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Turbine Engine Hot Section Technology 1986

On October 21 and 22, 1986, the Turbine Engine Hot Section Technology (HOST) Project of the NASA Lewis Research Center sponsored a workshop to discuss current research pertinent to turbine engine durability problems. Presentations were made concerning the hot-section environment and the behavior of combustion liners, turbine blades, and turbine vanes. The presentations were divided Into six sessions: Instrumentation, Combustion, Turbine Heat Transfer, Structural Analysis, Fatigue and Fracture, and Surface Protection. The principal objective of each session was to disseminate research results to date. Topics discussed included modeling of thermal and fluid-flow phenomena, structural analysis, fatigue and fracture, surface protective coatings, constitutive behavior of materials, stress-strain response, and life-prediction methods. Researchers from industry, academia, and government presented results of their work sponsored by the HOST Project. This publication contains extended abstracts and visual material presented during the workshop.

Turbine Engine Hot Section Technology (HOST)↗

Impact of welan gum on tricalcium aluminate-gypsum hydration

The retarding effect of welan gum on tricalcium aluminate-gypsum hydration, as a partial system of ordinary Portland cement (OPC) hydration, was investigated with several methods. The tricalcium aluminate-gypsum hydration behavior in the presence or absence of welan gum was researched by field emission gun scanning electron microscopy, X-ray diffraction and zeta potential analysis. Meanwhile, we studied the surface electrochemical properties and adsorption characteristics of welan gum by utilizing a zeta potential analyzer and UV-VIS absorption spectrophotometer. By adding welan gum, the morphology change of ettringite and retardation of hydration stages in tricalcium aluminate-gypsum system was observed. Moreover, we detected the adsorption behavior and zeta potential inversion of tricalcium aluminate and ettringite, as well as a rapid decrease in the zeta potential of tricalcium aluminate-gypsum system. The reduction on nucleation rate of ettringite and hydration activity of C{sub 3}A was also demonstrated. Thus, through the adsorption effect, welan gum induces a retarding behavior in tricalcium aluminate-gypsum hydration. Highlights: Black-Right-Pointing-Pointer Adsorption characteristics of welan gum on C{sub 3}A and ettringite have been studied. Black-Right-Pointing-Pointer C{sub 3}A-gypsum hydration behavior and the hydration products are examined in L/S = 3. Black-Right-Pointing-Pointer Welan gum retards the process of C{sub 3}A-gypsum hydration. Black-Right-Pointing-Pointer The addition of welan gum changes the nucleation growth of ettringite.

36 MATERIALS SCIENCE↗

Stochastic and hybrid-stress plate/shell finite elements for hot-section components

The research effort in the Center for the Advancement of Computational Mechanics at Georgia Tech has two main thrusts. The first of these is the development of special approaches for the numerical stress analysis of solids and structures whose material and geometric properties are uncertain. The second seeks to develop and implement high-efficiency plate and shell elements. The stochastic element method, currently being implemented, will be able to more accurately portray the probabilistic nature of stress, strain, and displacement in actual structures. Current research has provided a hybrid-stress shell element whose behavior is acceptable for aspect ratios as high as 30 to 1. Thus, substantially more complex analyses will be practicable as soon as this element is fully implemented. An additional advantage of the hybrid approach is that it permits more accurate stress-recovery at the upper and lower surfaces of the shell, an important consideration in high thickness-gradient applications. The software associated with the above research is being implemented in the form of extensions to the Nessus code. The hybrid shell element has been successfully tested in several small-deformation elastic analyses. The theoretical formulation of the stochastic elements is essentially complete; its implementation is just beginning.

Atluri, S. N.↗

Fast Charge Battery Electric Transit Bus In-Use Fleet Evaluation

The focus of this interim fleet evaluation is to characterize and evaluate the operating behavior of Foothill Transit's fast charge battery electric buses (BEBs). Future research will compare the BEBs' performance to conventional vehicles. In an effort to better understand the impacts of drive cycle characteristics on advanced vehicle technologies, researchers at the National Renewable Energy Laboratory analyzed over 148,000 km of in-use operational data, including driving and charging events. This analysis provides an unbiased evaluation of advanced vehicle technologies in real-world operation demonstrating the importance of understanding the effects of road grade and heating, ventilating and air conditioning requirements when deploying electric vehicles. The results of this analysis show that the Proterra BE35 demonstrated an operating energy efficiency of 1.34 kWh/km over the data reporting period.

