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At least 109 records · Page 6

All sources NASA NTRS DOE OSTI

NASA NTRS2012

NDT and SHM of Carbon Fiber Composites using Linear Drive MWM-Arrays

Carbon fiber composites are used in a wide range of structural applications due to their excellent specific strength and stiffness. However, the anisotropic mechanical and electrical properties associated with the fibers within each composite layer present challenges, and opportunities, for Nondestructive Testing (NDT) methods used to characterize and assess the structure condition. This includes composite condition after manufacture (such as fiber orientation and density, porosity, delamination, and bond strength) and during usage (such as damage from impact, fiber breakage, thermal exposure or applied stress). Ultrasonic and thermographic methods can address some of these challenges, but eddy current methods provide an alternative method for composite structures that contain a conducting material, such as carbon fibers or a metallic liner. This presentation reviews recent advances in the development of eddy current sensors and arrays for carbon fiber composite NDT and Structural Health Monitoring (SHM) applications. The focus is on eddy current sensor constructs with linear drive windings, such as MWM -Arrays, that induce currents primarily within the linear fibers of the composite. By combining this type of sensor construct with micromechanical models that relate composite constituent properties to measurable sensor responses, insight is obtained into the volumetric distribution of electrical properties within the composite and the associated manufacturing, damage, or strain conditions. With knowledge of the fiber layup, this MWM-Array technology is able to detect damage and strain/stress as a function of depth and fiber orientation. This work has been funded by NASA, NA V AIR and the Army for applications ranging from composite overwrapped pressure vessels (COPVs) to aircraft structures and rotorcraft blades. This presentation will specifically present background on the MWM-Array technology, results from the micromechanical modeling effort, and results from ongoing efforts for high resolution imaging and volumetric strain sensing.

Washabaugh, Andrew↗

NASA NTRS1950

The Development of a Hollow Blade for Exhaust Gas Turbines

The subject of the development of German hollow turbine blades for use with internal cooling is discussed in detail. The development of a suitable blade profile from cascade theory is described. Also a discussion of the temperature distribution and stresses in a turbine blade is presented. Various methods of manufacturing hollow blades and the methods by which they are mounted in the turbine rotor are presented in detail.

TURBINES - BLADES, HOLLOW↗

DOE OSTI2025

Continuous flow photochemical synthesis of metal–ceramic composite microparticles

We developed a UV-assisted microfluidic system to synthesize FeCrAl–Al 2 O 3 composite microparticles for additive manufacturing. Here, the system ensures precise particle size, morphology, and elemental distribution control. Increasing the dispensing pressure while keeping the oil flow rate constant resulted in larger microparticles. Laser fusing revealed FeCrAl and Al 2 O 3 phases, showing their potential as feedstocks for 3D printed heterogeneous materials such as FeCrAl/Al 2 O 3 bi-phase materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Vexcel Imaging's Suitability for Automatic Verification

Accurate, independently verified geospatial data is essential for automated calibration, validation, and operational decision-making. This study evaluated the positional accuracy of Vexcel Imaging™’s UltraCam® Osprey imagery (7.5 cm GSD) using globally distributed Continuously Operating Reference Stations (CORS) as independent control. Despite manufacturer claims of 15 cm horizontal accuracy, residual errors were consistently one to two orders of magnitude larger, with no subset of imagery meeting precision thresholds. These discrepancies cannot be explained by normal photogrammetric or environmental factors and raise concerns about the reliability of the imagery for high-precision tasks. The results demonstrate that Vexcel imagery, in its current form, is unsuitable for workflows requiring rigorous spatial accuracy or automated verification. At the same time, the reproducible validation framework developed in this study establishes a scalable method for assessing commercial imagery, ensuring that future products can be independently and objectively verified before operational adoption.

47 OTHER INSTRUMENTATION↗

NASA NTRS1987

Programming methodology for a general purpose automation controller

The General Purpose Automation Controller is a multi-processor architecture for automation programming. A methodology has been developed whose aim is to simplify the task of programming distributed real-time systems for users in research or manufacturing. Programs are built by configuring function blocks (low-level computations) into processes using data flow principles. These processes are activated through the verb mechanism. Verbs are divided into two classes: those which support devices, such as robot joint servos, and those which perform actions on devices, such as motion control. This programming methodology was developed in order to achieve the following goals: (1) specifications for real-time programs which are to a high degree independent of hardware considerations such as processor, bus, and interconnect technology; (2) a component approach to software, so that software required to support new devices and technologies can be integrated by reconfiguring existing building blocks; (3) resistance to error and ease of debugging; and (4) a powerful command language interface.

