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At least 703 records · Page 39

All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Print-Consistency and Process-Interaction for Inkjet-Printed Copper on Flexible Substrate

Printed electronics is a fastest growing and emerging technology that have shown much potential in several industries including automotive, wearables, healthcare, and aerospace. Its applications can be found not only in flexible but also in large area electronics. The technology provides an effective and convenient method to additively deposit conductive and insulating materials on any type of substrate. Comparing with traditional manufacturing processes, which involves chemical etching, this technology also comes to be relatively environmental friendly. Despite its status, it is not without its challenges. Starting from the material being compatible in the printer equipment to the point of achieving fine resolutions, and with excellent properties are some of the challenges that printed electronics face. Among the myriad of printing technologies such as Aerosol Jet, micro-dispensing, gravure printing, screen printing, Inkjet printing, Inkjet has gained much attention due to its low-cost, low material consumption, and roll-to-roll capability for mass manufacturing. The technology has been widely used in home and office, but recently gained interest in printed electronics in a research and development setting. Conductive materials used in Inkjet printing generally comprises of metal Nanoparticles that need to be thermally sintered for it to be conductive. The preferred metal of choice has been mostly silver due to its excellent electrical properties and ease in sintering. However, silver comes to be expensive than its counterpart copper. Since copper is prone to oxidation, much focus has been given towards photonic sintering that involves sudden burst of pulsed light at certain energy to sinter the copper Nanoparticles. With this technique, only the printed material gets sintered in a matter of seconds without having a great impact on its substrate, due to which it is also preferred in low temperature applications. With all the knowledge, there is still a large gap in the process side with copper where it is important to look how the print process affects the resolution of the print along with the effect of post-print processes on electrical and mechanical properties. In this paper, a copper Inkjet ink is utilized for understanding the effect of Inkjet print parameters on the ejected droplet and its resolution. Post-print process is also quantified using a photonic sintering equipment for excellent electrical and mechanical properties. To demonstrate the complete process, commercial-off-the-shelf components will also be mounted on the additively printed pads via Inkjet. Statistically, control charting technique will be utilized to understand the capability of the Inkjet process.

printed electronics↗

NASA NTRSDate not supplied

Printed Flexible Sensors for NASA Applications

As human spaceflight pushes beyond Low Earth Orbit (LEO), resupply of consumables becomes a significant challenge. One solution to this problem is In-Space Manufacturing (ISM), the capability to perform on-demand manufacturing and repair of consumables in an in-space environment. ISM offers significant flexibility to missions as it allows for a high degree of tailorability and reduction in launch mass. Leveraging advancements in fabrication, repair and recycling, ISM provides a highly sustainable and affordable solution to Exploration mission operations and logistics. In this talk, advances in printed electronics and sensors, ranging from nanomaterial ink development and hands-free fabrication methodologies to devices will be presented. Applications presented will include sensors for crew health monitoring, structural health monitoring and power generation.

sensors↗

NASA NTRSDate not supplied

In-Space Manufacturing to Support Human Spaceflight

As human spaceflight pushes beyond Low Earth Orbit (LEO), resupply of consumables becomes a significant challenge. One solution to this problem is In-Space Manufacturing (ISM), the capability to perform on-demand manufacturing and repair of consumables in an in-space environment. ISM offers significant flexibility to missions as it allows for a high degree of tailor ability and reduction in launch mass. Leveraging advancements in fabrication, repair and recycling, ISM provides a highly sustainable and affordable solution to exploration mission operations and logistics. In this talk, advances in printed electronics and sensors, ranging from nanomaterial ink development and hands-free fabrication methodologies to devices will be presented. Applications presented will include sensors for crew health monitoring along with supporting electronics. In the future, these devices will be fabricated and characterized on the International Space Station and the approach will be evaluated for future in-space manufacturing to support human spaceflight.

nanotechnology↗

NASA NTRSDate not supplied

Printed Sensors and Electronics for Sustained Human Spaceflight

In Space Manufacturing↗

NASA NTRSDate not supplied

In-situ Testing to Acquire HR-EBSD and DIC Strain Data Within a Coincident Domain

