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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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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Cookoff of Black Powder and Smokeless Powder

We have completed a series of both vented and sealed cookoff experiments of black powder and smokeless powder in our Sandia Instrumented Thermal Ignition (SITI) apparatus at bulk densities of 1078 and 729 kg/m 3 , respectively. The confining aluminum cylinder was ramped from room temperature to a set point temperature and then held at the setpoint temperature until ignition. The setpoint temperatures varied between 495 to 523 K for the black powder and 401 to 412 K for the more sensitive smokeless powder. The vented experiments show a significant delay in thermal ignition, indicating that the ignition is dependent on pressure. Post experimental debris shows greater violence for our smokeless powder experiments than our black powder experiments. A simplified universal cookoff model (UCM) was calibrated using the black powder and smokeless powder SITI data and used to predict pressurization and thermal ignition. The current work presents the first calibration of the UCM with a double base propellant. Finally, this work also presents the first pressure-dependent cookoff model for black powder and smokeless powder.

42 ENGINEERING↗
DOE OSTI2021

Fatigue of laser powder bed fusion processed 17-4 stainless steel using prior process exposed powder feedstock

The rapid pace of development seen in the metal additive manufacturing (AM) process of laser powder-bed fusion (LPBF) requires in-step advances in processes qualification to enable full-scale adoption. This particularly applies to quantifying how powder feedstock conditions impact end-component quality. Here this study examines how in-machine 17-4 stainless steel powder feedstocks are affected by prior LPBF processes, and how these effects impact subsequent builds. Examinations of powder morphology, chemistry, flowability, and rheology were conducted to characterize the powder conditions. The resultant effects of powder feedstock condition on produced component quasi-static tensile and high-cycle fatigue properties were analyzed. Fatigue life was analyzed using a reliability modeling approach that enabled a robust statistical comparison of life. Powder characteristics were found to evolve with powder exposure to prior LPBF processes, particularly in the extremes of powder size distribution and measures of bulk flow. No significant effects of these changes on tensile properties were observed. Reliability modeling methods, including the lognormal and Weibull distributions as well as the empirical survival function, are shown to be effective tools for modeling fatigue variability in LPBF manufactured components. Through these tools, fatigue life was found to be invariant with changes in powder condition.

42 ENGINEERING↗
DOE OSTI2019

Effect of Powder Shape and Size on Rheological, Thermal, and Segregation Properties of Low-Pressure Powder Injection Molding Feedstocks

Optimization of molding parameters at different filling stages requires that the characteristics of low-viscosity feedstocks must be properly known. In this study, the influence of the particle size (3, 7, and 12 μm) and powder morphology (gas- and water-atomized) was quantified using different feedstock formulations based on a 17-4 PH stainless steel powder, all combined with the same binder system. The specific heat capacity, viscosity, and segregation levels were assessed using a differential scanning calorimeter, a rotational rheometer, and a thermogravimetric analyzer, respectively. It was then shown that the feedstock prepared with the gas-atomized powder exhibits a higher specific heat capacity value when compared to a water-atomized powder (i.e., Cp varying from 0.6 to 0.3 J/g K, respectively). It was also shown that the feedstock viscosity profiles and the intensity of segregation both depend significantly on the powder shape and size used in the feedstock formulation. For short processing times (e.g., < 1 min spent in molten state), a feedstock formulated with coarse gas-atomized powder can be considered to be the best candidate for an injection process because its viscosity and segregation potential are relatively low (with a viscosity varying from 0.5 to 2 Pa s, and a volume fraction of powder close to 60 vol.%). Following this, the moldability index was used to predict that coarser water-atomized powder (i.e., 12 versus 7 μm) will not have a significant effect on the molding properties, and can be seen as a potential means of decreasing shrinkage during sintering without impacting the injection properties. For very long processing times, the magnitude of segregation remains insignificant for feedstock formulated with fine powder (i.e., a volume fraction of powder remaining close to 60 vol.%). However, this important gain (i.e., no segregation) comes with a significant increase in viscosity varying from 2 to 10 Pa s, resulting in a decrease in the molding properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Synthesis and magnetic performance of gadolinium powder produced with rotating disk atomization

