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DOE OSTI2020

Current challenges and potential directions towards precision microscale additive manufacturing – Part III: Energy induced deposition and hybrid electrochemical processes

The Part III of the four-part series of articles discusses the challenges and opportunities in microscale additive manufacturing processes, specifically focusing on energy-induced deposition and electrochemical processes. Compared to the direct ink write (DIW) and laser-based processes, the energy-induced deposition methods can fabricate high-resolution, high aspect ratio and complex parts, while the hybrid electrochemical process can be used to fabricate complex parts using a wide range of conductive and photoactive materials. However, the volumetric throughput of these processes is lower than their DIW and laser-based counterparts. The processes that have been explored in this process are Focused-ion Beam Induced Deposition (FIBID), Laser Chemical Vapor Deposition (LCVD), Menicus-confined Electrodeposition (MCED) and Laser-Enabled Electrochemical Printing (LECP). The range of processable materials, feature-size resolution, geometry and volumetric throughput are used as factors to evaluate the current state-of-the-art for these processes. Finally, novel approaches have been proposed in the article to address these challenges associated with microscale AM processes.

42 ENGINEERING↗

DOE OSTI2023

Rapid Laser Reactive Sintering of Garnet Li 6.4 La 3 Zr 1.4 Ta 0.6 O 12 and Li 6.1 La 3 Zr 2 Al 0.3 O 12 and Solid-State Electrolytes

All solid-state lithium-ion batteries (ASSLIBs) have gained significant interest in recent years due to their wide range of applications, including mobile devices, electric vehicles, and grid storage. Garnet-type Li 7 La 3 Zr 2 O 12 (LLZO) solid-state electrolyte (SSE) continues to be a significant player in the fabrication of ASSLIBs with excellent ionic conductivity on the order of 10 -3 S•cm -1 with the integration of dopants and sintering aids to assist conductivity and structural evolution during the sintering procedure. Traditional sintering techniques, such as solid-state sintering (SSS), have been proven to yield desirable crystal structures. However, the low ionic conductivity results from inferior microstructure, and lithium loss is a significant challenge. Recently, a relatively novel sintering process called rapid laser sintering (RLS) has shown great potential for achieving fully dense solid oxide electrolytes with less lithium loss, resulting in high ionic conductivity [1] [2] [3] [4]. Here, we applied a modified RLS method using precursor powders instead of pre-synthesized LLZO powders to fabricate Al-doped LLZO (Li 6.1 La 3 Zr 2 Al 0.3 O 12 + 13 wt% Li 2 CO 3 ) and Ta-doped LLZO (Li 6.4 La 3 Zr 1.4 Ta 0.6 O 12 + 5 wt% LiOH•H 2 O) dense electrolytes. This rapid laser reactive sintering (RLRS) could potentially reduce the number of processing steps and therefore lower the manufacturing cost. We hope the rapid high-temperature sintering can densify the electrolyte and avoid the lithium loss for achieving high lithium-ion conductivity. In this work, we optimized a combination of laser parameters (speed and power), initial precursor composition, and controlled atmospheres to discover the optimal conditions for reaching the efficacious crystal structure, microstructure, and ionic conductivity.

25 ENERGY STORAGE↗

NASA NTRS1979

Space manufacturing III; Proceedings of the Fourth Conference, Princeton University, Princeton, N.J., May 14-17, 1979

Papers are presented on the various technological, political, economic, environmental and social aspects of large manufacturing facilities in space. Specific topics include the potential global market for satellite solar power stations in 2025, the electrostatic separation of lunar soil, methods for extraterrestrial materials processing, the socio-political status of efforts toward the development of space manufacturing facilities, the financing of space industrialization, the optimization of space manufacturing systems, the design and project status of Mass Driver Two, and the use of laser-boosted lighter-than-air-vehicles as heavy-lift launch vehicles. Attention is also given to systems integration in the development of controlled ecological life support systems, the design of a space manufacturing facility to use lunar materials, high performance solar sails, the environmental effects of the satellite power system reference design, the guidance, trajectory and capture of lunar materials ejected from the moon by mass driver, the relative design merits of zero-gravity and one-gravity space environments, consciousness alteration in space and the prospecting and retrieval of asteroids.

