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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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15 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Large-scale additive manufacturing tooling for extrusion-compression molds

Carbon fiber reinforced polymer composites (CFPC) have been used in additive manufacturing (AM) due to both the high-strength-to-weight and superior-stiffness-to-weight ratios. CF AM is being considered for tooling applications. In AM, CFPCs are usually aligned along the deposition direction; however, it results in anisotropic thermal properties which affect the heat transfer and warpage of the final part. In this study, three male molds with different infill patterns were produced via the material extrusion additive manufacturing (EDF-AM) process. These include (a) 0°: infill pattern along the printing direction; (b) 90°: infill pattern perpendicular to the printing direction; and (c) 0°/90°: alternate layers along and perpendicular directions. The effect of the infill pattern on thermal conductivity was analyzed and observed that 0° infill (surface temperature: 79.2°C) had the highest conductivity; and 90° infill (surface temperature: 66.4°C) had the least.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of Internal Structure on Warpage in a Large-Scale Additive Manufacturing Process With Bio-Derived Composites

Extrusion-based large-format additive manufacturing (LFAM) often results in unintended deformation and failures due to thermal residual stress between layers. This LFAM involves a hot molten polymer deposited on a previously deposited and cooled layer, generating a temperature mismatch between the layers. The temperature discrepancy causes a thermal contraction mismatch, generating thermal residual stress. Due to the residual stress, printed structures experience warpage and delamination Therefore, understanding the heat distribution behavior is essential to preventing undesired deformation and failures. The goal of this study is to investigate the effect of infill patterns on heat distribution and deformation in an LFAM system. Wood fiber-reinforced polylactic acid was used as a sustainable and low-cost reinforcement material. A numerical model was developed to predict the temperature and deformation field with thermo-mechanical properties, which were measured by a dynamic mechanical analysis and a thermal expansion test. Simulations were performed on a box geometry with three different infill patterns. The simulation model was verified with temperature data gathered from an infrared camera. The results show good agreement between predicted and measured temperature profiles. The developed simulation model was applied to a roof tray with different infill patterns for a case study. We found that the different thermal mass distributions resulting from the various infill patterns affected the heat distribution and deformation. These findings contribute to a better understanding of the thermal and mechanical behavior of LFAM.

Jo, Eonyeon↗
DOE OSTI2023

Process-structure-property relationships for droplet-on-demand liquid-metal-jetted parts

Liquid metal jetting droplet-on-demand additive manufacturing is an attractive alternative to industry-standard, laser-based metal additive manufacturing techniques that use powder feedstocks and produce large heat affected zones. Liquid metal jetting provides a low feedstock footprint, minimal materials waste, less contamination and inclusions from feedstock, and is compatible with a large range of materials. However, little has been reported on the liquid metal jetting process-structure-property relationships that are crucial to understanding how to consistently print high quality metal parts. We investigate the effects of build plate temperature, infill pattern, and track raster rate on the macro- and microstructure, density, hardness, and tensile strength of metal parts created with our custom droplet-on-demand setup using pure tin feedstock as a surrogate for more relevant structural materials. We found that although the build plate temperature had the largest influence on the structure and properties, the infill pattern is an important factor for optimal structural integrity. It was observed that the track raster rate influenced track-to-track porosity and should be considered in toolpath development. Despite printing in ambient air, we could not identify oxide on the surface or in the bulk of the parts and saw no adverse effects on microstructure or tensile performance. The results and methods of this study will help guide future work in optimizing the liquid metal jetting process to reliably print parts using any liquid metal jetting system for a wide variety of metal feedstocks.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effect of toolpath in large-format additive manufacturing with bio-derived composites

There has been growing interest in integrating bio-derived composites into Large-format additive manufacturing (LFAM) feedstocks to reduce the use of petroleum-derived materials and reduce the overall carbon footprint of LFAM. However, these materials present unique challenges during manufacturing due to their variability, which can lead to unintended deformations and failures attributable to suboptimal process conditions. While numerical modelling has been extensively employed to simulate numerous manufacturing processes, its application in LFAM with bio-derived composites remains limited. This study addresses this gap by systematically developing a numerical model to simulate the LFAM process using bio-based materials, specifically wood fiber-reinforced polylactic acid (PLA/WF). Experimental investigations were conducted to characterise the thermal and mechanical properties of additively manufactured PLA/WF specimens. Numerical simulations were performed to predict temperature profiles and deformations during LFAM. The effect of varying infill patterns, internal structures, and tool paths on the temperature distribution and deformation of printed parts was explored using the developed model. This article aims to advance the utilisation of bio-derived composites in LFAM systems and provide a comprehensive understanding of the LFAM process. The findings offer valuable insights for optimising process parameters and enhancing the performance of LFAM with bio-based composites.

