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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 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Large-Scale Welding Process Simulation by GPU Parallelized Computing

The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small coupons and reduced order (from three-dimensional [3D] to two-dimensional [2D]), or inherent strain approximations were used for large structures. In this current study, an explicit finite element code based on a graphics processing unit was utilized to perform 3D transient thermomechanical simulation of structural components during welding. Laser brazing of aluminum alloy panels as representative of automotive manufacturing scenarios was simulated to predict out-of-plane distortion under different clamping conditions. The predicted deformation pattern and magnitude were validated by laser scanning data of physical assemblies. In addition, the code was used to investigate residual stresses developed during multipass arc welding of a nuclear industry pressurizer surge nozzle and subsequent welding repair where a 3D simulation was necessary. Taking the experimental data as reference, the 3D model predicted better residual stress distribution than a typical 2D asymmetrical model. Stress evolution in welding repair was also presented and discussed in this study. Furthermore, the efficient numerical model made it feasible to use integrated computational welding engineering to simulate welding processes for large-scale structures.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Selective laser melting of oxide dispersion strengthened MA956 alloy and its surface finishing by magnetic field assisted finishing

Selective laser melting (SLM) is a prominent metal additive manufacturing (AM) capable of processing a myriad of engineering materials with high precision and design freedom. However, similar to other AM processes, poor surface finishing has been an omnipresent problem in SLM technology. In this study, magnetic field assisted finishing (MAF) was used to finish SLM fabricated oxide dispersion strengthened (ODS) MA956, an iron-chromium-aluminum alloy. The effect of laser processing parameters on part density and surface roughness was first studied. Using a multi-objective optimization technique, the optimal parameters to obtain the highest density and lowest surface roughness were determined. Finally, MAF was applied to the parts built with the obtained optimal SLM parameters, but without significant improvement on the surfaces of as-printed samples. Hence, the surfaces of as-printed samples were post-processed (ground) to yield better initial surface conditions prior to MAF. The effect of initial roughness, iron particles size, and abrasive size on MAF performance was studied. Initial roughness had the most dominant effect followed by abrasive size. The underlying mechanism behind the dependency on initial roughness on final surface quality was analyzed by studying the change on the surface profiles with different starting initial roughness. The initial roughness required for MAF to be effective was determined. In conclusion, using the optimal processing conditions, MAF was applied to the post-processed samples to attain the final average surface roughness (R a ) as little as 0.36 μm starting from initial average roughness (R a ) of 1.53 μm.

36 MATERIALS SCIENCE↗
NASA NTRS2015

Summary of Liquid Oxygen/Hydrogen, Direct Metal Laser Sintering Injector Testing and Evaluation Effort at Marshall Space Flight Center

The last several years have witnessed a significant advancement in the area of additive manufacturing technology. One area that has seen substantial expansion in application has been laser sintering (or melting) in a powder bed. This technology is often termed 3D printing or various acronyms that may be industry, process, or company specific. Components manufactured via 3D printing have the potential to significantly reduce development and fabrication time and cost. The usefulness of 3D printed components is influenced by several factors such as material properties and surface roughness. This paper details three injectors that were designed, fabricated, and tested in order to evaluate the utility of 3D printed components for rocket engine applications. The three injectors were tested in a hot‐fire environment with chamber pressures of approximately 1400 psia. One injector was a 28 element design printed by Directed Manufacturing. The other two injectors were identical 40 element designs printed by Directed Manufacturing and Solid Concepts. All the injectors were swirl‐coaxial designs and were subscale versions of a full‐scale injector currently in fabrication. The test and evaluation programs for the 28 element and 40 element injectors provided a substantial amount of data that confirms the feasibility of 3D printed parts for future applications. The operating conditions of previously tested, conventionally manufactured injectors were reproduced in the 28 and 40 element programs in order to contrast the performance of each. Overall, the 3D printed injectors demonstrated comparable performance to the conventionally manufactured units. The design features of the aforementioned injectors can readily be implemented in future applications with a high degree of confidence.

