Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “3D PRINTING”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,009 records · Page 56
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Training Ultrasound Image Classification Deep-Learning Algorithms for Pneumothorax Detection Using a Synthetic Tissue Phantom Apparatus

Ultrasound (US) imaging is a critical tool in emergency and military medicine because of its portability and immediate nature. However, proper image interpretation requires skill, limiting its utility in remote applications for conditions such as pneumothorax (PTX) which requires rapid intervention. Artificial intelligence has the potential to automate ultrasound image analysis for various pathophysiological conditions. Training models require large data sets and a means of troubleshooting in real-time for ultrasound integration deployment, and they also require large animal models or clinical testing. Here, we detail the development of a dynamic synthetic tissue phantom model for PTX and its use in training image classification algorithms. The model comprises a synthetic gelatin phantom cast in a custom 3D-printed rib mold and a lung mimicking phantom. When compared to PTX images acquired in swine, images from the phantom were similar in both PTX negative and positive mimicking scenarios. We then used a deep learning image classification algorithm, which we previously developed for shrapnel detection, to accurately predict the presence of PTX in swine images by only training on phantom image sets, highlighting the utility for a tissue phantom for AI applications.

Boice, Emily N. (ORCID:0000000171802842)↗
DOE OSTI2023

A Novel Experimental Approach to Understand the Transport of Nanodrugs

Nanoparticle-based drugs offer attractive advantages like targeted delivery to the diseased site and size and shape-controlled properties. Therefore, understanding the particulate flow of the nanodrugs is important for effective delivery, accurate prediction of required dosage, and developing efficient drug delivery platforms for nanodrugs. In this study, the transport of nanodrugs including flow velocity and deposition is investigated using three model metal oxide nanodrugs of different sizes including iron oxide, zinc oxide, and combined Cu-Zn-Fe oxide synthesized via a modified polyol approach. The hydrodynamic size, size, morphology, chemical composition, crystal phase, and surface functional groups of the water-soluble nanodrugs were characterized via dynamic light scattering, transmission electron microscopy, scanning electron microscopy-energy dispersive X-ray, X-ray diffraction, and fourier transform infrared spectroscopy, respectively. Two different biomimetic flow channels with customized surfaces are developed via 3D printing to experimentally monitor the velocity and deposition of the different nanodrugs. A diffusion dominated mechanism of flow is seen in size ranges 92 nm to 110 nm of the nanodrugs, from the experimental velocity and mass loss profiles. The flow velocity analysis also shows that the transport of nanodrugs is controlled by sedimentation processes in the larger size ranges of 110–302 nm. However, the combined overview from experimental mass loss and velocity trends indicates presence of both diffusive and sedimentation forces in the 110–302 nm size ranges. It is also discovered that the nanodrugs with higher positive surface charges are transported faster through the two test channels, which also leads to lower deposition of these nanodrugs on the walls of the flow channels. The results from this study will be valuable in realizing reliable and cost-effective in vitro experimental approaches that can support in vivo methods to predict the flow of new nanodrugs.

36 MATERIALS SCIENCE↗
DOE OSTI2024

On the Flow of a Cement Suspension: The Effects of Nano-Silica and Fly Ash Particles

Additives such as nano-silica and fly ash are widely used in cement and concrete materials to improve the rheology of fresh cement and concrete and the performance of hardened materials and increase the sustainability of the cement and concrete industry by reducing the usage of Portland cement. Therefore, it is important to study the effect of these additives on the rheological behavior of fresh cement. In this paper, we study the pulsating Poiseuille flow of fresh cement in a horizontal pipe by considering two different additives and when they are combined (nano-silica, fly ash, combined nano-silica, and fly ash). To model the fresh cement suspension, we used a modified form of the power-law model to demonstrate the dependency of the cement viscosity on the shear rate and volume fraction of cement and the additive particles. The convection–diffusion equation was used to solve for the volume fraction. After solving the equations in the dimensionless forms, we conducted a parametric study to analyze the effects of nano-silica, fly ash, and combined nano-silica and fly ash additives on the velocity and volume fraction profiles of the cement suspension. According to the parametric study presented here, larger nano-silica content results in lower centerline velocity of the cement suspension and larger non-uniformity of the volume fraction. Compared to nano-silica, fly ash exhibits an opposite effect on the velocity. Larger fly ash content results in higher centerline velocity, while the effect of the fly ash on the volume fraction is not obvious. For cement suspension containing combined nano-silica and fly ash additives, nano-silica plays a dominant role in the flow behavior of the suspension. The findings of the study can help the design and operation of the pulsating flow of fresh cement mortars and concrete in the 3D printing industry.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Study of the Printability, Microstructures, and Mechanical Performances of Laser Powder Bed Fusion Built Haynes 230

