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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 361 records · Page 20

All sources NASA NTRS DOE OSTI

DOE OSTI2016

Technology Solutions Case Study: Southern Energy Homes, First DOE Zero Energy Ready Manufactured Home

The country’s first Zero Energy Ready manufactured home that is certified by the U.S. Department of Energy (DOE) is up and running in Russellville, Alabama. The manufactured home was built by a partnership between Southern Energy Homes and the Advanced Residential Integrated Energy Solutions Collaborative (ARIES), which is a DOE Building America team. The effort was part of a three-home study including a standard-code manufactured home and an ENERGY STAR® manufactured home. Cooling-season results showed that the building used half the space-conditioning energy of a manufactured home built to the U.S. Department of Housing and Urban Development’s (HUD’s) Manufactured Home Construction and Safety Standards. These standards are known collectively as the HUD Code, which is the building standard for all U.S. manufactured housing.

aries↗

DOE OSTI2025

Manufacturing Cost Analysis for PEM Electrolyzers and Perspectives for Future Cost Reduction

Electrolyzer capital costs strongly influence the total levelized cost of hydrogen production and have implications for hydrogen deployment. Current electrolyzer costs are high, and large cost reductions may be needed to achieve competitive hydrogen costs and targets. Understanding pathways for cost reduction via R&D and deployment is a critical research area for informed energy planning and enabling hydrogen use. This work presents bottom-up cost estimates of polymer electrolyte membrane (PEM) electrolyzer systems tied to design specifications and discusses perspectives for cost reduction opportunities based on ongoing research. We use a detailed manufacturing and process model for a 1 MW PEM electrolyzer stack and balance of plant (BOP) for rigorous cost estimation. This allows for robust estimates of component and manufacturing costs and examination of key cost contributors. Stack costs are dominated by material costs such as iridium and platinum catalysts, especially at high manufacturing rates; power electronics and hydrogen purification equipment are the largest contributors to BOP cost. At higher manufacturing rates, better equipment utilization could reduce stack costs significantly, and we estimate that experience and bulk purchasing will allow for cost reductions to some BOP components. Still, many well-established BOP technologies and stack material costs are less likely to see significant cost reductions at high manufacturing rates. As such, manufacturing scale is limited in how much it can reduce electrolyzer costs, and additional advances for cost reduction may be needed to achieve cost targets. It will likely take many combined strategies to achieve significant cost reductions for electrolyzers and enable low-cost hydrogen production. We can use our manufacturing cost model to quantify potential cost reductions from the considerations described above and demonstrate pathways to lower cost electrolyzers. This allows for better understanding of cost reduction strategies and enables more informed research, development, and deployment for electrolyzers.

cost↗

DOE OSTI2026

Securing The Future: 2026 Manufacturing & Critical Infrastructure Threat Landscape

This report outlines the current state of manufacturing weaknesses introduced by the complexities of modern environments, including cloud services and Internet of Things (IoT) devices, with particular attention paid to the unique vulnerabilities encountered by SMMs. It also highlights CyManII’s strategic initiatives and collaborative solutions to mitigate these risks and strengthen the cybersecurity posture of the manufacturing ecosystem. Utilizing data from 2025 to inform forward-looking mitigation strategies, this report provides manufacturers with a clear understanding of both current and emerging cybersecurity threats, as well as practical opportunities to strengthen their cyber ecosystems. The following sections detail key vulnerabilities and threat vectors, along with actionable mitigation strategies, many of which have been developed or piloted through CyManII-led efforts. A thorough understanding of these risks and mitigation strategies is essential for manufacturers seeking to strengthen the security and resilience of their manufacturing operations.

3D Printing↗

DOE OSTI2021

Spinning the digital thread with hybrid manufacturing

Integrated process monitoring and feedback capabilities for hybrid manufacturing have shown potential as a test platform for the development and implementation of the digital thread. Additionally, hybrid manufacturing alleviates the implementation of the digital thread as fewer systems are involved for a broader base of manufacturing operations. Researchers have developed coordinated process monitoring architectures to capture and leverage various existing data streams in the hybrid manufacturing process and improve the quality of manufactured components. This work is fundamentally different because it shows how common communication structures that exist on any commercial CNC can be used to enhance CNC based manufacturing processes.

