Manufacturing Supply Chain: Targeted Effects of Manufacturing Defects.
Abstract not provided.
Heinrichs, Todd D.↗
SEARCH · Engineering Papers
Results for “Manufacturing”
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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Advanced Manufacturing Initiative Improves U.S. Wind Manufacturing Competitiveness.
Abstract not provided.
Heinrichs, Todd D.↗
Optimization-based Design for Manufacturing: Using Plato to Incorporate Manufacturability Objectives into the Design Process.
Abstract not provided.
Clark, Brett W.↗
REAL DIRECT DIGITAL MANUFACTURING TRANSFORMS ADDITIVE MANUFACTURING
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LUO, YUEFENG↗
Manufacturing Science as the Pathway to Advanced Manufacturing
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Carpenter, John S.↗
Comparison of Three Measurement Modalities for 3D Characterization of Manufactured Features and Native Porosity in Additively Manufactured Titanium Alloy Parts
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Engineering - Aeronautics, Engineering, Optics and↗
Development of Additively Manufactured Complex Tools for Autoclave Cure Composites
IACMI Project 4.9, Tooling for Composites with Washout Features Produced by Additive Manufacturing, assembled a team including the industry lead, Ability Composites, NREL and Colorado State University (CSU). Ability Composites had originally expressed interest in alternate methods of producing tooling for composite parts. In follow-up discussions, it became clear that one of the bigger tooling challenges revolved around small production volume composite parts that were tooled on washout material due to the complex geometry. To build an understanding of the potential, both from a technology and a cost perspective, for replacing conventional washout tooling with 3D printed thermoplastic tooling, a number of commercially available dissolvable FDM printing materials were evaluated, leading to tooling representative of commercial articles of interest to Ability Composites. Ultimately, Ability Composites was able to directly compare autoclave processed prepreg composite parts produced on conventional washout tooling to composite parts molded on 3D printed dissolvable tooling produced at CSU. Small, laboratory test specimens were developed to investigate the structural performance of the candidate materials under autoclave processing conditions, which were nominally 121 °C (250 °F) and 345 kPa (50 psi). In addition, several internal structural configurations (infills) were evaluated under autoclave conditions using model materials. The results of these tests indicated that two materials, Stratasys ST 130 and Infinite Materials Solutions Aquasys 180 (AQ 180), were the best candidates, given the specified autoclave processing conditions. ST-130 was slightly more robust than AQ-180; however, the AQ-180 was carried forward as it was dissolvable in water, not requiring the basic solution needed to dissolve ST-130. Based on the preliminary material and 3D printed structures evaluations, larger tools with a truncated square pyramid geometry were created to produce prepreg composite test articles for 3D printed dissolvable tool evaluation under standard autoclave fabrication conditions. Two tools were manufactured using ST-130 and one tool using traditional ceramic washout tooling media. The tools were evaluated for geometric fidelity and surface roughness changes before and after carbon fiber/epoxy prepreg composites were manufactured on the tooling. The autoclave processing did not impact the geometry significantly and was completed at 121 °C and 345 kPa, indicating satisfactory tool performance. The results from surface roughness testing of both the resulting composite and the associated tooling indicated that an adequate surface resulted without the need for a surface sealing step, as was required for the conventional washout tooling. Based on results of the truncated pyramid tests as a basis, ST-130, AQ-120 and AQ-180 materials were carried forward to the tool geometry of interest to Ability Composites. These hollow rectangular bent ducts, which were complex in nature and not extractable after cure, were used to understand the impacts of tool material and thickness. One ST-130 tool was produced as a partially solid part, with an enclosed 40% dense infill region to reduce weight and material use. This was the same approach evaluated in the truncated pyramid portion of the study. This tool was to be envelope vacuum bagged and directly compared to a monolithic tool of conventional washout material. The traditional