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At least 937 records · Page 52
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

NASA's In-Space Manufacturing Project: A Roadmap for a Multimaterial Fabrication Laboratory in Space

Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS) provides a unique opportunity for NASA to partner with private industry for development and demonstration of the technologies needed to support exploration initiatives. One challenge that is critical to sustainable and safer exploration is the ability to manufacture and recycle materials in space. This paper provides an overview of NASA's in-space manufacturing (ISM) project, its past and current activities (2014-2017), and how technologies under development will ultimately culminate in a multimaterial fabrication laboratory ("ISM FabLab") to be deployed on the International Space Station in the early 2020s. ISM is a critical capability for the long endurance missions NASA seeks to undertake in the coming decades. An unanticipated failure that can be adapted for in low earth orbit, through a resupply launch or a return to earth, may instead result in a loss of mission while in transit to Mars. To have a suite of functional ISM capabilities that are compatible with NASA's exploration timeline, ISM must be equipped with the resources necessary to develop these technologies and deploy them for testing prior to the scheduled de-orbit of ISS in 2024. The presentation provides a broad overview of ISM projects activities culminating with the Fabrication Laboratory for ISS. In 2017, the in-space manufacturing project issued a broad agency announcement for this capability. Requirements of the Fabrication Laboratory as stated in the solicitation will be discussed. The FabLab will move NASA and private industry significantly closer to changing historical paradigms for human spaceflight where all materials used in space are launched from earth. While the current ISM FabLab will be tested on ISS, future systems are eventually intended for use in a deep space habitat or transit vehicle. The work of commercial companies funded under NASA's Small Business Innovative Research Program (SBIR) is also discussed, as these activities, from development of recyclable packaging for ISS to additive manufacturing capabilities for metals and electronics, could also potentially be infused into future exploration capabilities. Key data from ISM projects to date will also be summarized.

Prater, Tracie↗
NASA NTRS2018

Overview of Additive Manufacturing Initiatives at NASA Marshall Space Flight Center

NASA's In Space Manufacturing Initiative (ISM) includes: The case for ISM - why; ISM path to exploration - results from the 3D Printing In Zero-G Technology Demonstration - ISM challenges; In space Robotic Manufacturing and Assembly (IRMA); Additive construction. Additively Manufacturing (AM) development for liquid rocket engine space flight hardware. MSFC standard and specification for additively manufactured space flight hardware. Summary.

Clinton, R. G., Jr.↗
NASA NTRS2017

Ionic Polyimides: New High Performance Polymers for Additive Manufacturing

There is currently a very limited set of engineering polymers that have been demonstrated as viable for use in 3-D printing. Additive manufacturing of custom components will require a much larger array of polymers, especially those with physical, thermal, chemical, and mechanical properties that can be tailor-made. The development of ‘Ionic Polyimides’ offers a solution to this shortage by combining the well understood and widely accepted properties of conventional polyimides, with a new approach to polymer synthesis. Polyimides and polymeric ionic liquids (poly(ILs)) are at the forefront of advanced polymer materials, each with their own set of advantages and disadvantages. While it is clear that more types of polymer materials are needed for fused deposition modeling (FDM) additive manufacturing, there is a need to explore these classes of materials. The synthesis process developed by the Bara Research Group at the University of Alabama allows full control over polymer structure, nanostructure, thermal, electrical, and physical properties making them a prime candidate for use in the additive manufacturing process. Furthermore, the new process allows us to tailor-make a high strength polymer that can be used to fabricate filament feedstock instead of pellets for 3D printing. The primary objective of this proposal is to determine the relationship between molecular structure, physical properties, and performance of ionic polyimides. Further, we seek to determine their utility as materials suitable for additive manufacturing of components used in aerospace vehicles, with an emphasis on characterizing and simulating their thermal behaviors and properties. This proposal addresses the need for fundamental research on a customizable polymer filament feedstock for 3-D printing with tailor-made properties potentially making it superior to the commercial blends offered in industry today. The deliverables for this project are the creation of a database that will detail the relationships between the molecular structure and physical properties for the ionic polyimide of interest (e.g. Tg/Tm (Glass Transition Temperature divided by Melting Point)) relative to different ionic polyimide structures). This new database will provide a “road map” to the development of the first generation of materials and ultimately proof-of-concept.

