welding and brazing techniques could take months to accomplish with potential failures or leaks that could require fixes. The design process is also enhanced since it does not require the 3D model to be converted to 2-D drawings. The design and fabrication process can be sped up and improved with fewer errors to be accomplished in weeks instead of months.

Vickers, John↗
NASA NTRS2014

Novel Overhang Support Designs for Powder-Based Electron Beam Additive Manufacturing (EBAM)

NASA Marshall Space Flight Center, in collaboration with the University of Alabama, has developed a contact-free support structure used to fabricate overhang-type geometries via EBAM. The support structure is used for 3-D metal-printed components for the aerospace, automotive, biomedical and other industries. Current techniques use support structures to address deformation challenges inherent in 3-D metal printing. However, these structures (overhangs) are bonded to the component and need to be removed in post-processing using a mechanical tool. This new technology improves the overhang support structure design for components by eliminating associated geometric defects and post-processing requirements.

Nabors, Sammy A.↗
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 NTRS2007

Design Application Translates 2-D Graphics to 3-D Surfaces

Fabric Images Inc., specializing in the printing and manufacturing of fabric tension architecture for the retail, museum, and exhibit/tradeshow communities, designed software to translate 2-D graphics for 3-D surfaces prior to print production. Fabric Images' fabric-flattening design process models a 3-D surface based on computer-aided design (CAD) specifications. The surface geometry of the model is used to form a 2-D template, similar to a flattening process developed by NASA's Glenn Research Center. This template or pattern is then applied in the development of a 2-D graphic layout. Benefits of this process include 11.5 percent time savings per project, less material wasted, and the ability to improve upon graphic techniques and offer new design services. Partners include Exhibitgroup/Giltspur (end-user client: TAC Air, a division of Truman Arnold Companies Inc.), Jack Morton Worldwide (end-user client: Nickelodeon), as well as 3D Exhibits Inc., and MG Design Associates Corp.

Source record↗
NASA NTRS2005

3-D Packaging: A Technology Review

Traditional electronics are assembled as a planar arrangement of components on a printed circuit board (PCB) or other type of substrate. These planar assemblies may then be plugged into a motherboard or card cage creating a volume of electronics. This architecture is common in many military and space electronic systems as well as large computer and telecommunications systems and industrial electronics. The individual PCB assemblies can be replaced if defective or for system upgrade. Some applications are constrained by the volume or the shape of the system and are not compatible with the motherboard or card cage architecture. Examples include missiles, camcorders, and digital cameras. In these systems, planar rigid-flex substrates are folded to create complex 3-D shapes. The flex circuit serves the role of motherboard, providing interconnection between the rigid boards. An example of a planar rigid - flex assembly prior to folding is shown. In both architectures, the interconnection is effectively 2-D.

Strickland, Mark↗
NASA NTRS1999

Three-Dimensional Imaging

This chapter is concerned with three-dimensional imaging of fluid flows. Although relatively young, this field of research has already yielded an enormous range of techniques. These vary widely in cost and complexity, with the cheapest light sheet systems being within the budgets of most laboratories, and the most expensive Magnetic Resonance Imaging systems available to a select few. Taking the view that the most likely systems to be developed are those using light sheets, the authors will relate their knowledge and experience of such systems. Other systems will be described briefly and references provided. Flows are inherently three-dimensional in structure; even those generated around nominally 2-D surface geometry. It is becoming increasingly apparent to scientists and engineers that the three-dimensionalities, both large and small scale, are important in terms of overall flow structure and species, momentum, and energy transport. Furthermore, we are accustomed to seeing the world in three dimensions, so it is natural that we should wish to view, measure and interpret flows in three-dimensions. Unfortunately, 3-D images do not lend themselves to convenient presentation on the printed page, and this task is one of the challenges facing us.

Kelso, R. M.↗
NASA NTRS1989

Interactive displays in medical art

Medical illustration is a field of visual communication with a long history. Traditional medical illustrations are static, 2-D, printed images; highly realistic depictions of the gross morphology of anatomical structures. Today medicine requires the visualization of structures and processes that have never before been seen. Complex 3-D spatial relationships require interpretation from 2-D diagnostic imagery. Pictures that move in real time have become clinical and research tools for physicians. Medical illustrators are involved with the development of interactive visual displays for three different, but not discrete, functions: as educational materials, as clinical and research tools, and as data bases of standard imagery used to produce visuals. The production of interactive displays in the medical arts is examined.

Mcconathy, Deirdre Alla↗