Spherical powder is key for achieving good heat transfer and maintaining low pressure drop for heat transfer fluid in magnetocaloric regenerator. Obtaining relatively large spherical powder of rare earth metals that are extremely sensitive to oxygen is challenging. Comparing to gas atomization and plasma rotating electrode methods, rotating disk atomization (RDA) method is more robust for obtaining a small amount of powder with a short turn-around time, thereby, more suitable for research and development of new magnetocaloric materials. In this work, commercially bulk gadolinium was successfully atomized to produce spherical powder in the targeted 150–250 μm range. The obtained powder exhibited the expected magnetocaloric performance with a maximum change of magnetic entropy of 12.1 J/kg K and a maximum adiabatic temperature change of 12.8 K with an applied magnetic field of 7 T.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Influence of Powder Characteristics and Processing Methods on Creep Performance of Powder Metallurgy Hot Isostatic Pressed SS316

The U.S. nuclear energy expansion goals are driving the demand for manufacturing routes that can rapidly produce large, complex, near net shape components. Powder metallurgy hot isostatic pressing (PM HIP) is an advanced manufacturing technique that can be economically scaled-up, while alleviating the supply chain challenges that forging and casting face in terms of cost and lead time constraints. This makes PM-HIP a viable technology to aid and accelerate large-scale part manufacturing for nuclear applications. However, large-scale qualification and deployment of this technology require a thorough understanding of the influence of powder feedstock quality, powder handling history, hot isostatic pressing (HIP) parameters, and subsequent heat treatment on microstructural evolution and elevated temperature mechanical performance. The present work focusses on 316 austenitic stainless steel (SS316) which is most commonly used in high temperature environments for nuclear applications Results from this study show that PM HIPed SS316 meets ASME tensile requirements at room temperature and at elevated temperature. However, creep performance of PM-HIPed SS316 remains inferior to its wrought counterpart, demonstrating that tensile performance alone is not a reliable metric for long duration high temperature integrity. Further, this report delineates powder derived microstructural features that govern creep damage, with key evidences pointing to “microstructural inheritance” from gas atomized powder feedstocks. Commercial SS316 powders of varying chemical compositions and recycling histories were studies, and the results showed large differences in elemental segregation, oxide surface layers and secondary phase distributions. Multi-scale characterization revealed segregation of chromium, molybdenum, manganese and silicon at the boundaries and the precipitation of manganese-, silicon-, and molybdenum-oxides. During HIP consolidation, these surface oxides transform into decorated prior particle boundaries (PPBs) and grain boundary inclusions that persist through conventional post-HIP solution annealing treatment. The retained oxides in post-HIP microstructures were found to influence grain growth, precipitation behavior, and ultimately creep cavitation and fracture. Such post-HIP heat treatments are therefore limited by a complex trade-off between grain growth, and oxide coarsening which aggravate creep damage by acting as nucleation sites for cavities. The objective of this work is to establish an integrated processing–structure–property framework for PM-HIP 316 stainless steel by investigating the influence of powder feedstock characteristics in pre- and post-HIP processing as well as to understand the significance of post-HIP heat treatment on microstructural evolution and creep properties. The results from this report emphasize the significance of powder feedstock integrity in improving creep performance of PM-HIPed SS316, by highlight the effect of rapid solidification, elemental segregation, oxide formation and powder recycling on microstructural defect inheritance following HIP consolidation. Rather than considering HIP processing, solution annealing, and mechanical performance independently, this report treats powder production, HIP consolidation, post-HIP thermal processing, and creep deformation as interconnected stages within a continuous metallurgical process. The resulting framework will provide a scientific basis for developing feedstock engineering strategies capable of improving long-term reliability of PM-HIP stainless steels and accelerating their qualification for advanced nuclear applications.

