Engineering topics

Heineman, Jesse

Publications and source records attributed to Heineman, Jesse.

3 records

DOE OSTI2024

Additive Manufacturing for Large Displacement Unmanned Underwater Vehicles (LDUUVs)

Oak Ridge National Laboratory partnered with Anduril Industries to develop the process for adapting large format additive manufacturing for the production of underwater vehicles. This research started by defining and selecting a polymer for the vehicle panels. Coatings were tested at 9000PSI to ensure proper bonding to the 3D printed panels, then tensile tested to understand the mechanical properties. A vehicle panel fairing set was design optimized for the 3D printing process and then 3D printed. Additional work optimized coatings and tested additional reinforcements methods such as fiber weave and z-casting with fiber rods and resin. Finally, a full vehicle was constructed and successfully tested in open water by Anduril.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower

ORNL worked with Cadens, LLC to explore the use of additive manufacturing (AM) for the production of low-cost parts for low-head hydropower systems. Cadens develops design optimization software that leverages the flexible, low-cost, high-strength benefits of AM and composite materials, and operates a micro-hydro lab to test AM components in controlled environments. Until now Cadens’ tests have been limited in size to components that they can cost-effectively manufacture using local commercial systems. This project provided an opportunity for Cadens to scale up their modular AM hydropower parts using the capabilities of Big Area Additive Manufacturing (BAAM). This project was a success and resulted in the design and fabrication of several end use parts of a hydropower system using a Big Area Additive Manufacturing (BAAM) system. The fabricated parts include draft tube, thimble, runner housing mold, PVC end fitting and two PVC pipe supports. The components have been in use for more than three years without a 3D printed component failing.

13 HYDRO ENERGY↗

DOE OSTI2023

Large Format Composite Additive Manufacturing for Low-Head Hydropower

Hydropower with a small elevation change from inlet to outlet, known as “low-head” hydropower, is a relatively untapped resource for reliable green power generation. One major barrier to entry is the cost of the components needed to generate the power. Each installation site is unique, with various head levels, flow rates, and other unique site characteristics that drive up the cost of development and installation. As a result, custom-made components are necessary because the sites are intrinsically inefficient. However, customized parts are generally more expensive to manufacture than ready-made parts. Often times, the cost of custom-made components is so high that the low-head hydropower installation becomes non-viable. Additive manufacturing offers the ability to make custom components, ideal for one-off applications, at low costs that are well suited for the needs of low-head hydropower. Indirect additive manufacturing, such as making tools or dies rather than end use components, can also be used to make low-cost composite tooling as needed for these custom applications. This paper explores the use of additive manufacturing, both directly and indirectly, to produce the components of a turbine system for a low-head hydropower site. The parts were designed to form a unique modular system, which saves time for future designs and iterations. The system has operated for more than three years without failure at a test site in Wisconsin, USA. This work serves as a basis for future application of AM to low-head systems, in which the modular components can be customized for each unique hydropower installation.

36 MATERIALS SCIENCE↗