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NASA NTRSDate not supplied

Making & Breaking the Rules for DED Design

Design for Additive Manufacturing (DfAM) is widely used to describe design activities and guidelines employed in the creation of Additively Manufactured (AM) parts. Basic design rules for widely adopted processes like Powder Bed Fusion (PBF) are relatively understood including material performance, part size constraints, self-supporting angles, overhangs, wall thicknesses, and feature resolution. Complexity is often inherent with PBF using organically inspired solutions through generative design and topology optimization software to create designs that often cannot be realized via traditional manufacturing processes. The design rules for Directed Energy Deposition (DED) are less well known, and, in some cases, the lack of understanding is likely inhibiting broader application of the various DED processes. This presentation covers key design rules for DED fusion processes and elucidates opportunities like multi-material deposition and build approaches ranging from basic features to complex large-scale parts. Complementary to the opportunistic characteristics of DfAM for DED, Manufacture for AM (MfAM) encompasses the restrictive aspects of the manufacturing lifecycle with limitations due to bead width and wall thickness, self-supporting angles, surface texture, microstructural evolution, and residual stresses. AM enabled part design must always consider the entire value chain starting with incoming feedstock (e.g. plate, wire, or powder) and progressing through the printing process, post-processing (e.g. machining, inspection), and final system assembly. Key considerations, like the tradeoffs between feature resolution and build rate, for process and part selection and economic assessments will be discussed as DED is often traded against other AM processes. After highlighting typical DED design rules, we will also show how some of those rules can be broken via use cases and part designs that span the full spectrum of DED processes with examples of various DED part designs.

Additive Manufacturing↗

NASA NTRS2011

Lidar Remote Sensing for Characterizing Forest Vegetation - Special Issue. Foreword

The Silvilaser 2009 conference held in College Station, Texas, USA, was the ninth conference in the Silvilaser series, which started in 2002 with the international workshop on using lidar (Light Detection and Ranging) for analyzing forest structure, held in Victoria, British Columbia, Canada. Following the Canadian workshop, subsequent forestry-lidar conferences took place in Australia, Sweden, Germany, USA, Japan, Finland, and the United Kingdom (UK). By the time this Silvilaser 2009 special issue of PE&RS is published, the 10th international conference will have been held in Freiburg, Germany, and planning will be ongoing for the 11th meeting to take place in Tasmania, Australia, in October 2011. Papers presented at the 2005 conference held in Blacksburg, Virginia, USA, were assembled in a special issue of PE&RS published in December 2006. Other special issues resulting from previous conferences were published in journals such as the Canadian Journal of Remote Sensing (2003), the Scandinavian Journal of Forest Research (2004), and Japan s Journal of Forest Planning (2008). Given the conference history and the much longer record of publications on lidar applications for estimating forest biophysical parameters, which dates back to the early 1980s, we may consider lidar an established remote sensing technology for characterizing forest canopy structure and estimating forest biophysical parameters. Randy Wynne, a professor at Virginia Tech and the final keynote speaker at Silvilaser 2009, made the case that it was time to push 30 years of research into operations, along the lines of what has already been done to good effect in the Scandinavian countries. In Randy s words, it s time to "Just do it!" This special issue includes a selection of papers presented during the 2009 Silvilaser conference, which consisted of eight sections as follows: (1) biomass and carbon stock estimates, (2) tree species and forest type classification, (3) data fusion and integration, (4, 5, and 6) forest inventory, (7) silvicultural and ecological applications, and (8) terrestrial lidar applications. Within the constraint limiting the number of papers that could be fitted into the special issue we attempted to select those papers that best represented these conference topics and sections, giving special consideration to studies using forestry lidar data collected from each of the three platforms -- terrestrial, airborne, and spaceborne. Reflecting the international participation and reach of the conference, the studies presented here took place in the USA, Canada, Taiwan, the UK, and China.