monolithic ceramic tool was manufactured by Ability composites using CNC-based subtractive methods. An additional five dissolvable polymer tools, manufactured from ST-130, AQ-120, and AQ-180, using a hollow design were 3D printed and used to produce carbon fiber/epoxy composite evaluation articles. These hollow dissolvable tools were expected to be less influenced by the autoclave conditions as the wall was solid and vacuum bagging was inside and outside the tool. This alternative geometry was also evaluated as an option in techno-economic modeling. Print times were reduced from in excess of 3 days to under 30 hours, while surface quality and and tool integrity were substantially improved in the transition from the partially solid tool to the hollow tooling concept. Ability Composites produced autoclave-cured prepreg ducts on each of these tools. The autoclave conditions utilized were more severe than those of the initial trials, reaching temperatures of 160 °C and a pressure of 414 kPa. Under these conditions, the partially solid 3D printed tool with skin and 40% dense infill crushed significantly; however, the thicker ST-130 hollow tool showed good promise, deforming only slightly. The thinner hollow tool walls were unsuccessful as were the other materials. Overall, the hollow tool manufacturing process saved significant amounts of time and material in manufacturing as compared to the solid ducts and produced composite surface quality improvements compared to the traditional washout tooling. The TEM was developed to allow direct comparisons between conventional washout tool manufacturing processes and those developed at CSU. It also allowed for two separate 3D printed tool geometries to be analyzed and compared. In this case, the square bent duct tool geometry was determined to be representative of common washout tools. This geometry was compared with a scaled-up version of it to assess differences in the two manufacturing processes based on tool size. The model was developed to make use of user input in the form of geometry details, process steps, manufacturing parameters, bulk material costs, capital equipment costs, and general costs to calculate overall labor, material, capital equipment, and energy costs per manufactured tool for the conventional and additive manufacturing processes for the two representative geometries. It was also able to estimate step-by-step process times for the manufacturing process and geometries. Based on significant input from Ability Composites and CSU from their knowledge gained from hands-on manufacturing of the 3D printed bent duct tool geometry, costs and process times were calculated for the two manufacturing processes. Results showed that the additive manufacturing techniques developed at CSU can substantially reduce the costs of tool manufacturing by reducing labor times and material usage. This is because additive manufacturing is a relatively hands-off process and allows for the tool design to be optimized to reduce material usage. The disadvantage, however, is that process times for additive manufacturing are significantly longer. The three-dimensional (3D) printing process is slow if tight tolerances are required, but the analysis did show that print times could be reduced with the hollow tool geometry. Also, further advances in additive manufacturing could expedite the process. Costs and process times for the tool washout process were calculated separately. They showed that costs are relatively insignificant when compared to the overall tool manufacturing processes, but with increases in tool size, costs for the conventional manufacturing approach are larger than for additive manufacturing. Again, the washout process for conventional tools is very hands-on, whereas for additively manufactured tools the print medium is dissolved in an automated detergent bath at the sacrifice of process time. The analysis showed that optimizing the additively manufactured tools may also reduce washout times. Overall, Project 4.9 demonstrated that commercially available dissolvable 3D printing materials exist that can be used to produce dissolvable tooling capable of surviving prepreg composites fabrication under autoclave conditions of 121 °C (250 °F) and 345 kPa (50 psi). An alternative hollow dissolvable tool design was developed which was structurally superior to the initial concept and was cost and time effective versus conventional washout tooling. The 3D printed sacrificial tool required no added surface sealing steps prior to composite part layup and cure, offering a significant advantage over the porous conventional washout tooling.