For this project, an inked rubber stamp was applied to a small Inconel 625 specimen. The stamp transferred a thin pattern with microscale features for digital image correlation (DIC). The pattern is easily visible at lower voltages and thin enough to not obstruct backscattered electrons. The unique characteristics of the pattern enabled the concurrent acquisition of DIC and high-resolution electron backscatter diffraction (HR-EBSD) data while the specimen was loaded in-situ. The challenges of in-situ testing and combining EBSD with DIC measurements are discussed. By combining the elastic strains (from HR-EBSD) and total strains (from DIC) the result of this approach is an estimate of stress- strain behavior at points across the specimen surface. This combined dataset can then be used as higher-fidelity data in the calibration of crystal plasticity models.

Will Gilliland↗

NASA NTRSDate not supplied

Application of Digital Image Correlation in Wind Tunnel

Digital image correlation (DIC) is a non-contact measurement technique that has been used in various applications in multiple industries, from microscopic specimens all the way to large scale structures. This project involved using DIC to capture wing deflection under simulated wind loading at various angles of attack (AoA). A subscale model of a fixed-wing aircraft, shown in Figure 1, was used in the 14-footby 22-footsubsonicwind tunnel at the NASA Langley Research Center. The setup used two pairs of cameras mounted on the ceiling of the tunnel to view the starboard and port side wings. Aluminum framing was used to rigidly mount the cameras to beams in the ceiling. Camera setup challenges due to the confined space included obtaining even lighting and working around infrared (IR) cameras that were used to capture the flow over the wing. Remote connection was used to access data acquisition computers from computers in the control room. Eight measurement locations on each wing were made of 1-inch-diametercircular silver dry transfer decals that did not alter the air flow across the wing. These circles were speckled with a black ink pen and were used for the IR camera as well as for DIC systems. A mock setup outside the wind tunnel was used to optimize the camera setup and verify that the speckled tape provided sufficient correlation. DIC was used to track the position of seven locations as the AoA of the subscale model changed from −10 degrees to +10 degrees in 1-degree increments. The model was rotated at a fixed height about the center of the fuselage from −7 degrees to +10 degrees. The height of the model had to be lowered to achieve AoA slower than −7degrees due to geometric constraints of the cart supporting the model and the wind tunnel. The source of light was stationary relative to the model, so the exposure time had to be adjusted for different wing regions and AoA values. The three-dimensional (3D) visualization of the markings and the two-dimensional (2D) projection of these points onto the port wing at 0-degree AoA is shown in Figure 2.

Matlock Mennu↗

NASA NTRSDate not supplied

Additive Manufacturing of ZrC for Nuclear Thermal Propulsion Applications

Looking into the future, we are seeing that nuclear is becoming a more and more viable fuel source for space applications due to it being one of the safest energy forms, low greenhouse gas emissions, and inexpensive maintenance. National Aeronautics and Space Administration (NASA) and a few others are looking at nuclear fuels in relation to space travel, specifically in the form of Nuclear Thermal Propulsion (NTP) [1]. NTP provides the answer for space travel to Mars where chemical rockets would not complete the job. A concept art of what these spacecrafts could look like is shown (Figure 1). Uranium Carbide fuel has been chosen to heat a liquid propellant for propulsion. The complex fuel geometries required by space reactors can be achieved by novel techniques fairly easily, cheaply, and safely. In this specific study, we are looking at using Zirconium Carbide (ZrC) to use as a surrogate for Uranium Carbide (UC) due to their similar behaviors under high temperatures. An ink made with ZrC will be made and will be extruded into unique, complex geometries. This is a great starting point to test additive manufacturing on these ceramics.

