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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Nuclear response of additive manufactured GRCop-84 copper for use in Lower hybrid launchers in a fusion environment

Recent advances in selective laser melting (SLM) 3D printing technology allow additive manufacture of lower hybrid current drive (LHCD) RF launchers from a new material, Glenn Research Copper 84 (GRCop-84), a Cr 2 Nb (8 at. % Cr, 4 at. % Nb) precipitation hardened alloy, in configurations unachievable with conventional machining. Tensile strength and thermal conductivity are compared to other competing high conductivity copper alloys for fusion use. Swelling and conductivity at 100 DPA when exposed to the Hanford Fast Flux Test Facility neutron spectrum is predicted in the 1–2 % and 65-70% IACS range, respectively, by comparison to copper alloys with similar precipitate and grain size. Finally, self-similar ion irradiation of a GRCop-84 target at 430 °C to 20 DPA resulted in no noticeable void formation in FIB cross sections or TEM lamella.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Gas pore correlations in laser powder bed fusion of Al6061

Additive manufacturing (AM) of metal materials based on powder bed fusion technology is widely used now in many industries. A known limitation of this type of manufacturing is the formation of gas pores in the bulk material. Here we present a combined X-ray imaging and mid-infrared pyrometry study of pore formation in side-by-side tracks of Al6061 for different processing conditions using both in-situ and post-processing analysis. By carefully quantifying the distributions and correlations of pore positions, we show that an existing pore in one track often catalyzes the formation of another pore in an adjacent track. In a raster scan strategy commonly used to construct bulk material, this phenomenon has the result of forming subsurface perforations, or lines of pores transverse to the scanning direction in a rastered patch. If controlled, this effect can be eliminated to improve the yield strength of the build, or exploited to create programmable failures for specific purposes.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Influence of Thermophysical Property Variability on Thermal Predictions of Ti-6Al-4V

The additive manufacturing (AM) industry has experienced rapid growth in recent decades as industrial interest in the process has grown. Because of this, there are many groups interested in simulations of the AM process. However, the influence of thermophysical property variability on the melt pool geometry during processing of various AM alloys is unclear. The goal of my work at NASA Langley Research Center (LaRC) was to characterize this influence on Ti-6Al-4V during AM processing alongside developing a tool to enable equivalent studies on other AM materials. To facilitate this process, a database tool was developed to contain and organize thermophysical data previously reported by primary sources. The specific thermophysical properties of interest for this study were density, specific heat capacity, and conductivity. Thermal diffusivity was calculated using the other three properties. This data was then fit with a Gaussian distribution and then randomly sampled from using Monte Carlo random value sampling. Using the Rosenthal equation, this sample data was used to simulate the temperature field during additive manufacturing and extract the melt pool geometry. Specifically, the melt pool’s length, width, and depth. This process was repeated an arbitrary number of times, with the default being 1000. Once this information was obtained, histograms were made showing the distributions of the sizes of the melt pool’s length, width, and depth. Representative statistical metrics of the distributions were calculated (mean, standard deviation, and coefficient of variance). This work found that at the simulated processing values, the melt pool’s width and depth had a 5.7% variation while the length had a 3.2% variation. Additionally, a tool was constructed to graph a thermal color map representation of the melt pool for specific, arbitrary values of density, specific heat, and conductivity. This tool allowed for more efficient plotting of individual queries of the thermophysical properties. The results that were observed in the research were that values reported in literature vary and this variance can have a significant impact on the simulation. Predictions of the melt pool’s dimensions show that length has a standard deviation of approximately 6 μm, width has a standard deviation of approximately 5 μm, and depth can vary by approximately 3 μm. Considering the mean sizes of length, width, and depth are 185 μm, 88 μm, and 44 μm respectively, such a deviation is significant. This shows that depth, for example, could be more than 10% larger or smaller than expected. This demonstrates that variability in the reported thermophysical properties are not negligible and should be expected to have an influence on the results of the laser powder bed fusion additive manufacturing process. When simulating this process in the future, measures should be taken to account for this discrepancy and the uncertainty involved

Justin Martin↗
DOE OSTI2022

Novel Tube Design for Superheater Heat Exchanger Enabled Via Additive Manufacturing