The nickel-based superalloy, Haynes 230 (H230), is widely used in high-temperature applications, e.g., heat exchangers, because of its excellent high-temperature mechanical properties and corrosion resistance. As of today, H230 is not yet in common use for 3D printing, i.e., metal additive manufacturing (AM), primarily because of its hot cracking tendency under fast solidification. The ability to additively fabricate components in H230 attracts many applications that require the additional advantages leveraged by adopting AM, e.g., higher design complexity and faster prototyping. In this study, we fabricated nearly fully dense H230 in a laser powder bed fusion (L-PBF) process through parameter optimization. The efforts revealed the optimal process space which could guide future fabrication of H230 in various metal powder bed fusion processes. The metallurgical analysis identified the cracking problem, which was resolved by increasing the pre-heat temperature from 80 °C to 200 °C. A finite element simulation suggested that the pre-heat temperature has limited impacts on the maximum stress experienced by each location during solidification. Additionally, the crack morphology and the microstructural features imply that solidification and liquation cracking are the more probable mechanisms. Both the room temperature tensile test and the creep tests under two conditions, (a) 760 °C and 100 MPa and (b) 816 °C and 121 MPa, confirmed that the AM H230 has properties comparable to its wrought counterpart. The fractography showed that the heat treatment (anneal at 1200 °C for 2 h, followed by water quench) balances the strength and the ductility, while the printing defects did not appreciably accelerate part failure.

14 SOLAR ENERGY↗
DOE OSTI2021

Structural, Thermal, and Mechanical Characterization of a Thermally Conductive Polymer Composite for Heat Exchanger Applications

Polymer composites are being considered for numerous thermal applications because of their inherent benefits, such as light weight, corrosion resistance, and reduced cost. In this work, the microstructural, thermal, and mechanical properties of a 3D printed polymer composite with high thermal conductivity are examined using multiple characterization techniques. Infrared spectroscopy and X-ray diffraction reveal that the composite contains a polyphenylene sulfide matrix with graphitic fillers, which is responsible for the high thermal conductivity. Furthermore, differential scanning calorimetry determines that the glass transition and melting point of the composite are 87.6 °C and 285.6 °C, respectively. Thermogravimetric analysis reveals that the composite is thermally stable up to ~400 °C. Creep tests are performed at different isotherms to evaluate the long-term performance of the composite. The creep result indicates that the composite can maintain mechanical integrity when used below its glass transition temperature. Nanoindentation tests reveal that modulus and hardness of the composite is not significantly influenced by heating or creep conditions. These findings indicate that the composite is potentially suitable for heat exchanger applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Bubble-Free Frontal Polymerization of Acrylates via Redox-Initiated Free Radical Polymerization

Thermal frontal polymerization (FP) of acrylate monomers mixed with conventional peroxide initiators leads to significant bubble formation at the polymerizing front, limiting their practical applications. Redox initiators present a promising alternative to peroxide initiators, as they prevent the formation of gaseous byproducts during initiator decomposition and lower the front temperature, thereby enabling bubble-free FP. In this study, we investigate the FP of acrylate monomers of varying functionalities, including methyl methacrylate (MMA), 1,6-hexanediol diacrylate (HDDA), and trimethylolpropane triacrylate (TMPTA), using N,N -dimethylaniline/benzoyl peroxide (DMA/BPO) redox couple at room temperature and compare their front behavior, pot life, and bubble formation with those of same resin systems mixed with a conventional peroxide initiator, Luperox 231. The use of redox couples in FP of acrylates shows promise for rapid, energy-efficient manufacturing of polyacrylates and can enable new applications such as 3D printing and composite manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Smartphone-Based Device for Colorimetric Detection of MicroRNA Biomarkers Using Nanoparticle-Based Assay

