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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

AM Powder Flowability Capabilities at NASA Marshall Space Flight Center (MSFC)

Additive Manufacturing (AM) powder flowability is critical to metal 3D printing, because the more fluid the powder is, the better powder spreads. AM Powder Flowability Capabilities at NASA MSFC studies density, flow, particle size distribution, and morphology for programs such as Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT), ASTM Proficiency Testing for AM and Powder Metallurgy, and MSFC’s AM team. Examining and measuring powder characteristics is essential for improving flowability of AM powder and ensuring lot-to-lot consistency, which will help to prevent defects in manufactured parts. The Contamination Control Team (CCT) uses several methods to characterize AM powder. Optical particle size distribution and morphology analyses determine particle parameters including size, circularity, convexity, and dimensions. The Carney and Hall Flowmeter Funnel measures time it takes powder to flow through a funnel to compare relative flowability (free-flowing and non-free-flowing). In addition to this, the device utilizes a density cup which determines apparent density. Lastly, the Revolution Powder Analyzer measures dynamic powder flowability and behavior over time via digital imaging. Using the CCT’s lab, the team has produced ASTM Powder Proficiency Testing results with flow rates, apparent density, particle size distribution, and tap density on titanium-based and nickel-based powder and compared data with other companies/labs. Morphology data was also collected for various regolith simulant powder for the MMPACT program. Lastly, the CCT used morphology data to examine the flowability of Inconel 718 powder for Selective Laser Melting (SLM) and Directed Energy Deposition (DED) printers at MSFC. The CCT’s essential work in studying and enabling AM powder characterization has helped and will continue to help study new and refined powders in the AM industry.

Additive Manufacturing↗
NASA NTRSDate not supplied

Analysis of Additively Manufactured Inconel 718 Combustion Behavior in Promoted Oxygen Environments

Promoted combustion testing is a vital tool for engineers to establish the combustion and flammability characteristics of materials (metallic or otherwise) in oxygen enriched environments. Historically, much of the established data for metallic promoted combustion has been with regards to cast and wrought forms. However, with the emergence of additive manufacturing as a preferred method of fabrication, the need exists to evaluate how metals in that form behave. This paper will serve as a review of the work that has been done and an analysis of the nickel-based superalloy Inconel 718, a material popular for aerospace applications such as liquid fueled rocket components and turbine engines. Promoted combustion testing (per the ASTM G124 standard) was conducted on samples of both wrought and selective laser melted fabrication, to provide comparison of flammability response between materials produced by each manufacturing method. Additionally, post-build treatments were applied to test samples to identify any effects on performance provided by hot isostatic pressing, oxygen-getting wrap during HIP, stress relieving, and solutionizing/aging heat treatments. This study will utilize optical and scanning electron microscopy, energy dispersive spectroscopy, x-ray diffraction, and metallography to identify the differences in behavior of additively manufactured and wrought Inconel 718.

Additively Manufactured↗
NASA NTRS2016

Challenges in Laser Sintering of Melt-Processable Thermoset Imide Resin

Polymer Laser Sintering (LS) is an additive manufacturing technique that builds 3D models layer by layer using a laser to selectively melt cross sections in powdered polymeric materials, following sequential slices of the CAD model. LS generally uses thermoplastic polymeric powders, such as polyamides (i.e. Nylon), and the resultant 3D objects are often weaker in their strength compared to traditionally processed materials, due to the lack of polymer inter-chain connection in the z-direction. The objective of this project is to investigate the possibility of printing a melt-processable RTM370 imide resin powder terminated with reactive phenylethynyl groups by LS, followed by a postcure in order to promote additional crosslinking to achieve higher temperature (250-300 C) capability. A preliminary study to build tensile specimens by LS and the corresponding DSC and rheology study of RTM370 during LS process is presented.

Additive Manufacturing↗
NASA NTRS1993

Ar-40/Ar-39 age spectra of Apollo 15 impact melt rocks by laser step-heating and their bearing on the history of lunar basin formation

Results are reported on 26 high-resolution (16-51 steps) Ar-40/Ar-39 age spectra obtained on 12 Apollo-15 melt rocks of different composition using a continuous laser system on submg fragments of recrystallized melt and single-crystal plagioclase clasts from impact melt rocks collected at the Apennine Front where the Imbrium and Serenitatis basins intersect. A table is presented with the summary of the Ar-40/Ar-39 spectrum data, which represent 891 individual temperature step analyses. Also presented are 20 of the 26 age spectra along with their respective K/Ca plots. Melt rock fragments and plagioclase clasts from seven of the 12 samples analyzed yielded reproducible, intermediate-T Ar-40/Ar-39 age spectrum plateaus, which were interpreted as crystallization ages that represent the times of impact of bolides onto the lunar surface.

