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At least 1,171 records · Page 65

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf)thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen(LH2) and LOX/Methane(LCH4).

Al6061-RAM2↗

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf) thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen (LH2) and LOX/Methane (LCH4).

Al6061-RAM2↗

Additional Aviation Sustainability Strategies

Emissions from the aviation sector are expected to grow significantly in the next few decades due to growing demand for aviation. The U.S. fleet size has increased significantly in the past 20 years, growing from 2,132 aircraft to 5,485 aircraft. Similarly from 1990 to 2019, aviation emissions more than doubled, growing faster than any other transportation mode. These emissions include carbon dioxide (CO2), as well as non-CO2 sources including nitrogen oxides (NOx), sulfur dioxide (SO2), water (H2O), and particulate matter (soot). However, this report focuses specifically on CO2 emissions because the impacts from CO2 are well-understood and long-lived. There are also many climate goals tied to CO2 emissions, including the US Aviation Climate Action Plan which is pushing for net-zero in 2050. CO2 is a greenhouse, or heat-trapping, gas that comes from the extraction and burning of fossil fuels, from wildfires, and natural processes like volcanoes. Greenhouse gases absorb heat radiating from the Earth’s surface and release it in all directions, including back toward Earth’s surface. By adding more CO2 to the atmosphere, humans amplify the natural greenhouse effect, causing global temperature to rise. Since the onset of industrial times in 1750, human activities have raised atmospheric CO2 by 50%. Considering this challenge, the United States has set a climate goal to achieve net-zero CO2 emissions in the U.S. aviation sector by 2050 to reduce the environmental impact of aviation. Net-zero emissions refers to the amount of greenhouse gases (GHGs), such as CO2, methane or SO2, that are removed from the atmosphere being equal to those emitted by human activity. This contrasts with carbon-neutrality, which refers to no net release of carbon dioxide to the atmosphere, especially through offsetting emissions, that could be accomplished through a series of actions. As of 2022, the goal of net-zero has been adopted by much of the aviation industry including multiple airlines and countries. To reach net-zero by 2050, sustainable aviation fuels (SAFs) are identified as the technology that could provide the greatest impact within this timeframe. However, certain challenges may limit the production and/or adoption of SAFs in the marketplace, such as competition for feedstocks, production capacity, and high cost. In this case, SAFs would be insufficient to meet the net-zero CO2 emission goals. Therefore, in addition to SAFs, other strategies will be needed to close the gap on emissions produced as a result of SAF shortfalls or to enhance the impact of SAFs on reducing emissions. NASA’s Aeronautics Research Mission Directorate (ARMD) aims to examine these additional pathways to explore how its research may best contribute to the realization of net-zero emissions by 2050. Specifically, this effort considers strategies that can reduce emissions in the aviation sector in combination with the use of SAFs and carbon offsets while still meeting projected passenger demand. The strategies considered are not only feasible but also could be operationally scalable by 2050. The goal of this report is to investigate additional strategies such as alternative flight and ground operations, providing insight into the CO2 emission reduction potential and feasibility of strategy implementation by 2050.

Carbon Emissions↗

Emerging Technologies in the Built Environment: Geographic Information Science (GIS), 3D Printing, and Additive Manufacturing

Abstract 1: Geographic information systems emerged as a computer application in the late 1960s, led in part by projects at ORNL. The concept of a GIS has shifted through time in response to new applications and new technologies, and is now part of a much larger world of geospatial technology. This presentation discusses the relationship of GIS and estimating hourly and seasonal energy consumption profiles in the building sector at spatial scales down to the individual parcel. The method combines annual building energy simulations for city-specific prototypical buildings and commonly available geospatial data in a GIS framework. Abstract 2: This presentation focuses on 3D printing technologies and how they have rapidly evolved over the past couple of years. At a basic level, 3D printing produces physical models quickly and easily from 3D CAD, BIM (Building Information Models), and other digital data. Many AEC firms have adopted 3D printing as part of commercial building design development and project delivery. This presentation includes an overview of 3D printing, discusses its current use in building design, and talks about its future in relation to the HVAC industry. Abstract 3: This presentation discusses additive manufacturing and how it is revolutionizing the design of commercial and residential facilities. Additive manufacturing utilizes a broad range of direct manufacturing technologies, including electron beam melting, ultrasonic, extrusion, and laser metal deposition for rapid prototyping. While there is some overlap with the 3D printing talk, this presentation focuses on the materials aspect of additive manufacturing and also some of the more advanced technologies involved with rapid prototyping. These technologies include design of carbon fiber composites, lightweight metals processing, transient field processing, and more.

