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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
DOE OSTI2022

Oxidation Resistance in 1200°C Steam of a FeCrAl Alloy Fabricated by Three Metallurgical Processes

Abstract FeCrAl alloys are a leading candidate material for accident tolerant fuel cladding due to their good performance in both normal light-water reactor operating conditions as well as their resilience to high-temperature accident scenarios. For commercial-scale production, new fabrication techniques need to be investigated. In this study, the effects of fabrication methods on the high-temperature steam oxidation performance of C26M (Fe12Cr6Al2Mo in wt.%) were investigated. Three variants of C26M were manufactured: wrought (cast and forged) (WC26M), powder metallurgy hot isostatic pressing (PMC26M), and laser powder bed fusion additive manufacturing (AMC26M). All three variants were exposed to steam at 1200°C for 2 h. Results showed no significant variation in mass change between the variants after steam exposure. All three variants effectively formed stable protective alumina films with ~0.6–1.3 µ m thickness. This study suggests FeCrAl alloys have excellent resilience to high-temperature steam in nuclear reactor accident scenarios regardless of the fabrication method.

Materials Science↗
NASA NTRS2017

Development of a Continuum Damage Mechanics Material Model of a Graphite-Kevlar(Registered Trademark) Hybrid Fabric for Simulating the Impact Response of Energy Absorbing Kevlar(Registered Trademark) Hybrid Fabric for Simulating the Impact Response of Energy Absorbing

This paper describes the development of input properties for a continuum damage mechanics based material model, Mat 58, within LS-DYNA(Registered Trademark) to simulate the response of a graphite-Kevlar(Registered Trademark) hybrid plain weave fabric. A limited set of material characterization tests were performed on the hybrid graphite-Kevlar(Registered Trademark) fabric. Simple finite element models were executed in LS-DYNA(Registered Trademark) to simulate the material characterization tests and to verify the Mat 58 material model. Once verified, the Mat 58 model was used in finite element models of two composite energy absorbers: a conical-shaped design, designated the "conusoid," fabricated of four layers of hybrid graphite-Kevlar(Registered Trademark) fabric; and, a sinusoidal-shaped foam sandwich design, designated the "sinusoid," fabricated of the same hybrid fabric face sheets with a foam core. Dynamic crush tests were performed on components of the two energy absorbers, which were designed to limit average vertical accelerations to 25- to 40-g, to minimize peak crush loads, and to generate relatively long crush stroke values under dynamic loading conditions. Finite element models of the two energy absorbers utilized the Mat 58 model that had been verified through material characterization testing. Excellent predictions of the dynamic crushing response were obtained.

Jackson, Karen E.↗
DOE OSTI2023

Fabrication Development for SPT-SLIM, a Superconducting Spectrometer for Line Intensity Mapping

Line Intensity Mapping (LIM) is a new observational technique that uses low-resolution observations of line emission to efficiently trace the large-scale structure of the Universe out to high redshift. Common mm/sub-mm emission lines are accessible from ground-based observatories, and the requirements on the detectors for LIM at mm-wavelengths are well matched to the capabilities of large-format arrays of superconducting sensors. We describe the development of an R = lambda/Delta lambda = 300 on-chip superconducting filter-bank spectrometer covering the 120-180 GHz band for future mm-LIM experiments, focusing on SPT-SLIM, a pathfinder LIM instrument for the South Pole Telescope. Radiation is coupled from the telescope optical system to the spectrometer chip via an array of feedhorn-coupled orthomode transducers. Superconducting microstrip transmission lines then carry the signal to an array of channelizing half-wavelength resonators, and the output of each spectral channel is sensed by a lumped element kinetic inductance detector (leKID). Key areas of development include incorporating new low-loss dielectrics to improve both the achievable spectral resolution and optical efficiency and development of a robust fabrication process to create a galvanic connection between ultra-pure superconducting thin-films to realize multi-material (hybrid) leKIDs. We provide an overview of the spectrometer design, fabrication process, and prototype devices.

microstrip resonators↗
DOE OSTI2023

Highly cascaded first-order sapphire optical fiber Bragg gratings fabricated by a femtosecond laser

This Letter reports an innovative technique for fabricating large-scale, highly cascaded first-order sapphire optical fiber Bragg gratings (FBGs) using a femtosecond laser-assisted point-by-point inscription method. For the first time, to the best of our knowledge, this study successfully demonstrates a distributed array of 10 FBGs within highly multimode sapphire crystal fiber, made possible by employing a high-power laser technique to generate larger reflectors with a Gaussian intensity profile. These first-order FBGs offer advantages such as enhanced reflectivity, shorter fabrication time, and simplified spectral characteristics, making them easier to interpret compared with high-order FBGs. The FBGs’ resilience and effectiveness are analyzed by subjecting them to temperature tests, proving their capacity for accurate temperature monitoring up to 1500°C—a testament to their suitability for harsh environments. This novel approach broadens the scope for sensing and communication applications in sapphire fibers, particularly under challenging conditions. The novelty of our work lies in successfully overcoming the limitations of previous designs by integrating a cascade of 10 FBGs in sapphire fibers, thereby enhancing multiplexing capabilities, minimizing overlapping of FBG peaks, and ensuring reliable temperature monitoring in industries and applications with thermal gradients.

