Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Modeling of Metal AM”

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.

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

At least 469 records · Page 26

High temperature cyclic oxidation furnace testing at NASA Lewis Research Center

A standardized method of testing the cyclic oxidation resistance of various alloys in static air to 1200 C was developed and is routinely used at NASA Lewis Research Center. Test samples are automatically raised and lowered into a resistance wound furnace for a series of fixed interval heating and cooling cycles. Spall catchers collect the accumulated spall from each sample. The samples are weighed intermittently to generate specific weight change/time data. At various test times the samples and the accumulated spall are analyzed by X-ray diffraction. A computer program uses this gravimetric and X-ray data as input to print out the oxidation curves and specific weight change/time and X-ray results in a published format, organizes, and indexes the data. So far, several hundred Fe, Ni, and Co base alloys were tested using this same basic procedure and results form the basis of a series of cyclic oxidation handbooks to be published by NASA. Such specific weight change/time data were used to estimate the oxidative metal consumption by several computer modeling techniques to rank alloys and for use in life testing estimates.

Barrett, C. A.↗

High temperature cyclic oxidation furnace testing at NASA Lewis Research Center

A standardized method of testing the cyclic oxidation resistance of various alloys in static air up to 1200 C has been developed and routinely used at the NASA Lewis Research Center. Test samples are automatically raised and lowered into a resistance wound furnace for a series of fixed-interval heating and cooling cycles. Spall catchers collect the accumulated spall from each sample. The samples are weighed intermittently to generate specific weight change with time data. At various test times the samples and the accumulated spall are analyzed by X-ray diffraction. A computer program is used to print out the specific weight change versus time data and the X-ray data in tabular form and to plot the specific weight change versus time data in a publishable format. The data are also organized and indexed. So far several hundred Fe-, Ni-, and Co-base alloys have been tested using this basic procedure and will form the basis of a series of cyclic oxidation handbooks to be published by NASA. Such specific weight change/time data have been used to estimate the oxidative metal consumption by several computer modeling techniques both to rank alloys and to estimate life.

Barrett, C. A.↗

Mathematical and physical modelling of materials processing

Mathematical and physical modeling of turbulence phenomena in metals processing, electromagnetically driven flows in materials processing, gas-solid reactions, rapid solidification processes, the electroslag casting process, the role of cathodic depolarizers in the corrosion of aluminum in sea water, and predicting viscoelastic flows are described.

Source record↗

Aerothermal performance and damage tolerance of a Rene 41 metallic standoff thermal protection system at Mach 6.7

A flight-weight, metallic thermal protection system (TPS) model applicable to Earth-entry and hypersonic-cruise vehicles was subjected to multiple cycles of both radiant and aerothermal heating in order to evaluate its aerothermal performance, structural integrity, and damage tolerance. The TPS was designed for a maximum operating temperature of 2060 R and featured a shingled, corrugation-stiffened corrugated-skin heat shield of Rene 41, a nickel-base alloy. The model was subjected to 10 radiant heating tests and to 3 radiant preheat/aerothermal tests. Under radiant-heating conditions with a maximum surface temperature of 2050 R, the TPS performed as designed and limited the primary structure away from the support ribs to temperatures below 780 R. During the first attempt at aerothermal exposure, a failure in the panel-holder test fixture severely damaged the model. However, two radiant preheat/aerothermal tests were made with the damaged model to test its damage tolerance. During these tests, the damaged area did not enlarge; however, the rapidly increasing structural temperature measuring during these tests indicates that had the damaged area been exposed to aerodynamic heating for the entire trajectory, an aluminum burn-through would have occurred.

Avery, D. E.↗

Status of indium phosphide solar cell development at Spire

On-going development of indium phosphide solar cells for space applications is presented. The development is being carried out with a view towards both high conversion efficiency and simplicity of manufacture. The cell designs comprise the ion-implanted cell, the indium tin oxide top contact cell, and the epitaxial cell grown by metal organic chemical vapor deposition. Modelling data on the limit to the efficiency are presented and comparison is made to measured performance data.

Spitzer, M. B.↗

Quadrupolar Kondo effect in uranium heavy-electron materials?