36 MATERIALS SCIENCE↗
Magnify: A Final Technical Report of the American Energy and Manufacturing Competitiveness Partnership
The energy landscape has undergone profound transformation, with dramatic shifts having an impact on U.S. productivity, global investment, manufacturing operations, and job creation. The sense of urgency for a tighter linkage between clean technologies, energy and advanced manufacturing has only grown. Prior to 2009, the tone of the nation’s energy conversation was centered on how to deal with long-standing energy security challenges and scarcity. Today, the tone is focused on seizing emerging energy growth opportunities to transform America’s industrial base and job creation outlook—centering on energy abundance and strength. In this context, the Council on Competitiveness and the Department of Energy’s Office of Energy Efficiency & Renewable Energy (EERE) teamed in the American Energy & Manufacturing Competitiveness (AEMC) Partnership to tackle two major goals via a multi-year partnership. The AEMC Partnership identified means to: • Increase U.S. competitiveness in the production of clean energy products • Increase U.S. manufacturing competitiveness across the board by increasing energy productivity The AEMC Partnership has engaged hundreds of leaders from industry, academia, labor and government in a series of 9 regional, progressive dialogues; original research; and 4 national summits. The AEMC dialogues and summits spanned the United States—taking place in our nation’s greatest manufacturing, research, technology and innovation hotspots. The goals of the AEMC Partnership have been straightforward: • State and define key barriers, challenges, and problems in U.S. competitiveness in manufacturing of clean energy products, energy efficiency products, and advanced manufacturing products. • Dive deeply into these problems and generate policies, solutions, concepts and models where the U.S. public and private sectors can work together to solve these problems. • Catalyze policy solutions—including models for public-private partnership (PPP) pilots—to increase competitive manufacturing of clean energy and energy efficiency products in the USA. • Elevate and increase awareness of the importance and benefits of competitive clean energy manufacturing. • Understand how energy game-changers, like breakthrough technologies, impact U.S. clean energy and energy efficient manufacturing. The Council on Competitiveness worked with its stakeholder network to generate potential PPP concepts and proposals to advance the goals of the AEMC Partnership. Magnify outlines 2 PPP concepts—honed by dialogues, conversations, interviews and research—that could be carried out by EERE and/or the Council to increase the competitive production of clean energy products, energy efficient products, and advanced manufacturing in the USA. Magnify’s 2 PPP concepts aim to bridge very specific gaps in the nation’s innovation ecosystem: • Clean Energy Materials Accelerator: This PPP concept focuses on reducing the risks associated with deploying newly developed materials in commercial products and processes by creating a platform to identify and address common challenges; increasing access to existing materials qualification and characterization tools; and creating standards for advanced materials with leaders in industry, academic, government, and other organizations. Why accelerate materials production? As the AEMC Partnership Dialogue and supporting research from the public and private sectors have documented, countries that lead in making next-generation materials will gain significant competitive advantage by unleashing a new wave of manufacturing innovation. • Manufacturing and Energy Technology Accelerator: This PPP concept is a new, physical and virtual collaborative resource platform designed to connect the nation’s world-class innovation institutions—SMEs, large multinational companies, universities, national laboratories, etc.—to facilitate the transition of cutting-edge clean energy technologies into products, processes, or services that are manufactured in the United States. Why should public and private sector leaders in innovation partner to co-create a scale-up platform? The United States is already a mecca for the world’s greatest minds in science and technology—drawn to our shores by world-class universities and opportunities to work with global leaders in innovation. Unfortunately, when it comes time to bring their ideas to market, technologists and entrepreneurs often choose, or are forced, to locate manufacturing overseas. The United States must regain its position in the world as a national scale-up platform for next-generation technologies. A thorough explanation of these PPP concepts and the rationale behind these recommendations is provided in Part 3 of Magnify. Magnify is an important step on the critical journey to define barriers, challenges and problems in the manufacturing of clean energy products and energy efficient products—and further honing concepts for scalable, public-private partnerships—to increase the competitive manufacturing of clean energy and energy efficient products, and the energy productivity throughout the U.S. manufactur¬ing sector. The rest of the world is waking up to the opportunities associated with a strategic focus on manufacturing and energy competitiveness. Global competition is on the rise, and the stakes are high for the United States to act now, to act decisively, and to leverage inherent strengths to ensure a more prosperous, competitive future for decades to come.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Analysis of Supply Chains and Advanced Manufacturing of Small Hydropower Systems
