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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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NASA NTRS2001

Process for Making Ceramic Mold

An improved process for slip casting molds that can be more economically automated and that also exhibits greater dimensional stability is disclosed. The process involves subjecting an investment pattern, preferably made from wax, to successive cycles of wet-dipping in a slurry of colloidal, silica-based binder and dry powder-coating, or stuccoing with plaster of Paris or calcium sulfate mixtures to produce a multi-layer shell over the pattern. The invention as claimed entails applying a primary and a secondary coating to the investment pattern. At least two wet-dipping on in a primary slurry and dry-stuccoing cycles provide the primary coating, and an additional two wet-dippings and dry-stuccoing cycles provide the secondary, or back-up, coating. The primary and secondary coatings produce a multi-layered shell pattern. The multi-layered shell pattern is placed in a furnace first to cure and harden, and then to vaporize the investment pattern, leaving a detailed, high precision shell mold.

Buck, Gregory M.↗

DOE OSTI2025

Advanced Techniques for Energy Input Reduction in Gypsum Drying (Final Technical Report)

Dielectric heating was explored as a means of calcining gypsum to produce stucco, the wallboard precursor, with lower water demand and therefore lower drying energy.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2000

Application of Rapid Prototyping to the Investment Casting of Test Hardware (MSFC Center Director's Discretionary Fund Final Report, Project No. 98-08)

Investment casting masters of a selected propulsion hardware component, a fuel pump housing, were rapid prototyped on the several processes in-house, along with the new Z-Corp process acquired through this project. Also, tensile samples were prototyped and cast using the same significant parameters. The models were then shelled in-house using a commercial grade zircon-based slurry and stucco technique. Next, the shelled models were fired and cast by our in-house foundry contractor (IITRI), with NASA-23, a commonly used test hardware metal. The cast models are compared by their surface finish and overall appearance (i.e., the occurrence of pitting, warping, etc.), as well as dimensional accuracy.

Cooper, K. G.↗

DOE OSTI2024

Radio Frequency Calcination of Gypsum for Sustainable Wallboard Production

This presentation details several accomplishments in the dielectric calcination of gypsum to stucco. 1) Verification that gypsum can be calcined via RF heating, 2)Characterization of heating and mass loss curve for a nucleation propagation reaction under electromagnetics 3) Full parametric studies examining effect of free moisture on heating and calcination, and 4) Finite element model of process with high predictive capability. Overall, Industrial implementation could save up to 63% energy, 50% water, and reduce carbon emissions by 63% based on batch scale studies.

Tjards, Jacob↗