Aerospace castings produced from magnesium- lithium-silicon alloy.
Aerospace castings from light ternary Mg-Li-Si alloy, discussing fabrication development
AEROSPACE TECHNOLOGY↗
SEARCH · Engineering Papers
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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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ChatGPT and Other Large Language Models for Cybersecurity of Smart Grid Applications
Cybersecurity breaches targeting electrical substations constitute a significant threat to the integrity of the power grid, necessitating comprehensive defense and mitigation strategies. Any anomaly in information and communication technology (ICT) should be detected for secure communications between devices in digital substations. This paper proposes large language models (LLMs), e.g., ChatGPT, for the cybersecurity of IEC 61850-based communications. Multi-cast messages such as generic object oriented system events (GOOSE) and sampled values (SV) are used for case studies. The proposed LLM-based cybersecurity framework includes, for the first time, data pre-processing of communication systems and human-in-the-loop (HITL) training (considering the cybersecurity guidelines recommended by humans). The results show a comparative analysis of detected anomaly data carried out based on the performance evaluation metrics for different LLMs. A hardware-in-the-loop (HIL) testbed is used to generate and extract a dataset of IEC 61850 communications.
ChatGPT↗
Metal Matrix Composite Materials for Aerospace Applications
Metal matrix composites (MMC) are attractive materials for aerospace applications because of their high specific strength, high specific stiffness, and lower thermal expansion coefficient. They are affordable since complex parts can be produced by low cost casting process. As a result there are many commercial and Department of Defense applications of MMCs today. This seminar will give an overview of MMCs and their state-of-the-art technology assessment. Topics to be covered are types of MMCs, fabrication methods, product forms, applications, and material selection issues for design and manufacture. Some examples of current and future aerospace applications will also be presented and discussed.
Bhat, Biliyar N.↗
Advanced Material Developments with Laser Engineered Net Shaping
The Laser Engineered Net Shaping (LENS(Trademark)) process is a new technology to fabricate three-dimensional metallic components directly from CAD solid models. It directly fabricates metal hardware by injecting the metal powder of choice into the focal point of a 700W Nd:Yag laser as it traces the perimeter and fills of a part. The Rapid Prototype Laboratory at Marshall Space Flight Center is currently operating a OPTOMEC 750 LENS machine in evaluation experiments involving integration of this technology into various manufacturing processes associated with aerospace applications. This paper will cover our research finding about properties of samples created from Inconel 718 & SS316 using this process versus the same materials in cast & wrought conditions.
Williams, Glenn A.↗
New Outboard Motor Firing on All Pistons
Seven years ago, NASA was in the planning stages of producing an aluminum alloy with higher strength and resistance at elevated temperatures for aerospace applications. At that time, a major automobile manufacturer happened to approach NASA for solutions to lowering engine emissions and the costs associated with developing aluminum engine pistons. The Space Agency realized the answers to the manufacturer's problems could lie within the proposed alloy. Jonathan Lee, a structural materials engineer at Marshall Space Flight Center s Materials, Processes, and Manufacturing Department, and PoShou Chen, a scientist with Huntsville, Alabama-based Morgan Research Corporation, partook in the development project as the inventors. The resulting NASA High-Strength Aluminum Alloy, or "MSFC-398," was capable of casting metal components at both high volume and low cost, making it extremely attractive for commercial application, not just in automotives, but in a variety of other industries, as well. NASA patented the technology and introduced it for public licensing in 2001.
Source record↗
Developments on Reusable TPS Materials Based Upon Shuttle Tile
The insulating tiles used on the Space Shuttler Orbiter, principally AETB (Alumina Enhanced Thermal Barrier), have been seen by new vehicle developers in the aerospace industry as a fast-track approach for fielding a reusable thermal protection system (TPS) given the extensive use by both the Orbiter program and the current Orion vehicle. NASA has, and is, supporting the industry through technology transfer and commercial crew and payloads programs. However, the reusable TPS community is rapidly encountering challenges rooted in Orbiter’s and Orion’s dependence on legacy material and processes. With the aim of alleviating these issues, improving availability of reusable TPS, and strengthening the nation’s space economy, ongoing efforts at NASA Ames have focused on understanding process-property relationships in AETB as well as novel materials and technologies for reusable TPS. The first portion of this talk will address the effects of raw materials and processing conditions on the properties of AETB-8, including the raw materials used, mixing and casting parameters, and thermal history. Understanding these relationships, and how they extend to aerothermal performance, is instrumental in alleviating supply chain constraints and improving manufacturability. The implications of these finding on development of novel TPS materials and systems will be discussed. AETB will likely continue to fill a niche of relatively high performance with associated costs. There exists, therefore, a gap in developed reusable TPS for a lower cost, moderate performing material system. The later portion of this talk will touch on current development efforts at Ames focusing on reduced cost and ease of integration, which are being pursued in addition to AETB and higher performing systems. In addition to summarizing these efforts, an outlook for these projects and collaborations will be given.