The possibility of an electric quadrupole Kondo effect for a non-Kramers doublet on a uranium (U) ion is a cubic metallic host is demonstrated by model calculations showing a Kondo upturn in the resistivity, universal quenching of the quadrupolar moment, and a heavy-electron anomaly in the electronic specific heat. With inclusion of excited crystal-field levels, some of the unusual magnetic-response data in the heavy-electron superconductor UBe13 may be understood. Structural phase transitions at unprecedented low temperatures may occur in U-based heavy-electron materials.

Cox, D. L.↗

A flow-transfer device with nonmetallic diaphragms for propulsion wind tunnel models

The Langley Research Center has developed a new flow-transfer device for powered wind tunnel models in which the traditional metal bellows have been replaced with nonmetallic diaphragms. Two complete flow transfer assemblies have been fabricated and installed within a twin-jet propulsion simulation system. Calibrations of the force balance have been performed over a range of nozzle mass flow rates up to 15 lbs/sec in order to validate the nonmetallic diaphragm design concept. Results from these calibrations are compared to those obtained with flow-transfer devices utilizing metal bellows.

Capone, Francis J.↗

Abundances in the metal poor dwarf Ross 451

High dispersion echelle spectra of the high velocity subdwarf Ross 451 (= G236-080) were obtained using the 4-m telescope at Kitt Peak. Initial abundance determinations for six elements are presented, using absolute oscillator strengths and metal-poor stellar-atmosphere models.

Spiesman, William J.↗

Stellar evolution in blue populous clusters of the Small Magellanic Cloud and the problems of envelope semiconvection and convective core overshooting

New theoretical evolutionary sequences of models for stars with low metallicities, appropriate to the Small Magellanic Cloud, are derived with both standard Cox-Stewart opacities and the new Rogers-Iglesias opacities. Only those sequences with little or no convective core overshooting are found to be capable of reproducing the two most critical observations: the maximum effective temperature displayed by the hot evolved stars and the difference between the average bolometric magnitudes of the hot and cool evolved stars. An upper limit to the ratio of the mean overshoot distance beyond the classical Schwarzschild core boundary to the local pressure scale height is set at 0.2. It is inferred from the frequency of cool supergiants in NGC 330 that the Ledoux criterion, rather than the Schwarzschild criterion, for convection and semiconvection in the envelopes of massive stars is strongly favored. Residuals from the fitting for NGC 330 suggest the possibility of fast interior rotation in the stars of this cluster. NGC 330 and NGC 458 have ages of about 3 x 10 exp 7 and about 1 x 10 exp 8 yr, respectively.

Stothers, Richard B.↗

The Nichols Wing Cutting Equipment

Described here is wing cutting equipment for the economical production of metal wings for wind tunnel models. The machine will make any size of constant-section wing or strut up to one-sixth inch chord by 36-inch span and up to a thickness of one and one-quarter inches. It cuts a smooth, true model that is accurate to within two-thousandths of an inch on any ordinate. The holding jaws are so designed as to leave the model free of chip marks, and the only hand finishing necessary after the cutting is a rub with amunite to remove burrs. The actual change on ordinate in this finishing rub is less than .0002 inches.

Ford, James B↗

Investigation of Strain Aging in the Ordered Intermetallic Compound beta-NiAl

The phenomenon of strain aging has been investigated in polycrystalline and single crystal NiAl alloys at temperatures between 300 and 1200 K. Static strain aging studies revealed that after annealing at 1100 K for 7200 s (i.e., 2h) followed by furnace cooling, high purity, nitrogen-doped and titanium-doped polycrystalline alloys exhibited continuous yielding, while conventional-purity and carbon-doped alloys exhibited distinct yield points and Luders strains. Prestraining by hydrostatic pressurization removed the yield points, but they could be reintroduced by further annealing treatments. Yield points could be reintroduced more rapidly if the specimens were prestrained uniaxially rather than hydrostatically, owing to the arrangement of dislocations into cell structures during uniaxial deformation. The time dependence of the strain aging events followed at t(exp 2/3) relationship suggesting that the yield points observed in polycrystalline NiAl were the result of the pinning of mobile dislocations by interstitials, specifically carbon. Between 700 and 800 K, yield stress plateaus, yield stress transients upon a ten-fold increase in strain rate, work hardening peaks, and dips in the strain rate sensitivity (SRS) have been observed in conventional-purity and carbon-doped polycrystals. In single crystals, similar behavior was observed; in conventional-purity single crystals, however, the strain rate sensitivity became negative resulting in serrated yielding, whereas, the strain rate sensitivity stayed positive in high purity and in molybdenum-doped NiAl. These observations are indicative of dynamic strain aging (DSA) and are discussed in terms of conventional strain aging theories. The impact of these phenomena on the composition-structure-property relations are discerned. Finally, a good correlation has been demonstrated between the properties of NiAl alloys and a recently developed model for strain aging in metals and alloys developed by Reed-Hill et al.

