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12 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing of Ceramic Composites: Additive Manufacturing and Characterization of Ceramic Composites - Part III

This publication is the third part of a three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce ceramic matrix composite materials and aircraft engine components by the binder jet process. Different SiC powders with median sizes ranging from 9.3 to 53.0 microns were investigated solely and in powder blends in order to maximize powder packing. Various infiltration approaches were investigated to include polycarbosilane (SMP-10), phenolic, and liquid silicon. Single infiltrations of SMP-10 and phenolic only slightly filled in the interior. When the SMP-10 was loaded with sub-micron sized SiC powders, the infiltrant gave a much better result of filling in the interior. Silicon carbide fibers were added to the powder bed to make ceramic matrix composite materials. Microscopy showed that the fibers were well distributed with no preferred orientation on the horizontal plane and fibers in the vertical plane were at angles as much as 45deg. Secondary infiltration steps were necessary to further densify the material. Two to three extra infiltration steps of SMP-10 increased the density by 0.20 to 0.55 g/cc. However, the highest densities achieved were 2.10 to 2.15 g/cc. Mechanical tests consisting of 4 point bend tests were conducted. Samples from the two CMC panels had higher strengths and strains to failure than the samples from the two nonfiber reinforced panels. The highest strengths were from Set N with 65 vol% fiber loading which had an average strength of 66 MPa. Analysis of the fracture surfaces did not reveal pullout of the reinforcing fibers. Blunt fiber failure suggested that there was not composite behavior. The binder jet additive manufacturing method was used to also demonstrate the fabrication of turbine engine vane components of two different designs and sizes. The binder jet method has benefits over the conventional manufacturing of CMCs in that prototype and production parts can be fabricated quickly and economically with no tooling and extensive hand layup.

Additive Manufacturing↗
NASA NTRSDate not supplied

Additive Manufacture of Porous Zirconium Carbide for Nuclear Thermal Propulsion In-Core Insulators

Nuclear Thermal Propulsion (NTP) requires the use of in-core insulators to manage to thermal environment between high temperature fuel elements and lower temperature structural components. The unforgiving in-core operating conditions severely limit potential material candidates. Zirconium Carbide (ZrC) is a promising candidate due to a high melting temperature, high compressive strength, hardness, wear resistance, hydrogen compatibility, and low neutron absorption cross sections. However, fully dense ZrC is not an insulator but it has been found that the thermal conductivity of ZrC decreases by increasing porosity to approximately 60 % theoretical density (%TD). Previous methods for generating porous ZrC were difficult, expensive, and time consuming. Binder jet additive manufacture (AM) can print ceramic materials to near net shape. Binder jet AM is not utilized in many applications due to an inherently low post-sintering density on the order of 60 %TD. For this specific application the inherent lower density is leveraged as an advantage in production porous ZrC in order to control the thermal conductivity. A feasibility study was conducted to investigate binder jet AM parameter development for ZrC, heat treatment optimization (burn-out and sinter), microstructural characterization, mechanical testing, and thermal testing to generate near-net shape ZrC components with ~60 %TD with the desired thermal conductivity and mechanical strength.

Zirconium Carbide Additive Manufacture↗
NASA NTRSDate not supplied

Additive Manufacture of Porous Zirconium Carbide for Nuclear Thermal Propulsion In-Core Insulators

Nuclear Thermal Propulsion (NTP) requires the use of in-core insulators to manage to thermal environment between high temperature fuel elements and lower temperature structural components. The unforgiving in-core operating conditions severely limit potential material candidates. Zirconium Carbide (ZrC) is a promising candidate due to a high melting temperature, high compressive strength, hardness, wear resistance, hydrogen compatibility, and low neutron absorption cross sections. However, fully dense ZrC is not an insulator but it has been found that the thermal conductivity of ZrC decreases by increasing porosity to approximately 60 % theoretical density (%TD). Previous methods for generating porous ZrC were difficult, expensive, and time consuming. Binder jet additive manufacture (AM) can print ceramic materials to near net shape. Binder jet AM is not utilized in many applications due to an inherently low post-sintering density on the order of 60 %TD. For this specific application the inherent lower density is leveraged as an advantage in production porous ZrC in order to control the thermal conductivity. A feasibility study was conducted to investigate binder jet AM parameter development for ZrC, heat treatment optimization (burn-out and sinter), microstructural characterization, mechanical testing, and thermal testing to generate near-net shape ZrC components with ~60 %TD with the desired thermal conductivity and mechanical strength.

Zirconium Carbide Additive Manufacture↗
NASA NTRSDate not supplied

Additive Manufacture of Porous ZrC for NTP In-Core Insulators

Nuclear Thermal Propulsion (NTP) requires the use of in-core insulators to manage to thermal environment between high temperature fuel elements and lower temperature structural components. The unforgiving in-core operating conditions severely limit potential material candidates. Zirconium Carbide (ZrC) is a promising candidate due to a high melting temperature, high compressive strength, hardness, wear resistance, hydrogen compatibility, and low neutron absorption cross sections. However, fully dense ZrC is not an insulator but it has been found that the thermal conductivity of ZrC decreases by increasing porosity to approximately 60 % theoretical density (%TD). Previous methods for generating porous ZrC were difficult, expensive, and time consuming. Binder jet additive manufacture (AM) can print ceramic materials to near net shape. Binder jet AM is not utilized in many applications due to an inherently low post-sintering density on the order of 60 %TD. For this specific application the inherent lower density is leveraged as an advantage in production porous ZrC in order to control the thermal conductivity. A feasibility study was conducted to investigate binder jet AM parameter development for ZrC, heat treatment optimization (burn-out and sinter), microstructural characterization, mechanical testing, and thermal testing to generate near-net shape ZrC components with ~60 %TD with the desired thermal conductivity and mechanical strength.