Peter Edward Marshall↗
Developments on Reusable TPS Materials Based Upon Shuttle Tile
The insulating tiles used on the Space Shuttler Orbiter, principally AETB (Alumina Enhanced Thermal Barrier), have been seen by new vehicle developers in the aerospace industry as a fast-track approach for fielding a reusable thermal protection system (TPS) given the extensive use by both the Orbiter program and the current Orion vehicle. NASA has, and is, supporting the industry through technology transfer and commercial crew and payloads programs. However, the reusable TPS community is rapidly encountering challenges rooted in Orbiter’s and Orion’s dependence on legacy material and processes. With the aim of alleviating these issues, improving availability of reusable TPS, and strengthening the nation’s space economy, ongoing efforts at NASA Ames have focused on understanding process-property relationships in AETB as well as novel materials and technologies for reusable TPS. The first portion of this talk will address the effects of raw materials and processing conditions on the properties of AETB-8, including the raw materials used, mixing and casting parameters, and thermal history. Understanding these relationships, and how they extend to aerothermal performance, is instrumental in alleviating supply chain constraints and improving manufacturability. The implications of these finding on development of novel TPS materials and systems will be discussed. AETB will likely continue to fill a niche of relatively high performance with associated costs. There exists, therefore, a gap in developed reusable TPS for a lower cost, moderate performing material system. The later portion of this talk will touch on current development efforts at Ames focusing on reduced cost and ease of integration, which are being pursued in addition to AETB and higher performing systems. In addition to summarizing these efforts, an outlook for these projects and collaborations will be given.
Thermal Protection Systems↗
Design, Optimization, and Control of a 100 kW Electric Traction Motor Meeting or Exceeding DOE 2025 Targets
The overall objective of the electric motor portion of the Electric Drives Technology consortium is to research, develop, and test electric motors for use in electric vehicle applications capable of a peak power greater than 100 kW, power density greater than or equal to 50 kW/l, and a cost less than 3.3 $/kW. To meet the electric traction motor power density and cost targets a number of approaches were pursued simultaneously throughout the course of this project which address all of the major volumetric power density variables. The specific research thrusts at the Illinois Institute of Technology (IIT) are the following: multiphysics design for increased power density through maximum utilization of active materials, synthesis of electric machine windings and PM flux barriers with controlled space harmonics, high slot fill windings for increased current loadings or efficiency, aggressive cooling strategies, and design studies and prototype construction of candidate electric machines.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Precision cleaning verification of fluid components by air/water impingement and total carbon analysis
NASA personnel at Kennedy Space Center's Material Science Laboratory have developed new environmentally sound precision cleaning and verification techniques for systems and components found at the center. This technology is required to replace existing methods traditionally employing CFC-113. The new patent-pending technique of precision cleaning verification is for large components of cryogenic fluid systems. These are stainless steel, sand cast valve bodies with internal surface areas ranging from 0.2 to 0.9 sq m. Extrapolation of this technique to components of even larger sizes (by orders of magnitude) is planned. Currently, the verification process is completely manual. In the new technique, a high velocity, low volume water stream impacts the part to be verified. This process is referred to as Breathing Air/Water Impingement and forms the basis for the Impingement Verification System (IVS). The system is unique in that a gas stream is used to accelerate the water droplets to high speeds. Water is injected into the gas stream in a small, continuous amount. The air/water mixture is then passed through a converging/diverging nozzle where the gas is accelerated to supersonic velocities. These droplets impart sufficient energy to the precision cleaned surface to place non-volatile residue (NVR) contaminants into suspension in the water. The sample water is collected and its NVR level is determined by total organic carbon (TOC) analysis at 880 C. The TOC, in ppm carbon, is used to establish the NVR level. A correlation between the present gravimetric CFC113 NVR and the IVS NVR is found from experimental sensitivity factors measured for various contaminants. The sensitivity has the units of ppm of carbon per mg/sq ft of contaminant. In this paper, the equipment is described and data are presented showing the development of the sensitivity factors from a test set including four NVRs impinged from witness plates of 0.05 to 0.75 sq m.