42 ENGINEERING↗

DOE OSTI2017

An In-depth Review On the Scientific and Policy Issues Associated with Additive Manufacturing

Historically, manufacturing processes have been predominantly subtractive, i.e. three-dimensional objects were created by successively cutting material away from a solid block, by scraping, machining, turning or dissolving. Additive manufacturing (AM) or three-dimensional (3D) printing, in contrast, is controlled material addition, implemented by successively depositing layers of material until a predesigned shape is formed. AM represents an innovative manufacturing technology, and is set to transform production processes from design to manufacture, and to eventual distribution to end users, ultimately leading to an increase in energy efficiency and a reduction in gas emissions for future generation of industries. The unique capability of this technology to produce intricate geometries with customizable material properties has made it a widely interesting and welcome development among scientists, industry and the general public. Its wide acceptance has continued to make 3D printing technology more openly accessible, and low-cost desktop printing, with the capability to reproduce 3D objects from medical prostheses to weapons, is rapidly increasing in availability to the public. However, most research and media attention has been focused on the ingenuity of this ground-breaking technology and its wide range of possibilities. Very little consideration is being given to the adverse effects of the seemingly unstoppable advancement of AM technology and unrestricted access to 3D printing techniques. Also, proponents of AM technology rarely take into account the overall life-cycle cost and risks of failure of the manufactured part. Despite the promising prospects of this novel development, there are still concerns about how printed products will perform over time, the consistency of their quality, and the types and safety of materials used with this technology, especially with very large scale additive-manufactured products. This paper brings to light some scientific and policy risks and challenges concerning the material science and engineering aspects of these issues. Matters discussed include life-cycle cost analysis, end-product safety and quality assurance/control, regulation gaps, digital piracy, and resulting loopholes in safety and national security. The paper also presents potential options for curbing these risks, and otherwise adapting to the eventualities which, with certain inevitable factors in play, may lie beyond control.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2017

A Direct Manufacturing Cost Model for Solid‐Oxide Fuel Cell Stacks

Abstract This work details efforts to estimate the direct manufacturing cost of solid oxide fuel cell (SOFC) stack components for combined heat and power applications. The main research goals are to identify the major contributors to fuel cell stack manufacturing costs, examine the influence of both production volume and stack size on cost, and compare the results of the cost trajectories with the U.S. Department of Energy SOFC stack manufacturing cost target of $238 kWe −1 (in 2015) and industry reported cost projections and to identify critical areas for manufacturing research and development. Stack component direct manufacturing costs are modeled for net electricity capacity of 1, 10, 50, 100 and 250 kWe across annual production volumes of 10, 1,000, 10,000 and 50,000 systems per year. Overall stack manufacturing costs range from $5,387 kWe −1 to a minimum of about $166 kWe −1 for a 250 kWe system at 50,000 systems per year. To meet the manufacturing cost target of $238 kWe −1 , a minimum annual production of 100–250 MWe per year would be required. Reduction opportunities for stack cost are expected to be available, mainly with the adoption of thinner cells and stack components, higher levels of factory automation, and more sensitive in‐line defect diagnostics.

Scataglini, R.↗

DOE OSTI2024

Toolpath considerations for hybrid additive manufacturing

Hybrid additive manufacturing combines both additive and subtractive manufacturing processes to fabricate geometrically complex, dimensionally accurate parts that are difficult to make using either additive or subtractive manufacturing alone. Industrial applications for hybrid additive manufacturing include direct manufacturing (building whole parts), feature addition (adding onto existing parts), and remanufacturing or repair operations. To coordinate the additive and subtractive processes, computer-aided manufacturing (CAM) software must generate distinct toolpaths for each process. Each application requires different considerations and inputs when generating the toolpaths. For example, when building a part with an internal cavity that would otherwise be unmanufacturable due to reach or access limitations, a CAM must determine which layer(s) of deposition are appropriate to machine to create the internal cavity. This chapter explores the area of toolpath generation for hybrid manufacturing by discussing the necessary considerations that are unique to a hybrid process.