Superheater tubes are critical boiler components that operate at relatively higher temperatures and pressure. Amongst the primary concerns for these tubes is the deposition of ash particles on the tube surface, leading to the reduced thickness of the tube due to material corrosion, consequently causing early creep failure of the component. In this research, a novel tube design has been proposed which resembles a teardrop or ogive shape to reduce the drag and concurrently improve the creep life of the superheater tubes. To administer the practicality of novel tubes, metal additive manufacturing (AM), for instance, laser-powder bed fusion (L-PBF), has been proposed. These unconventional designs were assessed and compared with the baseline circular tube design for mechanical design requirements (hoop stress and creep life) and the particle and flue gas flow characteristics around the differently shaped tubes. A thermomechanical finite element (FE) analysis was performed for hoop stress calculations. This study also emphasizes on effect of circumferential thermal variation on hoop stress distribution in tubes. Therefore, a detailed two-dimensional (2D) thermal simulation has been performed to report the circumferential thermal variation on the tube. A computational fluid dynamics (CFD) analysis coupled with particle tracing was performed for gas flow visualization and particle tracing around the proposed shapes and baseline circular-shaped tube design. The Schlieren optic setup was built and leveraged for qualitative validation of the proposed design. The complete design methodology established in the paper shows teardrop-shaped tubes better in terms of drag and creep life in contrast to the circular-shaped tube.

42 ENGINEERING↗
DOE OSTI2023

A combination interferometric and morphological image processing approach to rapid quality assessment of additively manufactured cellular truss core components

Advanced manufacturing (AM) processes such as laser powder bed fusion (LPBF) are increasingly capable of fabricating components with useful and unprecedented mechanical properties by incorporating complex internal bracing structures. From the standpoint of quality control and assessment, however, internally complex assemblies present significant build-verification challenges. Here we propose a hybrid approach to the inspection involving the application of computer-aided speckle interferometry (CASI) and morphological image processing as a rapid, inexpensive, and facile method for AM quality control. The described methodology has low capital equipment costs, is full-field and non-contact, can be used in an industrial setting, and has very low requirements in terms of operator training and expertise. Consisting primarily of the combination of image processing software with a simple optical system of variable sensitivity, the method is shown to be effective for inspection of a titanium honeycomb component subjected to differential pressure. Results are compared to those achieved with computed tomography (CT), immersion ultrasound testing (UT), and optical holographic interferometry. Here we propose several possible processing strategies for automated quality assessment based on this powerful hybrid approach.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Additively Manufactured Molten Salt to Supercritical Carbon Dioxide Heat Exchanger

Design, fabrication, and experimental characterization of the performance of a molten salt (MS)-to-supercritical carbon dioxide (sCO 2 ) heat exchanger (HE) for concentrating solar power (CSP) applications using laser powder bed fusion (LPBF) additive manufacturing (AM) of nickel-based superalloys is presented in this report. The hypothesis is that such additively manufactured HEs will result in a monolithic, compact, low-pressure drop HE that is durable under cyclic operation at high temperature and high pressure in a corrosive salt environment. Two nickel-based superalloys were considered in the project- Haynes 230 (H230) and Haynes 282 (H282). Process windows for LPBF AM were established to provide dense low porosity parts for both alloys. Creep tests results on heat treated AM H230 and H282 samples showed that the AM fabricated specimens were as robust as the wrought specimens and showed no deficit in creep strength at high temperatures. Haynes 282 was down selected for the HE fabrication based on better dimensional tolerance, better corrosion resistance to chloride salt, and higher creep strength.

14 SOLAR ENERGY↗
NASA NTRSDate not supplied

Towards Integrated Computational Materials Engineering for Quantifying Performance Impacts of Microstructure and Defect Interactions in Powder Bed Fusion Parts

Powder bed fusion (PBF) additive manufacturing (AM) enables the creation of parts with complexity and functionality levels that were previously impossible with traditional manufacturing methods. By modifying the laser power, hatch spacing, or the numerous other processing parameters, the PBF process supports the production of a wide set of materials and geometries. However, that same process parameter design flexibility causes the process-design space of PBF to be massive and expensive to explore experimentally. Another challenge is quality variation across a build. As a part is being built, geometric variance between locations, such as at a thin-wall section vs. the bulk material, may cause the specified processing parameters to no longer be acceptable for producing defect-free printing. Furthermore, if the processing parameters deviate during the print process, it is difficult to assess if the part will still perform satisfactorily. Integrated Computational Materials Engineering (ICME) provides a way to understand and address these various challenges. This talk will present advancements in process-structure simulations of PBF at NASA Langley Research Center. The ability to simulate grain-scale PBF microstructures using the Physically Based Monte Carlo method will be demonstrated and compared to experimental measurements. Techniques for simulating three-dimensional lack-of-fusion and keyhole porosity defects based on the specific processing conditions and approaches for integrating the two porosity prediction techniques alongside the computational microstructure evolution models will be shown. Finally, the integration of simulated PBF microstructures, embedded process defects, and crystal plasticity finite element models to elucidate the interaction of porosity and microstructure on micromechanical fields will be demonstrated. These integrated techniques demonstrate an example of using ICME to relate processing to performance for PBF AM materials. With continued maturity, it is hoped that such ICME approaches will lead to next-generation computational-materials supported qualification and certification of AM parts.

