Results for “Casting Designs” — Page 5

NASA NTRS2006

Embedded Sensors for Measuring Surface Regression

The development and evaluation of new hybrid and solid rocket motors requires accurate characterization of the propellant surface regression as a function of key operational parameters. These characteristics establish the propellant flow rate and are prime design drivers affecting the propulsion system geometry, size, and overall performance. There is a similar need for the development of advanced ablative materials, and the use of conventional ablatives exposed to new operational environments. The Miniature Surface Regression Sensor (MSRS) was developed to serve these applications. It is designed to be cast or embedded in the material of interest and regresses along with it. During this process, the resistance of the sensor is related to its instantaneous length, allowing the real-time thickness of the host material to be established. The time derivative of this data reveals the instantaneous surface regression rate. The MSRS could also be adapted to perform similar measurements for a variety of other host materials when it is desired to monitor thicknesses and/or regression rate for purposes of safety, operational control, or research. For example, the sensor could be used to monitor the thicknesses of brake linings or racecar tires and indicate when they need to be replaced. At the time of this reporting, over 200 of these sensors have been installed into a variety of host materials. An MSRS can be made in either of two configurations, denoted ladder and continuous (see Figure 1). A ladder MSRS includes two highly electrically conductive legs, across which narrow strips of electrically resistive material are placed at small increments of length. These strips resemble the rungs of a ladder and are electrically equivalent to many tiny resistors connected in parallel. A substrate material provides structural support for the legs and rungs. The instantaneous sensor resistance is read by an external signal conditioner via wires attached to the conductive legs on the non-eroding end of the sensor. The sensor signal can be transmitted from inside a high-pressure chamber to the ambient environment, using commercially available feedthrough connectors. Miniaturized internal recorders or wireless data transmission could also potentially be employed to eliminate the need for producing penetrations in the chamber case. The rungs are designed so that as each successive rung is eroded away, the resistance changes by an amount that yields a readily measurable signal larger than the background noise. (In addition, signal-conditioning techniques are used in processing the resistance readings to mitigate the effect of noise.) Hence, each discrete change of resistance serves to indicate the arrival of the regressing host material front at the known depth of the affected resistor rung. The average rate of regression between two adjacent resistors can be calculated simply as the distance between the resistors divided by the time interval between their resistance jumps. Advanced data reduction techniques have also been developed to establish the instantaneous surface position and regression rate when the regressing front is between rungs.

Gramer, Daniel J.↗

NASA NTRS1984

Steps toward 8m honeycomb mirror blanks. III - 1.8m honeycomb sandwich blanks cast from borosilicate glass

The design, fabrication techniques, and equipment used for producing two 1.8-m honeycomb sandwich blanks, eventually leading to production of 8-m blanks, are reported. The procedure employed 85 cast hexagonal tiles at the bottom section, affixed against flotation by SiC bolts. The two plano concave mirrors are 1.83 m thick, weight 500 kg, and are each designed for 19 supports of astatic-lever type. Both blanks are of high quality and with an adequately low bubble content; one is to be figured to high-precision 0.25-arcsecond images, and is to be tested on the Multiple Mirror Telescope. Construction of a spin-casting facility based on the same principle is being planned for test-fabricating spin-cast mirrors on a smaller scale.

Angel, J. R. P.↗

NASA NTRS1993

In-flight simulation of high agility through active control: Taming complexity by design

The motivation for research into helicopter agility stems from the realization that marked improvements relative to current operational types are possible, yet there is a dearth of useful criteria for flying qualities at high performance levels. Several research laboratories are currently investing resources in developing second generation airborne rotorcraft simulators. The UK's focus has been the exploitation of agility through active control technology (ACT); this paper reviews the results of studies conducted to date. The conflict between safety and performance in flight research is highlighted and the various forms of safety net to protect against system failures are described. The role of the safety pilot, and the use of actuator and flight envelope limiting are discussed. It is argued that the deep complexity of a research ACT system can only be tamed through a requirement specification assembled using design principles and cast in an operational simulation form. Work along these lines conducted at DRA is described, including the use of the Jackson System Development method and associated Ada simulation.