Feldhausen, Thomas↗

DOE OSTI2019

Investigating Powder Spreading Dynamics in Additive Manufacturing Processes by In-situ High-speed X-ray Imaging

The quality of the powder bed is known to be one of the main factors that influence the quality of the part being manufactured by powderbed- based additive manufacturing processes. For example, in the laser powder bed fusion process, it has been demonstrated that improving the powder bed density and homogeneity improves the final quality of the part. Understanding powder spreading dynamics in the powder-bed-based additive manufacturing processes is critical for designing spreading structures and spreading parameters, identifying defect formation mechanisms in the powder bed, and guiding the design of optimized feedstock powders. Extensive efforts have been devoted to understand the fundamental mechanism of the powder flow and spreading process. Various powder flow testers were used to study the flow behavior of powders used in additive manufacturing. However, the powder flow conditions in flow meters are different from those in real additive manufacturing conditions. Models have also been developed to simulate and study the spreading process. The discrete element method (DEM) is currently the main tool for computationally simulating the spreading process. However, these models are based on many physical assumptions. Visible light cameras have been used recently to conduct in-situ study of powder spreading in additive manufacturing. Due to the limited resolution and penetration depth of visible light, it is extremely difficulty to study the particle-scale powder spreading dynamics. Here, to overcome the challenges of studying powder spreading dynamics under real additive manufacturing conditions, we developed an experimental approach to study the particle-scale powder spreading process with high spatial and temporal resolution using the high-speed high-energy X-ray imaging facility at beamline 32-ID-B of the APS. Figure 1 shows an overview of the research setup. It is composed of a vacuum chamber (building environment), an automatic powder spreading system, a laser system, an X-ray source (X-ray outlet), and an X-ray detection/imaging system.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Property Variations in Modern REBCO Coated Conductors from Multiple Manufacturers

The complex, multilayer structure of REBCO Coated Conductor (CC) poses significant challenges in the fabrication of high magnetic field devices where large stresses may initiate various forms of damage. Our goal is to peer below the cartoon representations of CC so that, amongst other things, we might better understand whether a CC from one manufacturer is interchangeable with that from another. This involves knowledge of a broad range of electromagnetic, geometric, microstructural, and J c (θ,B,T) properties, and their variations that collectively pose challenges for the fault tolerance of REBCO CC devices. Accordingly, comparative measurements of J c , visualization of flux penetration with Magneto-Optical Imaging (MOI), tape geometry from Scanning Electron Microscopy (SEM) of polished cross-sections, and extensive optical microscopy was performed on recently purchased samples from multiple manufacturers. Our analyses reveal many deviations from or characteristics absent from manufacturers’ specifications, while a comparison of different manufacturers’ mechanically and laser slit tapes shows a diverse array of slitting characteristics amongst the manufacturers and variation in properties those made to the same specification. Laser slit tapes from several manufacturers reveal ablated edges with damaged regions extending up to 50 μm, comparable to the damaged region found in the mechanically slit CC of this study. Overall, the aim of this study is to flesh out appropriate ways to understand the real conductor below the manufacturers’ cartoons to avoid surprises in our REBCO CC coil development program. The goal of this work was to perform a broad array of characterizations of the type needed for validation of purpose for making high field magnets: to our surprise we found a wide range of properties which greatly impact the mechanical strength and electromagnetic performance of solenoids composed of these conductors and reinforced the need for a broad characterization program for each conductor prior to its implementation.