Additive Manufacturing↗

NASA NTRS2026

NASA Weather Balloon Demonstration of an Additively Manufactured Antenna

Additive manufacturing (AM) enables low-cost, lightweight, and geometrically flexible antennas for rapid deployment missions. This work reports a left-hand circularly polarized magneto-electric dipole printed on a Radix dielectric with inkjet silver metallization and demonstrated as a process replacement for NASA weather-balloon RF hardware. By combining substrate fabrication and metallization, AM provides value for unrecoverable or field-replaceable systems. A physics based verification workflow links AM-specific material behavior to electromagnetic performance and yields bounded total, radiation, and mismatch efficiencies. Standard surface-impedance and roughness models failed to reproduce the frequency-dependent radiation loss observed in printed inks, underscoring the need for AM-specific conductor parameterization. Mission testing confirmed TDRSS link closure from NASA’s Columbia Scientific Balloon Facility and validated a repeatable print–measure–fly workflow for bounding RF performance and qualifying AM antennas for field use.

Peter Moschetti↗

NASA NTRSDate not supplied

NASA Weather Balloon Demonstration of an Additively Manufactured Antenna

Peter Moschetti↗

DOE OSTI2020

Influence of Coating Method on the Performance of Roll-to-Roll Coated PEM Fuel Cell Catalyst Layers

As production of fuel cell vehicles and power systems increases there is a need to understand the process science of fuel cell manufacturing. Industrial production of polymer electrolyte membrane fuel cell (PEMFC) electrodes will rely on continuous roll-to-roll (R2R) coating methods to meet the rates needed for mass production. There are a variety of coating methods that could be used to coat catalyst layers. The different physics of each method may result in different morphologies and performance. Here we present the results of a study comparing fuel cell catalyst layers coated using two R2R coating methods: slot-die and gravure. These two methods were selected because the physics of applying the liquid to the substrate is very different between the two cases. Pt/C catalysts layers were coated directly onto carbon-fiber gas diffusion media to create gas diffusion electrodes (GDEs), without the use of a decal transfer process. These GDEs were assembled into membrane electrode assemblies (MEAs) by hot pressing to Nafion membranes. In situ performance and other electrochemical diagnostics were used to determine the influence of coating method on catalyst layer electrochemical properties. Electron microscopy was utilized to understand the influence of coating method on electrode morphology and its influence on electrochemical properties. We also explored the influence of solvent ratio to understand the potential coupling between ink formulation and coating methodology.

DIRECT ENERGY CONVERSION,MATERIALS SCIENCE↗

DOE OSTI2020

AGR-5/6/7 Capsule Leach Station Hardware Qualification - Phase 1

Procedural changes to this document shall be logged and justified using the EQP Change Log below. Typographical errors do not need to be logged, but do require the Lead Engineers initials and date. Each entry shall be numbered (i.e., CN #1) for identification in the left-hand margin of the table. Each entry may include individual or groups of related procedural changes. Changes to the EQP shall made by pen and ink and/or addition of additional pages depending on the extent of the change.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Methods of preparing a safety battery

The present invention relates, in part, to methods of preparing a safety battery. Methods can include dispensing a safety ink formulation between the two poles of a battery. Upon exposure to moisture, the formulation provides an electrical connection between two poles, thus minimizing electrical discharge and/or reducing the formation of electrochemically generated ions at the pole(s).

Kaehr, Bryan James↗

DOE OSTI2020

Metal phosphide nanomaterials prepared from single source metal amides

The present invention provides a novel solution or route for metal phosphide (MPx) nanomaterials from the thermal decomposition of metal bis[bis(diisopropylphosphino)amide], M[N(PPri2)2]2, and/or single-source precursors. Synthetic routes to MPx nanomaterials may be used in energy applications including batteries, semiconductors, magnets, catalyst, lasers, inks, electrocatalysts and photodiodes.