Popescu, Sorin C.↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

additive manufacturing↗

NASA NTRS1985

Measurement of High Temperature Thermophysical Properties

Technique development and the application of electromagnetic levitation to thermophysical property measurement, including determining heats of fusion, heat capacities, and enthalpy increment functions for extremely refractory materials are discussed. Tungsten properties and the development of an apparatus employing electromagnetic levitation and electron beam heating capable of melting levitating tungsten high temperature heat content measurements by drop calorimetry are emphasized. The development of a prototype microcomputer data acquisition system suitable for controlling the ground based system, with consequent improvement in system handling, which can serve as a model for the system needed for flight experiments is described, which include the development of techniques for imaging pyrometry at temperatures above 3500 K, a semiautomatic calorimeter system capable of handling liquid tungsten, and development of a two color imaging pyrometer system.

Bonnell, D. W.↗

NASA NTRS2020

Technology Advancements for Channel Wall Nozzle Manufacturing In Liquid Rocket Engines

A regeneratively-cooled or dump-cooled nozzle is a critical component for expansion of hot gases to enable high temperature and performance in liquid rocket engines systems. Regeneratively-cooled channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design can be challenging to fabricate which results in extended lead times and higher costs. Some of these challenges include: 1) Unique and high temperature materials, 2) Tight tolerances on large parts during manufacturing and assembly to contain high pressure propellants, 3) Thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and complex tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) and U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements under evaluation for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on laser powder bed fusion (L-PBF), but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle, and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication technique. This publication presents an overview of the various channel wall nozzle manufacturing processes and materials under evaluation including results from the hot-fire testing. Future development and technology focus areas is also discussed relative to channel wall nozzle manufacturing.

Additive manufacturing↗

NASA NTRS2024

Short-Term Elevated Temperature Mechanical Performance and Microstructure of A Niobium-Zirconium Alloy Produced via Laser Powder Bed Fusion In-Situ Alloying

Nb-1Zr is a readily fabricable, dispersion-strengthened niobium alloy with improved elevated temperature properties compared to commercially pure niobium. This low to moderate strength niobium alloy is desirable in thermal management systems for fission power and propulsion applications; however, pre-alloyed spherical feedstock for powder-based additive manufacturing processes is generally unavailable. Laser powder bed fusion (L-PBF) in-situ alloying of a Nb-1Zr chemistry was performed using a high-purity niobium feedstock coated with 1 wt% of zirconium-based ceramic compound nano-powders: ZrO 2 , ZrC, and ZrH 2 . The additively manufactured material was mechanically tested at elevated temperatures within a controlled environment in the as-built condition. For comparison, traditionally manufactured wrought feedstock was also tested within an identical environment. Examination of the materials’ microstructure and short-term elevated temperature mechanical response determined: in-situ alloying of spherical Nb powder feedstock with Zr-based ceramic nanoparticles can be successfully implemented; the ZrO 2 addition offered the greatest elevated temperature stability and strength but exhibited brittle behavior; the ZrC addition achieved a balance of room temperature ductility and elevated temperature strength; and the ZrH 2 -modified material had the lowest as-built interstitial content and showed high ductility with mechanical performance most similar to wrought Nb-1Zr.

Niobium Alloy↗

NASA NTRS2002

Hypertonicity-induced transmitter release at Drosophila neuromuscular junctions is partly mediated by integrins and cAMP/protein kinase A