Clean energy manufacturing is a sector of increasing importance both in the United States and worldwide. In the United States, it has been presented as an engine for job creation in a sector of the U.S. economy that was hit hard by the 2008-2009 recession. The Clean Energy Manufacturing Analysis Center (CEMAC), sponsored by the U.S. Department of Energy (DOE), conducts credible, objective, industry-relevant, recurring, and consistent analyses of clean energy technologies. In this project, the National Renewable Energy Laboratory (NREL) and the Oak Ridge National Laboratory (ORNL) collaborated in a hydropower manufacturing and supply chain analysis primarily for U.S. small hydropower (SHP) market to provide insights on supply chain constraints, manufacturing cost, location factors, and opportunities for hydropower using advanced manufacturing technologies. The goal of the project is to improve understanding of the manufacturing opportunities in the U.S. hydropower supply chain, specific competitive advantages, and factors for manufacturing location decisions for SHP. These insights could be used to inform investment and research strategies, policy, and other decisions that could promote economic growth and strengthen U.S. manufacturing capabilities. The project scope included a design for manufacturing and assembly (DFMA) costs analysis and a levelized cost of electricity (LCOE) sensitivity analysis of modular, representative SHP turbines. A representative SHP system was chosen to be made up of two 5 megawatt (MW) turbines, as these Kaplan style turbines could be useable for many non-powered dams (NPDs) across the U.S. The sensitivity analysis used the Integrated Design and Assessment (IDEA) tool, which has helped highlight the impact of the turbine equipment cost on the potential capital expenditure (CAPEX) and LCOE of the installed, representative system. In addition, the project team analyzed international tradeflows (e.g., export and import of hydropower turbines and the parts used in hydropower systems). As part of this project, hydropower stakeholder interviews were undertaken to help identify insights related to hydropower manufacturing opportunities for U.S. players in SHP, the country-specific manufacturing advantages in the United States and threats, and key factors behind manufacturing location decisions made by the SHP industry. Key opportunities for the US SHP market and industry include: Foreign export markets such as Chile, China, Columbia, India and Japan, have an estimated 71,795 MW of technical potential that could be serviced with SHP installations. Utilization of existing manufacturing capacity and expertise, along with economies of scale benefits, could result in increased global competitiveness through lower investment requirements and component costs, which could lead to increased U.S. strength in the export of SHP systems and components. Technology advances such as modular turbine designs, standardized units for conduit systems, precast systems, and improved powertrain technologies could help reduce costs, particularly for manufacturing a small number of units. The DOE is also exploring modular hydropower designs, which would integrate standard independently-produced components, validated to meet multiple specifications. Using modules in product design simplifies manufacturing activities such as inspection, testing, assembly, and purchasing, may increase economies of scale to lower total system cost. There are significant opportunities for the use of composites and Additive Manufacturing (AM) for hydropower components, when design changes are made to hydropower systems. By taking advantage of the corrosion resistance, light-weighting and structural benefits, composites and AM could help significantly alter hydropower structures and installations.
13 HYDRO ENERGY↗
NASA Game Changing Development Program Manufacturing Innovation Project
This presentation examines the new NASA Manufacturing Innovation Project. The project is a part of the Game Changing Development Program which is one element of the Space Technology Programs Managed by Office of the Chief Technologist. The project includes innovative technologies in model-based manufacturing, digital additive manufacturing, and other next generation manufacturing tools. The project is also coupled with the larger federal initiatives in this area including the National Digital Engineering and Manufacturing Initiative and the Advanced Manufacturing Partnership. In addition to NASA, other interagency partners include the Department of Defense, Department of Commerce, NIST, Department of Energy, and the National Science Foundation. The development of game-changing manufacturing technologies are critical for NASA s mission of exploration, strengthening America s manufacturing competitiveness, and are highly related to current challenges in defense manufacturing activities. There is strong consensus across industry, academia, and government that the future competitiveness of U.S. industry will be determined, in large part, by a technologically advanced manufacturing sector. This presentation highlights the prospectus of next generation manufacturing technologies to the challenges faced NASA and by the Department of Defense. The project focuses on maturing innovative/high payoff model-based manufacturing technologies that may lead to entirely new approaches for a broad array of future NASA missions and solutions to significant national needs. Digital manufacturing and computer-integrated manufacturing "virtually" guarantee advantages in quality, speed, and cost and offer many long-term benefits across the entire product lifecycle. This paper addresses key enablers and emerging strategies in areas such as: Current government initiatives, Model-based manufacturing, and Additive manufacturing.