Bradford, G.↗

DOE OSTI2020

Performance of Public Film Cooling Geometries Produced Through Additive Manufacturing

Abstract Film cooling is an essential cooling technology to allow modern gas turbines to operate at high temperatures. For years, researchers in this community have worked to improve the effectiveness of film cooling configurations by maximizing the coolant coverage and minimizing the heat flux from the hot gas into the part. Working toward this goal has generated many promising film cooling concepts with unique shapes and configurations. However, until recently, many of these designs were challenging to manufacture in actual turbine hardware due to limitations with legacy manufacturing methods. Now, with the advances in additive manufacturing, it is possible to create turbine parts using high-temperature nickel alloys that feature detailed and unique geometry features. Armed with this new manufacturing power, this study aims to build and test the promising designs from the public literature that were previously difficult or impossible to implement. In this study, different cooling hole designs were manufactured in test coupons using a laser powder bed fusion process. Each nickel alloy coupon featured a single row of engine scale cooling holes, fed by a microchannel. To evaluate performance, the overall cooling effectiveness of each coupon was measured using a matched Biot test at engine relevant conditions. The results showed that certain hole shapes are better suited for additive manufacturing than others and that the manufacturing process can cause significant deviations from the performance reported in the literature.

Engineering↗

DOE OSTI2023

Effect of fiber reinforcement on the process parameters of injection molding manufacturing process

Use of fillers with the resin is common in injection molding manufacturing technique to enhance the stiffness and strength of the manufactured components. However, the addition of fillers changes the rheological and mechanical properties of the material, required adjustments in the process parameters used for the manufacturing. The present study aims to investigate this impact of fillers on the process parameters of the injection molding manufacturing process. Neat Acrylonitrile Butadiene Styrene (ABS) and ABS reinforced with short glass fibers are used as the materials to perform the comprehensive numerical analysis including complete process sequence, namely filling, packing, cooling and warpage. Parametric studies are conducted to optimize the manufacturing process for minimal warpage (or shrinkage) in the produced part. The selected process parameters for the parametric study include cooling time, packing pressure, and mold temperature, all of which directly impact the quality of the manufactured parts. The optimal values obtained for these parameters are compared to examine the effect fiber reinforcement has on the manufacturing process.

Garg, Nikhil↗

DOE OSTI2016

Bio-reinforced composite development for additive manufacturing: Nanocellulose-PLA

Additive manufacturing (AM) is transitioning from being only a prototyping method towards becoming a manufacturing technique for the quick production of parts with complex geometries. For the complete realization of this transition, the mechanical properties of the printed parts have to meet the requirements of actual load-bearing structural components. Integration of a reinforcing second phase into a polymer is a viable approach for the improvement of resins mechanical performance. Addition of carbon fibers into acrylonitrile-butadiene-styrene (ABS) has already been shown to improve its mechanical properties compared to the neat ABS resin (both additively manufactured), and led to the manufacture of world s first 3D-printed car. However, both ABS resin and carbon fibers are petroleum-based products, and there is a continuous search for alternative, bio-sourced, renewable materials as a feedstock for manufacturing. Towards this direction, we have investigated the potential of cellulose nanofibril-reinforced polylactic acid (PLA) resin systems as an alternative. CNF-PLA composite systems with up to 40 wt% CNF loadings were prepared via compression molding technique and tested. Significant improvements in both tensile strength (80%) and elastic modulus (128%) were observed. Filaments prepared from the same compositions were also successfully 3D-printed into tensile testing specimens with up to 30% CNF concentrations, and showed similar improvements in mechanical performance. Although CNFs were not individually dispersed in PLA matrix, they were observed to be well blended with the polymer based on SEM micrographs. In summary, preparation and 3D-printing of a 100% bio-based feedstock material with the mechanical properties comparable to the carbon fiber-ABS system was successfully demonstrated that it can open up new window of opportunities in the additive manufacturing industry. Acknowledgement Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC.

