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NASA NTRS2019

Development of a Design for Manufacturing Tool for Automated Fiber Placement Structures

Existing design processes for laminates constructed with automated fiber placement lack significant integration between the various software tools that compose the process. Tools for finite element analysis, computer aided drafting, stress analysis, tool path simulation, and manufacturing defect prediction are all critical parts of the design process. With traditional hand-layup laminates, the analysis performed with each of these tools could be fairly well decoupled from one another. However, for laminates generated by automated fiber placement, the disciplines can become significantly coupled, especially on structures with curvature. This gives rise to a need for integrated “design for manufacturing” software tools that are able to balance the competing objectives from each discipline. This paper describes the preliminary development of such a tool.

Noevere, August T.↗

DOE OSTI2022

An Open-Source Framework for the Computational Analysis and Design of Autothermal Chemical Processes

The main project object was to develop software tools for simulating non-equilibrium autothermal processes, improving the prospects for identifying and designing such systems. The project demonstrates the use of these tools to simulate autothermal pyrolysis, a process recently developed at the pilot-plant scale at Iowa State University. In such process, instead of externally heating a reactor to pro-vide the enthalpy of pyrolysis, sufficient oxygen in the form of air is introduced into the reactor to support partial oxidation of reactants and products with the exothermic energy released supporting endothermic pyrolysis reactions. A fluidized bed is used to assure good mixing of biomass and oxidant and provide an isothermal reaction environment. The amount of oxygen required depends upon the kind of biomass being pyrolyzed and parasitic heat losses from the reactor. For example, for woody biomass pyrolyzed under conditions that simulate adiabatic operation, equivalence ratios can be as low as 0.06, compared to 0.20 or higher for autothermal gasifiers. By removing the heat transfer bottleneck of conventional pyrolysis, operation in autothermal mode allowed a significant increase in reactor throughput process, approaching five times the throughput of the conventionally operated pyrolyzer. Different simulation strategies were considered and developed: a zero-dimensional chemistry model was used to verify the applicability of kinetic schemes to predict biomass fast pyrolysis in autothermal conditions. Conventional chemical reactor models such as the plug flow reactor and the partially stirred reactor were used to investigate the role of mixing in the fluidized bed pyrolyzer and to establish the impact of mixing time on the gas-phase reactions. A comprehensive multiphase computational fluid dynamics (mCFD) framework, including polydisperse granular phase modeling and detailed chemical kinetics was formulated and used to model the experimental setup for autothermal biomass fast pyrolysis at ISU. Multiphase CFD was also used to investigate the role of biomass feed positioning on the mixing of biomass in the pyrolizer. Finally, a reduced order model (ROM), suitable to be implemented in process simulators was obtained. Both the mCFD and the ROM were validated against experiments.

09 BIOMASS FUELS↗

NASA NTRS1989

Computer-aided software development process design

The authors describe an intelligent tool designed to aid managers of software development projects in planning, managing, and controlling the development process of medium- to large-scale software projects. Its purpose is to reduce uncertainties in the budget, personnel, and schedule planning of software development projects. It is based on dynamic model for the software development and maintenance life-cycle process. This dynamic process is composed of a number of time-varying, interacting developmental phases, each characterized by its intended functions and requirements. System dynamics is used as a modeling methodology. The resulting Software LIfe-Cycle Simulator (SLICS) and the hybrid expert simulation system of which it is a subsystem are described.

Lin, Chi Y.↗

DOE OSTI2020

Opportunities and Challenges in Metal Forming for Lightweighting: Review and Future Work

Abstract The purposes of this review are to summarize the historical progress in the last 60 years of lightweight metal forming, to analyze the state-of-the-art, and to identify future directions in the context of Cyber-physically enabled circular economy. In honoring the 100th anniversary of the establishment of the Manufacturing Engineering Division of ASME, this review paper first provides the impact of the metal forming sector on the economy and historical perspectives of metal forming research work published by the ASME Journal of Manufacturing Science and Engineering, followed by the motivations and trends in lightweighting. To achieve lightweighting, one needs to systematically consider: (1) materials and material characterization; (2) innovative forming processes; and (3) simulation tools for integrated part design and process design. A new approach for process innovation, i.e., the Performance-Constraints-Mechanism-Innovation (PCMI) framework, is proposed to systematically seek new processes. Finally, trends and challenges for the further development in circular economy are presented for future exploration.