The detection of microRNAs (miRNAs) is emerging as a clinically important tool for the non-invasive detection of a wide variety of diseases ranging from cancers and cardiovascular illnesses to infectious diseases. Over the years, miRNA detection schemes have become accessible to clinicians, but they still require sophisticated and bulky laboratory equipment and trained personnel to operate. The exceptional computing ability and ease of use of modern smartphones coupled with fieldable optical detection technologies can provide a useful and portable alternative to these laboratory systems. Herein, we present the development of a smartphone-based device called Krometriks, which is capable of simple and rapid colorimetric detection of microRNA (miRNAs) using a nanoparticle-based assay. The device consists of a smartphone, a 3D printed accessory, and a custom-built dedicated mobile app. We illustrate the utility of Krometriks for the detection of an important miRNA disease biomarker, miR-21, using a nanoplasmonics-based assay developed by our group. We show that Krometriks can detect miRNA down to nanomolar concentrations with detection results comparable to a laboratory-based benchtop spectrophotometer. With slight changes to the accessory design, Krometriks can be made compatible with different types of smartphone models and specifications. Thus, the Krometriks device offers a practical colorimetric platform that has the potential to provide accessible and affordable miRNA diagnostics for point-of-care and field applications in low-resource settings.

Krishnan, Tushar (ORCID:0000000342610336)↗
DOE OSTI2025

Mounted Accelerometer Frequency Response of Adhesive Products and Aluminum Frame Quick Mounts

An accelerometer mounting technique has large implications on the frequency range and accuracy of the measurement, with stiffness and the mass relative to the monitored structure as the primary concerns. The International Organization for Standardization (ISO) gives an extensive list in 5348:2021, detailing mounting methods, and provides recommendations for testing mounts that are not specifically defined. In the nuclear industry on the laboratory scale, there is a need for vibration measurements for predictive maintenance and process monitoring that are nondestructive and capable of working in high-temperature environments. Commercial adhesive products with easy application and removal were tested as nondestructive methods, while quick mounts to a commonly used aluminum frame were tested as nondestructive and have potential applicability in high-temperature environments. The sinusoidal excitation method was used, measuring frequencies from 50 Hz to 10 kHz in one-third octave band intervals, utilizing three accelerometers and comparing the results to those obtained with the stud-mounting method. Using the lowest ±3 dB threshold across each accelerometer, foam dots and poster strips were not successful, and foam tapes were accurate up to 2000 Hz, hose clamps and zip ties up to 800 Hz, and a custom 3D printed mount up to 1000 Hz. Knowing the limitations of each mounting technique allows for accurate measurements within the appropriate range.

47 - OTHER INSTRUMENTATION↗
DOE OSTI2021

A 1D Lyman-alpha Profile Camera for Plasma Edge Neutral Studies on the DIII-D Tokamak

A one dimensional, absolutely calibrated pinhole camera system was installed on the DIII-D tokamak to measure edge Lyman-alpha (Ly-a) emission from hydrogenic isotopes which can be used to infer neutral density and ionization rate proles. The system is composed of two cameras, each providing a toroidal fan of twenty lines of sight, viewing the plasma edge on the inboard and outboard side of DIII-D. The cameras' views lie in a horizontal plane 77 cm below the midplane. At its tangency radius, each channel provides a radial resolution of approximately 2 cm full width at half maximum (FWHM) with a total coverage of 22 cm. Each camera consists of a rectangular pinhole, Ly-a reflective mirror, narrow-band Ly-a transmission fiter, and a 20 channel AXUV photodetector. The combined mirror and transmission fiter have a FWHM of 5 nm, centered near the Ly-a wavelength of 121.6 nm and is capable of rejecting significant, parasitic carbon-III (C-III) emission from intrinsic plasma impurities. To provide a high spatial resolution measurement in a compact footprint, the camera utilizes advanced engineering and manufacturing techniques including 3D printing, high stability mirror mounts, and a novel alignment procedure. Absolutely calibrated, spatially resolved Ly-a brightness measurements utilize a bright, isolated line with low parasitic surface reflections and enable quantitative comparison to modeling to study divertor neutral leakage, main chamber fueling and radial particle transport.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Optically enhanced patternable photosensitivity via oxygen excitation