Dalrymple, G. B.↗
NASA NTRS2003

Thermal Property Measurement of Semiconductor Melt using Modified Laser Flash Method

This study further developed standard laser flash method to measure multiple thermal properties of semiconductor melts. The modified method can determine thermal diffusivity, thermal conductivity, and specific heat capacity of the melt simultaneously. The transient heat transfer process in the melt and its quartz container was numerically studied in detail. A fitting procedure based on numerical simulation results and the least root-mean-square error fitting to the experimental data was used to extract the values of specific heat capacity, thermal conductivity and thermal diffusivity. This modified method is a step forward from the standard laser flash method, which is usually used to measure thermal diffusivity of solids. The result for tellurium (Te) at 873 K: specific heat capacity 300.2 Joules per kilogram K, thermal conductivity 3.50 Watts per meter K, thermal diffusivity 2.04 x 10(exp -6) square meters per second, are within the range reported in literature. The uncertainty analysis showed the quantitative effect of sample geometry, transient temperature measured, and the energy of the laser pulse.

Lin, Bochuan↗
NASA NTRS1991

Ar-40/Ar-39 ages of six Apollo 15 impact melt rocks by laser step heating

Fifteen high resolution (21-51 step) Ar-40/Ar-39 age spectra are obtained for six Apollo 15 impact melt rocks of different compositions, using a continuous laser system on submilligram subsamples and on single crystal plagioclase clasts. Four of the six samples gave reproducible age spectra with well-defined intermediate temperature plateaus over 48 percent or more of the Ar-39 released; the plateaus are interpreted as crystallization ages. Samples 15304,7,69, 15294,6,21 and 15314,26,156 gave virtually identical plateau ages whose weighted mean is 3870 + or - 6 Ma. These three melt rocks differ in composition and likely formed in three separate impact events.

Dalrymple, G. B.↗
NASA NTRS2012

Laser Machining of Melt Infiltrated Ceramic Matrix Composite

As interest grows in considering the use of ceramic matrix composites for critical components, the effects of different machining techniques, and the resulting machined surfaces, on strength need to be understood. This work presents the characterization of a Melt Infiltrated SiC/SiC composite material system machined by different methods. While a range of machining approaches were initially considered, only diamond grinding and laser machining were investigated on a series of tensile coupons. The coupons were tested for residual tensile strength, after a stressed steam exposure cycle. The data clearly differentiated the laser machined coupons as having better capability for the samples tested. These results, along with micro-structural characterization, will be presented.

Jarmon, D. C.↗
NASA NTRS1992

Material transport in laser-heated diamond anvil cell melting experiments

A previously undocumented effect in the laser-heated diamond anvil cell, namely, the transport of molten species through the sample chamber, over distances large compared to the laser beam diameter, is presented. This effect is exploited to determine the melting behavior of high-pressure silicate assemblages of olivine composition. At pressures where beta-spinel is the phase melted, relative strengths of partitioning can be estimated for the incompatible elements studied. Iron was found to partition into the melt from beta-spinel less strongly than calcium, and slightly more strongly than manganese. At higher pressures, where a silicate perovskite/magnesiowuestite assemblage is melted, it is determined that silicate perovskite is the liquidus phase, with iron-rich magnesiowuestite accumulating at the end of the laser-melted stripe.

Campbell, Andrew J.↗
NASA NTRS1972

Study of the production of unique new glasses

A number of high new oxide glasses have been prepared by a laser-spin melting technique where droplets are ejected from a molten mass. Techniques have been developed for measuring the optical properties of most of the new glasses so produced. A preliminary study of processing equipment for producing new glasses in a zero gravity environment onboard manned space laboratory is reported. Induction and laser melting emerge as preferred techniques for melting spheroids of new glass compositions in space. Sample calculations for power required to induction melt new glass compositions are presented. Cooling rate calculations show that radiation cooling of the high melting materials results in very short cooling times for 1/2 inch diameters to temperatures where the spheroids can be handled.