New, Joshua Ryan↗

Metal-air cell with performance enhancing additive

Systems and methods drawn to an electrochemical cell comprising a low temperature ionic liquid comprising positive ions and negative ions and a performance enhancing additive added to the low temperature ionic liquid. The additive dissolves in the ionic liquid to form cations, which are coordinated with one or more negative ions forming ion complexes. The electrochemical cell also includes an air electrode configured to absorb and reduce oxygen. The ion complexes improve oxygen reduction thermodynamics and/or kinetics relative to the ionic liquid without the additive.

30 DIRECT ENERGY CONVERSION↗

High efficiency iron electrode and additives for use in rechargeable iron-based batteries

An iron electrode and a method of manufacturing an iron electrode for use in an iron-based rechargeable battery are disclosed. In one embodiment, the iron electrode includes carbonyl iron powder and one of a metal sulfide additive or metal oxide additive selected from the group of metals consisting of bismuth, lead, mercury, indium, gallium, and tin for suppressing hydrogen evolution at the iron electrode during charging of the iron-based rechargeable battery. An iron-air rechargeable battery including an iron electrode comprising carbonyl iron is also disclosed, as is an iron-air battery wherein at least one of the iron electrode and the electrolyte includes an organosulfur additive.

25 ENERGY STORAGE↗

APPROACHES TO GEOMETRIC DATA ANALYSIS ON BIG AREA ADDITIVELY MANUFACTURED (BAAM) PARTS

The promise of additive manufacturing is that a user can design and print complex geometries that are very difficult, if not impossible, to machine. The capabilities of 3D printing are restricted by a number of factors, including properties of the build material, time constraints, and geometric design restrictions. In this paper, a thorough accounting and study of the geometric restrictions that exist in the current iteration of additive manufacturing (AM) fused deposition modeling (FDM) technologies are discussed. Offline and online methodologies for collecting data sets for qualitative analysis of large scale AM, in particular Oak Ridge National Laboratory s (ORNL) big area additive manufacturing (BAAM) system, are summarized. In doing so, a survey of tools for designers and software developers is provided. In particular, strategies in which geometric data can be used as training sets for smarter AM technologies in the future are explained as well.

Dreifus, Gregory D↗

Process Modeling and Validation for Metal Big Area Additive Manufacturing

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to accelerate the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Simunovic, Srdjan↗

High performance, rapid thermal/UV curing epoxy resin for additive manufacturing of short and continuous carbon fiber epoxy composites

An additive manufacturing resin system including an additive manufacturing print head; a continuous carbon fiber or short carbon fibers operatively connected to the additive manufacturing print head; and a tailored resin operatively connected to the print head, wherein the tailored resin has a resin mass and wherein the tailored resin includes an epoxy component, a filler component, a catalyst component, and a chain extender component; wherein the epoxy component is 70-95% of the resin mass, wherein the filler component is 1-20% of the resin mass, wherein the catalyst component is 0.1-10% of the resin mass, and wherein the chain extender component is 0-50% of the resin mass.

36 MATERIALS SCIENCE↗

Producing carbon-based boundary films from catalytically active lubricant additives

A lubricant composition includes an oil including a plurality of long-chain hydrocarbon molecules. A quantity of a catalytically active metal-organic additive is mixed with the oil. The metal-organic additive is formulated to fragment the long-chain hydrocarbon molecules of the oil into at least one of dimers and trimers under the influence of at least one of a mechanical loading and a thermal loading. In some embodiments, the metal-organic additive includes a compound of formula II: ##STR00001## where: X is Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, Rf, Db, Sg, Bh, Hs, Mt, Ds, Rg or Cn, and R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are alkyl or alkyl halide.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

High Power Electron Gun for Metal Additive Manufacturing Based on Superconducting Technology

E-beam additive manufacturing is a rapidly growingindustry. Electron guns capable of reaching higher energiesand higher average power can enable larger melt pools,higher production speed, and permit broader range ofmaterials for metal additive applications. Such electronguns require technologies beyond those normally achievedwith DC high voltage sources. As an example,superconducting radio frequency (SRF) technology is anoption to achieve higher energy and higher power withexcellent efficiency. However, current SRF technologyrequires complex cryogenic systems to safely handlecryogenics gases or liquids such as Helium. Suchcomplexity severely restricts their usage to R&D facilities.In this talk, we introduce and describe, for the first time, anovel technique based on SRF technology to build a highpower, high energy electron gun for advanced metaladditive manufacturing applications. Our design is based ona technique which eliminates liquid Helium entirely. Ourmethod dramatically reduces the complexity and thusallows building practical, efficient, and modern electronsources for additive manufacturing.

43 PARTICLE ACCELERATORS↗

Precast Concrete Molds Fabricated with Big Area Additive Manufacturing

The traditional process of making precast concrete molds requires significant manual labor. The molds are made using hardwood, cost tens of thousands of dollars, and take weeks to build. Once built, a mold will last 5-10 pulls before becoming too heavily degraded to continue use. With additive manufacturing, the same mold can be built in eight hours, post-machined in eight hours, costs about $9000, and is project to last nearly 200 pulls. Oak Ridge National Laboratory has been working with Big Area Additive Manufacturing (BAAM) to fabricate concrete molds for a new high-rise apartment complex in New York. The molded pieces will form structural window supports for the hundreds of windows in building façade. The magnitude of window molds is where additive manufacturing can shine when producing the geometry. This paper will discuss the methods and findings of using BAAM to replace conventional precast concrete pattern making.