33 ADVANCED PROPULSION SYSTEMS↗

HgZnTe-based detectors for LWIR NASA applications

The initial goal was to grow and characterize HgZnTe and determine if it indeed had the advantageous properties that were predicted. Researchers grew both bulk and liquid phase epitaxial HgZnTe. It was determined that HgZnTe had the following properties: (1) microhardness at least 50 percent greater than HgCdTe of equivalent bandgap; (2) Hg annealing rates of at least 2 to 4 times longer than HgCdTe; and (3) higher Hg vacancy formation energies. This early work did not focus on one specific composition (x-value) of HgZnTe since NASA was interested in HgZnTe's potential for a variety of applications. Since the beginning of 1989, researchers have been concentrating, however, on the liquid phase growth of very long wavelength infrared (VLWIR) HgZnTe (cutoff approx. equals 17 microns at 65K) to address the requirements of the Earth Observing System (EOS). Since there are no device models to predict the advantages in reliability one can gain with increased microhardness, surface stability, etc., one must fabricate HgZnTe detectors and assess their relative bake stability (accelerated life test behavior) compared with HgCdTe devices fabricated in the same manner. Researchers chose to fabricate HIT detectors as a development vehicle for this program because high performance in the VLWIR has been demonstrated with HgCdTe HIT detectors and the HgCdTe HIT process should be applicable to HgZnTe. HIT detectors have a significant advantage for satellite applications since these devices dissipate much less power than conventional photoconductors to achieve the same responsivity.

Patten, Elizabeth A.↗

Design Protocols and Analytical Strategies that Incorporate Structural Reliability Models

Ceramic matrix composites (CMC) and intermetallic materials (e.g., single crystal nickel aluminide) are high performance materials that exhibit attractive mechanical, thermal, and chemical properties. These materials are critically important in advancing certain performance aspects of gas turbine engines. From an aerospace engineers perspective the new generation of ceramic composites and intermetallics offers a significant potential for raising the thrust/weight ratio and reducing NO(sub x) emissions of gas turbine engines. These aspects have increased interest in utilizing these materials in the hot sections of turbine engines. However, as these materials evolve and their performance characteristics improve a persistent need exists for state-of-the-art analytical methods that predict the response of components fabricated from CMC and intermetallic material systems. This need provided the motivation for the technology developed under this research effort. Continuous ceramic fiber composites exhibit an increase in work of fracture, which allows for 'graceful' rather than catastrophic failure. When loaded in the fiber direction these composites retain substantial strength capacity beyond the initiation of transverse matrix cracking despite the fact that neither of its constituents would exhibit such behavior if tested alone. As additional load is applied beyond first matrix cracking, the matrix tends to break in a series of cracks bridged by the ceramic fibers. Any additional load is born increasingly by the fibers until the ultimate strength of the composite is reached. Thus modeling efforts supported under this research effort have focused on predicting this sort of behavior. For single crystal intermetallics the issues that motivated the technology development involved questions relating to material behavior and component design. Thus the research effort supported by this grant had to determine the statistical nature and source of fracture in a high strength, NiAl single crystal turbine blade material; map a simplistic future strength envelope of the material; develop a statistically based reliability computer algorithm; verify the reliability model and computer algorithm-, and model stator vanes for rig tests. Thus establishing design protocols that enable the engineer to analyze and predict the mechanical behavior of ceramic composites and intermetallics would mitigate the prototype (trial and error) approach currently used by the engineering community. The primary objective of the research effort supported by this short term grant is the continued creation of enabling technologies for the macro-analysis of components fabricated from ceramic composites and intermetallic material systems. The creation of enabling technologies aids in shortening the product development cycle of components fabricated from the new high technology materials.