The frequency of quantal transmitter release increases upon application of hypertonic solutions. This effect bypasses the Ca(2+) triggering step, but requires the presence of key molecules involved in vesicle fusion, and hence could be a useful tool for dissecting the molecular process of vesicle fusion. We have examined the hypertonicity response at neuromuscular junctions of Drosophila embryos in Ca(2+)-free saline. Relative to wild-type, the response induced by puff application of hypertonic solution was enhanced in a mutant, dunce, in which the cAMP level is elevated, or in wild-type embryos treated with forskolin, an activator of adenylyl cyclase, while protein kinase A (PKA) inhibitors decreased it. The response was also smaller in a mutant, DC0, which lacks the major subunit of PKA. Thus the cAMP/PKA cascade is involved in the hypertonicity response. Peptides containing the sequence Arg-Gly-Asp (RGD), which inhibit binding of integrins to natural ligands, reduced the response, whereas a peptide containing the non-binding sequence Arg-Gly-Glu (RGE) did not. A reduced response persisted in a mutant, myospheroid, which expresses no integrins, and the response in DC0 was unaffected by RGD peptides. These data indicate that there are at lease two components in the hypertonicity response: one that is integrin mediated and involves the cAMP/PKA cascade, and another that is not integrin mediated and does not involve the cAMP/PKA cascade.

NASA Discipline Cell Biology↗

NASA NTRS1994

The NASA-JPL advanced propulsion program

The NASA Advanced Propulsion Concepts (APC) program at the Jet Propulsion Laboratory (JPL) consists of two main areas: The first involves cooperative modeling and research activities between JPL and various universities and industry; the second involves research at universities and industry that is directly supported by JPL. The cooperative research program consists of mission studies, research and development of ion engine technology using C-60 (Buckminsterfullerene) propellant, and research and development of lithium-propellant Lorentz-force accelerator (LFA) engine technology. The university/industry- supported research includes research (modeling and proof-of-concept experiments) in advanced, long-life electric propulsion, and in fusion propulsion. These propulsion concepts were selected primarily to cover a range of applications from near-term to far-term missions. For example, the long-lived pulsed-xenon thruster research that JPL is supporting at Princeton University addresses the near-term need for efficient, long-life attitude control and station-keeping propulsion for Earth-orbiting spacecraft. The C-60-propellant ion engine has the potential for good efficiency in a relatively low specific impulse (Isp) range (10,000 - 30,000 m/s) that is optimum for relatively fast (less than 100 day) cis-lunar (LEO/GEO/Lunar) missions employing near-term, high-specific mass electric propulsion vehicles. Research and modeling on the C-60-ion engine are currently being performed by JPL (engine demonstration), Caltech (C-60 properties), MIT (plume modeling), and USC (diagnostics). The Li-propellant LFA engine also has good efficiency in the modest Isp range (40,000 - 50,000 m/s) that is optimum for near-to-mid-term megawatt-class solar- and nuclear-electric propulsion vehicles used for Mars missions transporting cargo (in support of a piloted mission). Research and modeling on the Li-LFA engine are currently being performed by JPL (cathode development), Moscow Aviation Institute (engine testing), Thermacore (electrode development), as well as at MIT (plume modeling), and USC (diagnostics). Also, the mission performance of a nuclear-electric propulsion (NEP) Li-LFA Mars cargo vehicle is being modeled by JPL (mission analysis; thruster and power processor modeling) and the Rocketdyne Energy Technology and Engineering Center (ETEC) (power system modeling). Finally, the fusion propulsion research activities that JPL is supporting at Pennsylvania State University (PSU) and at Lawrenceville Plasma Physics (LPP) are aimed at far-term fast (less than 100 day round trip) piloted Mars missions and, in the very far term, interstellar missions.

Frisbee, Robert H.↗

NASA NTRSDate not supplied

Uncertainty Quantification and Sensitivity Analysis in Process-Structure-Property Simulations for Laser Powder Bed Fusion Additive Manufacturing