Roschli, Alex↗

Increasing Interlaminar Strength in Large Scale Additive Manufacturing

Interlaminar strength of extrusion-based additively manufactured parts is known to be weaker than the strength seen in the printed directions (X and Y). With Big Area Additive Manufacturing (BAAM), large parts lead to long layer times that are prone to splitting, sometimes referred to as delamination, between the layers. Fiber filled materials, such as carbon fiber reinforced ABS, are used to counter-act the effects of thermal expansion, but the fibers stay in-plane meaning that no fibers span from layer to layer, which helps counteract the weak interlaminar strength that causes splitting. A solution to this is a patent pending approach known as “z-pinning”. The process involves strategically positioning voids across multiple layers that will be backfilled with hot extrudate. This paper will explore the benefits and results of using “z-pinning” in large scale additive manufacturing.

Roschli, Alex↗

Role of Cyclic Phase Transitions in Additive Manufacturing of Metals and Alloys - Lessons Learned from Welding Science

Additive manufacturing (also known as 3D printing) of metals is considered to be a disruptive technology, able to produce limited number of high value components with topologically optimized geometries and functionalities. Realization of the above potential for real-world applications is stifled by lack of standard computational design tools; component certifications, varied starting powder feed stock compositions, methods to probe thermomechanical processes, microstructural homogeneity, residual stress, as well as, anisotropic static- and dynamic-material properties. Detailed research of direct energy deposition, laser- and electron-powder bed additive manufacturing demonstrates that the underlying physics of these processes are very similar to welding, except for complex boundary conditions. This paper will review published literature and on-going research with reference to fundamental aspects of heat and mass transfer, solidification under large (103 to 105 K/m) thermal gradients and (10-3 to 100 m/s) liquid solid-interface velocities, as well as, solid->solid transformation under repeated thermal excursions. Case studies on model based qualification of Ni- and Ti- alloy builds made by additive manufacturing (AM), based on the above fundamental knowledge will be discussed.

Babu, Sudarsanam Suresh↗

Semi-solid electrodes with gel polymer additive

Embodiments described herein relate generally to electrochemical cells having semi-solid electrodes that include a gel polymer additive such that the electrodes demonstrate longer cycle life while significantly retaining the electronic performance of the electrodes and the electrochemical cells formed therefrom. In some embodiments, a semi-solid electrode can include about 20% to about 75% by volume of an active material, about 0.5% to about 25% by volume of a conductive material, and about 20% to about 70% by volume of an electrolyte. The electrolyte further includes about 0.01% to about 1.5% by weight of a polymer additive. In some embodiments, the electrolyte can include about 0.1% to about 0.7% of the polymer additive.

25 ENERGY STORAGE↗

Additive manufacturing via direct writing of pure metal and eutectics through latent heat position control

An additive manufacturing system for producing metal parts from pure metal or eutectic alloys. The system includes an additive manufacturing print head, a print head heater system, an agitation system, a nozzle in the additive manufacturing print head, a reservoir for melting the metal, and a long heated tube for conditioning the alloy for extrusion in the semi-solid state through a nozzle.

Pascall, Andrew J.↗

Electrolyte additives for transition metal cyanometallate electrode stabilization

A method is provided for the self-repair of a transition metal cyanometallate (TMCM) battery electrode. The battery is made from a TMCM cathode, an anode, and an electrolyte including solution formed from a solvent and an alkali or alkaline earth salt. The electrolyte includes an additive represented as G-R-g: where G and g are independently include materials with nitrogen (N) sulfur (S), oxygen (O), or combinations of the above-recited elements; and where R is an alkene or alkane group. In response to charging and discharging the battery in a plurality of cycles, the method creates vacancies in a surface of the TMCM cathode. Then, the method fills the vacancies in the surface of the TMCM cathode with the electrolyte additive. An electrolyte and TMCM battery using the above-mentioned additives are also provided.

25 ENERGY STORAGE↗

Metal-air cell with performance enhancing additive

Systems and methods drawn to an electrochemical cell comprising a low temperature ionic liquid comprising positive ions and negative ions and a performance enhancing additive added to the low temperature ionic liquid. The additive dissolves in the ionic liquid to form cations, which are coordinated with one or more negative ions forming ion complexes. The electrochemical cell also includes an air electrode configured to absorb and reduce oxygen. The ion complexes improve oxygen reduction thermodynamics and/or kinetics relative to the ionic liquid without the additive.

Friesen, Cody A.↗