Duffy, Stephen F.↗

Design Protocols and Analytical Strategies that Incorporate Structural Reliability Models

Ceramic matrix composites (CMC) and intermetallic materials (e.g., single crystal nickel aluminide) are high performance materials that exhibit attractive mechanical, thermal and chemical properties. These materials are critically important in advancing certain performance aspects of gas turbine engines. From an aerospace engineer's perspective the new generation of ceramic composites and intermetallics offers a significant potential for raising the thrust/weight ratio and reducing NO(x) emissions of gas turbine engines. These aspects have increased interest in utilizing these materials in the hot sections of turbine engines. However, as these materials evolve and their performance characteristics improve a persistent need exists for state-of-the-art analytical methods that predict the response of components fabricated from CMC and intermetallic material systems. This need provided the motivation for the technology developed under this research effort. Continuous ceramic fiber composites exhibit an increase in work of fracture, which allows for "graceful" rather than catastrophic failure. When loaded in the fiber direction, these composites retain substantial strength capacity beyond the initiation of transverse matrix cracking despite the fact that neither of its constituents would exhibit such behavior if tested alone. As additional load is applied beyond first matrix cracking, the matrix tends to break in a series of cracks bridged by the ceramic fibers. Any additional load is born increasingly by the fibers until the ultimate strength of the composite is reached. Thus modeling efforts supported under this research effort have focused on predicting this sort of behavior. For single crystal intermetallics the issues that motivated the technology development involved questions relating to material behavior and component design. Thus the research effort supported by this grant had to determine the statistical nature and source of fracture in a high strength, NiAl single crystal turbine blade material; map a simplistic failure strength envelope of the material; develop a statistically based reliability computer algorithm, verify the reliability model and computer algorithm, and model stator vanes for rig tests. Thus establishing design protocols that enable the engineer to analyze and predict the mechanical behavior of ceramic composites and intermetallics would mitigate the prototype (trial and error) approach currently used by the engineering community. The primary objective of the research effort supported by this short term grant is the continued creation of enabling technologies for the macroanalysis of components fabricated from ceramic composites and intermetallic material systems. The creation of enabling technologies aids in shortening the product development cycle of components fabricated from the new high technology materials.

Duffy, Stephen F.↗

Strength of concrete structures under dynamic loading

The use of elastic supports is one the efficient methods of decreasing the dynamic loading. The paper describes the influence of elastic supports on the stress-strain state of steel concrete structures exposed to one-time dynamic loading resulting in failure. Oblique bending beams on elastic supports and their elastic, elastoplastic, and elastoplastic consolidation behavior are considered in this paper. For numerical calculations the developed computer program is used based on the finite element method. Research findings prove high efficiency of elastic supports under dynamic loading conditions. The most effective behavior of elastic supports is demonstrated at the elastoplastic stage. A good agreement is observed between the theoretical and experimental results.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Ligand-Sensitized Lanthanide Nanocrystals: Merging Solid-State Photophysics and Molecular Solution Chemistry

To date, the breadth of scientific research that has been devoted to investigating the photochemical and photophysical behavior of the lanthanide elements has generally fallen into one of two camps: solution studies of luminescent lanthanide metal-ligand complexes or investigations of solid-state nanoparticles, composed primarily of, or doped with, lanthan ide lumiphores. In the latter case, most research of lanthanide nanocolloids has precluded any investigations regarding the use of organic ligands to overcome the difficulties associated with f-f excitation of lanthanides. Instead, most work on condensed-phase lanthanide luminescence has centered on strategies such as d-f charge separation in divalent lanthanides and the sensitization of lanthanide excited states using quantum dots. Current work now aims at bridging the camps of condensed-phase lanthanide photophysics and the solution chemistry of ligand-lanthanide molecular complexes. Some recent efforts have partly focused on the fundamental characterization of NaGd 1-x Ln x F 4 nanoparticles featuring surface display of the sensitizer ligand 3,4,3-LI(1,2-HOPO), showing these structures to be capable of converting absorbed UV light into luminescence from Eu 3+ and Tb 3+ ions. Our results suggest such a use of the ligand sensitization as a tool of choice to overcome the constraints of UV solar spectrum/semiconductor band-gap mismatch and low absorption cross sections in solid-state lanthanide systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Composite fuselage shell structures research at NASA Langley Research Center

