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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

Integration of Design Data Into Automated Fiber Placement Process Planning Metrics

With the ever-expanding aviation industry, a need is arising for more rapid production of composite aircraft to meet increasing demand. State-of-the-art aircraft such as the Boeing 787showcase 50% composite material usage by weight, highlighting this emerging industry-wide adoption of the material system. Currently, many of the large structures associated with these aircraft are manufactured additively via Automated Fiber Placement (AFP). The AFP process shows great potential for efficient manufacturing, however unavoidable defects still occur because of tool surface geometry, placement errors, or poor process planning, resulting in decreased quality and throughput. Due to such effects, it is critical to incorporate design for manufacturing (DFM) principles to achieve the optimal manufacturing plan and resulting structure. This work will develop a methodology for incorporating design information into process planning metrics in an automated fashion to achieve an optimal set of process inputs.The analysis incorporates HyperX, Computer Aided Process Planning (CAPP) and Vericut Composite Programming (VCP). Safety margins from HyperX are imported into CAPP where AFP defects are mapped to the values. The resulting margins are then incorporated into the CAPP manufacturability algorithms, creating a design informed process planning analysis

Automated Fiber Placement↗
NASA NTRS2015

Targeted Structural Optimization with Additive Manufacturing of Metals

The recent advances in additive manufacturing (AM) of metals have now improved the state-of-the-art such that traditionally non-producible parts can be readily produced in a cost-effective way. Because of these advances in manufacturing technology, structural optimization techniques are well positioned to supplement and advance this new technology. The goal of this project is to develop a structural design, analysis, and optimization framework combined with AM to significantly light-weight the interior of metallic structures while maintaining the selected structural properties of the original solid. This is a new state-of-the-art capability to significantly reduce mass, while maintaining the structural integrity of the original design, something that can only be done with AM. In addition, this framework will couple the design, analysis, and fabrication process, meaning that what has been designed directly represents the produced part, thus closing the loop on the design cycle and removing human iteration between design and fabrication. This fundamental concept has applications from light-weighting launch vehicle components to in situ resource fabrication.

Burt, Adam↗
NASA NTRS2008

Concept of Operations Visualization for Ares I Production

Establishing Computer Aided Design models of the Ares I production facility, tooling and vehicle components and integrating them into manufacturing visualizations/simulations allows Boeing and NASA to collaborate real time early in the design/development cycle. This collaboration identifies cost effective and lean solutions that can be easily shared with Ares stakeholders (e.g., other NASA Centers and potential science users). These Ares I production visualizations and analyses by their nature serve as early manufacturing improvement precursors for other Constellation elements to be built at the Michoud Assembly Facility such as Ares V and the Altair Lander. Key to this Boeing and Marshall Space Flight Center collaboration has been the use of advanced virtual manufacturing tools to understand the existing Shuttle era infrastructure and trade potential modifications to support Ares I production. These approaches are then used to determine an optimal manufacturing configuration in terms of labor efficiency, safety and facility enhancements. These same models and tools can be used in an interactive simulation of Ares I and V flight to the Space Station or moon to educate the human space constituency (e.g., government, academia, media and the public) in order to increase national and international understanding of Constellation goals and benefits.

Chilton, Jim↗
NASA NTRS2019

A 3D-printed Broadband Millimeter Wave Absorber

We present the design, manufacturing technique, and characterization of a 3D-printed broadband graded index millimeter wave absorber. The absorber is additively manufactured using a fused filament fabrication (FFF) 3D printer out of a carbon-loaded high impact polystyrene (HIPS) filament and is designed using a space-filling curve to optimize manufacturability using said process. The absorber's reflectivity is measured from 63 GHz to 115 GHz and from 150 GHz to 215 GHz and is compared to electromagnetic simulations. The intended application is for terminating stray light in Cosmic Microwave Background (CMB) telescopes, and the absorber has been shown to survive cryogenic thermal cycling.

Matthew Petroff↗
NASA NTRS1993

Firmware Development Improves System Efficiency

Most manufacturing processes require physical pointwise positioning of the components or tools from one location to another. Typical mechanical systems utilize either stop-and-go or fixed feed-rate procession to accomplish the task. The first approach achieves positional accuracy but prolongs overall time and increases wear on the mechanical system. The second approach sustains the throughput but compromises positional accuracy. A computer firmware approach has been developed to optimize this point wise mechanism by utilizing programmable interrupt controls to synchronize engineering processes 'on the fly'. This principle has been implemented in an eddy current imaging system to demonstrate the improvement. Software programs were developed that enable a mechanical controller card to transmit interrupts to a system controller as a trigger signal to initiate an eddy current data acquisition routine. The advantages are: (1) optimized manufacturing processes, (2) increased throughput of the system, (3) improved positional accuracy, and (4) reduced wear and tear on the mechanical system.