Padfield, Gareth D.↗

NASA NTRS2013

Next Generation Lightweight Mirror Modeling Software

The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond machining of glasses and ceramics has created the need for more efficient means of generating finite element models of these structures. Traditional methods of assembling 400,000 + element models can take weeks of effort, severely limiting the range of possible optimization variables. This paper will introduce model generation software developed under NASA sponsorship for the design of both terrestrial and space based mirrors. The software deals with any current mirror manufacturing technique, single substrates, multiple arrays of substrates, as well as the ability to merge submodels into a single large model. The modeler generates both mirror and suspension system elements, suspensions can be created either for each individual petal or the whole mirror. A typical model generation of 250,000 nodes and 450,000 elements only takes 5-10 minutes, much of that time being variable input time. The program can create input decks for ANSYS, ABAQUS and NASTRAN. An archive/retrieval system permits creation of complete trade studies, varying cell size, depth, and petal size, suspension geometry with the ability to recall a particular set of parameters and make small or large changes with ease. The input decks created by the modeler are text files which can be modified by any editor, all the key shell thickness parameters are accessible and comments in deck identify which groups of elements are associated with these parameters. This again makes optimization easier. With ANSYS decks, the nodes representing support attachments are grouped into components; in ABAQUS these are SETS and in NASTRAN as GRIDPOINT SETS, this make integration of these models into large telescope or satellite models possible.

Arnold, William↗

NASA NTRS2013

Next-Generation Lightweight Mirror Modeling Software

The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond machining of glasses and ceramics has created the need for more efficient means of generating finite element models of these structures. Traditional methods of assembling 400,000 + element models can take weeks of effort, severely limiting the range of possible optimization variables. This paper will introduce model generation software developed under NASA sponsorship for the design of both terrestrial and space based mirrors. The software deals with any current mirror manufacturing technique, single substrates, multiple arrays of substrates, as well as the ability to merge submodels into a single large model. The modeler generates both mirror and suspension system elements, suspensions can be created either for each individual petal or the whole mirror. A typical model generation of 250,000 nodes and 450,000 elements only takes 5-10 minutes, much of that time being variable input time. The program can create input decks for ANSYS, ABAQUS and NASTRAN. An archive/retrieval system permits creation of complete trade studies, varying cell size, depth, and petal size, suspension geometry with the ability to recall a particular set of parameters and make small or large changes with ease. The input decks created by the modeler are text files which can be modified by any editor, all the key shell thickness parameters are accessible and comments in deck identify which groups of elements are associated with these parameters. This again makes optimization easier. With ANSYS decks, the nodes representing support attachments are grouped into components; in ABAQUS these are SETS and in NASTRAN as GRIDPOINT SETS, this make integration of these models into large telescope or satellite models possible

Arnold, William R., Sr.↗

NASA NTRS2013

Next Generation Lightweight Mirror Modeling Software

The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond machining of glasses and ceramics has created the need for more efficient means of generating finite element models of these structures. Traditional methods of assembling 400,000 + element models can take weeks of effort, severely limiting the range of possible optimization variables. This paper will introduce model generation software developed under NASA sponsorship for the design of both terrestrial and space based mirrors. The software deals with any current mirror manufacturing technique, single substrates, multiple arrays of substrates, as well as the ability to merge submodels into a single large model. The modeler generates both mirror and suspension system elements, suspensions can be created either for each individual petal or the whole mirror. A typical model generation of 250,000 nodes and 450,000 elements only takes 5-10 minutes, much of that time being variable input time. The program can create input decks for ANSYS, ABAQUS and NASTRAN. An archive/retrieval system permits creation of complete trade studies, varying cell size, depth, and petal size, suspension geometry with the ability to recall a particular set of parameters and make small or large changes with ease. The input decks created by the modeler are text files which can be modified by any editor, all the key shell thickness parameters are accessible and comments in deck identify which groups of elements are associated with these parameters. This again makes optimization easier. With ANSYS decks, the nodes representing support attachments are grouped into components; in ABAQUS these are SETS and in NASTRAN as GRIDPOINT SETS, this make integration of these models into large telescope or satellite models easier.

Arnold, William R., Sr.↗

DOE OSTI2021

Y-12 NATIONAL SECURITY COMPLEX LEU-MO FEEDSTOCK FABRICATION UPDATE

The Y-12 National Security Complex (Y-12) participates in the fuel fabrication pillar of lhe National Nuclear Security Administration's (NNSA's) Office of Material Minimization and Management (M3) Office of Conversion Pillar. Y-12's primary responsibility is to establish a reliable fabrication process of low-enriched uranium-molybdenum (LEU-Mo) feedstock tor United States High Performance Research Reactors (US HPRRs). This update compares US HPRR LEU-Mo feedstock fabrication ettorts over the past several casting campaigns at Y-12 which vary in process methodologies and fabrication parameters. With recent changes to the latest feedstock casting campaign, Process Design Standard-2 (PD-STD-2). Y-12 has seen a significant decrease in isotopic uranium variability of the fuel feedstock fabricated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Development of a Thin-Wall Magnesium side door Inner Panel for Automobiles

