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All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Economic Readiness Level Considerations for a Robust LEO Economy

The reduced gravity environment of space provides a unique opportunity to further our understanding of various materials phenomena involving the molten, fluidic and gaseous states as well as life science applications where, contrary to earlier beliefs, microgravity induces changes in single cells and simple organisms; not only in large organisms with a complex overall response to gravity (or lack thereof). The potential breadth of commercial opportunities in microgravity thus spans over many verticals of the private sector with applications ranging from fiber optics, high-resolution crystals, microencapsulation, 3D organs to perfume and color dyes. Overall, products manufactured in microgravity hold the promise to have key properties surpassing their best terrestrial counterparts. Commercialization, also known as taking a new technology to market, is a journey in itself where the business, economic, market and technological components must align to generate a successful outcome. A business perspective is very different than technology maturation, which can be measured with the usual Technology Readiness Level (TRL) approach. In order for a technology to be ready for commercialization, it must not only be mature (high TRL), but it must also have a compelling business case, and the means to scale up production must be identified and practical. Creating a sustainable economy in an emerging market such as microgravity is especially challenging because of the complexity (high risks, lack of standardization) involved in predicting future growth. This complexity can easily overwhelm the fact that many of the products have an attractive touch of space which aids with branding and marketing.This paper builds upon the concept of the verticals of microgravity, capturing not only new lines of investigations but also promising killer apps originating from microgravity to discuss and define the notion of Economic Readiness Level (ERL). To advance in ERL, the technology itself may not necessarily need to mature at all, but the understanding of its economic potential does. Building upon ERL, a model that ultimately leads to the creation of pathways for infusion of private capital and a sustainable commercial microgravity LEO-Earth economy will be discussed.

Cozmuta, Ioana↗
NASA NTRS2006

Modern Design of Resonant Edge-Slot Array Antennas

Resonant edge-slot (slotted-waveguide) array antennas can now be designed very accurately following a modern computational approach like that followed for some other microwave components. This modern approach makes it possible to design superior antennas at lower cost than was previously possible. Heretofore, the physical and engineering knowledge of resonant edge-slot array antennas had remained immature since they were introduced during World War II. This is because despite their mechanical simplicity, high reliability, and potential for operation with high efficiency, the electromagnetic behavior of resonant edge-slot antennas is very complex. Because engineering design formulas and curves for such antennas are not available in the open literature, designers have been forced to implement iterative processes of fabricating and testing multiple prototypes to derive design databases, each unique for a specific combination of operating frequency and set of waveguide tube dimensions. The expensive, time-consuming nature of these processes has inhibited the use of resonant edge-slot antennas. The present modern approach reduces costs by making it unnecessary to build and test multiple prototypes. As an additional benefit, this approach affords a capability to design an array of slots having different dimensions to taper the antenna illumination to reduce the amplitudes of unwanted side lobes. The heart of the modern approach is the use of the latest commercially available microwave-design software, which implements finite-element models of electromagnetic fields in and around waveguides, antenna elements, and similar components. Instead of building and testing prototypes, one builds a database and constructs design curves from the results of computational simulations for sets of design parameters. The figure shows a resonant edge-slot antenna designed following this approach. Intended for use as part of a radiometer operating at a frequency of 10.7 GHz, this antenna was fabricated from dimensions defined exclusively by results of computational simulations. The final design was found to be well optimized and to yield performance exceeding that initially required.

Gosselin, R. B.↗
NASA NTRS2022

Lunar Communications Services with Emphasis on Commercialization

In mid-2020 Lockheed Marin Space (LM) and NASA’s Jet Propulsion Laboratory (JPL) formed a working group to study and address the need for a lunar communications network to service a growing lunar economy, beginning with the initial crewed and robotic mission needs in 2024. Multiple commercial relay architectures were studied and evaluated for platform requirements, communications capabilities, and commercial business viability in a growing ecosystem. The evolution of communications needs around the Moon were mapped to infrastructure build out. Trade studies were performed to evaluate reliability and lifetime requirements, and the viability of various data protocols. Mission concepts and operations plans were developed for both initial mission support and future autonomous network support. This work has led to Lockheed Martin and JPL to evaluate a single dedicated relay satellite in a frozen lunar orbit, with simultaneous coverage of the far-side and south pole landing sites for over 10 hours per day as a first step towards a comprehensive solution to lunar connectivity. This first satellite is compatible with an ESPA Grande launch volume and would be capable of launching on a rideshare into a variety of orbits and trajectories. The satellite is equipped with both high- and low-rate communications relay payloads with software-defined radios and a delay/disruption tolerant networking protocol. The system is designed to service initial and future mission needs in a commercialized manner, enabling a new class of missions to the Moon. The relay satellite leverages prior spacecraft platform work with on-orbit heritage in a lunar environment expected by 2023.