09 BIOMASS FUELS↗

DOE OSTI2018

Environmental Cracking and Irradiation Resistant Stainless Steels by Additive Manufacturing

Metal additive manufacturing (AM), or metal 3D printing is an emergent advanced manufacturing method that can create near net shape geometries directly from computer models. This technology can provide the capability to rapidly fabricate complex parts that may be required to enhance the integrity of reactor internals components. Such opportunities may be observed during a plant refueling outage and AM parts can be rapidly custom designed, manufactured and deployed within the outage interval. Additive manufacturing of stainless steel (SS) components can add business benefits on fast delivery on repair hardware, installation tooling, new design prototypes tests, etc. For the nuclear industry, the supply chain is always an issue for reactor service. AM can provide through-life supply chain (40-60 years) for high-value low-volume components. In the meantime, the capability of generating complex geometries and functional gradient materials will improve the performance, reduce the overall component cost, plant asset management cost and increase the plant reliability by the improvement in materials performance in nuclear environments. While extensive work has been conducted regarding additively manufacturing of austenitic SS parts, most efforts focused only on basic attributes such as porosity, residual stress, basic tensile properties, along with components yield and process monitoring. Little work has been done to define and evaluate the material requirements for nuclear applications. Technical gaps exist, which limit this technology adoption in the nuclear industry, which includes high manufacturing cost, unknown risks, limited nuclear related data, lack of specification and qualification methods, and no prior business experience. The main objective of this program was to generate research data to address all these technical gaps and establish a commercial practice to use AM technology in the nuclear power industry. The detailed objectives are listed as follows: (1) Evaluate nuclear related properties of AM 316L SS, including microstructure, tensile properties, impact toughness, stress corrosion cracking (SCC), corrosion fatigue (CF), irradiation effects, and irradiation assisted stress corrosion cracking (IASCC). (2) Understand the correlations among laser processing, heat treatment, microstructure and SCC/irradiation properties; (3) Optimize and improve the manufacturing process to achieve enhanced nuclear application properties; (4) Fabricate, evaluate, qualify and test a prototype reactor component to demonstrate the commercial viability and cost benefit; (5) Create regulatory approval path and commercialization plans for the production of a commercial reactor component.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Basic Research Needs for Transformative Manufacturing

This report is based on a Basic Research Needs workshop for Transformative Manufacturing, which was held March 9 - 11, 2020. The focus of the workshop was to identify the basic science research priorities that could accelerate innovation to transform manufacturing in the future. This was the first workshop of its kind to examine how basic energy science can drive manufacturing forward and innovate new ways to manufacture goods. Five Priority Research Directions were identified that address these science challenges: (1) innovative synthetic approaches to enable scalable assembly of matter, (2) computational methods and theoretical models to transform how manufacturing processes are controlled, (3) new characterization tools that can handle the necessary complexity, scales, and processing speeds to meet manufacturing needs, (4) new science to address opportunities relevant to sustainable and energy efficient manufacturing, and (5) foundational approaches to co-design of materials, process, and products.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Plant Water Profiler: A Water Balance and True Cost of Water Calculator for Manufacturing Plants

As the uncertainty of a sustained water supply, regulatory constraints, competition among end users, and public scrutiny increases, a growing number of manufacturing sectors are adapting to current and emerging water-related risks by optimizing productivity and reducing waste. As a step toward increasing water use efficiency and making informed business decisions, corporations must make an effort to understand and track their water demands, losses, and costs associated with each subsystem within their facilities. Manufacturers are often unaware of the “true cost of water” (i.e., the total costs associated with procurement, treatment, and consumption of water, and wastewater disposal), which reduces the visibility of the actual impact of water-saving measures. To help manufacturers account for water procurement and use in manufacturing operations, quantify the true cost of water, and identify potential areas for water and associated energy cost savings, an open access tool—Plant Water Profiler (PWP)—was developed. The tool is based on water mass balance analysis and has been adopted as the core analysis tool for plant water use assessments, Water In-Plant Training (Water INPLT), as part of the US Department of Energy’s Better Plants program. During three pilot INPLTs conducted in 2019 at three manufacturing facilities, the PWP tool allowed users to understand water flows within the facilities and provided additional capabilities to analyze their water use. This paper describes the methodology behind the PWP tool and its implementation through pilot Water INPLT trainings delivered in three manufacturing facilities in the United States. The three case studies demonstrate opportunities to improve water efficiency and reduce associated costs and the challenges encountered in three different manufacturing sectors.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Quality Procedures for TCR Metal Core Structure Advanced Manufacturing Processes