Ajjarapu, Pavan [Oak Ridge National Laboratory (OR↗
DOE OSTI2020

A Review on Metallic Alloys Fabrication Using Elemental Powder Blends by Laser Powder Directed Energy Deposition Process

The laser powder directed energy deposition process is a metal additive manufacturing technique, which can fabricate metal parts with high geometric and material flexibility. The unique feature of in-situ powder feeding makes it possible to customize the elemental composition using elemental powder mixture during the fabrication process. Thus, it can be potentially applied to synthesize industrial alloys with low cost, modify alloys with different powder mixtures, and design novel alloys with location-dependent properties using elemental powder blends as feedstocks. This paper provides an overview of using a laser powder directed energy deposition method to fabricate various types of alloys by feeding elemental powder blends. At first, the advantage of laser powder directed energy deposition in manufacturing metal alloys is described in detail. Then, the state-of-the-art research and development in alloys fabricated by laser powder directed energy deposition through a mix of elemental powders in multiple categories is reviewed. Finally, critical technical challenges, mainly in composition control are discussed for future development.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Transient dynamics of powder spattering in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-energy x-ray imaging

Powder spattering is a major cause of defect formation and quality uncertainty in the laser powder bed fusion (LPBF) additive manufacturing (AM) process. It is very difficult to investigate this with either conventional characterization tools or modeling and simulation. The detailed dynamics of powder spattering in the LPBF are still not fully understood. Here, we report insights into the transient dynamics of powder spattering in the LPBF process that were observed with in-situ high-speed high-energy x-ray imaging. Powder motion dynamics, as functions of time, environment pressure, and location, are presented. The moving speed, acceleration, and driving force of powder motion that are induced by metal vapor jet/plume and argon gas flow are quantified. A schematic map showing the dynamics and mechanisms of powder motion during the LPBF process as functions of time and pressure is constructed. In conclusion, potential ways to mitigate powder spattering during the LPBF process are discussed and proposed, based on the revealed powder motion dynamics and mechanisms.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Transformations of Ti-5Al-5V-5Cr-3Mo powder due to reuse in laser powder bed fusion: A surface analytical approach

Reactive Ti-5Al-5 V-5Cr-3Mo (Ti5553) alloy feedstock powder is used in laser powder-bed fusion (LPBF). Due to the large quantity of powder necessary for LPBF, powder is reused numerous times under oxidizing environments. Transformations to the powder’s native surface oxide may impact the LPBF process and lead to deviations from expected behavior of printed parts. In this work, we present a multimodal characterization of new and reused powder by combining X-ray photoelectron spectroscopy (XPS), time-of-flight secondary ion mass spectrometry (ToF-SIMS), and transmission electron microscopy (TEM) of focused ion beam (FIB)-prepared cross sections of individual powder particles to understand how the surface oxide composition changes, grows, and becomes hydroxylated and hydrated due to reuse. We show that the native oxide film of Ti5553 powder is a hydroxylated mixed oxide composed of TiO 2 and Al 2 O 3 that grows from 5.6 +/- 0.7 nm to 8.3 +/- 1.1 nm due to reuse. Al oxide regions of the surface oxide become more hydroxylated during reuse in comparison to Ti oxide regions. This indicates that an outer oxide of pure TiO 2 may enhance recyclability of Ti5553 powder while the presence of Al oxides may decrease recyclability. Further characterization of surface transformations due to recyclability may eliminate unnecessary variation in LPBF.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Evolution of AISI 304L stainless steel part properties due to powder recycling in laser powder-bed fusion

Selective laser melting (SLM) is a powder-bed fusion process in Additive Manufacturing (AM) that uses a laser beam to selectively fuse layers of powder into near net-shape components with little porosity. However, inconsistencies in the part properties due to the presence of defects in as-built components has hindered the widespread adoption of SLM for industrial applications forcing researchers to study the sources of variation for quality control purposes. A critical area suspected of creating variation in the part properties is the feedstock, where batch-to-batch differences as well as changes in the powder properties with reuse have the potential to affect performance. During processing, laser spatter and condensate eject from the melt pool and deposit into the powder-bed surrounding the parts. These particulates, more commonly known as ejecta, differ morphologically and chemically from the virgin powder compromising its reusability. In this study, 304L stainless steel powder was recycled for a total of 5 times through a systematic approach aimed at accelerating powder degradation to reveal the influence on both the tensile and impact toughness properties. Through analysis of variance (ANOVA), it was found that tensile properties did not change with reuse, while the impact toughness showed a steady decline illustrating the differences in static and dynamic part properties due to powder recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2022

An instrument for in situ characterization of powder spreading dynamics in powder-bed-based additive manufacturing processes

