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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Additive Manufacturing Development and Hot-Fire Testing of Liquid Rocket Channel Wall Nozzles Using Blown Powder Directed Energy Deposition Inconel 625 and JBK-75 Alloys

Additive manufacturing (AM) is being investigated at NASA and across much of the rocket propulsion industry as an alternate fabrication technique to create complex geometries for liquid engine components that offers schedule and cost saving opportunities. The geometries that can be created using AM offer a significant advantage over traditional techniques. Internal complexities, such as internal coolant channels for combustion chambers and nozzles that would typically require several operations to manufacture traditionally can be fabricated in one process. Additionally, the coolant channels are closed out as a part of the AM build process, eliminating the complexities of a traditional process like brazing or plating. The primary additive manufacturing technique that has been evaluated is powder bed fusion (PBF), or selective laser melting (SLM), but there is a scale limitation for this technique. There are several alternate additive manufacturing techniques that are being investigated for large-scale nozzles and chambers including directed energy deposition (DED) processes. A significant advantage of the DED processes is the ability to adapt to a robotic or gantry CNC system with a localized purge or purge chamber, allowing unlimited build volume. This paper will discuss the development and hot-fire testing of channel-cooled nozzles fabricated utilizing one form of DED called blown powder deposition. This initial development work using blown powder DED is being explored to form the entire channel wall nozzle with integral coolant channels within a single AM build. Much of this development is focused on the design and DED-fabrication of complex and thin-walled features and on characterization of the materials properties produced with this techniques in order to evolve this process. Subscale nozzles were fabricated using this DED technique and hot-fire tested in Liquid Oxygen/Hydrogen (LOX/GH2) and LOX/Kerosene (LOX/RP-1) environments accumulating significant development time and cycles. The initial materials that were evaluated during this testing were high-strength nickel-based Inconel 625 and JBK-75. Further process development is being completed to increase the scale of this technology for large-scale nozzles. This paper will summarize the general design considerations for DED, specific channel-cooled nozzle design, manufacturing process development, property development, initial hot-fire testing and future developments to mature this technology for regeneratively-cooled nozzles. An overview of future development at NASA will also be discussed.

Gradl, Paul R.↗
NASA NTRS2019

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗
NASA NTRS2019

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul↗
NASA NTRS2018

NASA’s Plans for Development of Standards for Additive Manufactured Components

There are currently no NASA standards providing specific design and construction requirements for certification of additively manufactured parts. Several international standards organizations are developing standards for additive manufacturing; however, NASA mission schedules preclude the Agency from relying on these organizations to develop standards that are both timely and applicable. NASA and its program partners in manned spaceflight (the Commercial Crew Program, the Space Launch System and the Orion Multi-purpose Crew Vehicle) are actively developing additively manufactured parts for flight as early as 2018. To bridge this gap, NASA Marshall Space Flight Center (MSFC) has authored a center-level standard (MSFC-STD-3716)1 to establish standard practices for the Laser Powder Bed Fusion (L-PBF) process. In its draft form, the MSFC standard has been used as a basis for L-PBF process implementation for each of the manned space flight programs. The development of an Agency-level standard is proposed, which based upon the principles of MSFC-STD-3716, would have application to multiple additive manufacturing processes and be readily adaptable to all NASA programs.

Russell, Richard W.↗
NASA NTRSDate not supplied

Feasibility of Additive Manufacturing for Thermal Protection Systems

Thermal Protection Systems (TPS) use advanced materials to protect vehicles from aerodynamic heating during atmospheric entry. Manufacturing of these composite materials is often very time consuming and labor-intensive. Leveraging the additive manufacturing FDM (Fused Deposition Modeling) process enables NASA to design and manufacture advanced ablative TPS materials while reducing manufacturing time and cost. Since additive manufacturing is an automated process, it ensures part consistency over the entire heat shield area. The purpose for this presentation will be three-fold. 1) Introduce novel low-density ablative materials capable of utilizing additive manufacturing capabilities 2) show feasibility of additively manufacturing TPS coupons using the downselected TPS materials 3) Side by side comparison of high temperature test results for printable paste and state of the art low-density ablators

T. Boghozian↗
NASA NTRS2023

Additive Manufacturing of Oxide Dispersion Strengthened Multi Principle Element Alloys for Future Aerospace Applications