Grey, J.↗

DOE OSTI2025

Impact of Irradiation on Microstructure and Mechanical Properties of Materials Produced by Advanced Manufacturing

Advanced non-light water reactor designs, known as Generation IV (Gen IV) reactors, typically operate at higher temperatures and under more extreme radiation conditions than conventional light water reactors. A critical aspect of the successful deployment and advancement of Gen IV reactor designs is the selection of appropriate structural materials for specific applications, which necessitates the timely development of new materials and manufacturing processes. Advanced manufacturing (AM) offers numerous opportunities for innovative designs, enabling the production of high-performance components with potentially shorter development cycles compared to traditional manufacturing methods. However, a significant challenge in deploying AM technologies in the nuclear energy sector is the current lack of data on the irradiation performance of AM-produced components. This presentation will discuss neutron and ion irradiation results of AM materials, including stainless steel 316L, Grade 91, SA508, Inconel 718, and Inconel 625 materials. The materials were manufactured by AM, such as Powder Metallurgy Hot Isostatic Pressing (PM HIP), Laser Powder Bed Fusion (LPBF) and Directed Energy Deposition (DED). The effects of neutron irradiation on microstructure (e.g., dislocations, loops, and nanoclusters), tensile properties (e.g., strength and ductility), and ion irradiation on Irradiation-Assisted Stress Corrosion Cracking (IASCC) will be explored. Results are collected from several projects supported by the Nuclear Science User Facilities (NSUF) program.

36 - MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Principles of Directed Energy Deposition for Aerospace Applications

Metal Additive Manufacturing is changing how components are fabricated for rocket propulsion and aerospace applications. Many additive manufacturing technologies are evolving, and active research is being conducted across academia, industry, and government to advance processes, materials, design, post-processing and applications. While much focus has been on Laser Powder Bed Fusion (LPBF) techniques, several large-scale techniques are also rapidly evolving using directed energy deposition (DED).

Additive Manufacturing↗

DOE OSTI2022

Numerical and experimental investigation of the geometry dependent layer-wise evolution of temperature during laser powder bed fusion of Ti–6Al–4V

Abstract Laser powder bed fusion (L-PBF) is currently the additive manufacturing process with the widest industrial use for metal parts. Yet some hurdles persist on the way to a widespread industrial serial production, with reproducibility of the process and the resulting part properties being a major concern. As the geometry changes, so do the local boundary conditions for heat dissipation. Consequently, the use of global, geometry-independent processing parameters, which are today’s state of the art, may result in varying part properties or even defects. This paper presents a numerical simulation as a method to predict the geometry-dependent temperature evolution during the build. For demonstration, an overhang structure with varying angles towards the build platform was manufactured using Ti–6Al–4V. A calibrated infrared camera was integrated into a commercial L-PBF system to measure the temperature evolution over time for a total build height of 10 mm, and the results are used for validation of the simulation. It is shown that the simulation is capable of predicting the temperature between layers. The deviations between simulation and measurement remain in single digit range for smaller overhang structures (90°, 60° and 45°). For large overhang structures (30°), the simulation tends to over-predict the temperatures up to 15 °C. Experiments with varying process parameters showed the feasibility of energy reduction as compensation of the heat accumulation produced by overhang structures.

Li, Gefei (ORCID:0000000174837952)↗

DOE OSTI2024

A strong fracture-resistant high-entropy alloy with nano-bridged honeycomb microstructure intrinsically toughened by 3D-printing

Strengthening materials via conventional “top-down” processes generally involves restricting dislocation movement by precipitation or grain refinement, which invariably restricts the movement of dislocations away from, or towards, a crack tip, thereby severely compromising their fracture resistance. In the present study, a high-entropy alloy Al0.5CrCoFeNi is produced by the laser powder-bed fusion process, a “bottom-up” additive manufacturing process similar to how nature builds structures, with the microstructure resembling a nano-bridged honeycomb structure consisting of a face-centered cubic (fcc) matrix and an interwoven hexagonal net of an ordered body-centered cubic B2 phase. While the B2 phase, combined with high-dislocation density and solid-solution strengthening, provides strength to the material, the nano-bridges of dislocations connecting the fcc cells, i.e., the channels between the B2 phase on the cell boundaries, provide highways for dislocation movement away from the crack tip. Consequently, the nature-inspired microstructure imparts the material with an excellent combination of strength and toughness.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Real-time single-element-detection structured illumination optical metrology for laser powder bed fusion