Barile, Ronald G.↗
Precision Cleaning Verification of Fluid Components by Air/Water Impingement and Total Carbon Analysis
NASA personnel at Kennedy Space Center's Material Science Laboratory have developed new environmentally sound precision cleaning and verification techniques for systems and components found at the center. This technology is required to replace existing methods traditionally employing CFC-113. The new patent-pending technique of precision cleaning verification is for large components of cryogenic fluid systems. These are stainless steel, sand cast valve bodies with internal surface areas ranging from 0.2 to 0.9 m(exp 2). Extrapolation of this technique to components of even larger sizes (by orders of magnitude) is planned. Currently, the verification process is completely manual. In the new technique, a high velocity, low volume water stream impacts the part to be verified. This process is referred to as Breathing Air/Water Impingement and forms the basis for the Impingement Verification System (IVS). The system is unique in that a gas stream is used to accelerate the water droplets to high speeds. Water is injected into the gas stream in a small, continuous amount. The air/water mixture is then passed through a converging-diverging nozzle where the gas is accelerated to supersonic velocities. These droplets impart sufficient energy to the precision cleaned surface to place non-volatile residue (NVR) contaminants into suspension in the water. The sample water is collected and its NVR level is determined by total organic carbon (TOC) analysis at 880 C. The TOC, in ppm carbon, is used to establish the NVR level. A correlation between the present gravimetric CFC-113 NVR and the IVS NVR is found from experimental sensitivity factors measured for various contaminants. The sensitivity has the units of ppm of carbon per mg-ft(exp 2) of contaminant. In this paper, the equipment is described and data are presented showing the development of the sensitivity factors from a test set including four NVR's impinged from witness plates of 0.05 to 0.75 m(exp 2).
Barile, Ronald G.↗
Benefits of Hot Isostatic Pressure/Powdered Metal (HIP/PM) and Additive Manufacturing (AM) To Fabricate Advanced Energy System Components
Advanced Energy systems require large, complex components produced from materials capable of withstanding severe operating environments (high temperature, pressure, corrosivity). Such parts can be difficult to source, as conventional material processing technologies must be tailored to ensure a safe and cost effective approach to large-scale manufacture of quality structural advanced alloy components that meet the performance specifications of AE systems. (HIP/PM) has shown advantages over other manufacturing methods when working with these materials. For example, using HIP’ing in lieu of casting means significant savings in raw material costs, which for expensive, high-nickel alloys can be considerable for large-scale production. Use of HIP/PM also eliminates the difficulties resulting from reactivity of these materials in the molten state and facilitates manufacture of the large size requirements of the AE industry, producing a part that is defect and porosity free, thus further reducing or eliminating time and expense of post processing machining and weld repair. New advances in Additive Manufacturing (AM) techniques make it possible to further expand the benefits of HIP/PM in producing AE system components to create an even more robust manufacturing approach. Traditional techniques of welding and forming sheet metal to produce the HIP canisters can be time consuming and costly, with limitations on the complexity of part which can be achieved. A key benefit of AM is the freedom of design that it offers, so use of AM could overcome such challenges, ultimately enabling redesign of complete energy systems. A critical step toward this goal is material characterization of the required advanced alloys, for use in AM. Using Haynes 282, a high nickel alloy of interest to the Fossil Energy community, particularly for Advanced-UltraSuperCritical (AUSC) operating environments, as well as the crosscutting interests of the aerospace, defense and medical markets, this research pursued three new methods of manufacturing these advanced alloys: 1) Directly built AM parts; 2) AM cans for HIP/PM; and 3) AM cans produced in the final part material. The project utilized Carpenter atomized A-282 in varied mesh sizes customized for both AM and HIP, ExOne’s binderjet technology, the fastest metal 3D printing technique on the market at the current time, coupled with an alloy specific sintering profile to produce a sufficiently dense part for final HIP by Bodycote. Final parts were subjected to chemical and physical property tests and results were compared to published and gathered data. Chemistry results for all the parts were within the published criteria. Furthermore, the AM and HIP/PM parts showed measurable improvement over previous A282 HIP/PM results, in part due to an improved HT spec, and a marked improvement over results from A282 castings. These results indicate that combining AM and HIP/PM in the manner set forth in this project provides a credible manufacturing approach of these activities are set forth in this Final Technical Report.