Tolbert, Carol↗
U.S. Wind Energy Manufacturing and Supply Chain: A Competitiveness Analysis
The goal of the project was to develop a greater understanding of the key factors determining wind energy component manufacturing costs and pricing on a global basis in order to enhance the competitiveness of U.S. manufacturers, and to reduce installed systems cost. Multiple stakeholders including DOE, turbine OEMs, and large component manufactures will all benefit by better understanding the factors determining domestic competitiveness in the emerging offshore and next generation land-based wind industries. Major objectives of this project were to: 1. Carry out global cost and process comparisons for 5MW jacket foundations, blades, towers, and permanent magnet generators; 2. Assess U.S. manufacturers’ competitiveness and potential for cost reduction; 3. Facilitate informed decision-making on investments in U.S. manufacturing; 4. Develop an industry scorecard representing the readiness of the U.S. manufacturers’ to produce components for the next generations of wind turbines, nominally 3MW land-based and 5MW offshore; 5. Disseminate results through the GLWN Wind Supply Chain GIS Map, a free website that is the most comprehensive public database of U.S. wind energy suppliers; 6. Identify areas and develop recommendations to DOE on potential R&D areas to target for increasing domestic manufacturing competitiveness, per DOE’s Clean Energy Manufacturing Initiative (CEMI). Lists of Deliverables 1. Cost Breakdown Competitive Analyses of four product categories: tower, jacket foundation, blade, and permanent magnet (PM) generator. The cost breakdown for each component includes a complete Bill of Materials with net weights; general process steps for labor; and burden adjusted by each manufacturer for their process categories of SGA (sales general and administrative), engineering, logistics cost to a common U.S. port, and profit. 2. Value Stream Map Competitiveness Analysis: A tool that illustrates both information and material flow from the point of getting a customer order at the manufacturing plant; to the orders being forwarded by the manufacturing plant to the material suppliers; to the material being received at the manufacturing plant and processed through the system; to the final product being shipped to the Customer. 3. Competitiveness Scorecard: GLWN developed a Wind Industry Supply Chain Scorecard that reflects U.S. component manufacturers’ readiness to supply the next generation wind turbines, 3MW and 5MW, for land-based and offshore applications. 4. Wind Supply Chain Database & Map: Expand the current GLWN GIS Wind Supply Chain Map to include offshore elements. This is an on-line, free access, wind supply chain map that provides a platform for identifying active and emerging suppliers for the land-based and offshore wind industry, including turbine component manufacturers and wind farm construction service suppliers.
17 WIND ENERGY↗
Techno-Economic Wind Blade Manufacturing Model to Identify Opportunities for Cost Improvements Phase II IACMI Project 4.6/4.8
In IACMI Project 4.6 and IACMI Project 4.8, an Excel-based Techno-Economic Model (TEM) of the manufacturing process for composite wind turbine blades and a DELMIA Factory Flow Simulation of a generic wind blade manufacturing facility was developed. Together, these two tools provide a combined economic modeling capability that accounts for the material, labor, overhead and full-lifecycle operating costs associated with wind blade manufacturing as well as the impact of process flow and factory layout on overall manufacturing efficiency. The tools provide a novel means of detailed comparative analysis of the economic feasibility of proposed technologies and process changes for blade manufacturing. The modeling tools were developed with close support from members of industry and visits to multiple blade manufacturing facilities. With industry oversight, a detailed generalized manufacturing process plan and facility layout were developed with manufacturing parameters, material costs and economic factors based on historical data. Dassault Systèmes and the University of Texas at Dallas (UTD) contributed to the development of the Techno-Economic Model by providing macros to enable the generation of Bill of Material (BOM) data from a 3D blade design in either CATIA or NuMAD format, respectively. The TEM was built with the capability to directly import a Bill of Materials for economic analysis, and with the addition of the macros provided by Dassault and UTD, the TEM can directly import blade designs from both CATIA and NuMAD file formats. The modeling tools developed in Project 4.6 were used to investigate four wind blade manufacturing concepts in detail and select one to explore with laboratory-scale experimentation in Project 4.8. The four manufacturing concepts that were investigated were down-selected by the full project team from a larger list of concepts. The selections were made based on a number of criteria ranking viability and level of interest for each concept. The ‘One-Step Close’ manufacturing concept was ultimately selected for investigation in Project 4.8 and the demonstration was performed at the NREL CoMET facility. The TPI advanced manufacturing facility in Warren, RI contributed the production of several prototype components, the designs for which were developed by Janicki Industries. The demonstration project provided clear indication of the viability of the One-Step Close manufacturing concept for blade manufacturing and good validation of the Techno-Economic Model’s prediction of its economic impact.