Cast magnesium side door inner panels can provide a good combination of weight, functional, manufacturing and economical requirements. However, several challenges exist including casting technology for thin-wall part design, multi-material incompatibility and relatively low strength vs steel. A project has been initiated, supported by the US Department of Energy, to design and develop a lightweight frame-under-glass door having a thin-wall, full die-cast, magnesium inner panel. This development project is the first of its kind within North America. Phase I of the project is now complete and the 2.0mm magnesium design, through casting process enablers, has met or exceeded all stiffness requirements, with significant mass reduction and part consolidation. In addition, a corrosion mitigation strategy has been established using industry-accepted galvanic isolation methods and coating technologies.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Clean Steel Casting Production

Inclusions in steel castings can cause rework, scrap, poor machining, and reduced casting performance, which can obviously result in excess energy consumption. Significant progress in understanding inclusion source, formation and control has been made. Inclusions can be defined as non-metallic materials such as refractory, sand, slag, or coatings, embedded in a metallic matrix. This research project has focused on the mold filling aspects to examine the effects of pouring methods and gating designs on the steel casting cleanliness through water modeling, computer modeling, and melting/casting experiments. Early in the research project, comprehensive studies of bottom-pouring water modeling and low-alloy steel casting experiments were completed. The extent of air entrainment in bottom-poured large castings was demonstrated by water modeling. Current gating systems are designed to prevent air aspiration. However, air entrainment is equally harmful and no prevention measures are in current practice. In this study, new basin designs included a basin dam, submerged nozzle, and nozzle extension. The entrained air and inclusions from the gating system were significantly reduced using the new basin method. Near the end of the project, there has been close collaboration with Wescast Industries Inc., a company manufacturing automotive exhaust components. Both computer modeling using Magma software and melting/casting experiments on thin wall turbo-housing stainless steel castings were completed in this short period of time. Six gating designs were created, including the current gating on the pattern, non-pressurized, partially pressurized, naturally pressurized, naturally pressurized without filter, and radial choke gating without filter, for Magma modeling. The melt filling velocity and temperature were determined from the modeling. Based on the simulation results, three gating designs were chosen for further melting and casting experiments on the same casting pattern using the lip pouring method. It was observed again that gating designs greatly influenced the melt filling velocity and the number of inclusion defects. The radial choked gating showed improvements in casting cleanliness and yield over the other gatings, even though no mold filters were used in the gating system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2014

Lost Foam Thin Wall: Feasibility of Producing Lost Foam Castings in Aluminum and Magnesium Based Alloys

With the increased emphasis on vehicle weight reduction, production of near-net shape components by lost foam casting will make significant inroad into the next-generation of engineering component designs. The lost foam casting process is a cost effective method for producing complex castings using an expandable polystyrene pattern and un-bonded sand. The use of un-bonded molding media in the lost foam process will impose less constraint on the solidifying casting, making hot tearing less prevalent. This is especially true in Al-Mg and Al-Cu alloy systems that are prone to hot tearing when poured in rigid molds partially due to their long freezing range. Some of the unique advantages of using the lost foam casting process are closer dimensional tolerance, higher casting yield, and the elimination of sand cores and binders. Most of the aluminum alloys poured using the lost foam process are based on the Al-Si system. Very limited research work has been performed with Al-Mg and Al-Cu type alloys. With the increased emphasis on vehicle weight reduction, and given the high-strength-to-weight-ratio of magnesium, significant weight savings can be achieved by casting thin-wall (≤ 3 mm) engineering components from both aluminum- and magnesium-base alloys.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2006

Metallurgical Design and Development of NASA Crawler/Transporter Tread Belt Shoe Castings