Large-format additive manufacturing↗
DOE OSTI2026

Direct Ink Write and Processing of Complex 3D Marine Compatible Structures with Calcium Carbonate Slurries

Ocean acidification heavily impacts marine ecosystems by reducing calcification. Many coral-algae symbiotic relationships are in jeopardy due to the destruction of coral reefs. Here, a ceramic ink compatible with the direct ink write additive manufacturing technique was formulated and used to print marine compatible structures that could grow algae and restore that relationship. A diacrylate polymer was mixed with calcium carbonate, a material that comprises a coral skeleton, to create a slurry with shear thinning properties. Rheology studies were conducted to confirm printing properties and characterize the slurry. Printed parts demonstrated strong control over print features, including size and infill design. Various infill patterns and percentages were attempted to optimize printability and potential algae growth. Thermogravimetric analysis helped determine a logical burnout and sintering procedure to avoid large cracking. This project developed a printable and sinter-able calcium carbonate ceramic slurry for complex marine-compatible structures and algae growth. This research was conducted in the support of the Eco Reef project.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Hierarchical Composites Patterned via 3D Printed Cellular Fluidics

Additive manufacturing of freeform structures containing multiple materials with deterministic spatial arrangement and interactions remains a challenge for most 3D printing processes, due to complex fabrication tool requirements and limitations in printability of some material classes. Here, in this paper, a versatile method is reported to produce architected composites using the concept of cellular fluidics, in which lattices of unit cells are used as templating scaffolds to guide flowable infill materials in a programmed spatial pattern, upon which they are cured in place to produce a deterministically ordered multimaterial solid. The lattice design relies on the unit cell size, type, strut diameter, surface wetting, and distribution of cellular structures to control liquid flow and retention. Individual unit cells are tuned to achieve reliable infilling and combined into higher-order architectures to achieve multiscale composite materials with disparate mechanical properties, including those considered non-printable. Lattice design considerations for leveraging capillary phenomena and demonstrate several methods of patterning polymers in 3D-printed cellular fluidic structures are presented. The concept of tuning the compressive response of an architected composite using a flexible-elastomer as the lattice and a stiff-epoxy as the infill material is illustrated.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Evidence for an ice sheet/frozen lake in Utopia Planitia, Mars

Previous workers noted evidence for a lacustrine basin in Utopia Planitia, Mars. Geomorphic features within the basin that collectively suggest that water or ice may once have been present include channels within the basin, channels peripheral to the basin, etched basin floor, 'thumbprint' terrain (whorled patterns), polygonal outlines, smooth floors (infilled), shoreline indicators (terraces, platforms, lineaments), and small cratered cones (pseudo craters or pingos). The authors interpret these data to suggest that the basin may have been the locus of a large paleolake in the northern lowlands of Mars. Alternatively, the area was proposed to be part of an ancient circumpolar ocean. The hypothetical paleolake was probably frozen to some depth. In fact, features now present at its boundaries suggest that the edges may have been frozen solid. Plains units at the southwestern boundary of Utopia Planitia show ridges that were compared with those that form at the mouths of Antarctic ice streams, thumbprint terrain, and young, high deposits having lobate margins that suggest mudflows. Thumbprint terrains were interpreted as recessional moraines, ice-pushed ridges, or subglacially eroded tunnel valleys with eroded eskers. At the east boundary of Utopia Planitia, geologic mapping at 1:500,000 scale of the Granicus Valles area (MTM quadrangles 30227, 30222, and 25227) indicates the presence of a basal scarp around the northwest flank of Elysium that formed the east boundary of an ancient ice sheet.

Chapman, M. G.↗
DOE OSTI2023

7. Space-Filling Toolpath Generation

Space-filling toolpaths are used to fill whatever space remains on a layer after closed-loop contours have been planned. They provide structure to the object, both supporting the geometry and creating solid surfaces. As such, there are two main types of space-filling toolpaths: infill and skin. Infill paths are sparse and meant to cover a large area quickly. Infill is typically not visible once a print is complete, because infill is covered by skins. Skins are the solid space-filling toolpaths meant to solidify the top and bottom of the object, which, unlike the sides of the object, are not completely covered by layering contours. Space-filling paths are typically planned by projecting a pattern over the layer, clipping the pattern at the boundary of the object, and then linking the remaining portions of the pattern. A subcategory of skin paths, called gradual infill, can be employed to densify the infill when approaching a top skin layer so that the print path of the top skin is sufficiently supported. Space-filling paths come in a variety of patterns to optimize how the space is filled. This chapter will discuss space-filling path categories, how to find the space for each path type, and how to apply the path type to generate toolpaths.