17 WIND ENERGY↗
Study of Additive Manufacturing Applications to Geothermal Technologies Final Project Report
This report summarizes work performed to assess the potential for utilizing additive manufacturing (AM) to substantially improve either the availability, performance or cost basis for tools and components that are required for geothermal energy production. A systematic cataloging of geothermal activities, associated technologies, and current manufacturing methods was first undertaken. This included literature reviews as well as interviews with subject matter experts, service companies and OEMs. An industry workshop was held as part of this portion of the project to obtain input and concerns from a broad range of OEMs, service providers and end users. This workshop was also used to gage the current level of AM activity in industry, receptiveness to the use of AM manufactured parts, and any up front concerns that may exist. A summary of the workshop is presented in this report. Representative components and assemblies and their current manufacturing methods were then analyzed by additive manufacturing experts at a company called Senvol to determine the feasibility and required steps for producing parts by additive manufacturing. A step by step description of conventional manufacturing of the parts was also performed to establish a manufacturing baseline for comparison purposes. This analysis also considered and described the benefits of additively manufacturing the parts in terms of specific AM systems, material availability for AM, dimensional requirements and potential economic advantages. Details of the manufacturability assessment were summarized in a report which is included as a chapter in this document. The analysis of the AM subject matter experts was then be used by techno-economic analysts to perform a comparative economic evaluation of the manufacturing of select technologies by AM and conventional approaches. This activity leveraged ORNL expertise and prior experience in other applications. A framework based on assessing cost, volume production considerations, and time to manufacture was created to more easily discern the advantages or disadvantages of additive versus conventional manufacturing methods. The report concludes with a general assessment of the current applicability of AM for geothermal technologies, AM gaps and needs related to typical geothermal hardware, and the potential benefits and impacts of AM to geothermal energy production.
15 GEOTHERMAL ENERGY↗
Water intensity of photovoltaic module manufacturing at the terawatt scale
As the U.S. ramps photovoltaic (PV) manufacturing to the terawatt scale and emphasizes re-shoring manufacturing, potential regional impacts on the U.S. water supply should be considered, particularly since many PV companies rely almost exclusively on public water supplies for manufacturing. This work surveys the academic literature and PV manufacturer reports to estimate the water intensity of monocrystalline silicon, multicrystalline silicon, and cadmium telluride modules manufactured at the terawatt scale, determining that on average, cadmium telluride manufacturing is less water intensive on a per megawatt scale – this is anticipated to be true for all thin film PV manufacturing. While much lower than the water intensity of thermoelectric (e.g., coal) energy generation, significant issues and gaps with PV manufacturing data quality in academic studies are identified which cause estimates to vary by over 1000x (0.04 – 49 trillion liters/terawatt). Data issues are discussed and the need for accurate accounting of water resources (e.g., via continuous, updated information during PV manufacturing) is highlighted. The opportunity to reconfigure decommissioned thermoelectric sites to PV manufacturing is also explored. Finally, factors that influence PV manufacturing water intensity, from individual manufacturing steps to trends across the PV industry, are examined and water conservation opportunities are presented.
14 SOLAR ENERGY↗
Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps – Phase 2
As the wind turbine industry continues to develop, the technology surrounding the design, development, and manufacturing of blades requires advancement as well. Wind turbine blades continue to increase in size, increasing the cost and time associated with manufacturing. Simulation driven manufacturing cycle design is required for the industry to maintain manufacturing schedules and optimize the manufacturing process. A recent effort to reduce the cycle time of wind blade spar caps encountered a recurring manufacturing defect during the exotherm and curing of the resin system after filling in the vacuum-assisted resin transfer molding (VARTM) process. Thermal waves developed in sections of the spar cap resulting in unacceptable part tolerances, requiring the parts to be thrown out. The first phase of this IACMI project focused on characterizing the fabric and epoxy system used in manufacturing and simulating the manufacturing process to determine the root cause of the thermal waves. The second phase of this project refined and validated the manufacturing simulations. The simulation workflow was then used to analyze multiple cure cycle options to determine if the thermal waves would appear. The estimated filling time from the filling simulation was shown to match well to experiment, and the temperature history from the curing simulation lined up well with experiment. This indicates that these simulations could be used to evaluate future curing cycles to be used with manufacturing. It is recommended that the distortion simulation work be completed for this project, as it would allow for further manufacturing cycle evaluation through the prediction of stresses and strains in the part. This could provide indicators of defects like the thermal waves seen in manufacturing earlier.