The NASA Crawler/Transporters (CT-1 and CT-2) used to transport the Space Shuffles are one of the largest tracked vehicles in existence today. Two of these machines have been used to move space flight vehicles at Kennedy Space Center since the Apollo missions of the 1960's and relatively few modifications have been made to keep them operational. In September of 2003 during normal Crawler/Transporter operations cracks were observed along the roller pad surfaces of several tread belt shoes. Further examination showed 20 cracked shoes on CT-1 and 40 cracked shoes on CT-2 and a formal failure analysis investigation was undertaken while the cracked shoes were replaced. Six shoes were cross-sectioned with the fracture surfaces exposed and it was determined that the cracks were due to fatigue that initiated on the internal casting web channels at pre-existing casting defects and propagated through thickness both transgranularly and intergranularly between internal shrinkage cavities, porosity, and along austenitic and ferritic grain boundaries. The original shoes were cast during the 1960's using a modified 861330 steel with slightly higher levels of chromium, nickel and molybdenum followed by heat treatment to achieve a minimum tensile strength of 11 Oksi. Subsequent metallurgical analysis of the tread belt shoes after multiple failures showed excessive internal defects, alloy segregation, a nonuniform ferritic/ bainitic/martensitic microstructure, and low average tensile properties indicative of poor casting and poor heat-treatment. As a result, NASA funded an initiative to replace all of the tread belt shoes on both crawler/transporters along with a redesign of the alloy, manufacturing, and heat-treatment to create a homogeneous cast structure with uniform mechanical and metallurgical properties. ME Global, a wholly owned subsidiary of ME Elecmetal based in Minneapolis, MN was selected as manufacturing and design partner to develop the new shoes and this paper describes the research, development, and manufacturing that resulted in the successful delivery of 1044 new Crawler/Transporter tread belt shoes all meeting rigid metallurgical and mechanical design criteria derived from finite element modeling of the stress loads required for safe space shuttle transport.

Parker, Donald S.↗

NASA NTRS1994

Rapid prototype fabrication processes for high-performance thrust cells

The Thrust Cell Technologies Program (Air Force Phillips Laboratory Contract No. F04611-92-C-0050) is currently being performed by Rocketdyne to demonstrate advanced materials and fabrication technologies which can be utilized to produce low-cost, high-performance thrust cells for launch and space transportation rocket engines. Under Phase 2 of the Thrust Cell Technologies Program (TCTP), rapid prototyping and investment casting techniques are being employed to fabricate a 12,000-lbf thrust class combustion chamber for delivery and hot-fire testing at Phillips Lab. The integrated process of investment casting directly from rapid prototype patterns dramatically reduces design-to-delivery cycle time, and greatly enhances design flexibility over conventionally processed cast or machined parts.

Hunt, K.↗

NASA NTRS1980

Development of low-cost directionally-solidified turbine blades

A low-cost directionally solidified (DS) casting of turbine blades of high stress rupture is discussed. The process uses an exothermically heated mold; a newly designed solid blade was cast for the high-pressure turbine of the TFE731-3 turbofan engine. Ni-based alloys Mar-M 247 and Mar-M 200 + Hf were used. The solid DS blade replaced a conventionally cast IN100 component; a 40% cost saving is expected, with a 2.4% reduction in the takeoff specific fuel consumption. The DS Mar-M 247 blade has been selected for production in the TFE731-3B-100, and advanced version of the TFE731-3.

Hoppin, G. S., III↗

DOE OSTI2017

High-Throughput Study of Diffusion and Phase Transformation Kinetics of Magnesium-Based Systems for Automotive Cast Magnesium Alloys

The objective of the proposed study is to establish a scientific foundation on kinetic modeling of diffusion, phase precipitation, and casting/solidification, in order to accelerate the design and optimization of cast magnesium (Mg) alloys for weight reduction of U.S. automotive fleet. The team has performed the following tasks: 1) study diffusion kinetics of various Mg-containing binary systems using high-throughput diffusion multiples to establish reliable diffusivity and mobility databases for the Mg-aluminum (Al)-zinc (Zn)-tin (Sn)-calcium (Ca)-strontium (Sr)-manganese (Mn) systems; 2) study the precipitation kinetics (nucleation, growth and coarsening) using both innovative dual-anneal diffusion multiples and cast model alloys to provide large amounts of kinetic data (including interfacial energy) and microstructure atlases to enable implementation of the Kampmann-Wagner numerical model to simulate phase transformation kinetics of non-spherical/non-cuboidal precipitates in Mg alloys; 3) implement a micromodel to take into account back diffusion in the solid phase in order to predict microstructure and microsegregation in multicomponent Mg alloys during dendritic solidification especially under high pressure die-casting (HPDC) conditions; and, 4) widely disseminate the data, knowledge and information using the Materials Genome Initiative infrastructure (http://www.mgidata.org) as well as publications and digital data sharing to enable researchers to identify new pathways/routes to better cast Mg alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2022

A spatial superstructure approach to the optimal design of modular processes and supply chains