Weaver, Mark Lovell↗

Interfacial Surgery Determination of Succinonitrile and Succinonitrile-Acetone Alloy Using Surface Light Scattering Spectrometer

The objectives of this ground based research is to measure the liquid/vapor interfacial surface energies of succinonitrile (SCN) and alloys of succinonitrile and acetone using Surface Light Scattering Spectrometer. Liquid/vapor interfacial energy measurements will be made near and above the melting point and are the primary goal of this proposal. A measurement of viscosity also results from the Surface Light Scattering technique employed. Interfacial free energies between the phases enters into many analysis of phase transformation and flow, including nucleation, dendritic growth, interface stability, Ostwald ripening, and Marangoni flow. Succirionitrile (SCN) is useful as a model for the study of metal solidification, although it is an organic material, it has a BCC crystal structure and solidifies dendriticly like a metal. It is also transparent and has a low melting point (58.08 C). Succinonitrile has been and is being used extensively in NASAs Microgravity Materials Science and Fluid Physics programs and as well as in several ground-based and microgravity studies including the Isothermal Dendritic Growth Experiment (IDGE) due to Glicksman and coworkers and subsequently in several theoretical and numerical studies of dendritic growth. Previous measurements of succinonitrile (SCN) and alloys of succinonitrile and acetone surface tensions are extremely limited. We believe the data sought through this proposal have significant basic physical property data value and thus the work proposed will provide needed data in support of NASAs Microgravity program research.

Tin, Padetha↗

An Example of Economic Value in Rapid Prototyping

Today's modern machining projects are composed more and more of complicated and intricate structure due to a variety of reasons including the ability to computer model complex surfaces and forms. The cost of producing these forms can be extremely high not only in dollars but in time to complete. Changes are even more difficult to incorporate. The subject blade shown is an excellent example. Its complex form would have required hundreds of hours in fabrication for just a simple prototype. The procurement would have taken in the neighborhood of six weeks to complete. The actual fabrication would have been an equal amount of time to complete. An alternative to this process would have been a wood model. Although cheaper than a metal fabrication, it would be extremely time intensive and require in the neighborhood of a month to produce in-house.

Hauer, R. L.↗

Composite Overwrapped Pressure Vessel (COPV) Life Test

Recent attention has been focused on how NASA and its commercial partners have been placing less emphasis on testing and have become more dependent on analytical methods when evaluating design margins for fracture-critical components. Of high concern is the possible misuse of such analytic models for thin-walled metallic liners for composite overwrapped pressure vessels (COPVs). The NASA Engineering and Safety Center (NESC) has initiated an assessment to understand the limitations of linear-elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate behavior of small cracks in thin metal liners for COPVs. It has been observed that fabrication of some thin metallic liners results in a wide variation in microstructure morphology, which results in varying microscale crack growth mechanisms. The ultimate goal is to develop and demonstrate a test-based methodology validating the safe-life requirements for COPVs with thin, elastically responding metal liners where LEFM methods are not appropriate.