Barnett, Gregory↗
DOE OSTI2022

Predicting defects in laser powder bed fusion using in-situ thermal imaging data and machine learning

Variation in the local thermal history during the Laser Powder Bed Fusion (LPBF) process in Additive Manufacturing (AM) can cause micropore defects, which add to the uncertainty of the mechanical properties (e.g., fatigue life, tensile strength) of the built materials. In-situ sensing has been proposed for monitoring the AM process to minimize defects, but successful minimization requires establishing a quantitative relationship between the sensing data and the porosity, which is particularly challenging with a large number of variables (e.g., laser speed, power, scan path, powder property). Physics-based modeling can simulate such an in-situ sensing-porosity relationship, but it is computationally costly. In this work, we develop Machine Learning (ML) models that can use in-situ thermographic data to predict the micropore of LPBF stainless steel materials. This work considers two identified key features from the thermal histories: the time above the apparent melting threshold ($\tau$) and the maximum radiance ( T max ). These features are computed, stored for each voxel in the built material, and then used as inputs. The binary state of each voxel, either defective or normal, is the output. Different ML models are trained and tested for the binary classification task. In addition to using the thermal features of each voxel to predict its own state, the thermal features of neighboring voxels are also included as inputs. This is shown to improve the prediction accuracy, which is consistent with thermal transport physics around each voxel contributing to its final state. Among the models trained, the F1 scores on test sets reach above 0.96 for Random Forests. Feature importance analysis based on the ML models shows that T max is more important to the voxel state than $\tau$ . The analysis also finds that the thermal history of the voxels above the present voxel is more influential than those beneath it. Our study significantly extends the capability of using in-situ thermographic data to predict porosity in LPBF materials. Finally, since ML models are fast, they may play integral roles in the optimization and control of such AM technologies.

36 MATERIALS SCIENCE↗
NASA NTRS2019

Evaluation of an Alternate Method for Determining Yield Strength Offset Values for Selective Laser Sintered Polymeric Materials

Due to the unique characteristics of Additively Manufactured (AM) polymeric materials, typical mechanical strength characterization methods such as those commonly used for traditionally-processed polymers or composite materials can produce results that do not accurately represent material capabilities. In order to characterize mechanical properties of these materials, new test and analysis methods are required. As part of the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP), Boeing has evaluated true yield testing as an alternative or complimentary test to 0.2% offset yield testing for determining appropriate yield strength values of polymer materials. Previous testing has shown high strain, low modulus polymer materials such as selective laser sintered (SLS) Nylon 11 at elevated temperatures produce large variations in yield strength. The true yield test method was successful in finding the applied strain level when yield commences and appears to offer an increase in data robustness.

Henry, Chelsey↗
NASA NTRS2018

Thermophysical Properties of Nickel-Based Superalloys

The NASA Marshall Space Flight Center (MSFC) electrostatic levitation (ESL) laboratory has a long history of providing materials research and thermophysical property data. The lab can measure thermophysical properties such as density, surface tension, and viscosity of liquid materials, including elements, alloys, glasses, ceramics, and oxides. Nickel-based superalloys (e.g. Inconel, Hastelloy, and Waspaloy) have many high performance applications, including turbine engines for aerospace. Superalloy parts are typically manufactured by casting and forging. These processes generate both polycrystalline and monocrystalline parts. A relatively new method of fabrication of turbine disk materials is additive manufacturing, which is typically done for aerospace parts by powder-bed methods such as selective laser melting (SLM). Accurate modeling of casting and forging, as well as additively manufacturing processes, require thermophysical properties (density, surface tension, and viscosity). The thermophysical properties of liquid nickel-based superalloys, both conventional and additively manufactured, were measured at several temperatures in both undercooled and superheated condition. Surface tension and viscosity was measured using the oscillating drop method and density and thermal expansion was measured using edge detection methods.