Engineering↗

DOE OSTI2020

HPC4Mobilty w/ UCB

The purpose of this project is to examine the energy impact of urban-scale traffic for the Los Angeles Basin by developing and implementing a scalable traffic assignment model. An energy optimization function will be posed and when integrated into the optimization code for travel assignment it can be mathematically proven to converge. The energy optimization function can then be compared to the typical travel time optimization that is traditionally used in traffic assignment models. The analysis will begin with static traffic assignment models with the routing for all origin and destinations computed in parallel on high performance computing facilities. Convergence of the numerical methods rely on the solution of convex programs (or extensions of these). This step will mostly consist of demonstrating the ability to parallelize the Frank Wolfe algorithm on various platforms. This work will contribute to LBNL’s efforts to develop new processes, analytical tools, program designs, and business models to advance the state of the art in next-generation sustainable transportation solutions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

The E3SM Diagnostics Package (E3SM Diags v2.7): a Python-based diagnostics package for Earth system model evaluation

Abstract. The E3SM Diagnostics Package (E3SM Diags) is a modern, Python-based Earth system model (ESM) evaluation tool (with Python module name e3sm_diags), developed to support the Department of Energy (DOE) Energy Exascale Earth System Model (E3SM). E3SM Diags provides a wide suite of tools for evaluating native E3SM output, as well as ESM data on regular latitude–longitude grids, including output from Coupled Model Intercomparison Project (CMIP) class models. E3SM Diags is modeled after the National Center for Atmospheric Research (NCAR) Atmosphere Model Working Group (AMWG, 2022) diagnostics package. In its version 1 release, E3SM Diags included a set of core essential diagnostics to evaluate the mean physical climate from model simulations. As of version 2.7, more process-oriented and phenomenon-based evaluation diagnostics have been implemented, such as analysis of the quasi-biennial oscillation (QBO), the El Niño–Southern Oscillation (ENSO), streamflow, the diurnal cycle of precipitation, tropical cyclones, ozone and aerosol properties. An in situ dataset from DOE's Atmospheric Radiation Measurement (ARM) program has been integrated into the package for evaluating the representation of simulated cloud and precipitation processes. This tool is designed with enough flexibility to allow for the addition of new observational datasets and new diagnostic algorithms. Additional features include customizable figures; streamlined installation, configuration and execution; and multiprocessing for fast computation. The package uses an up-to-date observational data repository maintained by its developers, where recent datasets are added to the repository as they become available. Finally, several applications for the E3SM Diags module were introduced to fit a diverse set of use cases from the scientific community.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1974

Design, fabrication and test of graphite/epoxy metering truss structure components, phase 3

The design, materials, tooling, manufacturing processes, quality control, test procedures, and results associated with the fabrication and test of graphite/epoxy metering truss structure components exhibiting a near zero coefficient of thermal expansion are described. Analytical methods were utilized, with the aid of a computer program, to define the most efficient laminate configurations in terms of thermal behavior and structural requirements. This was followed by an extensive material characterization and selection program, conducted for several graphite/graphite/hybrid laminate systems to obtain experimental data in support of the analytical predictions. Mechanical property tests as well as the coefficient of thermal expansion tests were run on each laminate under study, the results of which were used as the selection criteria for the single most promising laminate. Further coefficient of thermal expansion measurement was successfully performed on three subcomponent tubes utilizing the selected laminate.

Source record↗

NASA NTRS1976

Advanced composite rudders for DC-10 aircraft: Design, manufacturing, and ground tests

Design synthesis, tooling and process development, manufacturing, and ground testing of a graphite epoxy rudder for the DC-10 commercial transport are discussed. The composite structure was fabricated using a unique processing method in which the thermal expansion characteristics of rubber tooling mandrels were used to generate curing pressures during an oven cure cycle. The ground test program resulted in certification of the rudder for passenger-carrying flights. Results of the structural and environmental tests are interpreted and detailed development of the rubber tooling and manufacturing process is described. Processing, tooling, and manufacturing problems encountered during fabrication of four development rudders and ten flight-service rudders are discussed and the results of corrective actions are described. Non-recurring and recurring manufacturing labor man-hours are tabulated at the detailed operation level. A weight reduction of 13.58 kg (33 percent) was attained in the composite rudder.