Kemp, Richard Alan↗

DOE OSTI2021

Inventory Management Improvement Project

The Lawrence Livermore National Laboratory (LLNL) conducts research and development for the National Nuclear Security Agency (NNSA) and its affiliates. The Polymer AM team at LLNL conducts research and development in 3D printing, specifically direct-ink-write, in accordance with LLNL and NNSA missions. The team is composed of machine operators, chemists, testing engineers, and project engineers across multiple lab spaces with one shared storage area at LLNL. The operations use a variety of different consumables and hardware to conduct research applications for LLNL and NNSA. These items are critical to performing operation tasks; if an item is out of stock, operations associated with the respective item could be suspended for weeks. As such, the Polymer AM team manages an inventory of spare consumables and hardware to ensure these items are always available. However, the current management system, an excel sheet managed by the project engineer group, is not intuitive in providing inventory information despite the high labor utilization needed to maintain the system. As such, the team is looking to improve their inventory management that can send notifications regarding inventory needs, accessible to other team members, provide all relevant information to a specific item, and store historical information for budget and operation planning. The proposed solution is a Computer Maintenance Management System (CMMS): a web-based management software that stores inventory information and provides automated notifications. The system will store information on each item including quantity in stock, technical information, supplier information, costs, lead times, and expiration date. The system has a notifications function that can send notifications to the respective team member’s when an item needs to be counted, item inventory is low, or an item is approaching their expiration date. Information for each item can be tracked over time creating data to be used for budget planning and process improvement purposes. Due to its web-based source, the system can be accessed by the respective team member viewing technical information, quantity, and purchasing information.

42 ENGINEERING↗

DOE OSTI2021

Inkjet-Based 3D Printing: From Quantum Dots to Steel Tools

Inkjet-based additive manufacturing (AM) technologies are highly versatile among manufacturing processes due to their ability to shape any material in powder or ink form. The two inkjet-based AM technologies are binder jetting and material jetting, and as each of their names suggest, the former uses inkjet to deposit binder into the actual build material and the latter uses inkjet to deposit the actual build material. With each of these technologies comes unique opportunities in the form of embedding functional components within the build, creating material gradients within parts by selectively layering feedstocks, shaping non-weldable materials, and creating low-cost tooling with conformal cooling channels. Dr. Amy Elliott at Oak Ridge National Laboratory has explored a variety of materials and approaches with inkjet-based manufacturing technologies, focusing on industry-relevant applications such as injection molding tooling and mining drills.

Elliott, Amy↗

DOE OSTI2021

Alternative low cost electrodes for hybrid flow batteries

An electrode for use in an all-iron redox flow battery is provided. In one example, the electrode may include a plastic mesh; and a coating on the plastic mesh. The coating may be a hydrophilic coating or a conductive coating and the electrode may have an electrode reaction potential is less than 0.8V. Further, a method of manufacturing a coated plastic mesh electrode for use in an all-iron redox flow battery is provided. In one example method, the steps include fabricating a plastic mesh, treating the plastic mesh by applying a solvent treatment or a plasma treatment or a mechanical abrasion treatment; coating the plastic mesh with a material selected from: carbon inks, metal oxides, and hydrophilic polymers.

Evans, Craig E.↗

DOE OSTI2022

Printed Microwave Connector

This paper describes the development of a printed, planar microwave connector operating from 1-7 GHz. The connector, which is based on a Grounded Coplanar Waveguide (GCPW) transmission line structure, is fabricated using 3D-printed thermoplastic material (PEEK) and conductive nanoparticle silver ink. Electromagnetic models were established to provide guidance on design tradeoffs and their impact on microwave performance. New mechanical designs were also developed to provide accurate alignment and robust connection of the two halves of the planar connector structure. Initial connector prototypes were fabricated to validate the new planar design using conventional double-sided copper laminates (Isola MT40). The designs were then implemented in an all-printed version of the connector. Electromagnetic models of the printed connectors were developed using the measured dielectric properties of printed PEEK. The insertion loss of the printed connectors was measured to be less than 1.7dB across the band.

Microwave Connector, printed electronics, additive↗

DOE OSTI2022

Additively manufactured metal energetic ligand precursors and combustion synthesis

Processes for tailoring the macroscopic shape, metallic composition, mechanical properties, and pore structure of nanoporous metal foams prepared through combustion synthesis via direct write 3D printing of metal energetic ligand precursor inks made with water and an organic thickening agent are disclosed. Such processes enable production of never before obtainable metal structures with hierarchical porosity, tailorable from the millimeter size regime to the nanometer size regime. Structures produced by these processes have numerous applications including, but not limited to, catalysts, heat exchangers, low density structural materials, biomedical implants, hydrogen storage medium, fuel cells, and batteries.

Tappan, Bryce↗