Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “built environment”

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 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A Novel High-Temperature Generator/Motor Design: With Applications in Geothermal Drilling and Other Industries

The National Renewable Energy Laboratory (NREL), in partnership with Tetra Corporation and TPL Inc, has an ongoing ARPA-E project related to an advanced high-temperature geothermal drilling system, and the power electronics necessary for this system. As part of this work, NREL designed, built and tested a high-temperature generator for power generation in a 250 degrees Celsius downhole drilling environment. This design exceeded initial performance targets at elevated temperature. NREL is investigating alternative applications for this design, as either a generator or motor capable of efficient performance at high temperature.

alternator↗
DOE OSTI2024

Environmental Degradation in Advanced Reactor Environments

The Advanced Materials and Manufacturing Technologies (AMMT) program operating under the Department of Energy Office of Nuclear Energy is accelerating the qualification and deployment of additively manufactured materials in advanced reactor environments. Laser powder bed fusion (LPBF) has emerged as a promising additive manufacturing technique to fabricate complex components with the potential of tailored material properties. In the nuclear industry, metal additive manufacturing can offer numerous advantages, such as reduced lead times, streamlined quality assurance, and cost-effective low-volume production of new and replacement components with conventional or novel materials and geometries. The rapid and effective qualification of the effect of processing variability on the performance and degradation of additively manufactured materials is essential for the deployment of these components into advanced reactor environments. This talk presents an overview of the Environmental Effects area activities within AMMT. AMMT is performing irradiation and corrosion testing of several materials built by LPBF, including 316L and 316H stainless steels. Our irradiation efforts encompass neutron irradiation testing and ion irradiation testing to provide a robust technical basis for understanding the effect of process variability on materials degradation. We develop focused irradiation test plans that align well with risk-informed and technologically inclusive approaches to licensing. We will also discuss our plans and specific concerns for corrosion testing additively manufactured material, with a primary focus on molten salt and liquid sodium environments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

OmniXAS: A universal deep-learning framework for materials x-ray absorption spectra

X-ray absorption spectroscopy (XAS) is a powerful characterization technique for probing the local chemical environment of absorbing atoms. However, analyzing XAS data presents significant challenges, often requiring extensive, computationally intensive simulations, as well as significant domain expertise. These limitations hinder the development of fast, robust XAS analysis pipelines that are essential in high-throughput studies and for autonomous experimentation. Here, we address these challenges with OmniXAS, a framework that contains a suite of transfer learning approaches for XAS prediction, each uniquely contributing to improved accuracy and efficiency, as demonstrated on the K-edge spectra database covering eight 3⁢d transition metals (Ti–Cu). The OmniXAS framework is built upon three distinct strategies. First, we use M3GNet [Nat. Comput. Sci. 2, 718 (2022)] to derive latent representations of the local chemical environment of absorption sites as input for XAS prediction, achieving significant improvements over conventional featurization techniques. Second, we employ a hierarchical transfer learning strategy, training a universal multitask model across elements before fine-tuning for element-specific predictions. Models based on this cascaded approach after elementwise fine-tuning outperform element-specific models by up to 69%. Third, we implement cross-fidelity transfer learning, adapting a universal model to predict spectra generated by simulation of a different fidelity with a much higher computational cost. This approach improves prediction accuracy by up to 11% over models trained on the target fidelity alone. Our approach significantly boosts the throughput of XAS modeling by orders of magnitude as compared to first-principles simulations and is extendable to XAS prediction for a broader range of elements. The proposed transfer learning framework is generalizable to enhance deep-learning models that target other properties in materials research.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Using Simulation to Analyze Acoustic Environments