47 OTHER INSTRUMENTATION↗
NASA NTRS1981

Development of molded, coated fabric joints: Fabric construction criteria for a spacesuit elbow joint

The design and fabrication of a molded, coated fabric elbow joint capable of operating reliably at 8 psi internal pressure for extended periods of flexure is considered. The overall design of the joint includes: (1) selection of heatsettable fiber of sufficient strengths; (2) choosing an optimum fabric construction; (3) a fatigue resistant; flexible coating; and (4) a molding technique. A polyester yarn of type 56 Dacron and a urethane coating system were selected. The relationships between yarn and weave parameters which lead to an optimum fabric construction for the 8 psi elbow joint are defined.

Olson, L. H.↗
NASA NTRS2011

Fabric circuits and method of manufacturing fabric circuits

A flexible, fabric-based circuit comprises a non-conductive flexible layer of fabric and a conductive flexible layer of fabric adjacent thereto. A non-conductive thread, an adhesive, and/or other means may be used for attaching the conductive layer to the non-conductive layer. In some embodiments, the layers are attached by a computer-driven embroidery machine at pre-determined portions or locations in accordance with a pre-determined attachment layout before automated cutting. In some other embodiments, an automated milling machine or a computer-driven laser using a pre-designed circuit trace as a template cuts the conductive layer so as to separate an undesired portion of the conductive layer from a desired portion of the conductive layer. Additional layers of conductive fabric may be attached in some embodiments to form a multi-layer construct.

Chu, Andrew W.↗
NASA NTRS1982

Space fabrication demonstration system composite beam cap fabricator

A detailed design for a prototype, composite beam cap fabricator was established. Inputs to this design included functional tests and system operating requirements. All required materials were procured, detail parts were fabricated, and one composite beam cap forming machine was assembled. The machine was demonstrated as a stand-alone system. Two 12-foot-long beam cap members were fabricated from laminates graphite/polysulfane or an equivalent material. One of these members, which as structurally tested in axial compression, failed at 490 pounds.

Source record↗
DOE OSTI2023

Advanced Fuel Cycle Cost Basis Report: Module D1-4 and Module D1-5 Ceramic Pelletized Sodium-Cooled Fast Reactor (SFR) Fuel Fabrication Ceramic Vibrocompacted Fuel Fabrication

This is a cost module that is part of the Advanced Fuel Cycle -- Cost Basis Report. Module D1-4: Nature of this module update (Rev 1) from previous advanced fuel cycle cost basis reports (AFCCBRs): new life cycle cost data on U,Pu SFR mixed oxide (MOX) fuels is derived from the Nonproliferation Assessment Systems Analysis Program (NASAP) conducted in the late 1970s. Highassay low-enriched uranium (HALEU) ceramic fuel is also discussed in more detail compared to earlier AFC-CBRs, since some advanced SFR concepts currently under development will require this HALEU fuel type for startup. Module D1-5: Nature of this FY-21 module update from previous AFC-CBRs: this module includes a few new references and a somewhat expanded discussion of vibrocompaction fuel fabrication technology. The WIT values for VIPAC are pegged directly to those for conventional LWR and SFR pelletized U,Pu MOX (note that this module now includes VIPAC MOX fuel for LWRs in addition to SFRs). Based on information from Russia, where VIPAC has been studied extensively, the unit costs are expressed as a percentage of those in the new updated Module D1-2 (pelletized U,Pu MOX) and new updated Module D1-4 (pelletized U,Pu MOX) for large NOAK fabrication facilities of the same production capacity. Since both ceramic pelletized MOX Modules D1-2 and D1-4 benefitted from analysis of 1970s NASAP data, by extension this Module D1-5 also benefits.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1995

Fabrication of the Advanced X-ray Astrophysics Facility (AXAF) Optics: A Deterministic, Precision Engineering Approach to Optical Fabrication