Process variations and process-induced defects like porosity cause significant uncertainty in the microstructure and mechanical behavior of additively manufactured metals. Establishing process-structure-property (PSP) relationships and quantifying uncertainty using experiments alone is costly, especially for structural applications where mechanical allowables must be established for qualification and certification. This work presents a PSP simulation framework for laser powder bed fusion with a focus on uncertainty quantification through probabilistic calibration and multi-fidelity uncertainty propagation. Motivated by phenomenological input parameters related to grain nucleation and growth that are difficult to characterize, a global sensitivity analysis (GSA) is completed. Through GSA, the most important input parameters are identified based on their influence on the statistical distributions of microstructural metrics that influence mechanical behavior, including grain size, morphology, and crystallographic texture. The results provide insight on what experiments are necessary to quantify and control PSP uncertainties, particularly those associated with the more challenging input parameters.

additive manufacturing↗

NASA NTRS1994

Metafusion: A breakthrough in metallurgy

The Metafuse Process is a patented development in the field of thin film coatings utilizing cold fusion which results in a true inter-dispersion of dissimilar materials along a gradual transition gradient through a boundary of several hundred atomic layers. The process is performed at ambient temperatures and pressures requiring relatively little energy and creating little or no heat. The process permits a remarkable range of material combinations and joining of materials which are normally incompatible. Initial applications include titanium carbide into and onto the copper resistance welding electrodes and tungsten carbide onto the cutting edges of tool steel blades. The process is achieved through application of an RF signal of low power and is based on the theory of vacancy fusion.

Joseph, Adrian A.↗

NASA NTRS1972

State-of-technology for joining TD-NiCr sheet

At the current state-of-technology there are many joining processes that can be used to make sound welds in TD-NiCr sheet. Some of these that are described in this report are electron beam welding, gas-tungsten arc welding, diffusion welding, resistance spot welding, resistance seam welding, and brazing. The strengths of the welds made by the various processes show considerable variation, especially at elevated temperatures. Most of the fusion welding processes tend to give weak welds at elevated temperatures (with the exception of fusion-type resistance spotwelds). However, solid-state welds have been made with parent metal properties. The process used for a specific application will be dictated by the specific joint requirements. In highly stressed joints at elevated temperatures, one of the solid-state processes, such as DFW, RSW (solid-state or fusion), and RSEW, offer the most promise.

Holko, K. H.↗

NASA NTRS1971

Unique intermetallic compounds prepared by shock wave synthesis

Technique compresses fine ground metallic powder mixture beyond crystal fusion point. Absence of vapor pressure voids and elimination of incongruous effects permit application of technique to large scale fabrication of intermetallic compounds with specific characteristics, e.g., semiconduction, superconduction, or magnetic properties.

Otto, G.↗

NASA NTRS1980

Alkali metal vapors - Laser spectroscopy and applications

The paper examines the rapidly expanding use of lasers for spectroscopic studies of alkali metal vapors. Since the alkali metals (lithium, sodium, potassium, rubidium and cesium) are theoretically simple ('visible hydrogen'), readily ionized, and strongly interacting with laser light, they represent ideal systems for quantitative understanding of microscopic interconversion mechanisms between photon (e.g., solar or laser), chemical, electrical and thermal energy. The possible implications of such understanding for a wide variety of practical applications (sodium lamps, thermionic converters, magnetohydrodynamic devices, new lasers, 'lithium waterfall' inertial confinement fusion reactors, etc.) are also discussed.

Stwalley, W. C.↗

NASA NTRS1991

Environmental Control Of A Genetic Process

E. coli bacteria altered to contain DNA sequence encoding production of hemoglobin made to produce hemoglobin at rates decreasing with increases in concentration of oxygen in culture media. Represents amplification of part of method described in "Cloned Hemoglobin Genes Enhance Growth Of Cells" (NPO-17517). Manipulation of promoter/regulator DNA sequences opens promising new subfield of recombinant-DNA technology for environmental control of expression of selected DNA sequences. New recombinant-DNA fusion gene products, expression vectors, and nucleotide-base sequences will emerge. Likely applications include such aerobic processes as manufacture of cloned proteins and synthesis of metabolites, production of chemicals by fermentation, enzymatic degradation, treatment of wastes, brewing, and variety of oxidative chemical reactions.