One of the main projects that was worked on this semester was creating an acoustic model for the Advanced Space Suit in Comsol Multiphysics. The geometry tools built into the software were used to create an accurate model of the helmet and upper torso of the suit. After running the simulation, plots of the sound pressure level within the suit were produced, as seen below in Figure 1. These plots show significant nulls which should be avoided when placing microphones inside the suit. In the future, this model can be easily adapted to changes in the suit design to determine optimal microphone placements and other acoustic properties. Another major project was creating an acoustic diverter that will potentially be used to route audio into the Space Station's Node 1. The concept of the project was to create geometry to divert sound from a neighboring module, the US Lab, into Node 1. By doing this, no new audio equipment would need to be installed in Node 1. After creating an initial design for the diverter, analysis was performed in Comsol in order to determine how changes in geometry would affect acoustic performance, as shown in Figure 2. These results were used to produce a physical prototype diverter on a 3D printer. With the physical prototype, testing was conducted in an anechoic chamber to determine the true effectiveness of the design, as seen in Figure 3. The results from this testing have been compared to the Comsol simulation results to analyze how closely the Comsol results are to real-world performance. While the Comsol results do not seem to closely resemble the real world performance, this testing has provided valuable insight into how much trust can be placed in the results of Comsol simulations. A final project that was worked on during this tour was the Audio Interface Unit (AIU) design for the Orion program. The AIU is a small device that will be used for as an audio communication device both during launch and on-orbit. The unit will have functions including push-to-talk buttons and volume control. With this project, an existing design was modified based on prior feedback that had been received. With the modified design, I created a 3D printed prototype, shown in Figure 4, which was then used in suited evaluations performed by crew members. The feedback received from those evaluations will be utilized to help create the best possible Orion AIU. As a whole, a number of different interesting engineering projects were worked on over the course of this semester. For many of these projects, acoustic simulations provided valuable insight into how different environments would respond to sound. While work is still underway to verify the results of these simulations, the results are fascinating because of the interesting ways that sound waves interact with the environment. Going forward, it will be interesting to see how closely these results can be matched by real-world test data.

Wood, Eric J.↗
NASA NTRS1988

Techniques for studying the effects of microgravity on model particle/cell systems

To study the direct effects of a low gravity environment on skeletal and cardiac muscle cells, experiments were initiated to determine whether skeletal and/or cardiac muscule cells would grow within the lumen of XM-80 hollow fibers (i.d. = 0.5 mm). Cells were prepared from skeletal or cardiac muscle tissue of 12 day embryos and were cultured for up to 7 days in the hollow fiber environment. Light microscopy revealed that cells proliferated to confluency over this period of time and fusion was apparent in the skeletal muscle cells. Once it was verified that cells would grow to confluency, additional XM-80 fibers containing cells were placed in a Clinostat in the horizontal position at 100 rpm. Fibers were stretched by a built-in spring mechanism to hold the fiber tightly at the center of rotation. Under these conditions, the gravity vector approaches zero and the cells are in an environment that simulates microgravity. Examination of skeletal muscle cells by electron microscopy revealed that myoblast fusion and myofibril accumulation were extensive. Although data obtained thus far are preliminary, they suggest that myofibril organization in chicken skeletal muscle cultures is somewhat more poorly defined in Clinostat rotated cultures than in controls that were not subjected to Clinostat conditions.

Young, Ronald B.↗
NASA NTRS1994

Navy Omni-Directional Vehicle (ODV) development program

The Omni-Directional Vehicle (ODV) development program sponsored by the Office of Naval Research at the Coastal Systems Station has investigated the application of ODV technology for use in the Navy shipboard environment. ODV technology as originally received by the Navy in the form of the Cadillac-Gage Side Mover Vehicle was applicable to the shipboard environment with the potential to overcome conditions of reduced traction, ship motion, decks heeled at high angles, obstacles, and confined spaces. Under the Navy program, ODV technology was investigated and a series of experimental vehicles were built and successfully tested under extremely demanding conditions. The ODV drive system has been found to be applicable to autonomous, remotely, or manually operated vehicles. Potential commercial applications include multi-directional forklift trucks, automatic guided vehicles employed in manufacturing environments, and remotely controlled platforms used in nuclear facilities or for hazardous waste clean up tasks.