Sturzenbecker, M. C.↗

NASA NTRS2004

Particulate Titanium Matrix Composites Tested--Show Promise for Space Propulsion Applications

Uniformly distributed particle-strengthened titanium matrix composites (TMCs) can be manufactured at lower cost than many types of continuous-fiber composites. The innovative manufacturing technology combines cold and hot isostatic pressing procedures to produce near-final-shape components. Material stiffness is increased up to 26-percent greater than that of components made with conventional titanium materials at no significant increase in the weight. The improved mechanical performance and low-cost manufacturing capability motivated an independent review to assess the improved properties of ceramic titanium carbide (TiC) particulate-reinforced titanium at elevated temperature. Researchers at the NASA Glenn Research Center creatively designed and executed deformation and durability tests to reveal operating regimes where these materials could lower the cost and weight of space propulsion systems. The program compares the elevated-temperature performance of titanium alloy Ti-6Al-4V matrix material to an alloy containing 10 wt% of TiC particles. Initial experiments showed that at these relatively low particle concentrations the material stiffness of the TMC was improved 20 percent over that of the plain Ti-6Al-4V alloy when tested at 427 C. The proportional limit and ultimate strength of the composite in tension are 21- and 14-percent greater than those of the plain alloy. Compression tests showed that the proportional limit is about 30 percent greater for TMC than for the plain alloy. The enhanced deformation resistance of the TMC was also evident in a series of tensile and compressive stress relaxation tests that were made. Specimens were subjected to tensile or compressive strain amplitudes of 0.75 percent for 24 hr followed by a return to zero strain imposed for 24 hr. The stress relaxation data were normalized with respect to the maximum stress for each case and plotted as a function of time in the following graph. Tensile stresses relaxed 19 percent for the TMC and 25 percent for the plain Ti-6Al-4V alloy. Compressive stresses relaxed 25 percent for the TMC and 39 percent for the plain Ti-6Al-4V alloy. The superior deformation resistance of the TMC extends to a creep rate that is 28-percent slower for the TMC when it is loaded to stress levels that are 26-percent higher than for the plain Ti-6Al-4V alloy.

Lerch, Bradley A.↗

DOE OSTI2025

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗

NASA NTRS2012

Availability Estimation for Facilities in Extreme Geographical Locations

A value added analysis for the Reliability. Availability and Maintainability of McMurdo Ground Station was developed, which will be a useful tool for system managers in sparing, maintenance planning and determining vital performance metrics needed for readiness assessment of the upgrades to the McMurdo System. Output of this study can also be used as inputs and recommendations for the application of Reliability Centered Maintenance (RCM) for the system. ReliaSoft's BlockSim. a commercial Reliability Analysis software package, has been used to model the availability of the system upgrade to the National Aeronautics and Space Administration (NASA) Near Earth Network (NEN) Ground Station at McMurdo Station in the Antarctica. The logistics challenges due to the closure of access to McMurdo Station during the Antarctic winter was modeled using a weighted composite of four Weibull distributions. one of the possible choices for statistical distributions throughout the software program and usually used to account for failure rates of components supplied by different manufacturers. The inaccessibility of the antenna site on a hill outside McMurdo Station throughout one year due to severe weather was modeled with a Weibull distribution for the repair crew availability. The Weibull distribution is based on an analysis of the available weather data for the antenna site for 2007 in combination with the rules for travel restrictions due to severe weather imposed by the administrating agency, the National Science Foundation (NSF). The simulations resulted in an upper bound for the system availability and allowed for identification of components that would improve availability based on a higher on-site spare count than initially planned.