Happe, R. A.↗
NASA NTRS2003

Modified Laser Flash Method for Thermal Properties Measurements and the Influence of Heat Convection

The study examined the effect of natural convection in applying the modified laser flash method to measure thermal properties of semiconductor melts. Common laser flash method uses a laser pulse to heat one side of a thin circular sample and measures the temperature response of the other side. Thermal diffusivity can be calculations based on a heat conduction analysis. For semiconductor melt, the sample is contained in a specially designed quartz cell with optical windows on both sides. When laser heats the vertical melt surface, the resulting natural convection can introduce errors in calculation based on heat conduction model alone. The effect of natural convection was studied by CFD simulations with experimental verification by temperature measurement. The CFD results indicated that natural convection would decrease the time needed for the rear side to reach its peak temperature, and also decrease the peak temperature slightly in our experimental configuration. Using the experimental data, the calculation using only heat conduction model resulted in a thermal diffusivity value is about 7.7% lower than that from the model with natural convection. Specific heat capacity was about the same, and the difference is within 1.6%, regardless of heat transfer models.

Lin, Bochuan↗
NASA NTRS2005

In Situ Resource Utilization (ISRU) Experiments for Mars Exploration

In situ resource utilization can best be described as living off the land. In our case the land is the planet Mars. ISRU is based on the idea that some fraction of the consumables, life support and propellant materials do not have to be flown from earth. Rather, they can be manufactured or extracted from resources already present on Mars. The primary resources on Mars are the atmosphere, polar caps and regolith. The atmosphere of Mars is mostly carbon dioxide as shown in the table below. The proportion of oxygen on the other hand is quite small. Still, there is quite a bit of oxygen in the Martian atmosphere, but it is unfortunately tied up with carbon. Thus, one of the goals of ISRU is the separation of breathable oxygen from the carbon dioxide. Several means of separation have been proposed. We have begun experiments on another approach for production of oxygen with carbon monoxide as a useful by product. Our work on a CO2 separator is described later in this report. Regolith melting is another means of obtaining materials. Two materials of interest are iron and silicon. Iron oxide is plentiful on Mars and is of obvious importance for structural components. Silicon is the foundation of solid state devices. Power generation on Mars may be accomplished using silicon solar cells. There is discussion of the feasibility of in situ production of solar cells. This would require a means of extracting silicon from the regolith. We have conducted several experiments concerning melting and glassification of the Mars soil simulant. Other summer faculty fellows have tried various means of processing the stimulant material. These include furnace melting, microwave melting and laser ablation. We have conducted several furnace melting experiments in both air and carbon dioxide environments. We have also carried out experiments to test spark melting in a carbon dioxide atmosphere. These experiments suggest the possibility of using arc melting in a reducing atmosphere. It is important to keep in mind that we are working with a soil stimulant. Any simulant, no matter how chemically similar it is to Martian regolith, may differ in mineralogy. The underlying assumption in this work is that once a glass is formed, any differences between simulant and regolith are unimportant. The exact means of forming the glass do, however, depend on the mineralogy of the regolith. A sample return mission is required to help answer these questions.

Marone, Matt↗
NASA NTRSDate not supplied

Silicon Partitioning Between Iron-Rich Metal and Silicate Melt: New Constraints From Aerodynamic Laser Levitation Furnace Experiments

The partitioning of light elements (e.g., Si, C, H, etc.) between silicate melts and iron metal alloys as a function of pressure and temperature is a critical constraint in defining the compositional evolution of planetary interiors. While there are a significant number of experimental studies in the literature that examine the various influences of oxygen fugacity, temperature, pressure, and composition on the metal-melt partitioning of silicon, it is difficult to disentangle the effects of each variable due to the nominally independent parameters (e.g., pressure, temperature, composition) being collinear. To better test for the independent effects of pressure, temperature, and melt composition on the partitioning of silicon between iron alloy and silicate melt, new high temperature (1800°–2500°C), rapid quench (~700°C/s) aerodynamic levitation laser-heating experiments in the Fe-Si-Mg-O (En65-Fa5-Si3-Fe27) system were conducted. This high temperature, low pressure method is ideal for these experiments because it eliminates the metal container as a sink for elements of interest to partition into, and it has a rapid quench rate that minimizes potential exsolution of silicon from the metal phase during quench cooling. Given the short run times of the levitation experiments (30–60 seconds), a time series at a lower temperature (1700°C) in a vertical gas-mixing muffle tube furnace was also conducted to assess equilibrium times of the bulk composition. All successful runs were imaged using back-scatter electron imaging and analyzed for phase composition using a JEOL 8530F field emission microprobe. These new data were added to a comprehensive and internally consistent data set created from published experiments, and subsequently modeled using parameters designed to minimize collinearity (e.g., optical basicity is used as a proxy for melt composition). High collinearity is found in the data set however between temperature and oxygen fugacity, precluding any model that contains both as nominally independent variables. The resulting model demonstrates a statistically significant effect of pressure, temperature, and melt composition on the partitioning of silicon in Fe-rich metal, which has implications for the formation of planetary cores in rocky planets and provides important constraints on potential bulk core compositions.