Chern, E. James↗
NASA NTRS2004

Experimentation Toward the Analysis of Gear Noise Sources Controlled by Sliding Friction and Surface Roughness

In helicopters and other rotorcraft, the gearbox is a major source of noise and vibration (N&V). The two N&V excitation mechanisms are the relative displacements between mating gears (transmission errors) and the friction associated with sliding between gear teeth. Historically, transmission errors have been minimized via improved manufacturing accuracies and tooth modifications. Yet, at high torque loads, noise levels are still relatively high though transmission errors might be somewhat minimal. This suggests that sliding friction is indeed a dominant noise source for high power density rotorcraft gearboxes. In reality, friction source mechanism is associated with surface roughness, lubrication regime properties, time-varying friction forces/torques and gear-mesh interface dynamics. Currently, the nature of these mechanisms is not well understood, while there is a definite need for analytical tools that incorporate sliding resistance and surface roughness, and predict their effects on the vibro- acoustic behavior of gears. Toward this end, an experiment was conducted to collect sound and vibration data on the NASA Glenn Gear-Noise Rig. Three iterations of the experiment were accomplished: Iteration 1 tested a baseline set of gears to establish a benchmark. Iteration 2 used a gear-set with low surface asperities to reduce the sliding friction excitation. Iteration 3 incorporated low viscosity oil with the baseline set of gears to examine the effect of lubrication. The results from this experiment will contribute to a two year project in collaboration with the Ohio State University to develop the necessary mathematical and computer models for analyzing geared systems and explain key physical phenomena seen in experiments. Given the importance of sliding friction in the gear dynamic and vibro-acoustic behavior of rotorcraft gearboxes, there is considerable potential for research & developmental activities. Better models and understanding will lead to quiet and reliable gear designs, as well as the selection of optimal manufacturing processes.

Asnani, Vivake M.↗
NASA NTRS1973

Development of advanced materials composites for use as insulations for LH2 tanks

A study of thread-reinforced polyurethane foam and glass fabric liner, serving as internally bonded insulation for space shuttle LH2 tanks, is reported. Emphasis was placed on an insulation system capable of reentry and multiple reuse in the shuttle environment. The optimized manufacturing parameters associated with each element of the composite are established and the results, showing successful completion of subscale system evaluation tests using the shuttle flight environmental requirements, are given.

Lemons, C. R.↗
NASA NTRSDate not supplied

Evaluation of Hydrolytic Degradation of Poly(lactic acid) (PLA) Matrices in Compression Molded Flax/PLA Composites

Poly(lactic acid) (PLA) is a bio-based plastic that is an attractive alternative to its petroleum-based counterparts because of its high strength and ease of thermal processing. In an effort to reduce the carbon footprint of fossil-fuel based polymer matrix composites, PLA along with naturally-occurring fibers are being explored to produce entirely bio-based replacements. Challenges in producing these composites occur due to the water affinity of the natural fibers and the susceptibility of the PLA to hydrolytic degradation. Hydrolysis of PLA occurs at elevated processing temperatures and can further be accelerated by the presence of water contained in the natural fibers. This talk will discuss the challenges and considerations associated with processing PLA in the presence of water-absorbing flax fibers to produce composites via compression molding. The thermal, physical, and mechanical properties of PLA/flax composites will be characterized at various processing times in an effort to identify optimal manufacturing conditions.