The mirror assembly of the AXAF observatory consists of four concentric, confocal, Wolter type 1 telescopes. Each telescope includes two conical grazing incidence mirrors, a paraboloid followed by a hyperboloid. Fabrication of these state-or-the-art optics is now complete, with predicted performance that surpasses the goals of the program. The fabrication of these optics, whose size and requirements exceed those of any previous x-ray mirrors, presented a challenging task requiring the use of precision engineering in many different forms. Virtually all of the equipment used for this effort required precision engineering. Accurate metrology required deterministic support of the mirrors in order to model the gravity distortions which will not be present on orbit. The primary axial instrument, known as the Precision Metrology Station (PMS), was a unique scanning Fizeau interferometer. After metrology was complete, the optics were placed in specially designed Glass Support Fixtures (GSF's) for installation on the Automated Cylindrical Grinder/Polishers (ACG/P's). The GSF's were custom molded for each mirror element to match the shape of the outer surface to minimize distortions of the inner surface. The final performance of the telescope is expected to far exceed the original goals and expectations of the program.

Gordon, T. E.↗
NASA NTRS2002

Hoop Tensile Characterization Of SiC/SiC Cylinders Fabricated From 2D Fabric

Tensile stress-strain properties in the hoop direction were obtained for 100-mm diameter SiC/SiC cylinders using ring specimens machined from the cylinder ends. The cylinders were fabricated from 2D balanced fabric with several material variants, including wall thickness (6, 8, and 12 plies), Sic fiber type (Sylramic, Sylramic-iBN, Hi-Nicalon, and Hi-Nicalon S), fiber sizing type, and matrix type (full CVI Sic, and partial CVI plus melt-infiltrated SiC-Si). Fiber ply splices existed in the all the hoops. Tensile hoop measurements were made at room temperature and 1200 C using hydrostatic ring test facilities. The hoop results are compared with in-plane data measured on flat panels using same material variants, but containing no splices.

Verrilli, Michael J.↗
NASA NTRS2008

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗
NASA NTRS2009

Tensile Properties and Microstructure of Inconel 718 Fabricated with Electron Beam Freeform Fabrication (EBF(sup 3))

Electron beam freeform fabrication (EBF3) direct metal deposition processing was used to fabricate two Inconel 718 single-bead-width wall builds and one multiple-bead-width block build. Specimens were machined to evaluate microstructure and room temperature tensile properties. The tensile strength and yield strength of the as-deposited material from the wall and block builds were greater than those for conventional Inconel 718 castings but were less than those for conventional cold-rolled sheet. Ductility levels for the EBF3 material were similar to those for conventionally-processed sheet and castings. An unexpected result was that the modulus of the EBF3-deposited Inconel 718 was significantly lower than that of the conventional material. This low modulus may be associated with a preferred crystallographic orientation resultant from the deposition and rapid solidification process. A heat treatment with a high solution treatment temperature resulted in a recrystallized microstructure and an increased modulus. However, the modulus was not increased to the level that is expected for Inconel 718.

Bird, R. Keith↗
NASA NTRS2010

Effect of Orientation on Tensile Properties of Inconel 718 Block Fabricated with Electron Beam Freeform Fabrication (EBF3)

Electron beam freeform fabrication (EBF3) direct metal deposition processing was used to fabricate an Inconel 718 bulk block deposit. Room temperature tensile properties were measured as a function of orientation and location within the block build. This study is a follow-on activity to previous work on Inconel 718 EBF3 deposits that were too narrow to allow properties to be measured in more than one orientation

Bird, R. Keith↗
DOE OSTI2025

Friction-based recycling: an evaluation of friction extrusion for fabricating Ti-6Al-4 V wire fabricated from machining chip feedstock

Abstract Titanium and its alloys are used in aviation and automobile industries due to their remarkable strength to weight ratio, but machining loss commonly is high with ~ 80 wt% of the material being converted to scrap. Recycling post-consumer Ti scrap directly into solid bulk products is a potential solution for repurposing valuable material. Further, eliminating fresh Ti sponge during recycling might lead to lower energy and greenhouse gas emissions. In this study, a solid-phase process known as friction extrusion was utilized to recycle Ti-6Al-4 V machining chips into solid wires which could be used as feedstock in additive manufacturing. The friction consolidation technique was first used to convert chips with varying degrees of oxygen content into solid billets for its use as feedstock material in subsequent friction extrusion. The extrudates were fabricated above the beta transition temperature, which was achieved by selecting the rotation rate and feed rate, to process the billets near 1000 °C using a tungsten-lanthana extrusion die. This work presents the first occurrence of friction extruded titanium alloy wires. The effect of friction extrusion on microstructural features, tensile properties, and texture are reported. Overall, the friction extrusion method is capable of directly recycling Ti-6Al-4 V scrap into extruded wire.

Friction Extrusion↗