Russell, Richard↗

Melt Pool Imaging using a Configurable Architecture Additive Testbed System

This paper describes the inline (coaxial to laser) near infrared (NIR) camera sensor on the Configurable Architecture Additive Testbed (CAAT). The CAAT is an instrument that provides the capability to investigate laser based additive manufacturing (AM) processes and is configured for the metal powder bed fusion process. A low cost NIR camera is radiometrically calibrated to obtain coaxial, inline, imagery of laser generated melt pools. The camera capabilities, system optical path, and the uncertainty in the temperature measurement from NIR surface area scans on a bare titanium alloy plate are presented and discussed. The surface radiance measurements are compared to optical microscopy images of the melt pool width and depth. A metallic additive manufacturing process thermal model is developed in order to predict thermal distributions during laser scanning. The predicted thermal distributions by the model for different configurations are compared to the coaxial NIR measurements and discussed.

Additive manufacturing↗

Chromospheric heating and metal deficiency in cool giants: Theoretical results versus observations

We compute acoustic shock wave-heated chromosphere models for moderately cool giant stars which differ greatly in metallicity. Subsequently, we simulate the emerging Mg II k lines assuming partial redistribution. The initial acoustic energy fluxes and the wave periods are taken from acoustic wave generation calculations based on traditional convection zone models. We find that the Mg II and Ca II core emissions are close to the observed basal flux limits which are common for giants and dwarfs. In addition, we find that the Mg II core emission is independent of the metallicity, in agreement with observations. We argue that these results should be considered as further evidence that the basal flux limits are indeed due to acoustic shock heating. The acoustic heating mechanism seems to be dominant in all nonmagnetic nonpulsating late-type stars.

Cuntz, M.↗

An Iron-Rain Model for Core Formation on Asteroid 4 Vesta

Asteroid 4 Vesta is differentiated into a crust, mantle, and core, as demonstrated by studies of the eucrite and diogenite meteorites and by data from NASA's Dawn spacecraft. Most models for the differentiation and thermal evolution of Vesta assume that the metal phase completely melts within 20 degrees of the eutectic temperature, well before the onset of silicate melting. In such a model, core formation initially happens by Darcy flow, but this is an inefficient process for liquid metal and solid silicate. However, the likely chemical composition of Vesta, similar to H chondrites with perhaps some CM or CV chondrite, has 13-16 weight percent S. For such compositions, metal-sulfide melting will not be complete until a temperature of at least 1350 degrees Centigrade. The silicate solidus for Vesta's composition is between 1100 and 1150 degrees Centigrade, and thus metal and silicate melting must have substantially overlapped in time on Vesta. In this chemically and physically more likely view of Vesta's evolution, metal sulfide drops will sink by Stokes flow through the partially molten silicate magma ocean in a process that can be envisioned as "iron rain". Measurements of eucrites show that moderately siderophile elements such as Ni, Mo, and W reached chemical equilibrium between the metal and silicate phases, which is an important test for any Vesta differentiation model. The equilibration time is a function of the initial metal grain size, which we take to be 25-45 microns based on recent measurements of H6 chondrites. For these sizes and reasonable silicate magma viscosities, equilibration occurs after a fall distance of just a few meters through the magma ocean. Although metal drops may grow in size by merger with other drops, which increases their settling velocities and decreases the total core formation time, the short equilibration distance ensures that the moderately siderophile elements will reach chemical equilibrium between metal and silicate before metal drop merger becomes important. In this model, there must be at least 30 percent melting of the silicate phase when metal melting is complete, corresponding to a crust thickness of at least 30 kilometers on Vesta, consistent with Dawn gravity observations. Greater degrees of silicate melting and a correspondingly thicker crust are possible if Vesta accreted sufficiently rapidly.

Kiefer, Walter S.↗

Modelling short channel mosfets for use in VLSI

In an investigation of metal oxide semiconductor field effect transistor (MOFSET) devices, a one-dimensional mathematical model of device dynamics was prepared, from which an accurate and computationally efficient drain current expression could be derived for subsequent parameter extraction. While a critical review revealed weaknesses in existing 1-D models (Pao-Sah, Pierret-Shields, Brews, and Van de Wiele), this new model in contrast was found to allow all the charge distributions to be continuous, to retain the inversion layer structure, and to include the contribution of current from the pinched-off part of the device. The model allows the source and drain to operate in different regimes. Numerical algorithms used for the evaluation of surface potentials in the various models are presented.

Klafter, Alex↗