Additive manufacturing↗
NASA NTRS1993

Characteristics of products generated by selective sintering and stereolithography rapid prototyping processes

The trend in the modern global economy towards free market policies has motivated companies to use rapid prototyping technologies to not only reduce product development cycle time but also to maintain their competitive edge. A rapid prototyping technology is one which combines computer aided design with computer controlled tracking of focussed high energy source (eg. lasers, heat) on modern ceramic powders, metallic powders, plastics or photosensitive liquid resins in order to produce prototypes or models. At present, except for the process of shape melting, most rapid prototyping processes generate products that are only dimensionally similar to those of the desired end product. There is an urgent need, therefore, to enhance the understanding of the characteristics of these processes in order to realize their potential for production. Currently, the commercial market is dominated by four rapid prototyping processes, namely selective laser sintering, stereolithography, fused deposition modelling and laminated object manufacturing. This phase of the research has focussed on the selective laser sintering and stereolithography rapid prototyping processes. A theoretical model for these processes is under development. Different rapid prototyping sites supplied test specimens (based on ASTM 638-84, Type I) that have been measured and tested to provide a data base on surface finish, dimensional variation and ultimate tensile strength. Further plans call for developing and verifying the theoretical models by carefully designed experiments. This will be a joint effort between NASA and other prototyping centers to generate a larger database, thus encouraging more widespread usage by product designers.

Cariapa, Vikram↗
DOE OSTI2021

Impact of Additive Manufacturing on Internal Cooling Channels With Varying Diameters and Build Directions

Abstract The use of additive manufacturing (AM) processes, such as direct metal laser sintering, provides the design freedom required to incorporate complex cooling schemes in gas turbine components. Additively manufactured turbine components have a range of cooling feature sizes and, because of the inherent three-dimensionality, a wide range of build angles. Previous studies have shown that AM built directions influence internal channel surface roughness that, in turn, augment heat transfer and pressure loss. This study investigates the impact of AM on channel feature size and builds direction relative to tolerance, surface roughness, pressure losses, and convective cooling. Multiple AM coupons were built from Inconel 718 consisting of channels with different diameters and a variety of build directions. An experimental rig was used to measure pressure drop to calculate friction factor and was used to impose a constant surface temperature boundary condition to collect Nusselt number over a range of Reynolds numbers. Significant variations in surface roughness and geometric deviations from the design intent were observed for distinct build directions and channel sizes. These differences led to notable impacts in friction factor and Nusselt number augmentations, which were a strong function of build angle.

Engineering↗
DOE OSTI2023

A Comparison of Solidification Structures and Submicroscale Cellular Segregation in Rapidly Solidified Stainless Steels Produced via Two-Piston Splat Quenching and Laser Powder Bed Fusion

Fusion-based additive manufacturing techniques leverage rapid solidification (RS) conditions to create parts with complex geometries, unique microscale/nanoscale morphological features, and elemental segregation. Three custom composition stainless steel alloys with varying chromium equivalence to nickel equivalence ratio (Cr eq /Ni eq ) between 1.53 and 1.95 were processed using laser powder bed fusion (LPBF) and/or two-piston splat quenching (SQ) to produce solidification rates estimated between 0.4 and 0.8 m/s. Both scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were utilized to collect high-resolution images, electron backscatter diffraction (EBSD) phase identification, and measure cellular segregation. Similar features were observed in both LPBF and SQ samples including phase and microstructure, nanoscale oxide particles, cell size, and segregation behavior. However, dislocation pileup was observed along the cell boundaries only in the LPBF austenite solidified microstructure. Targeted adjustment of the SQ feedstock Cr and Ni concentrations, within the ASTM A240 specification for 316L resulted in no observable impact on the cell size, oxide particle size, or magnitude of segregation. Also, the amount of Ni segregation in the ferrite solidified microstructures did not significantly differ, regardless of Cr/Ni eq or processing technique. Here, SQ is demonstrated as capable of simulating RS rates and microstructures similar to LPBF for use as an alternative screening tool for new RS alloy compositions.