Fischer, Gerd M.↗

NASA NTRS2001

Advanced Engineering Environments: Implications for Aerospace Manufacturing

There are significant challenges facing today's aerospace industry. Global competition, more complex products, geographically-distributed design teams, demands for lower cost, higher reliability and safer vehicles, and the need to incorporate the latest technologies quicker all face the developer of aerospace systems. New information technologies offer promising opportunities to develop advanced engineering environments (AEEs) to meet these challenges. Significant advances in the state-of-the-art of aerospace engineering practice are envisioned in the areas of engineering design and analytical tools, cost and risk tools, collaborative engineering, and high-fidelity simulations early in the development cycle. These advances will enable modeling and simulation of manufacturing methods, which will in turn allow manufacturing considerations to be included much earlier in the system development cycle. Significant cost savings, increased quality, and decreased manufacturing cycle time are expected to result. This paper will give an overview of the NASA's Intelligent Synthesis Environment, the agency initiative to develop an AEE, with a focus on the anticipated benefits in aerospace manufacturing.

Thomas, D.↗

DOE OSTI2025

Numerical framework for integrated additive manufacturing-compression molding (AM-CM) of thermoplastic composites

Additive manufacturing-compression molding (AM-CM) has emerged as a transformative technology in advanced composite manufacturing. Additive manufacturing (AM) offers high design flexibility and the ability to produce complex geometries with precisely aligned fibers in the preferred orientation. Compression molding (CM) enhances composite materials by providing excellent dimensional stability, reduced porosity, high production rates, and a smooth surface finish. Despite these advantages, extensive integrated analysis is required to optimize processing conditions for improved fiber orientation distribution (FOD) and porosity control. Here, this study develops a comprehensive numerical model to simulate the AM-CM manufacturing process. The model isolates the effects of both the AM and CM phases while also capturing their integration. Additionally, it accounts for heat transfer, temperature-dependent viscosity, and fiber orientation in the extruded fiber-filled polymer, accurately representing material behavior during processing. This approach enables the analysis of interactions between deposited beads of complex strand shapes and their interface regions after full compression. Moreover, the model predicts key parameters such as polymer flowability, fiber orientation, and temperature evolution in AM-CM parts. By optimizing processing conditions, it facilitates a controlled and predictable microstructure.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Additive Manufactured Composite Phase-Change Material for Thermal Energy Storage Applications

Phase-change materials play a critical role in industrial energy storage applications to drive efficiency improvements, thermal energy management, and carbon emissions reductions. Recently, it has been shown that rapid solidification of alloys with metastable immiscibility in the liquid phase has the potential to form unique microstructures in which a low-melting phase is uniformly distributed in a high-melting matrix. This feature can be exploited using additive manufacturing to produce components with complex geometries containing such unique phase-change microstructures. Phase-field simulations utilizing high-performance computing were used to provide a detailed description of the evolution of the active phase during service in terms of their morphology and composition in different polycrystalline matrix grain morphologies that are typically produced during additive manufacturing. Phase field simulations were performed using, MEUMAPPS-SL (Microstructure Evolution Using Massively Parallel Phase-field Simulations – Solid Liquid) code that was developed in-house by the Oak Ridge National Laboratory. The simulations utilized the capabilities of the Kestrel supercomputer at the National Renewable Energy Laboratory. The simulation results were compared with experimental results generated at Siemens Energy, Inc. The results indicate that the kinetics of liquid spreading along grain boundaries is largely determined by the mobility of the triple line along the intersection of the grain boundary liquid and the grain boundary plane.

25 ENERGY STORAGE↗

NASA NTRSDate not supplied

Coarsening Up: Expanding the Particle Size Distributions of Lunar Simulants to Encompass A Comprehensive Range of Regolith Granularity

Due to a paucity of lunar regolith samples, simulated granular materials (simulants) have been developed and deployed for a variety of engineering and research purposes in an attempt to meet the requirements for lunar exploration. Broadly speaking, these manufactured materials aim to replicate the compositional (i.e., mineralogy and chemistry) and physical (e.g., particle size distribution, particle shape) profiles of lunar soil samples collected during the Apollo missions. While creating a “near-perfect” lunar simulant is prohibitive due to the unique formative processes (i.e., meteorite impacts, solar wind implantation) and conditions (anhydrous, reducing environment and exposure to radiation on the surface over billions of years) encountered on the moon, certain granular properties of the regolith can be recreated with a high level of fidelity by leveraging contemporary technologies. A fundamental physical property and descriptor, grain size can be correlated between samples and replicated through processing; however, a holistic understanding of the particle size distribution of lunar regolith must be considered when creating analog materials. This study produces particle size distributions for Apollo 16 returned samples, incorporating the sieved out >1 cm coarse-grained fraction, in order to provide a more comprehensive characterization of surficial lunar regolith grain sizes for the development of highlands-type granular analog testing materials.