Oxide Dispersion Strengthened (ODS) materials have long been of interest for their high temperature applications, and additive manufacturing enables their manufacturing viability. The ODS multi-principle element alloy NiCoCr was prepared using powder metallurgy techniques, additively manufactured, and evaluated for its processingmicrostructure-property relationships. The high temperature foundations of nickel-base superalloys and ODS materials were combined with the manufacturing advantages of 3D printing and the chemical simplicity of NiCoCr to inspire this work, which was divided into powder and printed material assessments. The project was achieved through multiple iterative project loops to assess the processing parameters’ impact on the microstructure and mechanical properties of the feedstock powder and printed material. The powder investigations (Chapter 3) focused on understanding the oxide coating that formed on the metal powder following acoustic mixing. Time of Flight Secondary Ion Mass Spectrometry was used to semi-quantitatively assess the amount of yttrium on the surface of the mixed powders, and indicated that a combination of higher mixing condition energy and moderate mixing time resulted in the most oxide coating on the NiCoCr powder. The results were supported by a qualitative assessment of scanning electron images of coated powder particles. Following mixing, the ODS NiCoCr was consolidated by Laser Powder Bed Fusion. The evaluations of the printed material (Chapter 4) frst considered screening experiments including Archimedes’ density, porosity, and grain size and number metrics from electron backscatter diffraction data. After the ideal additive manufacturing parameters were identifed, both the oxide homogeneity and yield strength were discussed for the idealized printed material. Overall, the project suggests that the combined use of qualitative or semi-quantitative powder surface analysis with Archimedes’ density analyses can be a valid high-throughput technique which can lead to process optimization of Laser Powder Bed Fusion additively manufactured ODS material.

Laura G Wilson↗
NASA NTRSDate not supplied

Non-Additivity of the Midlatitude Circulation Response to Regional Arctic Temperature Anomalies: The Role of the Stratosphere

Previous studies have documented the impact of the Arctic sea ice loss and associated warming on the midlatitude weather and climate, especially the influence of sea ice retreat over the Barents-Kara Sea on the North Atlantic and Europe regions. However, less attention has been given to other geographical locations over the Arctic, and to the linear additivity of the circulation response to regional Arctic sea ice loss and temperature anomalies. Using a simplified dry dynamical core model, we demonstrate that responses to regional Arctic temperature anomalies over the Barents-Kara Sea, Baffin Bay-Davis Strait-Labrador Sea, and East Siberia-Chukchi Sea, separately, cause similar equatorward shift of the tropospheric jet, but different stratospheric polar vortex responses. Furthermore, responses to regional Arctic temperature anomalies are not linearly additive, and the residual resembles a positive Northern Annular Mode-like structure. Additional targeted experiments highlight the stratospheric influence in the non-additivity of the midlatitude tropospheric response.

Bithi De↗
DOE OSTI2021

Additive manufacturing of multi-component parts for customizable energetic systems

An apparatus, system, and method utilizes at least two separate components during the process of producing the final product. At least one component during the process is produced using additive manufacturing, and additional components are components that are combined with the additively manufactured part. The apparatus, system, and method includes at least one energetic component and at least one second inert component. An additive manufacturing system produces a scaffold of said first energetic component(s). A system adds the second component(s) to the scaffold to produce the energetic material product.

Sullivan, Kyle T.↗
DOE OSTI2022

Cathode additives for lithium-ion batteries

In some implementations, a cathode is formed by (1) providing a cathode additive including (a) a matrix including a lithium compound, and (b) metal nanostructures embedded in the matrix; and (2) combining the cathode additive with a cathode active material to form a mixture. In other implementations, a cathode is formed by (1) providing a cathode additive including a compound of lithium and at least one non-metal or metalloid; and (2) combining the cathode additive with a cathode active material to form a mixture.

25 ENERGY STORAGE↗
DOE OSTI2022

System and method for additive manufacturing with toolpath bridges and resultant structure

A system and method for improving additive manufacturing, including additive manufacturing toolpaths, is provided. The system and method includes a toolpath generator that obtains initial toolpaths of an object, identifies isolated paths in the toolpaths, and adds bridge connections between neighboring isolated paths in each layer to improve the toolpaths. The bridge connections facilitate the continuous and non-stop deposition of each layer according to improved toolpaths during additive manufacture, which can reduce total deposition time and improve the resultant additive manufacture.