Jackson, Enrique↗
NASA NTRS2018

Characterizing Performance of Additively Manufacturing Regenerative Cooled Combustion Chambers Through Hot Fire Testing

NASA Marshall Space Flight Center (MSFC) has developed several additive manufactured regenerative cooled combustion chambers from 2014 to present. Chambers have been constructed using the Selective Laser Melting (SLM) powder bed additive manufacturing (AM) technique. The materials used for the chambers has varied from Inconel 718, Inconel 625, GRCop-84, and C18150 metal alloys. The surface finish and build techniques used to successfully manufacture combustion chambers using the SLM AM result in as built surface finish and off nominal geometric features. This paper discusses and reviews the effects of surface roughness, flow area, and hydraulic performance of regenerative cooled combustion chambers. The thrust chambers designs tested ranged from 200 to 1,400 psia producing 1,000 to 35,000 lbf thrust. Empirical data from four test campaigns will be reviewed and related to design modeling parameters such as pressure drop, surface roughness, and actual fluid flow geometry. Correlation results with simple 2-D CFD modeling will also be presented. The goal of the work is to better understand how the finished additive manufactured component characteristics inside internal features can effect regenerative cooling chamber design. Adjustments to design methodology will be discussed and recommended based on the above results.

Garcia, C. P.↗
NASA NTRS2018

Additive Manufacturing of Liquid Rocket Engine Combustion Devices: A Summary of Process Developments and Hot-Fire Testing Results

Additive Manufacturing (AM) of metals is a processing technology that has significantly matured over the last decade. For liquid propellant rocket engines, the advantages of AM for replacing conventional manufacturing of complicated and expensive metallic components and assemblies are very attractive. AM can significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing for use in liquid rocket engine component design, development, and testing since 2010. The AM technique most often used at the NASA MSFC has been powder-bed fusion or selective laser melting (SLM), although other techniques including laser directed energy deposition (DED), arc-based deposition, and laser-wire cladding techniques have also been used to develop several components. The purpose of this paper is to discuss the various internal programs at the NASA MSFC using AM to develop combustion devices hardware. To date at the NASA MSFC, combustion devices component hardware ranging in size from 100 lbf to 35,000 lbf have been designed and manufactured using SLM and deposition-based AM processes, and many of these pieces have been hot-fire tested. Combustion devices component hardware have included thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. Ongoing and future developments for combustion devices have also included design of components sized for boost-class engines. Several design and hot-fire test iterations have been completed on these subscale and larger scale components, and a summary of these results will be presented as well.

Gradl, Paul↗
NASA NTRS2018

Space Technology Mission Directorate: Game Changing Development Program: Rapid Analysis and Manufacturing Propulsion Technology (RAMPT)

Technology Overview: The RAMPT (Rapid Analysis and Manufacturing Propulsion Technology) project will develop and advance large scale light-weight multi-metallic freeform manufacturing and composite overwrap techniques and analysis capabilities required to implement them to reduce design and fabrication cycles for regeneratively-cooled liquid rocket engine components; RAMPT will reduce design, fabrication, assembly schedules while allowing for reduced parts, increased reliability, significant weight reduction and a healthy American supply chain. Four technology areas developed: 1) Freeform Blown Powder Nozzle; 2) Composite overwrap structural jacket; 3) Bimetallic radial deposition for manifolds; 4) Modeling and analysis tools for Additive and Regen design. Exploration & Science Impact: Addresses longest lead, highest cost and heaviest component in engine; Applicable to Lunar Lander Engine, Booster Engines, Upper Stage Engines, and NTP (Nuclear Thermal Propulsion) Technology; Public-private partnerships with specialty industry vendors, government partners, Commercial Crew, and infusion into commercial space companies and manufacturers; SSTIP (NASA's Strategic Space Technology Investment Plan) Core Investment Area - Launch Propulsion Systems (TA01 (NASA Technology Area 01); Lightweight Space Structures and Materials (TA12); Manufacturing (TA12).