R. N. Kovtun↗

DOE OSTI2026

Picosecond measurements of plastic scintillator pulse shapes from gamma-ray interactions

An understanding of the pulse shape of organic scintillators can provide insight into scintillation mechanisms and inform the selection of the optimal detector material for a given application. Although the timing properties of organic scintillators have been extensively studied, significant discrepancies persist in reported rise and decay times. New plastic scintillating media have also been developed in recent years for which no literature data exist. The goal of this work is to provide high-precision measurements of the pulse shape of a suite of fast plastic organic scintillators from Eljen Technology—EJ-200, EJ-204, EJ-208, EJ-230, EJ-232, and EJ-232Q (with 0.5% benzophenone)—under excitation from $γ$-ray sources. The contributors to the system temporal resolution were quantified, and the dominant source of uncertainty was identified as the determination of the start time of a scintillation event. A pulse shape model was applied to the reconstructed temporal distributions, and rise and decay times were extracted and compared with manufacturer specifications. This work outlines a measurement approach to obtain the pulse shape of organic scintillators in response to $γ$-rays with temporal resolution on the order of tens of picoseconds, yielding data required for modeling plastic scintillator based detection systems for a range of applications.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS2012

Lunar Prospecting Using Thermal Wadis and Compact Rovers: Infrastructure for Surviving the Lunar Night - Part A

Recent missions have confirmed the existence of water and other volatiles on the Moon, both in permanently-shadowed craters and elsewhere. Non-volatile lunar resources may represent significant additional value as infrastructure or manufacturing feedstock. Characterization of lunar resources in terms of abundance concentrations, distribution, and recoverability is limited to in-situ Apollo samples and the expanding remote-sensing database. This paper introduces an approach to lunar resource prospecting supported by a simple lunar surface infrastructure based on the Thermal Wadi concept of thermal energy storage and using compact rovers equipped with appropriate prospecting sensors and demonstration resource extraction capabilities. Thermal Wadis are engineered sources of heat and power based on the storage and retrieval of solar-thermal energy in modified lunar regolith. Because Thermal Wadis keep compact prospecting rovers warm during periods of lunar darkness, the rovers are able to survive months to years on the lunar surface rather than just weeks without being required to carry the burdensome capability to do so. The resulting lower-cost, long-lived rovers represent a potential paradigm breakthrough in extra-terrestrial prospecting productivity and will enable the production of detailed resource maps. Integrating resource processing and other technology demonstrations that are based on the content of the resource maps will inform engineering economic studies that can define the true resource potential of the Moon. Once this resource potential is understood quantitatively, humans might return to the Moon with an economically sound objective including where to go, what to do upon arrival, and what to bring along.

Sacksteder, Kurt R.↗

NASA NTRS2013

Advanced Materials and Fabrication Techniques for the Orion Attitude Control Motor