Lehman, G. M.↗

NASA NTRS1994

Experimental design for the evaluation of high-T(sub c) superconductive thermal bridges in a sensor satellite

Infrared sensor satellites, which consist of cryogenic infrared sensor detectors, electrical instrumentation, and data acquisition systems, are used to monitor the conditions of the earth's upper atmosphere in order to evaluate its present and future changes. Currently, the electrical connections (instrumentation), which act as thermal bridges between the cryogenic infrared sensor and the significantly warmer data acquisition unit of the sensor satellite system, constitute a significant portion of the heat load on the cryogen. As a part of extending the mission life of the sensor satellite system, the researchers at the National Aeronautics and Space Administration's Langley Research Center (NASA-LaRC) are evaluating the effectiveness of replacing the currently used manganin wires with high-temperature superconductive (HTS) materials as the electrical connections (thermal bridges). In conjunction with the study being conducted at NASA-LaRC, the proposed research is to design a space experiment to determine the thermal savings on a cryogenic subsystem when manganin leads are replaced by HTS leads printed onto a substrate with a low thermal conductivity, and to determine the thermal conductivities of HTS materials. The experiment is designed to compare manganin wires with two different types of superconductors on substrates by determining the heat loss by the thermal bridges and providing temperature measurements for the estimation of thermal conductivity. A conductive mathematical model has been developed and used as a key tool in the design process and subsequent analysis.

Scott, Elaine P.↗

NASA NTRS1990

EDNA: Expert fault digraph analysis using CLIPS

Traditionally fault models are represented by trees. Recently, digraph models have been proposed (Sack). Digraph models closely imitate the real system dependencies and hence are easy to develop, validate and maintain. However, they can also contain directed cycles and analysis algorithms are hard to find. Available algorithms tend to be complicated and slow. On the other hand, the tree analysis (VGRH, Tayl) is well understood and rooted in vast research effort and analytical techniques. The tree analysis algorithms are sophisticated and orders of magnitude faster. Transformation of a digraph (cyclic) into trees (CLP, LP) is a viable approach to blend the advantages of the representations. Neither the digraphs nor the trees provide the ability to handle heuristic knowledge. An expert system, to capture the engineering knowledge, is essential. We propose an approach here, namely, expert network analysis. We combine the digraph representation and tree algorithms. The models are augmented by probabilistic and heuristic knowledge. CLIPS, an expert system shell from NASA-JSC will be used to develop a tool. The technique provides the ability to handle probabilities and heuristic knowledge. Mixed analysis, some nodes with probabilities, is possible. The tool provides graphics interface for input, query, and update. With the combined approach it is expected to be a valuable tool in the design process as well in the capture of final design knowledge.

Dixit, Vishweshwar V.↗

NASA NTRS2000

NASA's Aero-Space Technology

This presentation reviews the three pillars and the associated goals of NASA's Aero-Space Technology Enterprise. The three pillars for success are: (1) Global Civil Aviation, (2) Revolutionary Technology Leaps, (3) Advanced Space Transportation. The associated goals of the first pillar are to reduce accidents, emissions, and cost, and to increase the aviation system capacity. The goals of the second pillar are to reduce transoceanic travel time, revolutionize general aviation aircraft, and improve development capacity. The goals associated with the third pillar are to reduce the launch cost for low earth orbit and to reduce travel time for planetary missions. In order to meet these goals NASA must provide next-generation design capability for new and or experimental craft which enable a balance between reducing components of the design cycle by up to 50% and or increasing the confidence in design by 50%. These next-generation design tools, concepts, and processes will revolutionize vehicle development. The presentation finally reviews the importance of modeling and simulation in achieving the goals.

Milstead, Phil↗

NASA NTRS2007

Risk Management: A Practical Design Tool For Space Systems and Technology Development

Over the past two decades, risk management and risk analysis have emerged throughout the business community in the United States (US) as prominent planning and development strategies used to mitigate risk of failure and ensure a high return on investment (ROI) for business endeavors (financial and otherwise). They are generic tools that can be applied to any business regardless of the sector (i.e., government, university, private) and have been used by the Federal government in the form of institutional practices aimed at maximizing the probability of success in business activities. One US Federal agency that incorporates risk management and analysis techniques into business and/or engineering activities is the National Aeronautics and Space Administration (NASA). The present work is a discussion on mission, spacecraft and instrument design (as well as technology development) and the role of risk management, analysis and mitigation as a fundamental tool in the design process.