Khosla, Chaitan↗

NASA NTRS2011

Laser Peening Effects on Friction Stir Welding

Friction Stir Welding (FSW) is a welding technique that uses frictional heating combined with forging pressure to produce high strength bonds. It is attractive for aerospace applications. Although residual stresses in FSW are generally lower when compared to conventional fusion welds, recent work has shown that significant tensile residual stresses can be present in the weld after fabrication. Therefore, laser shock peening was investigated as a means of moderating the tensile residual stresses produced during welding. This slide presentation reviews the effect of Laser Peening on the weld, in tensile strength, strain, surface roughness, microhardness, surface wear/friction, and fatigue crack growth rates. The study concluded that the laser peening process can result in considerable improvement to crack initiaion, propagation and mechanical properties in FSW.

Hatamleh, Omar↗

NASA NTRS2023

Seasonal Forecasting Skill for the High Mountain Asia Region in the Goddard Earth Observing System

Seasonal variability of the global hydrologic cycle directly impacts human activities, including hazard assessment and mitigation, agricultural decisions, and water resources management. This is particularly true across the High Mountain Asia (HMA) region, where availability of water resources can change depending on local seasonality of the hydrologic cycle. Forecasting the atmospheric states and surface conditions, including hydrometeorological relevant variables, at subseasonal-to-seasonal (S2S) lead times of weeks-to-months is an area of active research and development. NASA’s 15 Goddard Earth Observing System (GEOS) S2S prediction system has been developed with this research goal in mind. Here, we benchmark the forecast skill of GEOS-S2S (version 2) hydrometeorological forecasts at 1-3 month lead times in the HMA region, including a portion of the Indian Subcontinent, during the retrospective forecast period, 1981-2016. To assess forecast skill, we evaluate 2-m air temperature, total precipitation, fractional snow cover, snow water equivalent, surface soil moisture, and terrestrial water storage forecasts against the Modern-Era Retrospective analysis for Research and 20 Applications, Version 2 (MERRA-2) and independent reanalysis data, satellite observations, and data fusion products. Anomaly correlation is highest when the forecasts are evaluated against MERRA-2 and particularly in variables with long memory in the climate system, likely due to similar initial conditions and model architecture used in GEOS-S2S and MERRA-2. When compared to MERRA-2, results for the 1-month forecast skill range from anomaly correlation of R anom =0.18 for precipitation to R anom =0.62 for soil moisture. Anomaly correlations are consistently lower when forecasts are 25 evaluated against independent observations; results for the 1-month forecast skill range from R anom =0.13 for snow water equivalent to R anom =0.24 for fractional snow cover. We find that, generally, hydrometeorological forecast skill is dependent on the forecast lead time, the memory of the variable within the physical system, and the validation dataset used. Overall, these results benchmark the GEOS-S2S system’s ability to forecast HMA hydrometeorology.

GEOS↗

NASA NTRSDate not supplied

Nb-1Zr L-PBF In-situ Alloying and Elevated Temperature Mechanical Performance

Nb-1Zr is a readily-fabricable, dispersion-strengthened niobium alloy with improved elevated temperature properties compared to commercially pure niobium. This moderate strength niobium alloy is desirable in thermal management systems for fission power and propulsion applications; however, pre-alloyed spherical feedstock is generally unavailable. Laser powder bed fusion (L-PBF) in-situ alloying of a Nb-1Zr chemistry was performed using a pure niobium feedstock coated with 1 wt% of zirconium-based ceramic compound nano-powders. The additively manufactured material was mechanically tested at elevated temperatures in a controlled environment in the as-built condition. For comparison, traditionally manufactured wrought feedstock was also tested under identical conditions. Examination of the materials’ microstructure and elevated temperature mechanical response aimed to determine the Zr-compound nano-powder addition with the best performance, and the overall feasibility of the in-situ alloying approach.

Niobium-based alloys↗