20 FOSSIL-FUELED POWER PLANTS↗
Additively Manufactured, Net Shape Powder Metallurgy Cans for Valves Used in Energy Production
Additive manufacturing (AM) has the potential to enable a paradigm shift in fabricating complex net shape components with yields over 90%, significantly increasing productivity, decreasing energy consumption during manufacturing and improving downstream energy efficiency. ORNL has developed a technology for producing large-scale additively manufactured polymer matrix composite components at deposition rates on the order of 100 lbs. per hour. This project utilized tools, dies and molds made from this technology to enable the net shape forming of cans for the powder metallurgy (PM) manufacturing of valves used in energy production plants. This approach has the potential to develop affordable valves with superior performance to castings. It will also lead to increased strength values, decreased wall thickness size, and the potential for higher yields (less machining). This project is critical for evaluating new methodologies for the fabrication of additively manufactured tooling, molds and dies that could be used across multiple industries. In the first phase of this project, a new methodology of creating a Powder Metallurgy and Hot Isostatic Pressing (PM-HIP) container by hydroforming sheet metal over additively manufactured (AM) dies was evaluated. The goal in this stage of development was to evaluate some of the new polymer matrix composite materials designed for deposition on large scale additive manufacturing systems as candidates for hydroforming steel and aluminum sheet to make thin gauge net shape components. In order to meet this objective, most research was performed on subscale tools in order to evaluate the processing pressures, material options, and gauge thicknesses most relevant to this approach. In addition, full scale AM tools (30% over final component geometry) were produced to demonstrate scalability, but were not used in testing. The first phase of this project has proven this concept has merit, but future studies are required to address minor tool failures that occurred in phase one due to geometry, cost of the process over other techniques, and demonstration of a full-scale tool that could then be used in (HIP). Lastly, this project provides the PM community a new approach in using hydroforming for the manufacturing of cans, a process that was not highly utilized for this purpose previously.
42 ENGINEERING↗
Application of superalloy powder metallurgy for aircraft engines
In the last decade, Government/Industry programs have advanced powder metallurgy-near-net-shape technology to permit the use of hot isostatic pressed (HIP) turbine disks in the commercial aircraft fleet. These disks offer a 30% savings of input weight and an 8% savings in cost compared in cast-and-wrought disks. Similar savings were demonstrated for other rotating engine components. A compressor rotor fabricated from hot-die-forged-HIP superalloy billets revealed input weight savings of 54% and cost savings of 35% compared to cast-and-wrought parts. Engine components can be produced from compositions such as Rene 95 and Astroloy by conventional casting and forging, by forging of HIP powder billets, or by direct consolidation of powder by HIP. However, each process produces differences in microstructure or introduces different defects in the parts. As a result, their mechanical properties are not necessarily identical. Acceptance methods should be developed which recognize and account for the differences.
Dreshfield, R. L.↗
CASPEr: an Approach to Characterize the Performance of Onboard Airplane Energy State and Automation Mode Prediction Functions
The Commercial Aviation Safety Team (CAST) has identified a set of safety enhancements to mitigate the risks of loss of control in-flight (LOCI) accidents and incidents involving commercial transport airplanes. In support of this, NASA has been developing technologies intended to enhance flight crew awareness of airplane systems, attitude, and energy state. This report describes preliminary ideas for a methodology to assess the goodness of onboard airplane energy state and automation mode prediction functions. The methodology is intended to contribute to the goal of moving these prediction technologies to the readiness level required for transition to industry and reduce the technology certification risks. In addition, this report describes a simulation-based approach named CASPEr (Characterization of Airplane State Prediction Error) to characterize the performance of these predictive functions over a wide range of operational conditions. The first exploratory version of this approach is described. The bulk of the report documents the initial results of tests to characterize the performance of an airplane trajectory prediction function. Future reports will give additional performance characterization results for this function and a complete description of the proposed methodology to assess such functions.