Silk, Eric A.↗

NASA NTRS2008

A Brief Introduction to the Theory of Friction Stir Welding

Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and is already an important welding process for the aerospace industry, where welds of optimal quality are demanded. The structure of welds determines weld properties. The structure of friction stir welds is determined by the flow field in the weld metal in the vicinity of the weld tool. A simple kinematic model of the FSW flow field developed at Marshall Space Flight Center, which enables the basic features of FSW microstructure to be understood and related to weld process parameters and tool design, is explained.

Nunes, Arthur C., Jr.↗

NASA NTRS2015

Pre-Mission Input Requirements to Enable Successful Sample Collection by a Remote Field/EVA Team

This paper is intended to evaluate the sample collection process with respect to sample characterization and decision making. In some cases, it may be sufficient to know whether a given outcrop or hand sample is the same as or different from previous sampling localities or samples. In other cases, it may be important to have more in-depth characterization of the sample, such as basic composition, mineralogy, and petrology, in order to effectively identify the best sample. Contextual field observations, in situ/handheld analysis, and backroom evaluation may all play a role in understanding field lithologies and their importance for return. For example, whether a rock is a breccia or a clast-laden impact melt may be difficult based on a single sample, but becomes clear as exploration of a field site puts it into context. The FINESSE (Field Investigations to Enable Solar System Science and Exploration) team is a new activity focused on a science and exploration field based research program aimed at generating strategic knowledge in preparation for the human and robotic exploration of the Moon, near-Earth asteroids (NEAs) and Phobos and Deimos. We used the FINESSE field excursion to the West Clearwater Lake Impact structure (WCIS) as an opportunity to test factors related to sampling decisions. In contract to other technology-driven NASA analog studies, The FINESSE WCIS activity is science-focused, and moreover, is sampling-focused, with the explicit intent to return the best samples for geochronology studies in the laboratory. This specific objective effectively reduces the number of variables in the goals of the field test and enables a more controlled investigation of the role of the crewmember in selecting samples. We formulated one hypothesis to test: that providing details regarding the analytical fate of the samples (e.g. geochronology, XRF/XRD, etc.) to the crew prior to their traverse will result in samples that are more likely to meet specific analytical objectives than samples collected in the absence of this premission information. We conducted three tests of this hypothesis. Our investigation was designed to document processes, tools and procedures for crew sampling of planetary targets. This is not meant to be a blind, controlled test of crew efficacy, but rather an effort to recognize the relevant variables that enter into sampling protocol and to develop recommendations for crew and backroom training in future endeavors. Methods: One of the primary FINESSE field deployment objectives was to collect impact melt rocks and impact melt-bearing breccias from a number of locations around the WCIS structure to enable high precision geochronology of the crater to be performed [1]. We conducted three tests at WCIS after two full days of team participation in field site activities, including using remote sensing data and geologic maps, hiking overland to become familiar with the terrain, and examining previously-collected samples from other islands. In addition, the team members shared their projects and techniques with the entire team. We chose our "crew members" as volunteers from the team, all of whom had had moderate training in geologic fieldwork and became familiar with the general field setting. The first two tests were short, focused tests of our hypothesis. Test A was to obtain hydrothermal vugs; Test B was to obtain impact melt and intrusive rock as well as the contact between the two to check for contact metamorphism and age differences. In both cases, the test director had prior knowledge of the site geology and had developed a study-specific objective for sampling prior to deployment. Prior to the field deployment, the crewmember was briefed on the sampling objective and the laboratory techniques that would be used on the samples. At the field sites (Fig. 2), the crewmember was given 30 minutes to survey a small section of outcrop (10-15 m) and acquire a suite of three samples. The crewmember talked through his process and the test director kept track of the timeline in verbal cues to the crewmember. At the conclusion, the team member conducting the scientific study appraised the samples and train of thought. Test C was a 90-minute EVA simulation using two crewmembers working out of line-of-sight in communication with a science backroom. The science objectives were determined by the science backroom team in advance using a Gigapan image of the outcrop (Fig. 1). The science team formulated hypotheses for the outcrop units and created sampling objectives for impact-melt lithologies; the science team turned these into a science plan, which they communicated to the crew in camp prior to crew deployment. As part of the science plan, the science team also discussed their sample needs in depth with the crewmembers, including laboratory methods, objectives, and samples sizes needed. During the deployment, the two crewmembers relayed real-time information to the science backroom by radio with no time delay. Both the crew and science team re-evaluated their hypotheses and science plans in real-time. Discussion: Upon evaluation, we found that the focused tests (Tests A and B) were successful in meeting their scientific objectives. The crewmember used their knowledge of how the samples were to be used in further study (technique, sample size, and scientific need) to focus on the sampling task. The crewmember was comfortable spending minimal time describing and mapping the outcrop. The crewmember used all available time to get a good sample. The larger test was unsuccessful in meeting the sampling objectives. When the crewmembers began describing the lithologies, it was quickly apparent that the lithologies were not as the backroom expected and had communicated to the crew. When the outcrop wasn't as expected, the crew members instinctively switched to field characterization mode, taking significant time to characterize and map the outcrop. One crew member admitted that he "kind of lost track" of the sampling strategy as he focused on the basic outcrop characterization. This is the logical first step in a field geology campaign, that a significant amount of time must be spent by the crew and backroom to understand the outcrop and its significance. Basic field characterization of an outcrop is a focused activity that takes significant time and training [2, 3]. Sampling of representational lithologies can be added to this activity for little cost [4]. However, we have shown that identification of unusual or specific samples for laboratory study also takes significant time and knowledge. We suggest that sampling of this type be considered a separate activity from field characterization, and that crewmembers be trained in sampling needs for different kinds of studies (representative lithologies vs. specialized samples) to acquire a mindset for sampling similar to field mapping. Sampling activities should be given a significant amount of specifically allocated time in scheduling EVA activities; and in the better case, that sampling be done as a second activity to a previously studied outcrop where both crew and backroom are comfortable with its context and characteristics. Our hypothesis posited that crewmember knowledge of how the samples would be used upon return would aid them in choosing relevant samples. Our testing bore this hypothesis out to some extent. We therefore recommend that crewmember training should include exposure to the laboratory techniques and analyses that will be used on the samples to foster this knowledge. There is also the potential for increasing crewmember contextual knowledge real-time in the field through the introduction of in situ geochemical technologies such as field portable XRF. The presence of field portable geochemical technology could enable the astronauts to interrogate the samples for K abundance real-time, ensuring they could collect valuable and dateable samples [5]. Though simulations such as these can teach us a fair bit about decision making processes and timeline building, one EVA participant noted that when he wasn't collecting "real" samples, he wasn't at his best. This effect suggests that higher-fidelity studies involving truly remote participants conducting actual scientific studies merit further attention to capture lessons for application to future crew situations.