17 WIND ENERGY↗
Preliminary Characterization and Evaluation on FFF Manufactured 316H and ODS Steels
The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Solid-state advanced manufacturing techniques can overcome some of the challenges in liquid-based additive manufacturing (AM) processes and should therefore be considered in material design and manufacturing as well. The work presented in this report forms part of a study on solid-state AM techniques of 316 stainless steels (SS) and oxide dispersion strengthened (ODS) steel components and supports the vision and goals of the AMMT program relevant to accelerate the development and deployment of advanced manufacturing processes. Achieving this can provide a safety improvement through larger safety margins, economic benefit for higher efficiency during operation, and a cost reduction through more effective manufacturing processes and less waste. This study provides preliminary information on development of the fused-filament fabrication (FFF) process using different powder types to demonstrate the sensitivity, and therefore the characterization of these sample components. The full solid-state manufacturing feasibility study will be completed and reported in a final feasibility evaluation during 2025. The study investigation used two 14YWT ODS powder batches, which provided information and the effect of different powder morphologies on manufacturability. The two 316SS powders demonstrated the effect of powder size on the manufacturability using FFF. Two product forms, namely a honeycomb structure and flat samples, were manufactured to demonstrate the flexibility of product form.
36 MATERIALS SCIENCE↗
Additive Component Manufacturing
State-of-the-art technology like additive manufacturing has not yet been thoroughly applied to fluid control valves. Many valve manufacturing issues such as flow passage machining, deep hole boring, and bi-metallic joining could successfully be addressed with this new technology. The goal of this project was to apply additive manufacturing technology specifically to the problems that fluid control valves present. In order to properly apply additive manufacturing processes to the design of control valves, the plan was to manufacture samples using metals compatible with low temperature, high pressure oxygen service and then tested. While vetting this project with manufacturers, it was determined that the materials chosen were not ideal for additive manufacturing due to their high reflectivity. Therefore, materials for this project were currently undergoing reevaluation and materials that are better suited for additive manufacturing may be substituted. During FY20, additional alloys were selected that would be both appropriate for high pressure oxygen environments as well appropriate for additive manufacturing processes. However, final bid for manufacturing was six times larger than the available funding for this project. Based on previous additive manufacturing projects, the scope and funding for this project were appropriate, but a suitable manufacturer willing to provide a reasonable proposal, was not found. Therefore, funds were de-obligated for this project, and then re-obligated to augment another FY20 CIF project.
Jonathan Dickey↗
Industrial Scale Demonstration of Smart Manufacturing, Achieving Transformational Energy Productivity Gains
While many U.S. manufacturing operations utilize optimization for individual unit processes, smart manufacturing (SM) systems that integrate manufacturing intelligence in real time across an entire production operation are rare in large companies and virtually nonexistent in smaller organizations. One example of an area where SM systems can be applied is in the management of waste heat. A smart system that not only seeks to recover waste heat, but also to use energy more efficiently, is a more cost-effective approach because energy use, waste energy loss and product output are optimized together. The overall objective of this project was to develop an industry-accepted SM Platform that enables smart systems by accelerating and lowering the cost of development and implementation scales for use in diverse sets of manufacturing industry sectors, manufacturing operations and company sizes. Specifically, the project (1) designed and demonstrated the application of a prototype SM Platform for two diverse commercial test beds, (2) demonstrated at one and estimated for the other test bed the potential reduction in waste heat generation, and (3) worked with leading automation vendors to catalyze low-cost commercialization of the technology developed. The Smart Manufacturing Application and Data Platform (SM Platform) developed during this project is an innovative approach that marries IT virtualization technologies with operational data and modeling system requirements to construct a ready-to-go platform for enabling sensor – data – modeling – actuation systems, driven by real-time plant data and performance metrics. This SM Platform allows manufacturing organizations, regardless of their industry or size, to assemble new operational systems at a much lower cost, optimizing process knowledge and improving energy productivity by integrating with existing process control and automation systems. Also developed during this