Mcgowen, Hillery↗
DOE OSTI2022

GeoSoilEnviroCARS (Sector 13) at the Advanced Photon Source: a comprehensive synchrotron radiation facility for Earth science research at ambient and extreme conditions

GeoSoilEnviroCARS (GSECARS) is a comprehensive analytical laboratory for Earth and environmental science research using X-ray beams from the Advanced Photon Source, Argonne National Laboratory. State-of-the-art instruments are available for (1) high-pressure/high- or low-temperature diffraction, total scattering, and spectroscopy (Brillouin, Raman, and VIS-IR) using the laser heated diamond anvil cell (DAC); (2) high-pressure/high-temperature diffraction, scattering, and imaging as well as acoustic emission (AE) and ultrasonics using the large-volume press (LVP); (3) powder, single crystal, and surface/interface diffraction; (4) X-ray absorption fine structure spectroscopy; (5) X-ray fluorescence microprobe analysis; and (6) microtomography. As shown here, experiments are facilitated by senior level staff who collaborate on all aspects of the analytical work including experiment design, sample preparation, data collection, data interpretation, and publication preparation. Both technical and scientific synergies occur as a result of the intimate association of the various techniques and scientists experienced in the applications of synchrotron radiation to Earth, environmental, and planetary science problems. The facility includes state-of-the-art instrumentation designed and built in-house, including custom X-ray optics, online and offline laser-based systems, specialized sample environments and positioning systems, as well as pixel-array and multi-crystal energy dispersive X-ray detectors, which are available to be shared among the experimental stations.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The impact of capillary heterogeneity on CO 2 flow and trapping across scales

Capillary heterogeneity has been identified over the last decade as a key control on subsurface CO 2 flow behavior during geological CO 2 sequestration. These heterogeneities can be formed in all sedimentary rocks, ranging from slight variations in the sand grain sizes to extensive sequences of interbedded sands, shales, and limestones. Capillary heterogeneity has been largely, although not entirely, overlooked in subsurface flow modeling because it is assumed to only directly influence fluid redistribution over scales of centimeters to meters. However, even small-scale fluid movements can result in dramatic impacts on the mobility and trapping of the CO 2 over kilometers. Therefore, neglecting capillary heterogeneity at multiple scales could potentially lead to errors in modeling and predicting field-scale plume migration. In this review paper, we aim to provide a consistent overview to (1) establish that capillary heterogeneity can have a major impact on CO 2 plume migration, (2) establish the respective length scales at which capillary heterogeneity matters, and (3) provide guidance for numerical modeling. This review covers pertinent literature and extracts key observations from the core to the field scales. Experimental studies have shown that millimeter-decimeter scale capillary heterogeneity can cause the so-called capillary heterogeneity trapping in addition to pore-scale residual trapping. Even at such a small scale, capillary heterogeneity can already lead to complex upscaled constitutive relationships, such as flow-rate dependent and anisotropic relative permeability, which affects field-scale CO 2 migration even when field-scale heterogeneities are present. Under gravity-dominated flow regimes, centimeter-meter scale capillary heterogeneity can entrap a significant amount of CO 2 at field scale, not just after imbibition but also during drainage. In certain cases, the presence of capillary heterogeneity can even completely stop the vertical movement of the CO 2 plume, hence greatly reducing leakage risks. At meter-kilometer scale, the influence of capillary heterogeneity is more pronounced and can hinder or redirect CO 2 migration in both lateral and vertical directions. The impact of capillary heterogeneity across multiple spatial scales poses a great challenge in modeling CO 2 migration at field scale, because it is practically impossible to build a field-scale earth model with grid blocks at millimeter scale. We recommend a hierarchical modeling approach to address this challenge. At field scale, earth models are built to capture geological features and heterogeneities in high but still practical grid resolutions. For each facies or rock type of the field-scale model, high- resolution meter-scale “conceptual” models are built with millimeter-scale grid blocks to capture representative fine-scale bedding geometries and heterogeneities in various environments of deposition, bridging the gap from subcore scale to the size of a field-scale simulation grid block. Upscaling is then used to preserve the smaller-scale flow dynamics of various rock types in field-scale simulations. Here, future work is needed to (1) refine, improve, and validate the hierarchical modeling approach; (2) build libraries of fine-scale bedding models for facies in various environments of deposition; (3) quantify multiscale capillary heterogeneity effects under subsurface uncertainties; (4) gain learning from different storage formations; and (5) establish best practices that balance accuracy and computational speed.