Torres-Pomales, Wilfredo↗
Understanding the Feasibility of MAB Phase Structures for Lunar Applications
During the ten-week internship, my work focused on synthesis, characterization, and tailoring the flowability of the MAB phase powders for improving the surface finish and decreasing porosity of 3D-printed MAB phase structures. My mentor for the project was Dr. Samuel Hocker from NASA Langley and my faculty advisor was Dr. Surojit Gupta from the University of North Dakota. I also collaborated with Daniel Trieff from the University of North Dakota in developing characterization paradigm of 3D printed samples. The microencapsulation was performed via novel solvent casting-based microencapsulation process pioneered in UND, wherein a polymer (PLA, PHA) was dissolved into dichloromethane and precipitated onto the surface of the MoAlB particles. Two 100mL samples of microencapsulated powder was outsourced to Particle Technology Labs for flowability testing along with a 100mL control sample to determine if microencapsulation is a valid method for improving the flowability. The microencapsulated powders were characterized using SEM, Differential Scanning Calorimetry, and optical microscopy. The SEM images showed no change between the pure and microencapsulated powders. The optical microscopy analysis indicated a reduction in reflectivity for the PLA microencapsulated powders as well as hydrophobic properties. Both results suggest that microencapsulation was successful as PLA is a hydrophobic polymer and the change in reflectivity could be a result of the light being dispersed through the polymer coating. A reflectivity analysis will be done to bring more perspective to these observations. If powder flowability is improved, then the project will move forward with testing the printability of the microencapsulated powders and characterizing the structures using the designed characterization protocol. We are waiting for the DSC results. The characterization protocol for the 3D-printed MAB structures included a visual inspection of the plates to rule out any samples that had spalled or delaminated, optical microscopy to document surface features, porosity, and decomposition, and cleaning of the plates using an ultrasonic bath in preparation for SEM, EDS, and profilometry analyses.
MAB Phase↗
Transforming nanoscale VO 2 (B) into a scalable sodium-ion electrode
The intermittent nature of renewable energies requires highly reliable grid-level energy storage approaches. A critical consideration in developing this technology is the areal capacity which determines battery performance and influences the cost of battery technology. Of related importance is finding new ways of developing scalable electrodes. In recent years, three-dimensional (3D) printing of conductive scaffolds has emerged as an alternative to overcome the scalability limitations of commercial tape cast electrodes. The research carried out in the current study demonstrates a successful scalability pathway for nanoscale VO 2 (B), a desirable cathode for sodium-ion batteries which has a nano-flower morphology with a crystallite size < 20 nm. By electrodepositing VO 2 (B) onto a graphene aerogel scaffold, we were able to achieve mass loading of over 100 mg·cm −2 and still possess an areal capacity of 10 mAh·cm −2 at a current density of 5 mA·cm −2 . Moreover, after 1000 cycles, these electrodes retained 75% to 80% of their initial capacity. Even at high loading levels, the electrodeposited VO 2 (B) exhibits pseudocapacitive material signatures such as a box-like voltammetry response, linear galvanostatic response, and no phase change upon lithiation. The scalability of the VO 2 (B) electrode is demonstrated in a series of experiments which show the areal capacity to scale upon increase in both mass loading and electrode thickness, with only small changes in specific capacity. Furthermore, this study establishes that nanoscale materials can be scaled up to achieve thick electrodes without compromising their electrochemical properties.
additive manufacturing↗
History of Melt-Processing System at SRNL
Capabilities of Melt Treatment Technology • Research Reactor Aluminum SNF (can extend to SS and Mg Clad Fuel) Aluminum Cladding Alloy • Typical thickness = 38 mils • Boehmite layer > 50 µm • Fuel Core • U -Alx, U308-Al; U3Si2-Al • Fabricated by cast extrusion or powder metallurgy • Enrichment = 20% to > 90% U235 • Typical Reactor Burnup = 5% to 55% • Thermal Output: <100 W, after 10 Years in storage
Adams, Thad M.↗
Miscibility-Function Relations in Organic Solar Cells: Significance of Optimal Miscibility in Relation to Percolation
Polymer solar cells (PSCs) continue to be a promising low-cost and lead-free photovoltaic technology. Of critical importance to PSCs is understanding and manipulating the composition of the amorphous mixed phase, which is governed by the thermodynamic molecular interactions of the polymer donor and acceptor molecules and the kinetics of the casting process. This progress report clarifies and defines nomenclature relating to miscibility and its relevance and implications to PSC devices in light of new developments. Utilizing a scanning transmission X-ray microscopy method, the temperature dependences of “molecular miscibility” in the presence of fullerene crystals, now referred to liquidus miscibility, are presented for a number of representative blends. An emphasis is placed on relating the amorphous miscibility of high-efficiency PSC blends at a given processing temperature with their actual device performance and stability. It is shown and argued that a system with an amorphous miscibility close to percolation exhibits the most stable morphology. Furthermore, an approach is outlined to convert liquidus miscibility to an effective Flory–Huggins interaction parameter χ. Crucially, determination of temperature-dependent amorphous miscibility paves a way to rationally optimize the stability and mixing behaviors of PSCs at actual processing and operating temperatures.
14 SOLAR ENERGY↗