Rhenium, with its high melting temperature, excellent elevated temperature properties, and lack of a ductile-to-brittle transition temperature (DBTT), is ideally suited for the hot gas components of the ACM (Attitude Control Motor), and other high-temperature applications. However, the high cost of rhenium makes fabricating these components using conventional fabrication techniques prohibitive. Therefore, near-net-shape forming techniques were investigated for producing cost-effective rhenium and rhenium alloy components for the ACM and other propulsion applications. During this investigation, electrochemical forming (EL-Form ) techniques were evaluated for producing the hot gas components. The investigation focused on demonstrating that EL-Form processing techniques could be used to produce the ACM flow distributor. Once the EL-Form processing techniques were established, a representative rhenium flow distributor was fabricated, and samples were harvested for material properties testing at both room and elevated temperatures. As a lower cost and lighter weight alternative to an all-rhenium component, rhenium- coated graphite and carbon-carbon were also evaluated. The rhenium-coated components were thermal-cycle tested to verify that they could withstand the expected thermal loads during service. High-temperature electroforming is based on electrochemical deposition of compact layers of metals onto a mandrel of the desired shape. Mandrels used for electro-deposition of near-net shaped parts are generally fabricated from high-density graphite. The graphite mandrel is easily machined and does not react with the molten electrolyte. For near-net shape components, the inner surface of the electroformed part replicates the polished graphite mandrel. During processing, the mandrel itself becomes the cathode, and scrap or refined refractory metal is the anode. Refractory metal atoms from the anode material are ionized in the molten electrolytic solution, and are deposited onto the cathodic mandrel by electrochemical reduction. Rotation of the mandrel ensures uniform distribution of refractory material. The EL-Form process allows for manufacturing in an inert atmosphere with deposition rates from 0.0004 to 0.002 in./h (10.2 to 50.8 m/h). Thicknesses typically range from microns to greater than 0.5 in. (13 mm). The refractory component produced is fabricated, dependably, to within one micron of the desired tolerances with no shrinkage or distortion as in other refractory metal manufacture techniques. The electroforming process has been used to produce solid, nonporous deposits of rhenium, iridium, niobium, tungsten, and their alloys.

Gorti, Sridhar↗

NASA NTRS2016

Rapid Fabrication Techniques for Liquid Rocket Channel Wall Nozzles

The functions of a regeneratively-cooled nozzle are to (1) expand combustion gases to increase exhaust gas velocity while, (2) maintaining adequate wall temperatures to prevent structural failure, and (3) transfer heat from the hot gases to the coolant fluid to promote injector performance and stability. Regeneratively-cooled nozzles are grouped into two categories: tube-wall nozzles and channel wall nozzles. A channel wall nozzle is designed with an internal liner containing a series of integral coolant channels that are closed out with an external jacket. Manifolds are attached at each end of the nozzle to distribute coolant to and away from the channels. A variety of manufacturing techniques have been explored for channel wall nozzles, including state of the art laser-welded closeouts and pressure-assisted braze closeouts. This paper discusses techniques that NASA MSFC is evaluating for rapid fabrication of channel wall nozzles that address liner fabrication, slotting techniques and liner closeout techniques. Techniques being evaluated for liner fabrication include large-scale additive manufacturing of freeform-deposition structures to create the liner blanks. Abrasive water jet milling is being evaluated for cutting the complex coolant channel geometries. Techniques being considered for rapid closeout of the slotted liners include freeform deposition, explosive bonding and Cold Spray. Each of these techniques, development work and results are discussed in further detail in this paper.

Gradl, Paul R.↗

DOE OSTI2024

Nanostructured Alumina Forming Austenitic Alloy (NAFA) Production using Advanced Manufacturing

Alumina-forming austenitic (AFA) alloys are well known for their exceptional corrosion-resistant properties due to the formation of a dense oxide scale beneficial in their application as a nuclear material. However, use of the alloys in core material applications is limited due to the high nickel-transmutation and helium generation rate in service, leading to swelling and reduced lifetimes. Enhancing the sink strength to pin gas bubbles and increasing gas management of the material may mitigate many of the degradation phenomena expected during alloy deployment (such as high-temperature helium embrittlement and cavity swelling for lead-cooled fast-reactor applications). Nanostructured materials are usually produced using a time-consuming and expensive batch process like mechanical alloying to achieve the fine homogenous distribution of nanoprecipitates throughout the matrix material. Integrating the nanoprecipitates in modern additive manufacturing processes has proven difficult, as the required nano-sizes or number densities cannot be achieved simultaneously. Efforts to increase the number density of precipitates by adding more precipitate-forming rare-earth elements led to agglomeration of such elements, while the nano-sized precipitates did not form in sufficient quantity when not enough rare-earth element was use. In this work a novel approach to advanced manufacturing and the fabrication of Nanostructured AFA (NAFA) materials was chosen. A dual precipitate-forming NAFA steel with a chemistry more suitable for advanced reactor applications was produced to create an environmentally resistant, high-sink-strength austenitic alloy for advanced reactor cladding applications.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Nanostructured Alumina-Forming Austenitic Alloy (NAFA) Production Using Advanced Manufacturing

36 MATERIALS SCIENCE↗