A method is disclosed for performing a three dimensional (3D) printing process. The method involves generating a primary light beam having a wavelength sufficient to initiate polymerization of a photoresin, and patterning the primary light beam into a patterned primary beam. The patterned primary beam may be directed toward an ultraviolet (UV) or visible light sensitive photoresin to initiate polymerization of select areas of the photoresin. The photoresin may be illuminated with a secondary light beam having a wavelength of about 765 nm to stimulate triplet oxygen into singlet oxygen, to thus control oxygen inhibition in additional areas bordering the select areas, to control polymerization inhibition in the additional areas bordering the select areas.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Inventory Management Improvement Project

The Lawrence Livermore National Laboratory (LLNL) conducts research and development for the National Nuclear Security Agency (NNSA) and its affiliates. The Polymer AM team at LLNL conducts research and development in 3D printing, specifically direct-ink-write, in accordance with LLNL and NNSA missions. The team is composed of machine operators, chemists, testing engineers, and project engineers across multiple lab spaces with one shared storage area at LLNL. The operations use a variety of different consumables and hardware to conduct research applications for LLNL and NNSA. These items are critical to performing operation tasks; if an item is out of stock, operations associated with the respective item could be suspended for weeks. As such, the Polymer AM team manages an inventory of spare consumables and hardware to ensure these items are always available. However, the current management system, an excel sheet managed by the project engineer group, is not intuitive in providing inventory information despite the high labor utilization needed to maintain the system. As such, the team is looking to improve their inventory management that can send notifications regarding inventory needs, accessible to other team members, provide all relevant information to a specific item, and store historical information for budget and operation planning. The proposed solution is a Computer Maintenance Management System (CMMS): a web-based management software that stores inventory information and provides automated notifications. The system will store information on each item including quantity in stock, technical information, supplier information, costs, lead times, and expiration date. The system has a notifications function that can send notifications to the respective team member’s when an item needs to be counted, item inventory is low, or an item is approaching their expiration date. Information for each item can be tracked over time creating data to be used for budget planning and process improvement purposes. Due to its web-based source, the system can be accessed by the respective team member viewing technical information, quantity, and purchasing information.

42 ENGINEERING↗
DOE OSTI2021

3D printable feedstock inks for signal control or computation

A 3D printable feedstock ink is disclosed for use in a 3D printing process where the ink is flowed through a printing nozzle. The ink may be made up of a non-conductive flowable material and a plurality of chiplets contained in the non-conductive flowable material in random orientations. The chiplets may form a plurality of percolating chiplet networks within the non-conductive flowable material as ones of the chiplets contact one another. Each one of the chiplets has a predetermined circuit characteristic which is responsive to a predetermined electrical signal, and which becomes electrically conductive when the predetermined electrical signal is applied to the ink, to thus form at least one conductive signal path through the ink.

Murialdo, Maxwell↗
DOE OSTI2021

Optically enhanced patternable photosensitivity via oxygen excitation

The present disclosure relates to a method for performing a three dimensional (3D) printing process. A primary light beam having a wavelength sufficient to initiate polymerization of a photoresin is generated and patterned into a patterned primary beam. The patterned primary beam is directed toward an ultraviolet (UV) or visible light sensitive photoresin to initiate polymerization of select areas of the photoresin. The photoresin is also illuminated with a secondary light beam having a wavelength of at least one of about 765 nm, 1064 nm, or 1273 nm. The secondary light beam stimulates triplet oxygen into singlet oxygen, which controls oxygen inhibition in additional areas bordering the select areas, to enable controlled polymerization inhibition in the additional areas bordering the select areas.