Fuselage structures for transport aircraft represent a significant percentage of both the weight and the cost of these aircraft primary structures. Composite materials offer the potential for reducing both the weight and the cost of transport fuselage structures, but only limited studies of the response and failure of composite fuselage structures have been conducted for transport aircraft. The behavior of these important primary structures must be understood, and the structural mechanics methodology for analyzing and designing these complex stiffened shell structures must be validated in the laboratory. The effects of local gradients and discontinuities on fuselage shell behavior and the effects of local damage on pressure containment must be thoroughly understood before composite fuselage structures can be used for commercial aircraft. This paper describes the research being conducted and planned at NASA LaRC to help understand the critical behavior or composite fuselage structures and to validate the structural mechanics methodology being developed for stiffened composite fuselage shell structure subjected to combined internal pressure and mechanical loads. Stiffened shell and curved stiffened panel designs are currently being developed and analyzed, and these designs will be fabricated and then tested at Langley to study critical fuselage shell behavior and to validate structural analysis and design methodology. The research includes studies of the effects of combined internal pressure and mechanical loads on nonlinear stiffened panel and shell behavior, the effects of cutouts and other gradient-producing discontinuities on composite shell response, and the effects of local damage on pressure containment and residual strength. Scaling laws are being developed that relate full-scale and subscale behavior of composite fuselage shells. Failure mechanisms are being identified and advanced designs will be developed based on what is learned from early results from the LaRC research activities. Results from combined load tests will be used to validate analytical models of critical nonlinear response mechanisms as well as shell scaling laws.

Starnes, James H., Jr.↗

High Speed Research Program Sonic Fatigue

The objective of this sonic fatigue summary is to provide major findings and technical results of studies, initiated in 1994, to assess sonic fatigue behavior of structure that is being considered for the High Speed Civil Transport (HSCT). High Speed Research (HSR) program objectives in the area of sonic fatigue were to predict inlet, exhaust and boundary layer acoustic loads; measure high cycle fatigue data for materials developed during the HSR program; develop advanced sonic fatigue calculation methods to reduce required conservatism in airframe designs; develop damping techniques for sonic fatigue reduction where weight effective; develop wing and fuselage sonic fatigue design requirements; and perform sonic fatigue analyses on HSCT structural concepts to provide guidance to design teams. All goals were partially achieved, but none were completed due to the premature conclusion of the HSR program. A summary of major program findings and recommendations for continued effort are included in the report.

Rizzi, Stephen A.↗

Comparative post-irradiation examination of high burnup U-19Pu-10Zr: Assessing steady-state irradiation behavior against historical and modeled fuel performance

Here, the development of next-generation sodium-cooled fast reactors necessitates comprehensive research on metallic fuels to maximize economic performance while ensuring safe operation. In this study, we investigated the steady-state irradiation behavior of two high burnup U-19Pu-10Zr fuel pins, DP-36 and DP-40, in preparation for planned safety testing. Post-irradiation examination (PIE) was performed to quantify fuel column elongation, regions of low-density at the top of the fuel column, pin deformation, fission product distribution, fractional fission gas release, microstructural evolution, and fuel constituent redistribution. Benchmarking against existing PIE data from U-19Pu-10Zr fuel pins irradiated in EBR-II revealed consistent patterns in fuel column elongation and cladding diametral strain. However, both pins exhibited longer low-density structures, and destructive examination of DP-36 revealed more complex constituent redistribution patterns compared to previously reported data for ternary fuel pins. The steady-state irradiation of both pins was also modeled using BISON. Comparisons of PIE results with modeled predictions showed overall agreement in fractional fission gas release but consistent overestimation of axial and radial swelling due to gaseous and solid swelling models. These findings underscore the critical importance of pre-test characterization on test and sibling pins to accurately capture steady-state fuel behavior ahead of transient testing, thus establishing a baseline for post-test comparison. Additionally, these analyses identified key data gaps that warrant further investigation to improve the understanding and prediction of fuel swelling, thereby enhancing the synergy between modeling and experimental efforts in supporting accident testing.