Laser powder bed fusion (LPBF) is a type of metal additive manufacturing which could benefit from improved process monitoring to improve quality control. We demonstrate, for the first time to our knowledge, the coaxial monitoring of melt track formation in steel powder with spatial frequency modulation imaging (SPIFI), an enhanced-resolution imaging technique which uses a photodiode to record one-dimensional images. Using a custom live-display software and a high-speed SPIFI geometry, we offset the SPIFI field of view from the fusing beam to monitor different regions of the LPBF melt pool and surrounding area. This demonstrates the potential of SPIFI to monitor spatial features within the melt pool in real-time with increased data efficiency.

Hunter, Scott (ORCID:0009000886150312)↗

DOE OSTI2020

Metal Alloy and RHEA Additive Manufacturing for Nuclear Energy and Aerospace Applications

An open-literature search was conducted to consider the current status of the additive manufacturing (AM) industry with respect to metal alloys and refractory high entropy alloys (RHEAs). Key areas of interest include methodologies and applications that are suitable for the nuclear and aerospace industries, as well as other industrial applications. We investigated various promising 3D metal technologies, with emphasis on cost, operation, throughput, maintenance, and output volume size. In addition, technical issues and the current status of the metal printing market are summarized. The project scope also included the manufacturing of open-literature RHEA test coupons at Sandia's laser engineered net shape (LENS) machine.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Additive Manufacturing of Tool Steels

This article provides a brief overview of additive manufacturing (AM) of tool steels via various AM technologies such as laser powder bed fusion, electron powder bed fusion, blown powder directed energy deposition, and binder jet AM. The discussion includes process overview and covers the mechanism, advantages, and applications of each of these techniques.

Nandwana, Peeyush↗

NASA NTRS1967

Manufacturing engineering research at MSFC. Research achievements review, volume 1

Manufacturing engineering research - contamination control, remote welding methods, zero gravity simulation, laser applications, buoyancy simulation, and space electron beam welding

Source record↗

NASA NTRS1985

Tone excited jets. I - Introduction

The major objective of the present study is an understanding of the mechanism of broadband jet noise augmentation due to upstream excitation, in terms of the relationship between excitation characteristics, changes in large scale and/or small scale turbulence structure of the jet, and sound radiated to the far field under both static and simulated forward velocity conditions. A systematic set of acoustic measurements was accordingly made for a range of flow conditions in the acoustic research facilities of a large transport aircraft manufacturer. After analyzing acoustic results, turbulence measurements were made with a laser velocimeter for those jet conditions at which jet noise amplification was important. A theory was developed to account for static and in-flight simulation results.

Tanna, H. K.↗

NASA NTRS2019

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗

NASA NTRS2019

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Gradl, Paul↗

NASA NTRS2019

HERMeS Thruster Magnetic Field Topology Optimization Study: Performance, Stability, and Wear Results

NASA's Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5kW Technology Demonstration Unit-1 (TDU-1) has been the subject of extensive technology maturation in preparation for flight system development. The TDU-1 thruster implements a magnetically shielded field topology and has demonstrated the elimination of the discharge channel erosion as a life limiting mechanism. Extensive wear testing the TDU Hall thrusters has identified the thruster front pole covers as the next life limiting component. This effort aims to explore and investigate alternate magnetic field topologies to assess whether reductions in the front pole cover erosion can be attained while still maintaining very low erosion rates on the discharge channel walls. Four candidate magnetic field topologies that reduce the effectiveness of the shielding along the discharge channel walls with the intent to also reduce the erosion rates along the front pole covers were designed. Three of the four candidate magnetic field topologies (B1, B2, and B4) have been manufactured and were subjected to an extensive test campaign that includes laser induced fluorescence (LIF), performance, stability, wear, plume, and thermal characterization. In Phase I, LIF measurements along the discharge chamber centerline found that upstream retraction of the thruster's peak magnetic field does result in an upstream shift of the acceleration zone but the magnitude of the shift does not correspond one-to-one to the shift in the location of the peak radial magnetic field magnitude. Phase II test segment results found at a normalized thruster magnetic field setting of 1, the thruster performance was very similar for all configurations. Discharge current waveforms ripple data indicated that configurations Bo, B1, and B2 has similar oscillatory profiles with the B2 configuration transitioning to higher oscillatory mode at 400V instead of the 450V observed for configurations B0 and B1. Configuration B4 ripple data indicates that the thruster was operating in a very oscillatory mode above 350V. Inner front pole cover erosion rates for configuration B1 were approximately 65% relative to B0 and the erosion rates for configuration B2 were 40% relative to B0. Analysis of the performance, stability, and wear test results of configurations B0, B1, B2, and B4 indicates that configuration B2 may present an alternative option for B0 because it mostly maintained the same performance and stability as configuration B0 but with 40% of the inner front pole cover erosion rate.