sample collection↗

NASA NTRS2016

Pre-Mission Input Requirements to Enable Successful Sample Collection by A Remote Field/EVA Team

The FINESSE (Field Investigations to Enable Solar System Science and Exploration) team, part of the Solar System Exploration Virtual Institute (SSERVI), is a field-based research program aimed at generating strategic knowledge in preparation for human and robotic exploration of the Moon, near-Earth asteroids, Phobos and Deimos, and beyond. In contract to other technology-driven NASA analog studies, The FINESSE WCIS activity is science-focused and, moreover, is sampling-focused with the explicit intent to return the best samples for geochronology studies in the laboratory. We used the FINESSE field excursion to the West Clearwater Lake Impact structure (WCIS) as an opportunity to test factors related to sampling decisions. We examined the in situ sample characterization and real-time decision-making process of the astronauts, with a guiding hypothesis that pre-mission training that included detailed background information on the analytical fate of a sample would better enable future astronauts to select samples that would best meet science requirements. We conducted three tests of this hypothesis over several days in the field. Our investigation was designed to document processes, tools and procedures for crew sampling of planetary targets. This was not meant to be a blind, controlled test of crew efficacy, but rather an effort to explicitly recognize the relevant variables that enter into sampling protocol and to be able to develop recommendations for crew and backroom training in future endeavors.

FINESSE↗

DOE OSTI2025

Exploration of High Depth-to-Width Ratio Micro Friction Stir Welding on Thin 6061-T6 Aluminum Butt Joints

In the autogenous joining process of thin 6061-T6 aluminum plates, micro friction stir welding (μFSW) is employed to explore the limitations of high depth to width ratio (HDWR) welding. In this explorative study, 1.25mm plate is joined in a butt joint fashion, multiple HDWR μFSW tools are developed, and the welding parameters are optimized to create a DWR greater than 0.4. A proposed method of implementing induction preheating to the joint is presented and the subsequent characterization of the welds are discussed. Upon completion of the project, the limitations on HDWR μFSW will be more accurately defined, and the best weld will be characterized to determine some of metallurgical properties. This study further expands the operating window for autogenous welding with solid state processes on thin aluminum plate as well as highlight methods for process improvement for tooling design and pre-heating methods.