The Transformational Challenge Reactor (TCR) Manufacturing WBS# 3.02.04.02 organization is responsible for the advanced manufacturing process, research, development, and implementation that supports the TCR program under the TCR Additive Manufacturing (AM) Thrust. Advanced manufacturing at Oak Ridge National Laboratory (ORNL) includes the development and capabilities to use modern advanced manufacturing techniques, such as AM (e.g., 3D printing) and other novel methods, to rapidly design, develop, produce, finish, and characterize parts, samples, and components to support the nuclear and other high-quality standards industries. Deliverable # M2TC-20OR04020110 involved the development of TCR quality procedures for the TCR metal core structure by using the advanced manufacturing processes being developed at ORNL’s Manufacturing Demonstration Facility (MDF) and other ORNL locations. This report discusses the details of these procedures.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Advanced Manufacturing and Materials for Hydropower: Challenges and Opportunities

Hydropower is a well-established industry that has been largely contributing to the global generation of clean and renewable energy for more than a century. In the United States in 2021, it accounted for 30% of all renewable energy generation and 6.1% of the total energy portfolio. Hydropower technology and designs have been optimized throughout the years, but manufacturing of hydropower components still relies heavily on traditional methods and materials. Changes in global energy production systems and international supply chain issues are inspiring the manufacturing sector to reconsider their processes. Similarly, the hydropower industry is facing manufacturing challenges stemming from well-known maintenance issues, environmental impact mitigations, and changes in operations. These challenges, along with continued innovation in new hydropower and pumped storage development and modernization of the fleet, present an opportunity for advanced manufacturing and materials (AMM) to provide immense value to the hydropower industry. In support of the US Department of Energy’s (DOE’s) Water Power Technologies Office (WPTO), this report aims to characterize the current and emerging manufacturing-related challenges in US hydropower and to identify the high-impact opportunities in AMM that could address these challenges. The results highlighted in this report were collected through literature review, individual stakeholder interviews, and an in-person workshop organized at DOE’s Oak Ridge National Laboratory Manufacturing Demonstration Facility that brought together hydropower industry stakeholders, advanced manufacturing R&D, and the government.

13 HYDRO ENERGY↗

DOE OSTI2023

Feasibility Studies and Downselection of New Materials and Manufacturing Technologies for Nuclear Applications

This report is intended to present the results of multi-laboratory collaborative studies on the feasibility and downselection of the structural materials that are newly considered for application to future nuclear energy technologies. The Advanced Materials and Manufacturing Techniques (AMMT) program has been implemented to develop cross-cutting technologies in support of a broad range of nuclear reactor technologies and to maintain U.S. leadership in materials and manufacturing technologies for nuclear energy applications. In line with these program objectives, this collaborative studies aim to explore new materials utilizing advanced manufacturing technologies. The FY23 research scope consists of the feasibility studies on new materials and relevant advanced manufacturing technologies, collection of materials properties data and knowledge through experiments and literature survey, and development and application of decision criteria matrix for downselecting candidate materials and manufacturing technologies. The three-laboratory efforts for FY23 have focused on the three new material groups including oxide dispersion strengthened (ODS) materials, refractory composites and alloys, and high entropy alloys (HEAs) investigated, respectively, by Oak Ridge National Laboratory (ORNL) (work package: CT-23OR130406), Los Alamos National Laboratory (LANL) (CT-23LA130403) and Pacific Northwest National Laboratory (PNNL) (CT-23PN130408). The execution of this multi-lab research aimed to provide the AMMT program a merit-based feasibility study identifying an accelerated development path for these materials. A collaborative approach for achieving this goal was to develop a common materials evaluation criteria matrix and apply to all new candidate materials for the evaluation and prioritization of new materials using advanced manufacturing processes. The decision criteria matrix created is a matrix of criteria which a prospective material is scored against. The evaluation criteria are divided into four categories: Application Space, Environmental Compatibility, Physical & Mechanical Properties, and Manufacturability. Materials are given a score from 1−5 for each criterion, with the highest score (5) essentially mean that a material has the most near-term potential for application. Application of the decision criteria matrix will provide guidance to the future research on new materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