Kamhawi, Hani↗

NASA NTRSDate not supplied

HERMeS Thruster Magnetic Field Topology Optimization Study: Plasma Plume Results

NASA’s Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5-kW Technology Demonstration Unit-1 (TDU-1) has been the subject of extensive technology maturation in preparation for flight system development. The magnetic optimization study aims to explore and investigate alternate magnetic field topologies. Four candidate magnetic field topologies that reduce the effectiveness of the shielding along the discharge channel walls with the intent to also reduce the erosion rates along the front pole covers were designed. Three of the four candidate magnetic field topologies (B1, B2, and B4) have been manufactured and were subjected to an extensive test campaign that included laser induced fluorescence (LIF), performance, stability, wear, and plume characterization. In Phase I, LIF measurements along the discharge chamber centerline found that upstream retraction of the thruster’s peak magnetic field does result in an upstream shift of the acceleration zone, but the magnitude of the shift does not correspond one-to-one to the shift in the location of the peak radial magnetic field magnitude. Phase II test segment results found that at a normalized thruster magnetic field setting of 1, the thruster performance and discharge current oscillations were very similar for configurations B0-B2. Also in Phase II abbreviated wear tests found that average inner front pole cover erosion rates for configuration B1 were approximately 65% of those at B0, and the average erosion rates for configuration B2 were approximately 35% of those at B0. This paper reports on the detailed plasma plume mapping results for configurations B0-B4. Faraday probe results indicate that, at 600 V operation, the plume divergence increased slightly for the B4 configuration when compared to B0-B2. Wien filter spectrometer results found that at 600 V, lower multiply-charged species fractions were attained as the thruster transitioned from configurations B0 to B4. Finally, retarding potential analyzer results found that at 600 V operation and at angles above 60,˚ significantly lower high-energy ion content was found for configurations B2 and B4 when compared to B0 and B1.

Electric propulsion,.Hall thruster, laser diagnost↗

NASA NTRS1983

Lightweight solar array blanket tooling, laser welding and cover process technology

A two phase technology investigation was performed to demonstrate effective methods for integrating 50 micrometer thin solar cells into ultralightweight module designs. During the first phase, innovative tooling was developed which allows lightweight blankets to be fabricated in a manufacturing environment with acceptable yields. During the second phase, the tooling was improved and the feasibility of laser processing of lightweight arrays was confirmed. The development of the cell/interconnect registration tool and interconnect bonding by laser welding is described.

Dillard, P. A.↗

DOE OSTI2025

Defect And Damage Characterization Of Additively Manufactured Titanium Alloy Ti-5553 Using Traditional Computed Tomography Volume Segmentation And Machine Learning Algorithms

The mechanical response of a component is affected by defects, such as porosity, arising from the laser powder bed fusion (LPBF) fabrication process. Thus, it is important to develop accurate and efficient inspection methods for identifying porosity. In this work, porosity identified in an X-ray computed tomography (XCT) volume of a Ti-5553 coupon was compared to pores identified in a serial sectioned volume that represented the ground truth. The porosity of the XCT scan was identified using contrast-based, ISO-based, and machine learning (ML) methods for segmentation. Large inherent porosity was easy to identify, but the ISO thresholding still struggled due to the intensity gradient resulting from both the beam hardening in XCT and the uneven lighting of the serial sectioning panels. Further, the results show that ML-based methods were better suited for identifying small pores and reducing the amount of false positives. Additionally, high strain-rate impact testing was done on some of the XCT samples as well as post-mortem XCT inspection, and the same suite of segmentation and quantification tools were used to identify the large spallation cavities. The comparison of porosity pre- and post-mortem provides insight on the influence of the LPBF porosity on the formation of spall cavities.

36 MATERIALS SCIENCE↗