In powder-bed-based metal additive manufacturing (AM), the visualization and analysis of the powder spreading process are critical for understanding the powder spreading dynamics and mechanisms. Unfortunately, the high spreading speeds, the small size of the powder, and the opacity of the materials present a great challenge for directly observing the powder spreading behavior. In this study, we report a compact and flexible powder spreading system for in situ characterization of the dynamics of the powders during the spreading process by high-speed x-ray imaging. The system enables the tracing of individual powder movement within the narrow gap between the recoater and the substrate at variable spreading speeds from 17 to 322 mm/s. The instrument and method reported here provide a powerful tool for studying powder spreading physics in AM processes and for investigating the physics of granular material flow behavior in a confined environment.

47 OTHER INSTRUMENTATION↗
DOE OSTI2019

Mechanical Alloying and Powder Forging of 18%Cr Oxide Dispersion-Strengthened Steel Produced Using Elemental Powders

Oxide dispersion-strengthened (ODS) ferritic steels are potential materials for cladding tubes in fast breeder fission reactors. These are mostly prepared by mechanical alloying of yttria powder with pre-alloyed powders. Using elemental powders offers flexibility in the choice of alloy compositions. Here we report mechanical alloying of Fe-18Cr-2W-0.2Ti-0.35Y{sub 2}O{sub 3} (compositions in wt.%) ODS steel using elemental powders of Fe, Cr, W and Ti with yttria powder. After 5 h of milling, no significant changes in particle size and crystallite size were observed. Powders milled for 5 and 7 h were consolidated through powder forging route. The optimum milling time for mechanical alloying could be determined only after evaluating the forgings. It is difficult to achieve recrystallization in ODS alloys. The forging process parameters were optimized to achieve a dense alloy with a fine recrystallized microstructure. Factors leading to recrystallization are discussed. It is shown that recrystallization in ODS steels is more likely to occur during forging as compared to extrusion/rolling. The powder forging route offers several advantages over the conventional extrusion or HIP routes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effect of Blown Powder Directed Energy Deposition Angle On Overspray Contamination

Abstract Blown powder directed energy deposition (DED) hybrid machine tools are particularly beneficial when the net shape of a component is to be manufactured in an additive and machined interleaved fashion. This investigation seeks to analyze the effect of the additive head lean angle relative to the part on blown powder DED surface contamination due to overspray. These hybrid DED platforms are commonly installed on multi-axis machining systems where the lean of the deposition head relative to the component surface can be controlled by tilting the component. The blown powder DED process has a 10–50% lower catchment efficiency as compared to wire fed DED systems. This excess powder is still fed towards the deposition location where the particles are heated by the laser and rebound off the melt pool. Some of these heated particles impact the previously machined thin-wall surface. While the deposition process and tool path planning process has been evaluated, the effect of the overspray due to lean angle of the deposition head on the previously thin-wall machined surface is not yet fully understood. This investigation found that minimum lean angle coincides with minimal overspray effect with nearly no contamination. If a lean angle is required, the maximum lean angle possible should be implemented for the smallest effected overspray area on the machined surface which was found to decrease the affect zone by half compared to intermediate lean angles. A diameter divergence was also noticed as the deposition angle was increased. In this study, a thorough analysis of the surface and geometric effects when depositing thin-walled components at varying angles is completed. It has been shown that part quality can be significantly affected by lean angle and thus must be incorporated as an additional design consideration in the manufacturing process.

Heinrich, Lauren↗
DOE OSTI2017

Friction consolidation of gas-atomized Fe−Si powders for soft magnetic applications