SanSoucie, Michael P.↗
NASA NTRSDate not supplied

Making & Breaking the Rules for DED Design

Design for Additive Manufacturing (DfAM) is widely used to describe design activities and guidelines employed in the creation of Additively Manufactured (AM) parts. Basic design rules for widely adopted processes like Powder Bed Fusion (PBF) are relatively understood including material performance, part size constraints, self-supporting angles, overhangs, wall thicknesses, and feature resolution. Complexity is often inherent with PBF using organically inspired solutions through generative design and topology optimization software to create designs that often cannot be realized via traditional manufacturing processes. The design rules for Directed Energy Deposition (DED) are less well known, and, in some cases, the lack of understanding is likely inhibiting broader application of the various DED processes. This presentation covers key design rules for DED fusion processes and elucidates opportunities like multi-material deposition and build approaches ranging from basic features to complex large-scale parts. Complementary to the opportunistic characteristics of DfAM for DED, Manufacture for AM (MfAM) encompasses the restrictive aspects of the manufacturing lifecycle with limitations due to bead width and wall thickness, self-supporting angles, surface texture, microstructural evolution, and residual stresses. AM enabled part design must always consider the entire value chain starting with incoming feedstock (e.g. plate, wire, or powder) and progressing through the printing process, post-processing (e.g. machining, inspection), and final system assembly. Key considerations, like the tradeoffs between feature resolution and build rate, for process and part selection and economic assessments will be discussed as DED is often traded against other AM processes. After highlighting typical DED design rules, we will also show how some of those rules can be broken via use cases and part designs that span the full spectrum of DED processes with examples of various DED part designs.

Additive Manufacturing↗
NASA NTRS2019

Additive Manufacturing of NASA HR-1 Material for Liquid Rocket Engine Component Applications

NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 was originally developed at NASA in the 1990’s and derived from JBK-75 to increase strength and ductility in high-pressure hydrogen environments. The NASA HR-1 chemistry was formulated to meet requirements for liquid rocket engine applications, specifically components used in a high-pressure hydrogen environment. Recent developments using additive manufacturing (AM) have made this material an attractive option for channel-cooled nozzles under the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) program and other liquid rocket engine component applications. The RAMPT program has baselined to fully evolve and characterize NASA HR-1 material. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for channel-cooled nozzles in high heat flux environments. Initial development and characterization has been completed using blown powder Directed Energy Deposition (DED) and Laser Powder Bed Fusion (L-PBF) additive manufacturing techniques to develop material test samples and nozzle hardware. NASA HR-1 powder has been sourced and characterized from several powder suppliers, and a series of development and hardware samples completed fabrication using DED and L-PBF. Characterization of the material has included heat treatment development, metallography, chemistry evaluations, mechanical testing, measurement of thermophysical properties, and fabrication of relevant nozzle hardware to demonstrate feasibility. This paper presents results from the process and early materials development and provide future development work including hardware fabrication.

Katsarelis, Colton↗
DOE OSTI2021

How Austenitic Is a Martensitic Steel Produced by Laser Powder Bed Fusion? A Cautionary Tale

Accurate phase fraction analysis is an essential element of the microstructural characterization of alloys and often serves as a basis to quantify effects such as heat treatment or mechanical deformation. Additive manufacturing (AM) of metals, due to the intrinsic nonequilibrium solidification and spatial variability, creates additional challenges for the proper quantification of phase fraction. Such challenges are exacerbated when the alloy itself is prone to deformation-induced phase transformation. Using commonly available in-house X-ray diffraction (XRD) and electron backscatter diffraction (EBSD) and less commonly used synchrotron-based high-energy X-ray diffraction, we characterized nitrogen-atomized 17-4 precipitation-hardening martensitic stainless steel, a class of AM alloy that has received broad attention within the AM research community. On the same build, our measurements recovered the entire range of reported values on the austenite phase fractions of as-built AM 17-4 in literature, from ≈100% martensite to ≈100% austenite. Aided by Calphad simulation, our experimental findings established that our as-built AM 17-4 is almost fully austenitic and that in-house XRD and EBSD measurements are subject to significant uncertainties created by the specimen’s surface finish. Hence, measurements made using these techniques must be understood in their correct context. Our results carry significant implications, not only to AM 17-4 but also to AM alloys that are susceptible to deformation-induced structure transformation and suggest that characterizations with less accessible but bulk sensitive techniques such as synchrotron-based high energy X-ray diffraction or neutron diffraction may be required for proper understanding of these materials.