Capillary heterogeneity↗
DOE OSTI2019

Ultra Efficient Light Duty Powertrain with Gasoline Low Temperature Combustion (Final Report)

This document details the work completed during Project DE-EE0006839 ‘Ultra Efficient Light Duty Powertrain with Gasoline Low Temperature Combustion’. All tasks from the project’s Statement of Project Objectives are discussed. Final demonstration data is also presented and discussed. Further project details can be found in the Quarterly Technicial Reports that were submitted during the course of the project and are stored on the EERE Project Management Center Website. The goal of this project was to develop, implement and demonstrate a low temperature combustion approach called Gasoline Direct Injection Compression Ignition (GDCI) that provides high thermal efficiency with low NOx and PM emissions. The project target was to demonstrate a 35% fuel economy improvement over the baseline vehicle while meeting Tier 3 emissions levels. At the start of this project, GDCI was a moderately mature combustion technology, due in large part to advances made during a Delphi Technologies program funded through an earlier Department of Energy Advanced Technology Powertrains (ATP) opportunity; under that earlier contract, DE-EE0003258, Delphi Technologies assembled a team with complementary industrial and academic experience, and led this team to advance the technology from the original fundamental work to the state of art embodied by a first-generation (Gen 1) multi-cylinder GDCI engine. Key activities during that project centered on engine and combustion chamber design, and development of fuel injection equipment, valvetrain and advanced controls. Performance results with the Gen 1 engine in a development vehicle demonstrated that GDCI had the capability to operate using Low Temperature Combustion (LTC) over a broad speed-load range. Based on benchmarking work, efficiency for the Gen 1 GDCI engine compared favorably overall to production light-duty diesel engines. The second DOE funded project, DE-EE0006839, focused on a number of technical risks and issues that were left to be resolved for GDCI to become a production-viable technology. These risks were:GDCI combustion system refinement to achieve near-ideal air/fuel mixture preparation for high efficiency and low HC and CO emissions; Transient control development for low temperature combustion with high EGR levels during real-world transient driving maneuvers and over a broader range of ambient conditions; Aftertreatment system design that is effective in dealing with the low-temperature challenges of a highly efficient engine. The project was executed in two phases. Phase 1 leveraged the development vehicle from the Advanced Technologies Powertrain 1 (ATP1) project, DE-EE0003258. That vehicle was used as an initial test bed in the development of a high performance low temperature exhaust aftertreatment system. The vehicle was also used to develop calibration refinements for improved exhaust emissions and fuel efficiency. Samples of a new GDCI development level engine, called Gen2 GDCI (and developed outside of the first DOE funded project), were also used during Phase 1 to develop refined controller hardware and control algorithms, as well as improved sensors and actuators. The Gen2 engine was then retrofitted into the development vehicle from the ATP1 project and used for controls refinement and calibration of GDCI to achieve improved cold start, drivability and robustness to real world environments and fuel variations. During Phase 2 of the project, Gen3 versions of the GDCI engine were designed and built specifically for this project based on experience from the earlier engines. These engines were designed to be production-like in construction and, when combined with refined control systems and project specific low temperature exhaust aftertreatment, were intended to support the goal of meeting Tier 3 emissions levels at a vehicle level. Though great progress had been made advancing the GDCI combustion process, and despite extensive presentations of our work on the technology at various conferences and in direct meetings with automotive companies, none of the US domestic automotive OEMs had shown an interest in adopting this combustion process as part of their technology planning as the project approached the Go/No-Go point at the end of Budget Period 3. As a result of this low-level of interest both the US Department of Energy and Delphi Technologies received in this technology from domestic auto manufactures, Delphi Technologies elected a ‘No-Go’ status for the gate between Budget Period 3 and Budget Period 4 which terminated the project without spending any Budget Period 4 funds. The project team concluded that the dynamometer mapping of the most recent level of hardware, combined with the vehicle level simulation by Argonne National Laboratory, was sufficient to document the capabilities and potential of the combustion process without spending the time and money to do the controls development and full calibration necessary for a demonstration vehicle.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1973

Vectorcardiogram

System measures electrocardiographic potentials to produce precise quantitative measurement of changes that occur in individual's cardiac function. System is rugged, built to sustain extremes of temperature, pressure, humidity, shock, and vibration. It can also be used in pure oxygen environment without danger of combustion.

Costello, M.↗
NASA NTRS1980

Mechanical-load indicator

By rotation of washerlike part, mechanical indicator shows when predetermined compression or tension load has been reached. Indicator consists of bolt, sleeve, load-indicating washer, and nut. Besides application as load indicator, device has uses as remote indicator of mechanical action. Rotating washer can also act as sequencer, signaling action to begin upon attainment of certain load. It can be used, for example, to initiate work cycle after stored energy has been built up in hydraulic or pneumatic power equipment. It can also be used as remote, nonelectrical switch in hazardous environments.