Soft magnetic materials are often limited in scalability due to conventional processes that do not retain beneficial microstructures, and their associated physical properties, during densification. In this work, friction consolidation (FC) has been studied to fabricate Fe−Si soft magnetic materials from gas-atomized powder precursors. Fe−Si powder is consolidated using variable pressure and tool rotation speed in an effort to evaluate this unique densification approach for potential improvements in magnetic properties. FC, due to the high shear deformation involved, is shown to result in uniform gradual grain structure refinement across the consolidated workpiece from the center nearest the tool to the edge. Magnetic properties along different orientations indicate little, if any, textural orientation in the refined grain structure. The effect of annealing on the magnetic properties is evaluated and shown to decrease coercivity. FC processing was able to retain the magnetization of the original gas-atomized powders but further process optimization is needed to reach the optimal coercivity for the soft magnetic materials applications. - Highlights: •Friction stir processing was utilized to consolidate Fe−Si soft magnetic powders. •The resultant microstructure and magnetic properties were correlated to the processing conditions. •Friction consolidation refined the grain size of the materials by ~ 40%. •Annealing successfully reduced the coercivity induced by the stress during processing. •The results shine light on the possible scaling up of nanostructured materials.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Vacuum powder injector and method of impregnating fiber with powder

A method and apparatus uniformly impregnate stranded material with dry powder such as low solubility, high melt flow polymer powder to produce, for example, composite prepregs. The stranded material is expanded in an impregnation chamber by an influx of air so that the powder, which may enter through the same inlet as the air, penetrates to the center of the stranded material. The stranded material then is contracted for holding the powder therein. The stranded material and powder may be pulled through the impregnation chamber in the same direction by vacuum. Larger particles of powder which do not fully penetrate the stranded material may be combed into the stranded material and powder which does not impregnate the stranded material may be collected and reused.

Working, Dennis C.↗
NASA NTRS1994

Superconducting YBa2Cu3O7 Powder: Reduction of Carbon, Moisture, and Impurity Phase Concentrations in Commercial Powders and the Reactivity with Moisture and Carbon Dioxide

The purpose of this study was to determine the experimental parameters under which commercially pure YBa2Cu3O7 (1237) powders would be converted into a single phase (1237) powder only. Carbon (present as carbonate) and impurity phase concentrations in the (1237) powder are very dependent upon the firing temperatures, heat-treating temperatures and times, and atmosphere, while the moisture concentration is not. YBa2Cu3O7 powder with about 0.03 wt/%, carbon, 0.03 wt% moisture, and low impurity phase concentrations was obtained. Moisture and carbon concentrations in heat-treated powders did not increase significantly after 48 and 72 h of exposure to air, respectively, and after 144 h of exposure they were less than 0.26 and 0.08 wt/%, respectively. The (1237) powder first reacts with moisture and then hydroxide reacts with CO2. Firing the as received powders in air led to the decomposition of the superconducting (1237) phase.

Stecura, Stephan↗
DOE OSTI2022

Impact of Nozzle Condition on Powder Catchment Efficiency for Coaxial Powder Direct Energy Deposition

Blown powder directed energy deposition is well-designed for fine resolution additive manufacturing processing. Coaxial powder deposition heads use an outer layer of shielding gas directed by an outer nozzle to prevent oxidation occurring during the powder melting process. Powder blown feedstock catchment efficiency can be as low as 50-80% whereas wire deposition systems are closer to 98% efficient. The present study evaluates the impact of directed energy deposition nozzle condition on catchment efficiency. Changes in the overall outer shielding gas nozzle length has been found to increase material usage efficiency by 10% through convergence of the powder flow. The results of this experiment show that for coaxial powder deposition head design, if the standoff distance can safely be decreased, powder catchment efficiency can be increased as the outer shielding gas nozzle is increased in length, or the standoff distance is decreased.

Heinrich, Lauren↗
DOE OSTI2022

Impact of Nozzle Condition on Powder Catchment Efficiency for Coaxial Powder Direct Energy Deposition

Blown powder directed energy deposition is well-designed for fine resolution additive manufacturing processing. Coaxial powder deposition heads use an outer layer of shielding gas directed by an outer nozzle to prevent oxidation occurring during the powder melting process. Powder blown feedstock catchment efficiency can be as low as 50-80% whereas wire deposition systems are closer to 98% efficient. The present study evaluates the impact of directed energy deposition nozzle condition on catchment efficiency. Changes in the overall outer shielding gas nozzle length has been found to increase material usage efficiency by 10% through convergence of the powder flow. The results of this experiment show that for coaxial powder deposition head design, if the standoff distance can safely be decreased, powder catchment efficiency can be increased as the outer shielding gas nozzle is increased in length, or the standoff distance is decreased.

Heinrich, Lauren↗