Hensleigh, Ryan↗
DOE OSTI2022

Experimental Investigation of a Phase Change Material Charged Finned-Tube Heat Exchanger

Understanding different thermal performance aspects of phase change material heat exchangers (PCM-HX) is critical for designing future energy-efficient thermal energy storage systems. This paper presents an experimental performance analysis of a vertically oriented annular finned-tube PCM-HX in a cylindrical container tested under six different melting and solidification test conditions, varied by heat transfer fluid’s (HTF) inlet temperatures and flow directions. The PCM-HX structure with 20 evenly spaced fins was 3D printed in aluminum, and the PCM-HX container was 285 mm in height. The PCM-HX average porosity was 89.7%, where the PCM mass was 246.4 g. Water served as the HTF, and a PCM with a nominal phase change temperature of 35 °C was selected. Instead of opaque conventional insulation sheets, a combination of air-and-argon-filled see-through insulation cylinders was assembled with the PCM-HX to visualize the phase-change phenomena, while minimizing the uncertainties due to heat loss. In total, there were 78 T-type thermocouples installed in the test section which allows a more precise assessment of thermal mass and heat loss, which are often neglected in similar studies found in the literature. We validated the reliability of the test facility as the repeated test results had negligible deviations under the same test conditions. The energy balances between the estimated theoretical and experimentally calculated PCM storage, considering heat loss and thermal mass, were within ±9% deviation for all test conditions. From the experimental investigations, we made several following observations. It was found that the melting pattern of the finned-tube PCM-HX with small gaps between the container wall and the fins was largely affected by the HTF flow directions, unlike the typical straight annular tube PCM-HX. For effective charging and discharging processes, a combination of upward melting and downward solidification is recommended to shorten the test duration. However, an upward solidification should be considered to minimize the cavity formation between the fins caused by the PCM volume contraction during the solidification process.

25 ENERGY STORAGE↗
DOE OSTI2022

Cooperative Research and Development Agreement between National Energy Technology Laboratory and West Virginia University Research Corporation (Abstract)

The National Energy Technology Laboratory (NETL) and West Virginia University Research Corporation (Participant) will collaborate on the testing of a 3D printed sparger in a temperature and pressure chamber, for the purpose of supporting the “American-Made Geothermal Prize” competition, designed to catalyze manufacturing innovation in the American geothermal industry by harnessing the rapid advances additive manufacturing can provide in improving design, fabrication, and functionality, which is accomplished through a series of prize competitions and the development of a diverse and powerful support network that leverages national laboratories, energy incubators, and other resources from across the United States. The intent is to connect competitor teams with national laboratories that can help accelerate the development of innovative solutions and products. Teams who have won the Set!, Go!, Make! Contests are eligible to utilize vouchers at national laboratories to advance their ideas.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

2.2.1.410 - Significant Cost Reduction Potential for Wave Energy Conversion Devices with Variable-Geometry Modules

The Technology Commercialization Fund (TCF) award is built upon NREL's previous research exploring a bottom-fixed variable-geometry oscillating surge wave energy converter (VGOSWEC); however, unlike previous investigations, the VGOSWEC will be raised off the sea floor. Researchers believe that advances in offshore pilings and foundations, such as 3D printing, will provide low cost and easily deployable structures. There are several benefits to designing a raised VGOSWEC such as 1) reducing issues with sediment transport and environmental impacts near shore, 2) less expensive deployment and installation as work boats will not risk grounding in shallow water, and 3) deeper water deployments improve the wave resource.

oscillating surge wave energy converter↗
DOE OSTI2022

Additively manufactured metal energetic ligand precursors and combustion synthesis

Processes for tailoring the macroscopic shape, metallic composition, mechanical properties, and pore structure of nanoporous metal foams prepared through combustion synthesis via direct write 3D printing of metal energetic ligand precursor inks made with water and an organic thickening agent are disclosed. Such processes enable production of never before obtainable metal structures with hierarchical porosity, tailorable from the millimeter size regime to the nanometer size regime. Structures produced by these processes have numerous applications including, but not limited to, catalysts, heat exchangers, low density structural materials, biomedical implants, hydrogen storage medium, fuel cells, and batteries.

Tappan, Bryce↗
DOE OSTI2022

Hierarchical triply periodic minimal surface structures as heat exchangers and reactors

The present disclosure relates to a transport mechanism apparatus for transporting at least one of a gas or a fluid. The transport mechanism may have an inlet, an outlet and a triply periodic minimal surface (TPMS) structure. The TPMS structure is formed in a layer-by-layer three dimensional (3D) printing operation to include cells propagating in three dimensions, where the cells include wall portions having openings, and where the cells form a plurality of flow paths throughout the transport mechanism from the inlet to the outlet, and where the cells form the inlet and the outlet.

Roy, Pratanu↗