17-4 steel↗
DOE OSTI2020

Wire-Based Additive Manufacturing of Stainless Steel Components

In this work three different wire-fed additive manufacturing (AM) processes were employed to evaluate differences between laser, arc, and electron beam heat sources used for high-deposition-rate AM on the order of 1 kg/h. Optimum weld and build parameters were developed independently to match the characteristics of each heat source using 308L stainless steel welding wire as the feedstock. Laser-wire AM was made with the lowest energy per unit length of weld and had the best control of the melt pool and surface finish. Wire arc-based AM had an intermediate energy per unit length of weld of approximately 5× that of the laser process, while electron beam wire AM had the highest energy per unit length of weld at approximately 10× that of the laser process. Analysis of the parts that were built included evaluation of mechanical properties and microstructures, and these properties are discussed with respect to the difference in input energy and cooling rates. Results show that all three processes build parts with properties that exceed those of annealed 304L wrought stainless steel. However, significant differences exist between the processes, and the results presented here can be used to help select the best wire-fed process for a given high-deposition-rate application.

36 MATERIALS SCIENCE↗
DOE OSTI2025

High temperature tensile properties of H13 tool steel fabricated via binder jet additive manufacturing

H13 is one of the most used steels for hot work tooling applications like die casting. Binder jet additive manufacturing (BJAM) offers a cost-effective solution to fabricate tools with performance enhancing features like internal cooling channels. While full densification of BJAM H13 has been demonstrated in the literature, the room and high temperature tensile properties of the material, and the effect of post-process treatments like hot isostatic pressing (HIP), and heat treatment (HT) are unknown. Here we use HIP+HT to obtain a combination of ultimate tensile strength (UTS) and elongation to failure that is superior to H13 fabricated via laser powder bed fusion and wire arc additive manufacturing. HIP+HT BJAM H13 has a superior UTS (1836 MPa) compared with conventionally processed (1671 MPa) H13 but has lower plastic elongation. We report that as-sintered samples have an extensive network of continuous grain boundary (GB) carbides that contribute to brittle fracture. HIP+HT results in partial dissolution of GB carbides and formation of a fine martensitic microstructure resulting in superior tensile strength and elongation compared with as-sintered H13. We use thermo-kinetic calculations to rationalize the effects of HIP+HT on microstructure and properties.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Design of a GRCop-42 Regeneratively Cooled Thrust Chamber Assembly and Feed System

An additively manufactured thrust chamber assembly was designed and printed using laser powder bed fusion. The NASA-developed material GRCop-42 was used for its high strength and high temperature characteristics. The combustion chamber and nozzle utilize regenerative coolant channels to achieve long duration hot fire tests. Design for additive manufacturing was used to create geometries not easily attainable with traditional machining. The thrust chamber assembly was post processed to ensure print quality and verify for testing. A feed system – encompassing all propellant lines, valves, sensors, and tanks – was designed and built to enable steady state, pressure regulated testing. Pressure transducers, thermocouples, and load cells were placed to enable measurements of the propellant properties and engine performance. Venturis and orifices were used throughout the system to control the flow rates to the thrust chamber. Aside from providing propellants, the feed system provides pressure using nitrogen, and purges the lines during shutdown. The design process for this testing platform is described. A testing campaign on the hardware will be conducted by the Akronauts Rocket Design Team at the University of Akron in Spring 2023.

Dillon M. Petty↗
NASA NTRSDate not supplied

Design of a GRCop-42 Regeneratively Cooled Thrust Chamber Assembly and Feed System

An additively manufactured thrust chamber assembly was designed and printed using laser powder bed fusion. The NASA-developed material GRCop-42 was used for its high strength and high temperature characteristics. The combustion chamber and nozzle utilize regenerative coolant channels to achieve long duration hot fire tests. Design for additive manufacturing was used to create geometries not easily attainable with traditional machining. The thrust chamber assembly was post processed to ensure print quality and verify for testing. A feed system – encompassing all propellant lines, valves, sensors, and tanks – was designed and built to enable steady state, pressure regulated testing. Pressure transducers, thermocouples, and load cells were placed to enable measurements of the propellant properties and engine performance. Venturis and orifices were used throughout the system to control the flow rates to the thrust chamber. Aside from providing propellants, the feed system provides pressure using nitrogen, and purges the lines during shutdown. The design process for this testing platform is described. A testing campaign on the hardware will be conducted by the Akronauts Rocket Design Team at the University of Akron in Spring 2023.