Natural Materials↗
NASA NTRS1979

Optimization of space manufacturing systems

Four separate analyses are detailed: transportation to low earth orbit, orbit-to-orbit optimization, parametric analysis of SPS logistics based on earth and lunar source locations, and an overall program option optimization implemented with linear programming. It is found that smaller vehicles are favored for earth launch, with the current Space Shuttle being right at optimum payload size. Fully reusable launch vehicles represent a savings of 50% over the Space Shuttle; increased reliability with less maintenance could further double the savings. An optimization of orbit-to-orbit propulsion systems using lunar oxygen for propellants shows that ion propulsion is preferable by a 3:1 cost margin over a mass driver reaction engine at optimum values; however, ion engines cannot yet operate in the lower exhaust velocity range where the optimum lies, and total program costs between the two systems are ambiguous. Heavier payloads favor the use of a MDRE. A parametric model of a space manufacturing facility is proposed, and used to analyze recurring costs, total costs, and net present value discounted cash flows. Parameters studied include productivity, effects of discounting, materials source tradeoffs, economic viability of closed-cycle habitats, and effects of varying degrees of nonterrestrial SPS materials needed from earth. Finally, candidate optimal scenarios are chosen, and implemented in a linear program with external constraints in order to arrive at an optimum blend of SPS production strategies in order to maximize returns.

Akin, D. L.↗
NASA NTRSDate not supplied

Development and Optimization of Additively Manufactured NASA HR-1 for Space Applications

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with fabrication of complex propulsion component designs. Laser powder directed energy deposition (LP-DED) and laser powder bed fusion (L-PBF) are metal AM technologies that have effectively been used to produce a variety of parts for space applications. These technologies have enabled new designs and materials for these applications. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. One such metal alloy being developed for these applications is NASA HR-1. A high-strength Fe-Ni based superalloy, NASA HR-1 was designed to resist high pressure hydrogen environment embrittlement, oxidation, and corrosion. AM technologies have enabled the manufacturing of NASA HR-1 to be a feasible material for components in hydrogen environments. Development efforts for NASA HR-1 have completed build and heat treatment optimization, material characterization, thermophysical property testing, and mechanical testing in air and hydrogen environments to mature the understanding of the material. This presentation will summarize the development of NASA HR-1 for AM including composition and heat treatment optimization, microstructure characterization, and results of mechanical testing in air and high pressure hydrogen.

Additive Manufacturing↗
NASA NTRSDate not supplied

Integration of Structural Analysis and Manufacturing Process Planning for Global Optimization with Automated Fiber Placement

Design of mass-efficient composite structures intended for Automated Fiber Placement (AFP) requires close interaction between structural analysis and manufacturing process planning. Tools exist for each of these disciplines, but software interplay has been insufficient for rapid and efficient design iteration. Within the NASA Advanced Composites Consortium (ACC), the Design for Manufacturing (DFM) task has made significant progress towards linking these disciplines and respective software – HyperX (design), CAPP (process planning), and VCP (tool path generation). The initial focus in previous work was on data exchange between disciplines. The ability to both export and consume composite design and manufacturing data to and from each tool. This paper focuses on the effort to automate and streamline the connection between the tools listed above, with the goal of being able to automatically generate a composite AFP design that is mass-efficient and manufacturable. The optimization method being pursued is a bi-level approach, where each tool performs optimization within its discipline. The optimization in HyperX is focused on mass and laminate strength, while CAPP is focused on maximizing manufacturability. VCP is used to generate fiber paths for each design iteration. These sub-processes are wrapped with a global level optimization, driven by HyperX, used to converge the design. This paper describes the current state of this effort, which is a completed HyperX-VCP iteration loop and initial work on the HyperX-CAPP iteration loop. Additionally, example results are shown for a wind blade structure with double curvature.

Automated Fiber Placement↗
NASA NTRS1989

Applications of integrated design/analysis systems in aerospace structural design

Integrated structural analysis and design systems and structural optimization procedures are being used in a production environment. Successful use of these systems requires experienced personnel. Interactive computer graphics can and will play a significant role in the analysis, optimization, design and manufacturing areas. Practical structural optimization procedures are tools that must be made available to the team. Much work still needs to be done to tie finite-element modeling to actual design details which are being tracked on systems such as CADAM or CATIA. More work needs to be done to automate the detailed design and analysis process. More emphasis should be placed on the real design problems.

Mason, Philip↗
NASA NTRS1993

Optimization of composite laminates

Design of composite structures can be viewed as a multi-faceted task, one which requires integration of issues related to composite mechanics, structural analysis, optimization, and manufacturing. The major coverage of the paper is on the issue of optimization, with special emphasis on the use of optimization for designing with discrete and integer valued variables required for the stacking-sequence optimization. Different techniques that can be used for stacking sequence optimization are introduced, and different aspects of their application are demonstrated for laminate buckling optimization.

Gurdal, Zafer↗
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↗