project is a methodology for developing energy productivity metrics that use real-time process information and provide comparisons for potential, practical, and actual performance, as well as examples and the methodology for provisioning of an Energy Dashboard that displays alternatives to optimize energy use within specific business contexts aimed at helping improve energy productivity and reduce emissions in U.S. manufacturing. The SM Platform designed utilizes current manufacturing, operational and IT industry standards. The platform can be used to expedite sensor – data – model – actuation system development and deployment in a cloud-based environment using a novel end-to-end workflow as a service capability that is already integrated with data connection, ingestion, and contextualization services. In addition, the methodology for development of energy productivity metrics and reusable application templates called Toolkits have been defined so that they can be tailored to a specific business situation. The project’s two test beds, one in a hydrogen production plant and the other in a forging, heat treatment, and machining operation, utilize sensor-driven modeling, measurement, and simulation systems. In these two test beds, the implementation of these as a comprehensive system has made it possible for energy productivity to be managed in real-time throughout the plant and enterprise using an energy dashboard. The development pathway to direct machine actuation was articulated. During the first year, the project team developed the most highly instrumented steam-methane reformer (SMR) in the U.S. using infrared cameras and thermocouples. Real-time data are streamed to high fidelity and reduced-order models for analysis. A high fidelity CFD model, parallelized in the SM Platform cloud environment, was demonstrated for operational use. This is the first real-time operational productivity system of a steam methane reformer using both high fidelity and data-driven models together in a real time situation to balance natural gas flow to the reformer tubes. An infrared camera system was developed and shown to outperform thermocouples in coverage, accuracy, reliability, and cost effectiveness for use in a high temperature, harsh environment. A forging, heat-treating, machining line operation test bed includes new instrumentation for data capture analysis, modeling, and simulation and will be integrated into SM Platform workflows so that business performance can be managed in real-time. Composable metrics were developed using the SM Platform to drive improvements in energy productivity, environmental performance, safety, asset management, costs, and overall operations. A major focus of the SM systems developed was optimization of energy productivity at the enterprise level, which resulted in reductions in waste heat generation for the two project test beds. Reductions in the waste heat generated will result in greater energy savings than will waste heat recovery due to inefficiencies in the heat transfer process. For the SMR test bed an efficiency improvement of 1 – 2% with a corresponding waste heat reduction of 5% were demonstrated. It should be noted that the test bed SMR unit had an efficiency of more than 90% as compared to 70 to 80% efficiencies of most SMR units. So implementation of similar SM systems at typical SMR units could yield more than 15 to 25% waste heat reductions. Similarly the forging, heat-treating, machining line operation test bed is a DOE AMO Platinum Level Superior Energy Performance plant with a much higher than typical overall operating efficiency. For this test bed heat integration using recuperators is estimated to result in fuel savings of 15.9% due to waste heat recovery compared to the base case without recuperators with negligible changes in part exit conditions. This results in an 18.9% energy efficiency improvement. The project team estimates that broad multi-sector adoption of the developed technology could reduce waste heat generation by an amount equivalent to 1.3% of total U.S. energy use. This waste heat reduction is associated with 69 million tons reduction in annual carbon dioxide emissions. Other potential benefits include reducing process times, solid and liquid wastes, environmental impacts, and water use. It is estimated that this investment has an anticipated payback period of less than one year in energy-intensive applications. The SM Platform could also reduce the costs of deploying SM systems by 50% in manufacturing operations. Commercialization of the SM Platform will require significant cross-industry collaboration and technology provider market changes. Steps taken toward commercialization included 1) analyzing savings from deployment of the SM Platform and 2) holding SM Platform workshops, webinars, and conferences with targeted individual industry segments, with a focus on small and medium-sized organizations. An upgraded community website has been established as a portal for accessing and distributing information. Most importantly, the SM platform enabling technology developed during this project and its commercialization will continue, evolve and expand under the Clean Energy Smart Manufacturing Innovation Institute (CESMII).
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