Roschli, Alex↗
NASA NTRS1992

Floor-fractured crater models for igneous crater modification on Venus

Although crater modification on the Earth, Moon, and Mars results from surface erosion and crater infilling, a significant number of craters on the Moon also exhibit distinctive patterns of crater-centered fracturing and volcanism that can be modeled as the result of igneous crater modification. Here, we consider the possible effects of Venus surface conditions on this model, describe two examples of such crater modification, and then briefly discuss the constraints these craters place on conditions at depth.

Wichman, R. W.↗
DOE OSTI2023

Natural Fracture Pattern Development Using 3D Coupled Numerical Model: Mechanics and Diagenesis

In the earth's crust, while tectonic processes can mechanically create natural fractures, cementation can simultaneously grow on the surfaces of the fractures. This crystallization can affect the growth of the fractures. To more accurately address the modeling of natural fracture development, both mechanical deformation and chemical diagenesis should be carried out in an integrated manner. Here, we achieve this with a three-dimensional (3D) simulator that couples mechanical and chemical processes for natural fracture pattern development in layer confined situations. Tectonic loading over geologic time is mimicked by displacement driven boundary conditions in a 3D displacement discontinuity method (DDM) scheme. Quartz diagenesis competes with mechanical fracture opening, resulting in three different cementation conditions - open, bridging or fully infilled – which define fracture element stiffness that is used as feedback within the 3D-DDM code during propagation. An important milestone of this work is that this coupled structural diagenetic model can reproduce power-law aperture population statistics which cannot be generated using mechanics alone. More accurately estimated mechanical fracture apertures and their cementation condition is a critical step toward better permeability estimation and fluid path analysis for subsurface reservoirs.

58 GEOSCIENCES↗
NASA NTRS1992

The Zhamanshin impact feature: A new class of complex crater?

The record of 10-km-scale impact events of Quaternary age includes only two 'proven' impact structures: the Zhamanshin Impact Feature (ZIF) and the Bosumtwi Impact Crater (BIC). What makes these impact landforms interesting from the standpoint of recent Earth history is their almost total lack of morphologic similarity, in spite of similar absolute ages and dimensions. The BIC resembles pristine complex craters on the Moon to first order (i.e., 'U'-shaped topographic cross section with preserved rim), while the ZIF displays virtually none of the typical morphologic elements of a 13- to 14-km-diameter complex crater. Indeed, this apparent lack of a craterlike surficial topographic expression initially led Soviet geologists to conclude that the structure was only 5.5 to 6 km in diameter and at least 4.5 Ma in age. However, more recent drilling and geophysical observations at the ZIF have indicated that its pre-erosional diameter is at least 13.5 km, and that its age is most probably 0.87 Ma. Why the present topographic expression of a 13.5-km complex impact crater less than 1 m.y. old most closely resembles heavily degraded Mesozoic shield craters such as Lappajarvi is a question of considerable debate. Hypotheses for the lack of a clearly defined craterlike form at the ZIF include a highly oblique impact, a low-strength 'cometary' projectile, weak or water-saturated target materials, and anomalous erosion patterns. The problem remains unresolved because typical erosion rates within the arid sedimentary platform environment of central Kazakhstan in which the ZIF is located are typically low; it would require at least a factor of 10 greater erosion at the ZIF in order to degrade the near-rim ejecta typical of a 13.5-km complex crater by hundreds of meters in only 0.87 Ma, and to partially infill an inner cavity with 27 cu km (an equivalent uniform thickness of infill of 166 m). Our analysis of the degree of erosion and infill at the ZIF calls for rates in the 0.19 to 0.38 mm/yr range over the lifetime of the landform, which are a factor of 10 to 20 in excess of typical rates for the Kazakhstan semidesert.

Garvin, J. B.↗
DOE OSTI2021

Unraveling the Combined Effects of Ice and Permafrost on Arctic Delta Morphodynamics

Arctic delta channel dynamics and coastal deposition patterns are uniquely affected by ice and permafrost. Building on previous experiments that documented the individual effects of ice and permafrost, we conducted new numerical modeling experiments to examine the combined influences of ice thickness and permafrost erodibility. We quantified the effects of ice, permafrost, and their combination on channel migration, avulsion, and persistence; onshore and nearshore deposition; and large-scale delta morphology. Both ice and permafrost limited channel mobility, enhanced overbank deposition, and roughened shorelines. Thick ice increased offshore channel incision and sediment delivery. Permafrost stabilized channels and focused deposition that led to enhanced channel levee development. The increased levee deposition limited widespread channel infilling leading to the preservation of abandoned channels. Levee growth was enhanced by overbank flooding due to ice-driven changes in water surface elevations. Furthermore, this flooding led to more extensive levees on deltas with both ice and permafrost compared to deltas with only permafrost. Ice also preserved small channels, leading to size-dependent channel persistence: the presence of ice in the channels reduced the fraction of time small channels remained active relative to larger channels. Resistant permafrost damped this effect, as smaller and more distal channels were active earlier in the flood on deltas with resistant permafrost likely due to the smaller number of channels on permafrost-laden deltas. Finally, our results suggest that the loss of both ice and permafrost will increase channel mobility, decrease overbank flooding, increase shoreline progradation rates, and decrease offshore transport of riverine fluxes.