BISON↗

Emphasizing Spectrum Management for Sustainable Development Research and Applications in Disaster Management

NASA's spaceborne Earth and Heliospheric Observatories and airborne sensors provide a plethora of measurements. These measurements are used in science research to understand the climatology of our home planet and the solar fluxes and cycle of the only star in our solar system 'Sun' which is critical driver for the retention of life on Earth. Specifically, these measurements help us to understand the water and energy cycle, the carbon cycle, weather and climate, atmospheric chemistry, solar variability, and solid Earth and interior to feed into sophisticated mathematical models to analyze and predict the Earth's behavior as an integrated system. The main thrust of this research is on improving the prediction capability in the areas of weather, long term climate and solid Earth processes, and further help the humanity and future generations in terms of societal benefits in managing natural disasters, sustainability issues and many more. This work is further linked with our contributions in the Global Earth Observing System of Systems (GEOSS) Specifically, the data and knowledge resulting from the Earth observing systems and analytical models of the Earth can be made available for assimilation into decision support systems to serve society for disaster management. Through partnerships with national and international agencies and organizations, NASA's Science Mission Directorate's, Applied Sciences Program contributes to benchmarking practical uses of observations and predictions from Earth science remote sensing systems research. The objective is to establish innovative solutions using Earth observations and science information to provide decision support that can be adapted in applications of national and international priority. We along with the international community will continue this critical field of investigation by using our existing and future sensors from space, airborne and insitue environment. In our quest to expanding our knowledge, there will be a need for deploying additional sensors to obtain high spatial, temporal and spectral resolution measurements. These sensors operate in multiple spectral band ranging from UV, visible, infrared, microwave and radio frequency ranges. Of a particular concern is the microwave frequency bands which play a key role in land, ocean, moisture sensing. This is because of a growing commercial demand in the area of high speed broadband communication all over the world, the electronic manufacturers are looking into high frequency microwave spectral bands. This may present a risk to the remote sensing sensors because of additional sources of noise that can impair the highly sensitive passive remote sensing instruments.

Ambrose, Stephen↗

Development of a material property database on selected ceramic matrix composite materials

Ceramic Matrix Composites, with fiber/whisker/particulate reinforcement, possess the attractive properties of ceramics such as high melting temperature, high strength and stiffness at high temperature, low density, excellent environmental resistance, combined with improved toughness and mechanical reliability. These unique properties have made these composites an enabling technology for thermomechanically demanding applications in high temperature, high stress and aggressive environments. On a broader scale, CMC's are anticipated to be applicable in aircraft propulsion, space propulsion, power and structures, in addition to ground based applications. However, it is also true that for any serious commitment of the material toward any of the intended critical thermo-mechanical applications to materialize, vigorous research has to be conducted for a thorough understanding of the mechanical and thermal behavior of CMC's. The high technology of CMC'S is far from being mature. In view of this growing need for CMC data, researchers all over the world have found themselves drawn into the characterization of CMC's such as C/SiC, SiC/SiC, SiC/Al203, SiC/Glass, SiC/C, SiC/Blackglas. A significant amount of data has been generated by the industries, national laboratories and educational institutions in the United States of America. NASA/Marshall Space Flight Center intends to collect the 'pedigreed' CMC data and store those in a CMC database within MAPTIS (Materials and Processes Technical Information System). The task of compilation of the CMC database is a monumental one and requires efforts in various directions. The project started in the form of a summer faculty fellowship in 1994 and has spilled into the months that followed and into the summer faculty fellowship of 1995 and has the prospect of continuing into the future for a healthy growth, which of course depends to a large extent on how fast CMC data are generated. The 10-week long summer fellowship has concentrated, basically, on establishing the procedure for a smooth transfer of data into a CMC database on MAPTIS which is a vital part of the following broader picture of the project.

Mahanta, Kamala↗

The Micromechanics of the Moving Contact Line

The proposed research is divided into three components concerned with molecular structure, molecular orientation, and continuum averages of discrete systems. In the experimental program, we propose exploring how changes in interfacial molecular structure generate contact line motion. Rather than rely on the electrostatic and electrokinetic fields arising from the molecules themselves, we augment their interactions by an imposed field at the solid/liquid interface. By controling the field, we can manipulate the molecular structure at the solid/liquid interface. In response to controlled changes in molecular structure, we observe the resultant contact line motion. In the analytical portion of the proposed research we seek to formulate a system of equations governing fluid motion which accounts for the orientation of fluid molecules. In preliminary work, we have focused on describing how molecular orientation affects the forces generated at the moving contact line. Ideally, as assumed above, the discrete behavior of molecules can be averaged into a continuum theory. In the numerical portion of the proposed research, we inquire whether the contact line region is, in fact, large enough to possess a well-defined average. Additionally, we ask what types of behavior distinguish discrete systems from continuum systems. Might the smallness of the contact line region, in itself, lead to behavior different from that in the bulk? Taken together, our proposed research seeks to identify and accurately account for some of the molecular dynamics of the moving contact line, and attempts to formulate a description from which one can compute the forces at the moving contact line.