Kim, Seokpum↗
DOE OSTI2023

Additives for improving autoignition reactivity of hydrocarbon-based fuels

According to various aspects, an additive for a hydrocarbon-based fuel has a formula (I), in which R 1 , R 2 , and R 3 are each independently selected from —H, —CH 3 , or —CH 2 CH 3 , and at least one of R 1 , R 2 , and R 3 is not —H. The additive improves an autoignition reactivity of the hydrocarbon-based fuel. The additive can be present in the fuel composition including the additive and the hydrocarbon-based fuel in an amount of 0.1% by volume to 5% by volume. The hydrocarbon-based fuel can comprise gasoline or diesel.

Lopez Pintor, Dario↗
DOE OSTI2024

High-Temperature Oxidation Behavior of Wrought and Additive Manufactured Ni-based Alloys in Direct-Fired Supercritical CO2 Power Cycle Environments

Materials selection is a key concern for corrosion resistance in elevated temperature and pressure direct-fired supercritical CO2 (sCO2) power cycles. Herein, the wrought product form of alloy H282, as well as several additional nickel-based commercial alloys (230, 263, 617, 625, 740H), were exposed to direct-fired supercritical CO2 conditions (95CO2 – 4H2O – 1O2) at 750 °C and 20 MPa for over 2,000 h. Additionally, additive manufactured (AM) 282 produced by laser powder bed fusion (LPBF) were also included in the exposures. This paper focuses primarily on the differences observed in the degradation behavior of the wrought and additively manufactured materials. AM samples in the as-printed state were found to form less protective oxide scales resulting in higher oxidation rates compared to wrought samples. However, applying a 600 grit surface finish to the AM samples modified the oxidation behavior to closely resemble that of the wrought material. The AM samples formed Mo-rich carbides in the alloy beneath the oxide following sCO2 exposure, implying potentially higher levels of carbon uptake relative to the wrought material. Conversely, the AM samples seemed to be less affected by water-assisted oxide volatilization compared to the wrought material. The results are discussed in terms of the potential compatibility issues that may arise when using Ni-based alloys in the hot portions of direct-fired sCO2 power cycles, particularly in the case of thin-walled components.

Carney, Casey↗
DOE OSTI2023

Investigating Marine Environmental Degradation Of Additive Manufacturing Materials For Renewable Energy Applications

Marine renewable energy is a relatively young industry where there is a great need for rapid prototyping in design-build-test campaigns to quickly mature ground-breaking technologies. Additive manufacturing has an important role to play in the industry; however, little information is available to marine energy developers to help inform them on which additive manufacturing materials are appropriate for harsh marine environments. This paper presents an initial study on the mechanical characterization of polymeric additive manufacturing materials and degradation effects due to the marine environment. Ultem 9085, acrylonitrile styrene acrylate (ASA), and chopped carbon-filled Nylon, as well as continuous carbon and glass fiber reinforced Nylon were chosen for this study. Samples were manufactured to perform a variety of tension, shear, and compression mechanical characterization tests on the materials. Half of the samples were conditioned in Pacific Ocean water for approximately 6 months at the Pacific Northwest National Laboratory’s Marine and Coastal Research Laboratory before being returned for mechanical characterization. The mechanical testing results showed that the Ultem 9085 and ASA materials experienced little to no degradation in stiffness or strength after exposure to the marine environment. On the other hand, the Nylon-based materials suffered significant stiffness and strength degradation (over 50% in some cases) after environmental conditioning. Ultimately, these results should serve as starting points to allow marine renewable energy developers to make informed additive manufacturing material choices for their prototype deployments.

Murdy, Paul↗
DOE OSTI2024

System and method for additively manufacturing porous parts via salt micro-spheres

A system and method of additively manufacturing a part via salt micro-spheres. The method includes mixing salt micro-spheres with an additive manufacturing material to form an additive manufacturing material mixture. The additive manufacturing material mixture is deposited on a build platform layer by layer and cured so as to create a structure having pores formed by the salt micro-spheres. The salt micro-spheres may then be dissolved and flushed from the pores.

LaPlant, Steven Todd↗
DOE OSTI2024

System and method for tracking reinforcement member placement in an additively manufactured structure

The present application presents novel systems and methods for tracking reinforcement member placement in an additively manufactured structure that are simple, accurate, non-labor-intensive, and cost-effective. The present application also presents a novel method of manufacturing a tower structure comprising: depositing, via an additive printing system, a first printed layer of a wall with a printhead assembly, the wall at least partially circumscribing a vertical axis of the tower structure; positioning a first reinforcement member on the first printed layer; depositing, via the additive printing system, a second printed layer of the wall with the printhead assembly on the first reinforcement member, the second printed layer configured to hold a second reinforcement member thereon; and determining, via an optical sensor of the additive printing system, a position for placing the second reinforcement member based on the first reinforcement member positioning.