Metal↗
NASA NTRS2021

Melt Pool Imaging using a Configurable Architecture Additive Testbed System

This paper describes the inline (coaxial to laser) near infrared (NIR) camera sensor on the Configurable Architecture Additive Testbed (CAAT). The CAAT is an instrument that provides the capability to investigate laser based additive manufacturing (AM) processes and is configured for the metal powder bed fusion process. A low cost NIR camera is radiometrically calibrated to obtain coaxial, inline, imagery of laser generated melt pools. The camera capabilities, system optical path, and the uncertainty in the temperature measurement from NIR surface area scans on a bare titanium alloy plate are presented and discussed. The surface radiance measurements are compared to optical microscopy images of the melt pool width and depth. A metallic additive manufacturing process thermal model is developed in order to predict thermal distributions during laser scanning. The predicted thermal distributions by the model for different configurations are compared to the coaxial NIR measurements and discussed.

Additive manufacturing↗
NASA NTRS1985

Improved Melt-Level Control System

Laser feedback control automatically maintains silicon melt levels. During long-term growth of dendritic-web silicon, silicon melt level controlled and held nearly constant using laser feedback system to sense level of melt and control silicon-pellet feed rate.

Meier, D. L.↗
NASA NTRS1998

Laser Heated Oxide Fiber Growth Using Melt Modulation Technique

As a reinforcement for structural composites, single crystal alumina fibers offer low density, high modulus, and high creep resistance. In this study, the laser heated float zone approach was employed to grow c-axis Al2O3 continuous fibers of high purity and high strength. A new melt modulation technique, laser scanning, avoids the formation of surface induced ripples and allows the growth of 50 micro-m diameter sapphire fibers with strengths (approx. 7 GPa) significantly greater than either commercially available fibers grown by the edge-defined film growth process (approx. 2-3 GPa) or laboratory fibers grown by stationary laser heating (approx. 5 GPa). The present work suggests that surface striations are the predominant defects controlling the tensile strength of laser-scanned fibers at room temperature. Several possible mechanisms for inducing surface striations are systematically discussed for several oxide fiber compositions.

Sayir, Ali↗
NASA NTRS1986

Laser Vacuum Furnace for Zone Refining

Laser beam scanned to produce moving melt zone. Experimental laser vacuum furnace scans crystalline wafer with high-power CO2-laser beam to generate precise melt zone with precise control of temperature gradients around zone. Intended for zone refining of silicon or other semiconductors in low gravity, apparatus used in normal gravity.

Griner, D. B.↗
NASA NTRS1982

Performance of laser glazed Zr02 TBCs in cyclic oxidation and corrosion burner test rigs

The performance of laser glazed zirconia thermal barrier coatings (TBCs) was evaluated in cyclic oxidation and cyclic corrosion tests. Plasma sprayed zirconia coatings of two thicknesses were partially melted with a CO2 laser. The power density of the focused laser beam was varied from 35 to 75 W/sq mm, while the scanning speed was about 80 cm per minute. In cyclic oxidation tests, the specimens were heated in a burner rig for 6 minutes and cooled for 3 minutes. It is indicated that the laser treated samples have the same life as the untreated ones. However, in corrosion tests, in which the burner rig flame contained 100 PPM sodium fuel equivalent, the laser treated samples exhibit nearly a fourfold life improvement over that of the reference samples vary. In both tests, the lives of the samples inversely with the thickness of the laser melted layer of zirconia.

Zaplatynsky, I.↗