Dillon M. Petty↗
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 NTRS2011

Multiple-Zone Diffractive Optic Element for Laser Ranging Applications

A diffractive optic element (DOE) can be used as a beam splitter to generate multiple laser beams from a single input laser beam. This technology has been recently used in LRO s Lunar Orbiter Laser Altimeter (LOLA) instrument to generate five laser beams that measure the lunar topography from a 50-km nominal mapping orbit (see figure). An extension of this approach is to use a multiple-zone DOE to allow a laser altimeter instrument to operate over a wider range of distances. In particular, a multiple-zone DOE could be used for applications that require both mapping and landing on a planetary body. In this case, the laser altimeter operating range would need to extend from several hundred kilometers down to a few meters. The innovator was recently involved in an investigation how to modify the LOLA instrument for the OSIRIS asteroid mapping and sample return mission. One approach is to replace the DOE in the LOLA laser beam expander assembly with a multiple-zone DOE that would allow for the simultaneous illumination of the asteroid with mapping and landing laser beams. The proposed OSIRIS multiple-zone DOE would generate the same LOLA five-beam output pattern for high-altitude topographic mapping, but would simultaneously generate a wide divergence angle beam using a small portion of the total laser energy for the approach and landing portion of the mission. Only a few percent of the total laser energy is required for approach and landing operations as the return signal increases as the inverse square of the ranging height. A wide divergence beam could be implemented by making the center of the DOE a diffractive or refractive negative lens. The beam energy and beam divergence characteristics of a multiple-zone DOE could be easily tailored to meet the requirements of other missions that require laser ranging data. Current single-zone DOE lithographic manufacturing techniques could also be used to fabricate a multiple-zone DOE by masking the different DOE zones during the manufacturing process, and the same space-compatible DOE substrates (fused silica, sapphire) that are used on standard DOE s could be used for multiple- zone DOE s. DOEs are an elegant and cost-effective optical design option for spacebased laser altimeters that require multiple output laser beams. The use of multiple-zone DOEs would allow for the design and optimization of a laser altimeter instrument required to operate over a large range of target distances, such as those designed to both map and land on a planetary body. In addition to space-based laser altimeters, this technology could find applications in military or commercial unmanned aerial vehicles (UAVs) that fly at an altitude of several kilometers and need to land. It is also conceivable that variations of this approach could be used in land-based applications such as collision avoidance and robotic control of cars, trains, and ships.

Ramos-Izquierdo, Luis A.↗
DOE OSTI2020

Microstructural banding of directed energy deposition-additively manufactured 316L stainless steel

The microstructures of 316 L stainless steel created by rapid solidification are investigated here by comparing the similar microstructures of individual hatches of directed energy deposition additive manufacturing (DED-AM) and those of single, laser surface-melted tracks formed on a solid plate. High recoil pressure, which is exponentially dependent on the laser beam power density, induces convection of the melt pool, which causes formation of microstructural bands in the as-solidified microstructure. The microstructural bands are associated with changes in the chromium concentration and are a significant component of the inhomogeneous microstructure of DED-AM.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The development of an augmented machine learning approach for the additive manufacturing of thermoelectric materials

Through the integration of machine learning (ML) techniques alongside additive manufacturing (AM) experimentation, we demonstrate an iterative process to rapidly predict laser-material interactions and melt pool geometries throughout the build parameter space for a bismuth telluride thermoelectric (TE) material. In doing so, we determined process parameters that created crack-free, highly dense (>99 %) n-type bismuth telluride (Bi 2 Te 2.7 Se 0.3 ) parts through laser powder bed fusion (LPBF). Furthermore, the ML-assisted understanding of the processing space allowed for the identification of build parameters that successfully yielded geometrically enhanced Bi 2 Te 2.7 Se 0.3 parts with reduced build times and no increase in experimental effort.

36 MATERIALS SCIENCE↗