Shambaugh, Colton↗

NASA NTRS2015

Evolving Design Criteria for Very Large Aperture Space Based Telescopes and Their Influence on the Need for Integrated Tools in the Optimization Process

NASA's Advanced Mirror Technology Development (AMTD) program has been developing the means to design and build the future generations of space based telescopes. With the nearing completion of the James Webb Space Telescope (JWST), the astrophysics community is already starting to define the requirements for follow-on observatories. The restrictions of available launch vehicles and the possibilities of planned future vehicles have fueled the competition between monolithic primaries (with better optical quality) and segmented primaries (with larger apertures, but with diffraction, costs and figure control issues). Regardless of the current shroud sizes and lift capacities, these competing architectures share the need for rapid design tools. As part of the AMTD program a number of tools have been developed and tested to speed up the design process. Starting with the Arnold Mirror Modeler (which creates Finite Element Models (FEM) for structural analysis) and now also feeds these models into thermal stability analyses. They share common file formats and interchangeable results. During the development of the program, numerous trade studies were created for 4-meter and 8-meter monolithic primaries, complete with support systems. Evaluation of these results has led to a better understanding of how the specification drives the results. This paper will show some of the early trade studies for typical specification requirements such as lowest mirror bending frequency and suspension system lowest frequency. The results use representative allowable stress values for each mirror substrate material and construction method and generic material properties. These studies lead to some interesting relationships between feasible designs and the realities of actually trying to build these mirrors. Much of the traditional specifications were developed for much smaller systems, where the mass and volume of the primary where a small portion of the overall satellite. JWST shows us that as the aperture grows, the primary takes up the majority of the mass and volume and the established rules need to be adjusted. For example, a small change in lowest frequency requirement can change the cost by millions of dollars. The paper uses numerous trade studies created during the software development phase of the Arnold Mirror Modeler to illustrate the influences of system specifications on the design space. The future telescopes will require better performance, stability and documented feasibility to meet the hurdles of today's budget and schedules realities. AMTD is developing the tools, but the basic system planning mentality also has to adopt to the requirements of these very large and complex physical structures.

Arnold, William R., Sr.↗

DOE OSTI2021

Development of Additively Manufactured Complex Tools for Autoclave Cure Composites