42 ENGINEERING↗
DOE OSTI2020

Microstructure–Property Correlation in a Laser Powder Bed Fusion Processed High-Strength AF-9628 Steel

Laser powder bed fusion additive manufacturing (LPBF-AM) of a low-alloy, high-performance AF-9628 steel results in exceptionally high strength and good ductility. The reasons for such mechanical properties are investigated through detailed microscopy performed at several length scales. Thus, the characterization of melt pool, porosity, grain morphology, phases, and dislocations is performed in the as-printed material. The as-printed material consists of only 0.004 vol% of uniformly distributed porosity, single-phase martensitic laths with an average lath size of ≈2.5 μm, the absence of carbides indicating interstitial trapping of C atom, and high dislocation density in the martensitic laths. Experimental data through microscopy are then fed in analytical models for calculating strengthening contributions from various strengthening mechanisms. Calculated yield strength agrees well with experimentally determined value, and therefore, activation of various strengthening mechanisms is established in as-printed AF-9628.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effect of processing parameters and strut dimensions on the microstructures and hardness of stainless steel 316L lattice-emulating structures made by powder bed fusion

In this study, we present the effects of input processing parameters and strut thickness (in square struts) on microstructure and properties in laser powder bed fusion additively manufactured stainless steel 316L lattice-emulating structures. Lattice-emulating X-structures with square cross-sections of 1.5, 1.0, and 0.5 mm were fabricated using three different parameter sets with varying power, speed, and therefore, linear energy density. Grain size and morphology were shown to be dictated by epitaxial growth, which was dependent on weld pool morphology. Additionally, grain size and morphology were shown to change across the thickness direction of the struts (from the bottom inclined surface to the top inclined surface). The spatial variation in grain size was reflected by changes in hardness through the thickness of each strut. The 0.5 mm struts exhibited more significant grain elongation in the strut direction and larger sub-grain solidification cell diameters than their thicker counterparts. The larger sub-grain solidification cell diameters in the 0.5 mm samples resulted in correspondingly lower hardness values when compared to samples of higher thicknesses.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Shock compression behavior of stainless steel 316L octet-truss lattice structures

Lattice structures offer desirable mechanical properties for applications of energy absorption and impact mitigation but limited research has been carried out on their shock compression behavior. In this work, the shock compression behavior of stainless steel 316L (SS316L) octet-truss lattice structures was investigated through experimental techniques and numerical simulations. Plate impact experiments with high-speed imaging were conducted at impact velocities of 270 – 390 m/s on lattice specimens with 5x5x10 unit cell geometries additively manufactured (AM) using direct metal laser sintering. High-speed imaging together with digital image correlation was used to extract full-field measurements and define a two-wave structure consisting of an elastic wave and planar compaction (shock) wave which propagated along the impact direction. A linear shock velocity versus particle velocity relation was found to approximate the measurements with a unit slope and a linear fit constant equal to the crushing speed. Furthermore, the shock velocity versus particle velocity relation, full-field measurements, and elastic limit together with the Eulerian form of the Rankine-Hugoniot jump conditions were used to find relations for the stress and internal energy behind the shock. Stress behind the shock increased with relative density and particle velocity, and specific internal energy converged to a single curve similar to that of bulk AM SS316L. Explicit finite element analysis using the Johnson-Cook constitutive model demonstrated similar shock behavior observed in experiments and a linear shock velocity versus particle velocity relation and corresponding Hugoniot calculations were found to be in agreement with experimental results. Numerical simulations confirmed negligible effects of exterior versus interior measurements and further validated the application of one-dimensional shock theory.

42 ENGINEERING↗
DOE OSTI2023

Single-Phase Jet Impingement Cooling for a Power-Dense Silicon Carbide Power Module

The adoption of silicon carbide (SiC) devices in the electric vehicle (EV) industry is increasing due to their superior performance over silicon devices. SiC devices enable further miniaturization of EV inverters, increasing their power density, which results in thermal management challenges. Here in this paper, the limits of single-phase jet impingement cooling are explored for an automotive SiC power module. We propose embedding pin fins in the direct-bonded-copper (DBC) substrate of the power module package using laser powder bed fusion additive manufacturing. The thermalhydraulic performance of the DBC-embedded pin fins is compared against folded fins that are directly soldered to the DBC substrate. A heat conduction analysis was conducted on a SiC package to determine the target heat transfer coefficient (HTC) for the heat sink. A water-ethylene glycol (WEG) jet impingement on the proposed concepts was studied using unit-cell models to achieve the target HTC. The studied designs put emphasis on the reliability and manufacturability requirements of the automotive industry. The thermal performance of DBC-embedded pin fins outperformed the DBC-soldered folded fins. The performance of the DBC-embedded pin fins is benchmarked against WEG-based cooling systems of commercial EVs. With the proposed cooling solution, we have shown a pathway of reducing the specific thermal resistance by 75% compared to BMW i3 thermal management system without any penalty on pressure drop or parasitic power.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Mechanical Properties of Additively Manufactured 316L Stainless Steel Before and After Neutron Irradiation (FY21)