RAMPT↗
NASA NTRS2019

Development of an Additively Manufactured Capacitive Humidity Sensor for the International Space Station

The ability to measure humidity on the International Space Station and other long-duration spaceflight missions is a crucial part of the onboard systems. For example, the Environmental Control and Life Support System (ECLSS) needs to know the amount of humidity in the air to make decisions about whether it should spend power to run the dehumidifier systems to attempt to reclaim that water. Other issues can arise if the humidity reaches too high of levels and condensation builds up on electrical components. With that in mind, it is vital that the spacecraft keeps spare sensors on board or has the ability to manufacture new sensors on demand. An additively manufactured sensor would be additionally beneficial because it would save space onboard that would normally be taken up by spares, save money from costly resupply missions, and allow the sensor to be constantly updated with the most effective design. This Technical Memorandum outlines a development process carried out to design, manufacture, and test an additively manufactured humidity sensor.

Chang, K. T.↗
NASA NTRS2018

Tailored Wingbox Structures through Additive Manufacturing: A Summary of Ongoing Research at NASA LaRC

The use of wingbox structural design for improved performance (i.e., fuel burn reduction) of subsonic transports is driven by two trends: reduced structural weight and increased wingspan. These two trends are in direct competition, as the increased span will exacerbate the structural reaction to aerodynamic loading, and the reduced structural weight will nominally weaken the aircraft’s ability to handle this response. Novel structural configurations, enabled by recent improvements in manufacturing, may be critical toward bridging this gap.This paper summarizes pertinent activities at the NASA Langley Research Center in terms of additive manufacturing of metallic wing structures and substructures. Numerical design optimization activities are summarized as well, in order to understand where on a wingbox an additively-manufactured part may be useful and the way in which that part beneficially impacts the flight physics. The paper concludes with a discussion of how these two research paths may be better married in order to fully integrate both the benefits and realistic limitations of additive manufacturing and numerical structural design.

Stanford, Bret. K.↗
NASA NTRS2019

Fracture Control for Additive Manufactured Spacecraft Structures

Final Paper is attached. This paper discusses how the intent of current NASA fracture control requirements may be applied to "fracture critical" additive manufactured spacecraft hardware. Fracture control is a multi-discipline design and certification methodology that is applied in order to mitigate catastrophic failure of structures resulting from growth of an undetected crack-like defect. The methodology is defined in existing spacecraft standards and is required by NASA on all human-rated space structures. Recently, standards have been published by NASA to define materials and processes requirements for certain metallic additive manufactured hardware, but procedures for fracture control implementation on additive manufactured parts are not yet addressed in detail in any standard or guidance document.The discussion contained herein is necessary at this time as new guidance in this area should be founded collaboratively by the technical community at large including industry, academia, and government. Three Fracture Control Certification Methods are proposed for discussion. Additionally, a concept for "Design for AM fracture control" is introduced. The goals of this paper are to further expose the need for maturing additive manufacturing fracture control guidance in the spacecraft industry and to generate discussion on what this guidance should consist of.