Kenny, Christopher James↗
DOE OSTI2021

Silicon Anodes with Improved Calendar Life Enabled By Multivalent Additives

Silicon is widely recognized as the most promising upgrade for graphite anodes due to its much higher capacity, natural abundance, and ability to be directly applied in the slurry-based, roll-to-roll production lines. However, in addition to the fast capacity decay, silicon anodes also suffer from inferior calendar life in practical applications due to the unstable solid-electrode interface (SEI). Until now, strategies to effectively improve the calendar life by tailored SEIs remain largely unclear, especially in high-Si content, zero-graphite anodes. Here, silicon anodes with superior calendar life are developed by adding small concentrations of multivalent salts into the baseline electrolyte. The Ca additive reacts with the F ions in the electrolyte, forming a layer of nanocrystalline CaF 2 that is closely coated around the silicon particles. The CaF 2 -enabled new SEI is strong and dense, which effectively protects the silicon core from side reactions, leading to lower capacity decay after calendar aging at high voltage. More importantly, the Ca additive is effective universally for all available commercial silicon or SiO sources. This study provides a feasible and low-cost solution for developing silicon anodes with long calendar life, paving the way towards commercially viable silicon anodes.

25 ENERGY STORAGE↗
DOE OSTI2020

Effects of heat treatment and build orientation on the evolution of $ϵ$ and $α'$ martensite and strength during compressive loading of additively manufactured 304L stainless steel

In this paper, the effect of heat-treatment and build orientation on martensitic phase transformation in additively manufactured (AM) 304L stainless steel is studied and compared with conventionally produced wrought material. The relationships between observed martensitic transformations and material microstructures and their effects on mechanical strength are established through experimental observations. In situ high-energy X-ray powder diffraction measurements were performed to monitor the evolution of $ϵ$ and $α'$ martensite during compressive loading of stainless steel. Electron backscatter diffraction (EBSD) was used to provide insight on initial grain morphology, crystallographic misorientation within grains, and crystallographic texture. Heat treatment alters the microstructure of AM samples creating different initial conditions. This difference in starting microstructure resulted in variability in martensitic transformation during compressive deformation. The rate of martensitic transformation decreased for AM samples treated with temperatures up to 1100°C, after which the AM microstructures recrystallized, resulting in increased rate of martensitic transformation for those samples treated at higher temperatures. It was also observed that aligning the axis of compression with the AM build direction resulted in a lower rate of strain-induced martensite formation as opposed to aligning the compression axis perpendicular to it. More favorable distribution of crystal orientations in the latter loading orientation promoted martensitic transformation. These and additional experimental observations from EBSD in terms of kernel average misorientation, mean grain orientation spread, and mean crystallite size reveal strong microstructural effects on strength of additively manufactured metallic materials.

304L stainless steel↗
DOE OSTI2026

Understanding the Thermal Physics and Metallurgy of Metal Big Area Additive Manufacturing

The research goal of this EPSCoR-DOE partnership is to mitigate defects in parts made using a new type of additive manufacturing (AM) process called metal Big Area Additive Manufacturing (m-BAAM). To realize this goal, the PIs will detect and correct defects in the part as it is being printed by combining fundamental knowledge of the thermal physics and metallurgy of m-BAAM with in-process sensor data. Developed at the DOE-funded Manufacturing Demonstration Facility at Oak Ridge National Laboratory, the m-BAAM process involves one or more robots working together to produce a part by fusing metal wire layer-by-layer using arc welding. The process can print large metal parts such as turbine blades, which is not possible using other AM processes. In addition, m-BAAM production rates are more than ten times faster than other AM processes while requiring one-tenth of the material cost. Despite their potential to become a critical force multiplier in the energy generation industry, m-BAAM parts may fail to print accurately due to retention of heat and uneven cooling. Overheating and anomalous cooling rates in turn can cause inconsistencies in the microstructure, leading to sudden failure when used in safety-critical applications. In other words, flaw formation in m-BAAM parts is governed by the thermal history – intensity and spatial distribution of heat inside the part during printing. The thermal history is a complex function of the part shape and process settings such as welding energy, path taken by the welding torch for deposition (tool path), wire feed rate, among others.

36 MATERIALS SCIENCE↗