This report presents the materials property data of additively manufactured (AM) 316L stainless steel (SS) accumulated for the assessment of core materials in the Transformational Challenge Reactor (TCR) program. The TCR manufacturing approach includes using the laser powder bed fusion (LPBF) method for metallic (316L and Inconel 718) components. To assess the mechanical performance of printed components in reactor-relevant conditions and build a property database for the AM materials, mechanical tests and evaluations were performed before and after neutron irradiation. Miniature tensile specimens were irradiated in the High Flux Isotope Reactor to 0.2, 2, 8, and 10 dpa at target temperatures of 300 and 600°C. Postirradiation evaluation for the 0.2 and 2 dpa specimens was performed during FY20 and FY21, and the results are presented and discussed in this document.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Automation and Quality Control for CMS Outer Tracker Module Assembly at Fermilab’s SiDet

Automation and quality control techniques for 2S and PS sensor modules for the CMS Outer Tracker for the HL-LHC era have been developed at the Silicon Detector facility at Fermilab. Examples include a laser scanning procedure to check manufacturing specifications for the 2S sensor modules, and an automated gluing process to accurately assemble PS sensor modules. Processes were verified and documented for the production stage of the Outer Tracker.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Effects of Surface Treatments on the Outgassing of 3D-Printed 316L Stainless Steel.

Fermi National Accelerator Laboratory (Fermilab) is a world leader in designing and operating particle accelerators for nuclear and particle physics research. These accelerators rely on electric fields to propel particle beams, which are then directed and focused using magnetic fields. To ensure these beams travel without interference, they must move through an ultra-high vacuum environment, typically around 10⁻⁹ torr. Maintaining such a vacuum requires materials with exceptionally low outgassing rates. 316L stainless steel is a common material choice for vacuum systems due to its low outgassing rates, excellent corrosion resistance, non-magnetic properties, and high mechanical strength. When manufactured using traditional methods like machining, extrusion, and casting, the vacuum properties of 316L stainless steel are well understood. However, the behavior of 316L stainless steel produced through additive manufacturing, such as Direct Metal Laser Sintering (DMLS), is not as well documented. This study aims to determine the outgassing rate of 316L stainless steel fabricated using DMLS. The investigation focuses on measuring the outgassing rates of 1.5 2 vacuum reducers and evaluating the effects of surface preparation techniques, such as mechanical polishing and electropolishing, on the outgassing performance. Understanding the outgassing performance of 3D-printed 316L stainless steel could enable Fermilab engineers to adopt this fabrication method for producing complex parts designed for ultra-high vacuum environments. These advancements have the potential to benefit projects, such as the Long-Baseline Neutrino Facility (LBNF) and the Proton Improvement Plan-II (PIP-II), by improving design flexibility and fostering innovation in accelerator development.

Cloud, Jaiden [Central State University]↗
DOE OSTI2025

Microstructure & Mechanical Properties of Scaled Thermally Aged LPBF 316H SS Builds

As part of the US Department of Energy’s Advanced Materials and Manufacturing Technologies program’s mission to accelerate qualification of advanced manufacturing pathways for nuclear applications, laser powder bed fusion (LPBF) 316H stainless steel (SS) has been selected as a model system to develop a rapid code case framework. This effort directly addresses the grand challenges of (1)expanding the limited portfolio of materials currently codified for elevated-temperature nuclear structural service under Section III, Division 5of the American Society of Mechanical Engineers’ Boiler and Pressure Vessel Code; and (2) significantly reducing qualification timelines that traditionally exceed a decade. The strategic importance of LPBF 316H lies in its immediate industrial relevance, existing data foundation from wrought 316H, and alignment with ongoing code case development for LPBF 316L.Prior work revealed accelerated precipitation of deleterious secondary phases and reduced creep ductility in as-printed LPBF 316H. Building on that prior research, FY2025activities focused on establishing an understanding of the key failure mechanisms of crept 316H specimens to aid in code case development and on evaluating stress relief (SR) parameters on the high-temperature performance and thermal aging-induced degradation of tensile and fracture behavior in LPBF316H.

36 MATERIALS SCIENCE↗