Han, Minsub↗

Engineering Precisely Controlled Negative and Zero Thermal Expansion Behaviors in Metal-Organic Frameworks

Positive thermal expansion can cause significant stress or even catastrophic device failure in applications where materials are placed in confined environments. At material interfaces such as coatings, thermal expansion effects can also lead to cracking and peeling behavior. The ability to impart controlled thermal expansion properties in an array of designs via additive manufacturing technologies would mitigate such problems and bring significant value to various materials science and engineering challenges. Negative thermal expansion materials are of interest for composite material applications whereby they can compensate for the behavior of a positive thermal expansion matrix. This Truman Fellowship LDRD research project presents complimentary experimental and molecular modeling results towards the fundamental understanding and development of metal-organic framework (MOF) materials with controlled thermal expansion properties. Design strategies for imparting precisely tailored negative, zero, and positive thermal expansion regimes in MOFs are studied and the implications of these design strategies for the use of MOFs as an emergent negative thermal expansion material class are examined. Challenges towards exploiting this nanoscale behavior at length scales relevant to composite material systems are introduced. ACKNOWLEDGEMENTS I will be forever grateful to the Truman Fellowship Selection Committee for providing me with the opportunity to pursue this research project. The unique opportunity to carry out this exciting scientific research with all of the resources and support that Sandia has to offer has been a truly rewarding experience. I would like to especially thank Yolanda Moreno for her endless assistance throughout my time as a Truman Fellow. It is hard to imagine a more supportive and stimulating scientific environment to carry out this research. I would also like to thank all of my colleagues and the individuals that have collaborated with me throughout this Fellowship, both internal and external to Sandia. Many of you appear as co-authors on the publications resulting from this LDRD, including especially fruitful collaborations with researchers at the Georgia Institute of Technology and the University of Amsterdam. I cannot express enough my gratitude for the significant role that you all played in shaping my educational experience and the success during my time at Sandia as a Truman Fellow.

36 MATERIALS SCIENCE↗

Biomedical Polar Research Workshop Minutes

This workshop was conducted to provide a background of NASA and National Science Foundation goals, an overview of previous and current biomedical research, and a discussion about areas of potential future joint activities. The objectives of the joint research were: (1) to develop an understanding of the physiological, psychological, and behavioral alterations and adaptations to extreme environments of the polar regions; (2) to ensure the health, well-being, and performance of humans in these environments; and (3) to promote the application of biomedical research to improve the quality of life in all environments.

Source record↗

Long-term thermal aging behavior and strength reduction in a laser powder bed fusion 316H stainless steel

The long-term thermal stability of structural alloys is essential for ensuring the safe and reliable operation of nuclear reactors and other power plants. While extensive research has explored the effects of thermal aging on conventional stainless steels, the behavior of additively manufactured (AM) alloys remains less understood. This study examines the thermal aging response of laser powder bed fusion (LPBF) 316H stainless steel (SS) at temperatures ranging from 550 °C to 750 °C over durations of up to 10,000 h (approximately 1.14 years). Advanced characterization techniques, including electron microscopy and synchrotron X-ray diffraction, were used to investigate dislocation recovery and phase evolution. Based on these findings, a time-temperature-precipitation (TTP) diagram was developed for LPBF 316H SS, revealing a 10- to100-fold acceleration in precipitation kinetics compared to wrought 316H SS. A physics-informed model was calibrated using the short-term experimental data, enabling predictions of average precipitate sizes, volume fractions of M 23 C 6 and Laves phases, and changes in molybdenum solute concentration for aging up to 1 × 10⁶ h (114 years). These microstructural insights were further utilized to estimate yield strength and extrapolate strength reduction factors over the extended aging period. Despite the accelerated aging kinetics, LPBF 316H SS demonstrated superior yield strength retention compared to its wrought counterpart. In conclusion, this study establishes a framework for evaluating long-term performance using short-term experimental data and supports the accelerated qualification of AM materials for high-temperature structural applications.

Laser powder bed fusion↗