58 GEOSCIENCES↗
DOE OSTI2022

Particle Migration in Large Cross-Section Ceramic On-Demand Extrusion Components

Ceramic On-Demand Extrusion (CODE) is a direct ink writing process which allows for the creation of near theoretically dense ceramic components with large cross-sections due to oil-assisted drying. Here, Yttria-stabilized zirconia (YSZ) colloidal pastes were used in CODE to produce dense (multi-road infill and ≳ 98% relative density), large continuous volume (> 1 cm 3 ), and high fidelity (nozzle diameters ≲ 1 mm) structural ceramic components with nanoparticle feedstocks (~d 50 ≲ 1 µm). However, many of these printed components underwent significant particle migration after forming. The reason for this particle migration defect was investigated using the coffee-ring effect for dilute solutions and rheological methods for dense suspensions. Modifications to the colloidal paste, such as changes in solids loading, pH, or surfactant concentration were explored as to their effectiveness to mitigate the defect. Ultimately, paste formulation and printing trade-offs are discussed with respect to the post-printing defect and as to general direct-write patterning.

36 MATERIALS SCIENCE↗
NASA NTRS2019

Diurnal and Seasonal Solar Induced Chlorophyll Fluorescence and Photosynthesis in a Boreal Scots Pine Canopy

Solar induced chlorophyll fluorescence has been shown to be increasingly an useful proxy for the estimation of gross primary productivity (GPP), at a range of spatial scales. Here, we explore the seasonality in a continuous time series of canopy solar induced fluorescence (hereafter SiF) and its relation to canopy gross primary production (GPP), canopy light use efficiency (LUE), and direct estimates of leaf level photochemical efficiency in an evergreen canopy. SiF was calculated using infilling in two bands from the incoming and reflected radiance using a pair of Ocean Optics USB2000+ spectrometers operated in a dual field of view mode, sampling at a 30 min time step using custom written automated software, from early spring through until autumn in 2011. The optical system was mounted on a tower of 18 m height adjacent to an eddy covariance system, to observe a boreal forest ecosystem dominated by Scots pine. (Pinus sylvestris) A Walz MONITORING-PAM, multi fluorimeter system, was simultaneously mounted within the canopy adjacent to the footprint sampled by the optical system. Following correction of the SiF data for O2 and structural effects, SiF, SiF yield, LUE, the photochemicsl reflectance index (PRI), and the normalized difference vegetation index (NDVI) exhibited a seasonal pattern that followed GPP sampled by the eddy covariance system. Due to the complexities of solar azimuth and zenith angle (SZA) over the season on the SiF signal, correlations between SiF, SiF yield, GPP, and LUE were assessed on SZA <50° and under strictly clear sky conditions. Correlations found, even under these screened scenarios, resulted around ~r2 = 0.3. The diurnal responses of SiF, SiF yield, PAM estimates of effective quantum yield (ΔF/Fm′), and meteorological parameters demonstrated some agreement over the diurnal cycle. The challenges inherent in SiF retrievals in boreal evergreen ecosystems are discussed.

photosynthetic↗
DOE OSTI2021

Design, upgrade and characterization of the silicon photomultiplier front-end for the AMIGA detector at the Pierre Auger Observatory

AMIGA (Auger Muons and Infill for the Ground Array) is an upgrade of the Pierre Auger Observatory to complement the study of ultra-high-energy cosmic rays (UHECR) by measuring the muon content of extensive air showers (EAS). It consists of an array of 61 water Cherenkov detectors on a denser spacing in combination with underground scintillation detectors used for muon density measurement. Each detector is composed of three scintillation modules, with 10 m 2 detection area per module, buried at 2.3 m depth, resulting in a total detection area of 30 m 2 . Silicon photomultiplier sensors (SiPM) measure the amount of scintillation light generated by charged particles traversing the modules. In this paper, the design of the front-end electronics to process the signals of those SiPMs and test results from the laboratory and from the Pierre Auger Observatory are described. Compared to our previous prototype, the new electronics shows a higher performance, higher efficiency and lower power consumption, and it has a new acquisition system with increased dynamic range that allows measurements closer to the shower core. The new acquisition system is based on the measurement of the total charge signal that the muonic component of the cosmic ray shower generates in the detector.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