Omar Mireles↗
NASA NTRS2019

Advanced CMCs, Additive Manufacturing, and Joining/Integration Technologies

An overview of ceramic matrix composite (CMC) and additive manufacturing capabilities at GRC is provided. The additive manufacturing methods include laminated object manufacturing (LOM), binder jetting, 3-D printing, extrusion, direct writing and multi-materials additive manufacturing. Examples are given of GRC's extensive experience in the development and implementation of CMCs in various aerospace systems. Additive manufacturing offers significant advantages in fabricating preforms, ceramics, and CMCs. They will have to be selectively applied to "traditional" components but can also enable new applications. Additive manufacturing of lightweight and multifunctional polymer composites can provide wide ranging properties. Multi-material printing approaches could provide new opportunities to explore and expand the design envelope. Joining and Integration technologies, gaskets and sealants, as well as repair and refurbishment are also keys for Hypersonic applications.

Grady, Joseph E.↗
NASA NTRS2016

Additive Manufacturing of Silicon Carbide-Based Ceramic Matrix Composites: Technical Challenges and Opportunities

Advanced SiC-based ceramic matrix composites offer significant contributions toward reducing fuel burn and emissions by enabling high overall pressure ratio (OPR) of gas turbine engines and reducing or eliminating cooling air in the hot-section components, such as shrouds, combustor liners, vanes, and blades. Additive manufacturing (AM), which allows high value, custom designed parts layer by layer, has been demonstrated for metals and polymer matrix composites. However, there has been limited activity on additive manufacturing of ceramic matrix composites (CMCs). In this presentation, laminated object manufacturing (LOM), binder jet process, and 3-D printing approaches for developing ceramic composite materials are presented. For the laminated object manufacturing (LOM), fiber prepreg laminates were cut into shape with a laser and stacked to form the desired part followed by high temperature heat treatments. For the binder jet, processing optimization was pursued through silicon carbide powder blending, infiltration with and without SiC nano powder loading, and integration of fibers into the powder bed. Scanning electron microscopy was conducted along with XRD, TGA, and mechanical testing. Various technical challenges and opportunities for additive manufacturing of ceramics and CMCs will be presented.

ceramic matrix composites↗
NASA NTRS2019

Additive Manufacturing of Multi-Material Systems for Aerospace Applications

Additive manufacturing methods for producing single materials are rapidly improving. The resulting material properties and microstructures are becoming more comparable to those of conventionally fabricated materials. However, the need for multi-functional and complex structures and components requires additional innovations in manufacturing such as multi-material and hybrid additive manufacturing approaches. Additive manufacturing machines with multiple print capabilities and combinations of AM, machining, and conventional processing methods will further open up design spaces and possibilities. In this presentation, several examples of the needs and methods for multi-material fabrication will be discussed with a focus on aerospace applications. Direct printing of silver coils in conjunction with fused deposition modeling, machined parts, and, binder jetting is being developed for innovative stator designs. Binder jetting of silicon-based materials with powder bed additions is being developed for heat exchanger applications. Additive manufacturing of bi-material systems is being pursued to fabricate lightweight, integrated, multifunctional structures.

multi-materials↗
NASA NTRS2014

A Fully Non-metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

manufacturing↗
NASA NTRS2019

Enabling Additive Manufacturing Technologies for Advanced Aero Propulsion Materials & Components

Additive manufacturing (AM) technologies are enabling for advanced high performance, propulsion component designs in electric motors1-2 and turbine engine systems in future electrified aircraft. AM offers significant benefits over conventional manufacturing to fabricate components that are more compact, lighter weight, geometrically complex, innovatively cooled, integrated, multi-material, and multifunctional. For turbine engine applications, silicon carbide (SiC) based composites are being pursued using binder jetting and laminated object manufacturing (LOM) for components such as shrouds, vanes, and recuperators. For electric motor applications, additive processes are being applied toward optimized component designs to include the housing, rotor, and stators with 3-D printing and wire imbedded coils and with direct printed 3-phase coils. The electrical conductivity of silver conductor coils optimized by evaluating alternate sintering methods and additions of graphene and carbon nanostructures will be presented. Potential benefits of new electric motor components in improving temperature capability, efficiency, and power density for reductions in energy consumption and emissions will be discussed.

Halbig, Michael C.↗
NASA NTRS2019

Additive Manufacturing Technologies for Aerospace Applications

An overview will be provided on NASA GRC activities in additive manufacturing (AM) technology development for advanced high performance, propulsion component designs in electric motors and turbine engine systems in future electrified aircraft. AM offers significant benefits over conventional manufacturing to fabricate components that are more compact, lighter weight, geometrically complex, innovatively cooled, integrated, multi-material, and multifunctional. For turbine engine applications, silicon carbide (SiC) based composites are being pursued using binder jetting. For electric motor applications, additive processes are being applied toward optimized component designs to include the housing, rotor, and stators with 3-D printing and wire imbedded coils and with direct printed 3-phase coils. The will be an emphasis on capabilities in additive manufacturing.

Halbig, Michael C.↗
NASA NTRS2015

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute, represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies to fabricate polymer matrix composite and ceramic matrix composite turbine engine components. The benefits include: 50 weight reduction compared to metallic parts, reduced manufacturing costs, reduced part count and rapid design iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature polymer filaments. The CMC effort uses a binder jet process to fabricate silicon carbide test coupons and demonstration articles. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The research project includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

Ceramics↗
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↗