Appleberry, W. T.↗
NASA NTRS2002

Demonstration of a Spoken Dialogue Interface for Planning Activities of a Semi-autonomous Robot

Planning and scheduling in the face of uncertainty and change pushes the capabilities of both planning and dialogue technologies by requiring complex negotiation to arrive at a workable plan. Planning for use of semi-autonomous robots involves negotiation among multiple participants with competing scientific and engineering goals to co-construct a complex plan. In NASA applications this plan construction is done under severe time pressure so having a dialogue interface to the plan construction tools can aid rapid completion of the process. But, this will put significant demands on spoken dialogue technology, particularly in the areas of dialogue management and generation. The dialogue interface will need to be able to handle the complex dialogue strategies that occur in negotiation dialogues, including hypotheticals and revisions, and the generation component will require an ability to summarize complex plans. This demonstration will describe a work in progress towards building a spoken dialogue interface to the EUROPA planner for the purposes of planning and scheduling the activities of a semi-autonomous robot. A prototype interface has been built for planning the schedule of the Personal Satellite Assistant (PSA), a mobile robot designed for micro-gravity environments that is intended for use on the Space Shuttle and International Space Station. The spoken dialogue interface gives the user the capability to ask for a description of the plan, ask specific questions about the plan, and update or modify the plan. We anticipate that a spoken dialogue interface to the planner will provide a natural augmentation or alternative to the visualization interface, in situations in which the user needs very targeted information about the plan, in situations where natural language can express complex ideas more concisely than GUI actions, or in situations in which a graphical user interface is not appropriate.

Dowding, John↗
NASA NTRS2012

Overview of an Indoor Sonic Boom Simulator at NASA Langley Research Center

A facility has been constructed at NASA Langley Research Center to simulate the soundscape inside residential houses that are exposed to environmental noise from aircraft. This controllable indoor listening environment, the Interior Effects Room, enables systematic study of parameters that affect psychoacoustic response. The single-room facility, built using typical residential construction methods and materials, is surrounded on adjacent sides by two arrays of loudspeakers in close proximity to the exterior walls. The arrays, containing 52 subwoofers and 52 mid-range speakers, have a usable bandwidth of 3 Hz to 5 kHz and sufficient output to allow study of sonic boom noise. In addition to these exterior arrays, satellite speakers placed inside the room are used to augment the transmitted sound with rattle and other audible contact ]induced noise that can result from low frequency excitation of a residential house. The layout of the facility, operational characteristics, acoustic characteristics and equalization approaches are summarized.

Klos, Jacob↗
NASA NTRS2014

Robot Task Commander with Extensible Programming Environment

A system for developing distributed robot application-level software includes a robot having an associated control module which controls motion of the robot in response to a commanded task, and a robot task commander (RTC) in networked communication with the control module over a network transport layer (NTL). The RTC includes a script engine(s) and a GUI, with a processor and a centralized library of library blocks constructed from an interpretive computer programming code and having input and output connections. The GUI provides access to a Visual Programming Language (VPL) environment and a text editor. In executing a method, the VPL is opened, a task for the robot is built from the code library blocks, and data is assigned to input and output connections identifying input and output data for each block. A task sequence(s) is sent to the control module(s) over the NTL to command execution of the task.

Hart, Stephen W↗
NASA NTRS2015

Fundamentals for Team Based Rehearsals and the Differences Between Low Earth and Deep Space Missions

Presentation to be presented at the 2015 IEEE Aerospace Conference, Big Sky, Montana, March 7-14-2015.Rehearsals are mission level readiness tests that exercise personnel, operational process, and flight products, in a near flight like environment. The program is started 6-9 months prior to launch and is used to ensure the final as built system will meet mission goals (i.e. validation). On Deep Space missions you rehearse cruise activities post launch!Focus on critical activities to the mission, (i.e. propulsive maneuvers, instrument commissioning and any first time events or coordinating activities that involve major stakeholders).