McElroy, Mark↗
NASA NTRS2019

Manufacturing Process Development for Adhesively Bonded Joints in Large-Scale Space Structures

In order to take full advantage of the weight savings and performance gains offered by the use of composite materials in large-scale space structures, adhesively bonded joints must be considered. While bonded joint manufacturing at laboratory scale can be straightforward, the same manufacturing processes are not trivial at full scale. Surface preparation becomes particularly challenging (a viable process must yield consistent results over a large application area and be repeatable for multiple application sites), as does the application of heat to cure the doublers and/or bond them to the primary structure (the nature and scale of assembled or partially assembled aerospace structures often necessitates an out-of-oven/out-of-autoclave approach). In this work, bonded joint manufacturing processes are adapted for a full-scale (approximately 30 feet in diameter at the aft end) composite payload adapter at the NASA Marshall Space Flight Center. By iterating across a range of variables, process parameters for adhesively bonded joints on a large-scale composite structure have been developed. Primary findings are presented with respect to overarching bonded joint manufacturing concepts so as to maximize the applicability of this work to similar material systems and structures.

Guin, William E.↗
NASA NTRS2018

NASA’s Plans for Development of Standards for Additive Manufactured Components

There are currently no NASA standards providing specific design and construction requirements for certification of additively manufactured parts. Several international standards organizations are developing standards for additive manufacturing; however, NASA mission schedules preclude the Agency from relying on these organizations to develop standards that are both timely and applicable. NASA and its program partners in manned spaceflight (the Commercial Crew Program, the Space Launch System and the Orion Multi-purpose Crew Vehicle) are actively developing additively manufactured parts for flight as early as 2018. To bridge this gap, NASA Marshall Space Flight Center (MSFC) has authored a center-level standard (MSFC-STD-3716)1 to establish standard practices for the Laser Powder Bed Fusion (L-PBF) process. In its draft form, the MSFC standard has been used as a basis for L-PBF process implementation for each of the manned space flight programs. The development of an Agency-level standard is proposed, which based upon the principles of MSFC-STD-3716, would have application to multiple additive manufacturing processes and be readily adaptable to all NASA programs.

Russell, Richard W.↗
NASA NTRS2019

CAMIEM: Compact Additively Manufactured Innovative Electric Motor

New manufacturing methods are needed to obtain innovative electric motor designs that have much higher power densities and/or efficiencies compared to the current state-of-the-art. Additive manufacturing offers the potential to radically change motor designs so that they have compact designs, multi-material components, innovative cooling, and optimally designed and manufactured components. New component designs enabled by additive manufacturing technologies have been designed and were fabricated to include the housing, rotors, stator cooling ring, a direct printed stator, and a wire embedded stator. The new components were integrated into the motor and tested evaluate the performance gains in comparison to the baseline electric motor configuration. Partners on the sub-project include NASA GRC, NASA LaRC, NASA AFRC, LaunchPoint Technologies, and the University of Texas El Paso.

Halbig, Michael C.↗
NASA NTRS2019

Additive Manufacturing of Oxide Dispersion Strengthened (ODS) Nickel-Based Superalloys

Additive manufacturing of oxide dispersion strengthened (ODS) Ni-based superalloys, via powder bed techniques, could enable near-net-shape manufacturing of intricately shaped components for aerospace applications. This has the potential to transform the design and manufacturing of hot sections of engines which face demands for ever-rising operating temperatures. The goal of this project is to lay the scientific foundation for additive manufacturing of ODS alloys. The objective of this poster is to present work to date as well as proposed future work.

Wilson, Laura G.↗
NASA NTRS2018

Rapid Tools for an AFP Manufacturing Defects Assessment Framework

This work formulates an automated fiber placement (AFP) defects assessment framework. Such framework assumes AFP manufacturing processes are able to identify manufacturing defects via automated inspection systems and intends to provide rapid analysis tools to create a defect assessment loop. The defect assessment loop defines an automated analysis process during AFP manufacturing to minimize the number of manual repairs on the part, thus accelerating AFP manufacturing of composite structures. This defects assessment loop advantages automated inspection data to evaluate the influence of encountered AFP defects on a ply-by-ply basis. Structural evaluation is based on strength criteria using local-global finite element models. Local models affect the global part model via material property reductions. Schemes to reduce material properties using the local models are the main enablers of this framework’s automated assessment capability. Finally, we discuss the main technical challenges to realize the feasibility of this framework.