Modularity is a design principle that aims to provide flexibility for spatio-temporal assembly/disassembly and reconfiguration of systems. This design principle can be applied to multiscale (hierarchical) manufacturing systems that connect units, processes, facilities, and entire supply chains. Designing modular systems is challenging because of the need to capture spatial interdependencies that arise between system components due to product exchange/transport between components and due to product transformation in such components. In this work, we propose an optimization framework to facilitate the design of modular manufacturing systems. Central to our approach is the concept of a spatial superstructure, which is a graph that captures all possible system configurations and interdependencies between components. The spatial superstructure is a generalization of the notion of a superstructure and of a p-graph used in process design, in that it encodes spatial (geographical) context of the system components. Here, we show that this generalization facilitates the simultaneous design and analysis of processes, facilities, and of supply chains. Our framework aims to select the system topology from the spatial superstructure that minimizes design cost and that maximizes design modularity. We show that this design problem can be cast as a mixed-integer, multi-objective optimization formulation. We demonstrate these capabilities using a case study arising in the design of a plastic waste upcycling supply chain.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1981

Sputtered protective coatings for die casting dies

Three experimental research designs investigating candidate materials and processes involved in protective die surface coating procedures by sputter deposition, using ion beam technologies, are discussed. Various pre-test results show that none of the coatings remained completely intact for 15,000 test cycles. The longest lifetime was observed for coatings such as tungsten, platinum, and molybdenum which reduced thermal fatigue, but exhibited oxidation and suppressed crack initiation only as long as the coating did not fracture. Final test results confirmed earlier findings and coatings with Pt and W proved to be the candidate materials to be used on a die surface to increase die life. In the W-coated specimens, which remained intact on the surface after thermal fatigue testing, no oxidation was found under the coating, although a few cracks formed on the surface where the coating broke down. Further research is planned.

Mirtich, M. J.↗

DOE OSTI2020

Design and Development of Low Weight, Titanium Aluminide Airfoils for High Performance Industrial Gas Turbines meeting 65% Combined Cycle Efficiency (Final Report)

This project funded under DOE-FOA-0001816 was performed with the intent of evaluating the potential of utilizing a low density, high specific strength Titanium Aluminide (TiAl) alloy in a large annulus last stage gas turbine blade with the intent of improving combined cycle gas turbine efficiency toward a goal of reaching 65% efficiency. The project consisted of identifying a potentially suitable TiAl material for manufacture of such a large blade by investment casting. This included estimation of design properties for the selected alloy, trade studies using a baseline design created for a nickel based alloy cast in the TiAl alloy to evaluate potential design changes required for the use of this material and optimization of a prototype design for the same baseline application using the selected TiAl alloy. Several rounds of optimization were completed with the intent of meeting the baseline design targets with a resulting design that showed at least equivalent performance in terms of creep, LCF/TMF, HCF and aerodynamic damping potential. While it was found that significant reductions in blade loading on the disk were possible, the design resulting from the optimization met most lifing targets at the baseline size, but showed a reduction in margins in some areas in comparison to the Ni-based baseline design. Additionally, it was found that the low strain tolerance of the TiAl alloy for temperatures at and below the operational temperature of the attachment resulted in marginal, although still acceptable, creep rupture performance of the design. Due to results indicating the reduced potential for increasing turbine annulus compared to expectations a Phase II award was not proposed and it is not recommended to pursue additional design optimization efforts until further material advances with TiAl materials are achieved.

03 NATURAL GAS↗

DOE OSTI2021

In situ synchrotron investigation of degenerate graphite nodule evolution in ductile cast iron

Ductile cast irons (DCIs) are of increasing importance in the renewable energy and transportation sectors. The distribution and morphology of the graphite nodules, in particular the formation of degenerate features during solidification, dictate the mechanical performance of DCIs. In situ high-speed synchrotron X-ray tomography was used to capture the evolution of graphite nodules during solidification of DCI, including degenerate features and the effect of the carbon concentration field. The degeneration of nodules is observed to increase with re-melting cycles, which is attributed to Mg-loss. The dendritic primary austenite and carbon concentration gradients in the surrounding liquid phase were found to control nodule morphology by locally restricting and promoting growth. A coupled diffusion-mechanical model was developed, confirming the experimentally informed hypothesis that protrusions form through liquation cracking of the austenite shell and subsequent localised growth. In conclusion, these results provide valuable insights into the solidification kinetics of cast irons, supporting the design of advanced alloys.

36 MATERIALS SCIENCE↗