IACMI Project 4.9, Tooling for Composites with Washout Features Produced by Additive Manufacturing, assembled a team including the industry lead, Ability Composites, NREL and Colorado State University (CSU). Ability Composites had originally expressed interest in alternate methods of producing tooling for composite parts. In follow-up discussions, it became clear that one of the bigger tooling challenges revolved around small production volume composite parts that were tooled on washout material due to the complex geometry. To build an understanding of the potential, both from a technology and a cost perspective, for replacing conventional washout tooling with 3D printed thermoplastic tooling, a number of commercially available dissolvable FDM printing materials were evaluated, leading to tooling representative of commercial articles of interest to Ability Composites. Ultimately, Ability Composites was able to directly compare autoclave processed prepreg composite parts produced on conventional washout tooling to composite parts molded on 3D printed dissolvable tooling produced at CSU. Small, laboratory test specimens were developed to investigate the structural performance of the candidate materials under autoclave processing conditions, which were nominally 121 °C (250 °F) and 345 kPa (50 psi). In addition, several internal structural configurations (infills) were evaluated under autoclave conditions using model materials. The results of these tests indicated that two materials, Stratasys ST 130 and Infinite Materials Solutions Aquasys 180 (AQ 180), were the best candidates, given the specified autoclave processing conditions. ST-130 was slightly more robust than AQ-180; however, the AQ-180 was carried forward as it was dissolvable in water, not requiring the basic solution needed to dissolve ST-130. Based on the preliminary material and 3D printed structures evaluations, larger tools with a truncated square pyramid geometry were created to produce prepreg composite test articles for 3D printed dissolvable tool evaluation under standard autoclave fabrication conditions. Two tools were manufactured using ST-130 and one tool using traditional ceramic washout tooling media. The tools were evaluated for geometric fidelity and surface roughness changes before and after carbon fiber/epoxy prepreg composites were manufactured on the tooling. The autoclave processing did not impact the geometry significantly and was completed at 121 °C and 345 kPa, indicating satisfactory tool performance. The results from surface roughness testing of both the resulting composite and the associated tooling indicated that an adequate surface resulted without the need for a surface sealing step, as was required for the conventional washout tooling. Based on results of the truncated pyramid tests as a basis, ST-130, AQ-120 and AQ-180 materials were carried forward to the tool geometry of interest to Ability Composites. These hollow rectangular bent ducts, which were complex in nature and not extractable after cure, were used to understand the impacts of tool material and thickness. One ST-130 tool was produced as a partially solid part, with an enclosed 40% dense infill region to reduce weight and material use. This was the same approach evaluated in the truncated pyramid portion of the study. This tool was to be envelope vacuum bagged and directly compared to a monolithic tool of conventional washout material. The traditional monolithic ceramic tool was manufactured by Ability composites using CNC-based subtractive methods. An additional five dissolvable polymer tools, manufactured from ST-130, AQ-120, and AQ-180, using a hollow design were 3D printed and used to produce carbon fiber/epoxy composite evaluation articles. These hollow dissolvable tools were expected to be less influenced by the autoclave conditions as the wall was solid and vacuum bagging was inside and outside the tool. This alternative geometry was also evaluated as an option in techno-economic modeling. Print times were reduced from in excess of 3 days to under 30 hours, while surface quality and and tool integrity were substantially improved in the transition from the partially solid tool to the hollow tooling concept. Ability Composites produced autoclave-cured prepreg ducts on each of these tools. The autoclave conditions utilized were more severe than those of the initial trials, reaching temperatures of 160 °C and a pressure of 414 kPa. Under these conditions, the partially solid 3D printed tool with skin and 40% dense infill crushed significantly; however, the thicker ST-130 hollow tool showed good promise, deforming only slightly. The thinner hollow tool walls were unsuccessful as were the other materials. Overall, the hollow tool manufacturing process saved significant amounts of time and material in manufacturing as compared to the solid ducts and produced composite surface quality improvements compared to the traditional washout tooling. The TEM was developed to allow direct comparisons between conventional washout tool manufacturing processes and those developed at CSU. It also allowed for two separate 3D printed tool geometries to be analyzed and compared. In this case, the square bent duct tool geometry was determined to be representative of common washout tools. This geometry was compared with a scaled-up version of it to assess differences in the two manufacturing processes based on tool size. The model was developed to make use of user input in the form of geometry details, process steps, manufacturing parameters, bulk material costs, capital equipment costs, and general costs to calculate overall labor, material, capital equipment, and energy costs per manufactured tool for the conventional and additive manufacturing processes for the two representative geometries. It was also able to estimate step-by-step process times for the manufacturing process and geometries. Based on significant input from Ability Composites and CSU from their knowledge gained from hands-on manufacturing of the 3D printed bent duct tool geometry, costs and process times were calculated for the two manufacturing processes. Results showed that the additive manufacturing techniques developed at CSU can substantially reduce the costs of tool manufacturing by reducing labor times and material usage. This is because additive manufacturing is a relatively hands-off process and allows for the tool design to be optimized to reduce material usage. The disadvantage, however, is that process times for additive manufacturing are significantly longer. The three-dimensional (3D) printing process is slow if tight tolerances are required, but the analysis did show that print times could be reduced with the hollow tool geometry. Also, further advances in additive manufacturing could expedite the process. Costs and process times for the tool washout process were calculated separately. They showed that costs are relatively insignificant when compared to the overall tool manufacturing processes, but with increases in tool size, costs for the conventional manufacturing approach are larger than for additive manufacturing. Again, the washout process for conventional tools is very hands-on, whereas for additively manufactured tools the print medium is dissolved in an automated detergent bath at the sacrifice of process time. The analysis showed that optimizing the additively manufactured tools may also reduce washout times. Overall, Project 4.9 demonstrated that commercially available dissolvable 3D printing materials exist that can be used to produce dissolvable tooling capable of surviving prepreg composites fabrication under autoclave conditions of 121 °C (250 °F) and 345 kPa (50 psi). An alternative hollow dissolvable tool design was developed which was structurally superior to the initial concept and was cost and time effective versus conventional washout tooling. The 3D printed sacrificial tool required no added surface sealing steps prior to composite part layup and cure, offering a significant advantage over the porous conventional washout tooling.

36 MATERIALS SCIENCE↗