Bahamonde Jacome, Luis G.↗
NASA NTRS2019

Automated Fiber Placement of Composite Wind Tunnel Blades: Process Planning and Manufacturing

The ability to accurately manufacture large complex shapes in a consistent and repeatable manner has led to Automated Fiber Placement (AFP) being the predominant mode of manufacturing for large composite aerospace structures today. Currently, AFP is being considered for medium- and small-scale parts. Composite wind tunnel blades have traditionally been fabricated by hand layup for pre-impregnated or dry fabrics with resin infusion. Though well proven, the traditional fabrication method is laborious and tedious, and hence expensive. The project described in this paper used the Integral Structural Assembly of Advanced Composites (ISAAC) facility at the NASA Langley Research Center to build a manufacturing demonstration unit (MDU) with a shape representative of a wind tunnel blade. This MDU is used to discuss tooling, process planning, and fabrication. Additionally, details of the generic manufacturing workflow are presented.

Harik, Ramy↗
NASA NTRSDate not supplied

Metal Fused Filament Fabrication of Titanium Alloy for In Space Manufacturing

NASA is developing materials and processes for the in-space manufacturing of many items for the International Space Station (ISS) and future exploration platforms. These new manufacturing processes will require the further development of current 3D printing processes to achieve high-performance metal parts within the power and space constraints of the ISS. Manufacturing Ti-6Al-4V alloy parts with 3D printing using a metal fused filament fabrication (MF3) process is an alternative process to the Direct Metal Laser Sintering (DMLS) of the metal powders additive manufacturing process. Our initial work fabricating Ti-6Al-4V parts from Ti-6Al-4V powder-binder feedstock and processed with the MF3 process has resulted in 95-97% sintered densities. The current development work of optimized sintered properties investigates the effects of variation in sintering time, temperature, and vacuum on the sintered properties of Ti-6Al-4V MF3 printed tensile bars. Sintered properties such as density, hardness, and tensile properties were characterized followed by microstructural and chemical (O/C/N) analysis to understand the role of sintering process on the ensuing material properties. Future development of the MF3 process will also involve investigation of the effects of micro-milling the Ti-64Al-4V powder to nanometer particle sizes and the investigation of laser sintering of the 3D printed devices. This new micro-milling technique will have broad application to other areas that require particle size reduction of hard metallic materials, such as Nuclear Thermal Propulsion and other NASA technologies. Laser sintering in lieu of high temperature thermal sintering should allow for significant power reduction and improved processing speeds.

sintering, alloys, 3D printing↗
NASA NTRSDate not supplied

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗
NASA NTRS2022

(Preliminary) Effects of Ball Milling Zeolite Powders for Use in Additively Manufactured Solid Sorbents

Zeolite 13X is favorable to be used as an adsorbent in carbon dioxide (CO2) removal from the spacecraft cabin air. Reducing the size of the zeolite particles and particle size distribution is thought to increase the capacity of CO2 adsorption of the zeolite 13X powder, and potentially increase its manufacturability as a paste for additive manufacturing or slip casting. This paper will go into detail on the process of using ball milling in order to reduce particle size and particle size distribution of commercial zeolite 13X powder, as well as to characterize CO2 adsorption and manufacturability of the milled powder. Both dry and wet ball milling was analyzed during the experiment. Studies were also ran on the amount of time the powder was milled, rotational speed of the milling machine, ball to powder ratio, ball to jar ratio, and ethanol to powder ratio. The processed powder was then characterized through laser diffraction, SEM, and surface measurement techniques to show that particle size and particle size distribution could be reduced, and to show the effect of the reduced particle size and particle size distribution on CO2 adsorption and manufacturability.

zeolite↗