Deep Space Missions↗
NASA NTRS2022

NASA Orbital Debris Engineering Model (ORDEM) 3.1: Model Verification and Validation

The NASA Orbital Debris Engineering Model (ORDEM) 3.1 Model Verification and Validation (V&V) document accompanies the delivery of the latest ORDEM 3.1 model (Vavrin & Manis, 2019) and provides a detailed description of the V&V activities used to verify that the model was built correctly and validate the model against independent, real world sources of data obtained from sampling the orbital debris environment. This ORDEM 3.1 Model V&V document, along with the related ORDEM 3.1 Model Process document – which covers details of the mathematical, statistical, and physical basis of the model – are intended to inform credibility assessments, risk analyses, uncertainty characterizations, and other applications derived from use of the model by the ORDEM 3.1 user community.

Timothy Kennedy↗
DOE OSTI2021

Assembling a Cyber Range to Evaluate Artificial Intelligence / Machine Learning (AI/ML) Security Tools

In this case study, we will describe the design and assembly of a cyber security test range we have built at Oak Ridge National Laboratory in Oak Ridge, TN, USA. The range is designed to provide a flexible environment to evaluate cyber security tools—particularly those involving AI/ML—in a way that provides realistic environments and where we can control the experiments to determine the strengths and weaknesses of the tools. We have designed in the ability to repeat the evaluations, so additional tools can be evaluated and compared at a later time. The system is one that can be scaled up or down for experiment sizes. At the time of the conference we will have completed two full-scale, national, government challenges on this range. These challenges are evaluating the performance and operating costs for AI/ML-based cyber security tools for application into large, government-sized environments. These evaluations will be described, in order to provide motivation and context for various design decisions and adaptations we have made. The first challenge measured end-point security tools against 100K malware samples chosen across a range of types. The second is network detection of attempted penetration and exploitations with varying levels of covertness in a high-volume, business network. The scale of each of these challenges is requiring us to create automation systems to repeat the experiments identically for each tool. Preventing there being easy signs of malicious activity for the AI/ML tools to focus on has been a particularly interesting and challenging aspect of designing and executing these challenge events. After the events, the range continues to be used for other research such as adversarial machine learning where the repeatability, scale, and automation required for the national challenge events become essential elements for research.

Nichols, Jeff↗
DOE OSTI2021

SURFACE FINISHING AND ELECTROLESS NICKEL PLATING OF ADDITIVELY MANUFACTURED (AM) METAL COMPONENTS

This study investigates the application of electroless nickel deposition on additively manufactured stainless steel samples. Current additive manufacturing (AM) technologies produce metal components with a rough surface. Rough surfaces generally exhibit fatigue characteristics, increasing the probability of initiating a crack or fracture to the printed part. For this reason, the direct use of as-produced parts in a finished product cannot be actualized, which presents a challenge. Post-processing of the AM parts is therefore required to smoothen the surface. This study analyzes chempolish (CP) and electropolish (EP) surface finishing techniques for post-processing AM stainless steel components CP has a great advantage in creating uniform, smooth surfaces regardless of size or part geometry EP creates an extremely smooth surface, which reduces the surface roughness to the sub-micrometer level. In this study, we also investigate nickel deposition on EP, CP, and as-built AM components using electroless nickel solutions. Electroless nickel plating is a method of alloy treatment designed to increase manufactured component's hardness and surface resistance to the unrelenting environment. The electroless nickel plating process is more straightforward than its counterpart electroplating.. We use low-phosphorus (2-5% P), medium-phosphorus (6-9% P), and high-phosphorus (10-13% P). These Ni deposition experiments were optimized using the L9 Taguchi design of experiments (TDOE), which compromises the prosperous content in the solution, surface finish, plane of the geometry, and bath temperature. The pre-and post-processed surface of the AM parts was characterized by KEYENCE Digital MicroscopeVHX-7000 and Phenom XL Desktop SEM. The experimental results show that electroless nickel deposition produces uniform Ni coating on the additively manufactured components up to 20 μm per hour. Mechanical properties of as-built and Ni coated AM samples were analyzed by applying a standard 10 N scratch test. Nickel coated AM samples were up to two times scratch resistant compared to the as-built samples. This study suggests electroless nickel plating is a robust viable option for surface hardening and finishing AM components for various applications and operating conditions.

Keywords: additive manufacturing, fatigue, chempol↗