Davarian, Faramaz↗
DOE OSTI2021

A novel approach to mitigating the potential release of radioisotopes under fire conditions - enhancing fire resiliency of radiological contamination fixatives during deactivation & decommissioning activities

Savannah River National Laboratory (SRNL), in close collaboration with the Florida International University Applied Research Center (FIU ARC), successfully executed a technology development activity on behalf of the Department of Energy, Office of Environmental Management (DOE EM). The purpose of the activity was to improve the capability of fixative technologies in immobilizing residual contamination when exposed to thermal stressors as postulated in accident scenarios in Basis for Interim Operations (BIO) documents across the DOE EM complex. The effort resulted in the test and evaluation of a down-selected, commercial-off-the-shelf (COTS) intumescent technology in a radioactive environment at the Savannah River Site (SRS) Building 235-F Plutonium Fuel Form (PuFF) Facility and highlighted the potential use of this technology as a stand-alone, fire retardant fixative. Furthermore, this activity highlighted significant shortfalls in common fixatives currently used to support decommissioning activities and brought to the forefront the need for a methodical, uniformed approach to certifying fixative technologies for operational use in Deactivation and Decommissioning (D&D) activities. An essential component of this research was to evaluate the state of industry fixatives currently in use and set the foundation for comparison to alternative technological solutions. A baseline of five (5) commonly used fixatives and decontamination gels (hereafter collectively referred to as fixatives) was conducted, and notable shortfalls and deficiencies were revealed, particularly when exposed to thermal, water, and other environmental stressors. At temperatures as low as 300 °F - 400 °F (148.89 °C – 204.44 °C), all commonly used fixatives melted from the substrates within 3-5 minutes of exposure, resulting in contaminant transport. Significant degradation in terms of mass loss, desiccation, and off-gassing occurred, and the chemical breakdown of the polymer was so complete researchers assessed there would likely have been a release of residual contamination. Additional vulnerabilities became evident when exposed to water immersion and high humidity; existing fixatives took up water, swelling and frequently delaminating from the substrate, once again increasing the likelihood of a contaminant release.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Ion-Pair Proton Exchange Membrane Fuel Cells for Heavy-duty Transportation

The purpose of this project is to build a fuel cell prototype that demonstrates high temperature proton exchange membrane fuel cell technology (HT PEMFC) commercial readiness. It advances from a technology baseline established in a prior CRADA in which these same Parties collaborated during the years 2020-2024. These efforts are aligned with the intentions of the DOE Hydrogen Fuel Cell Technology Office (HFTO) L’Innovator Pilot Program. Participant observes that its US-based competitive advantage may be improved by further optimizing Laboratory inventions. This CRADA is intended to further improve National Laboratory compositions and to develop commercial HT PEMFC membrane electrode assemblies (MEAs) that perform over a range of operating temperatures and relative humidity, that generate power from both low grade and pure hydrogen, and that are resistant to air impurities. Participant’s goal is to advance the commercial competitiveness of National Laboratory technologies in fuel cell products for heavy-duty truck integrators, for stationary power generation, marine applications, and for emerging interest from commercial aviation. The Parties will collaborate on producing a HT PEMFC MEA that integrates LANL ion pair technology and Brookhaven catalyst technology. The Laboratories plan to research and develop compositions for testing and evaluation. The participant will manufacture multiple MEAs based on the Laboratory compositions and will enable selected customers to validate performance characteristics. The Laboratories will convey to Participant the methods of making the National Laboratory compositions such that Participant may reproduce and then scale Laboratory methods into commercial production. Throughout the project, the Laboratories and Participant will iteratively test and optimize the compositions of materials of the MEAs, intending to optimize characteristics such as power density and lifecycle durability. Participant’s intended customers include fuel cells for large trucks, aviation, power back up, marine, and portable power.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS1988

The design of an intelligent human-computer interface for the test, control and monitor system

The graphical intelligence and assistance capabilities of a human-computer interface for the Test, Control, and Monitor System at Kennedy Space Center are explored. The report focuses on how a particular commercial off-the-shelf graphical software package, Data Views, can be used to produce tools that build widgets such as menus, text panels, graphs, icons, windows, and ultimately complete interfaces for monitoring data from an application; controlling an application by providing input data to it; and testing an application by both monitoring and controlling it. A complete set of tools for building interfaces is described in a manual for the TCMS toolkit. Simple tools create primitive widgets such as lines, rectangles and text strings. Intermediate level tools create pictographs from primitive widgets, and connect processes to either text strings or pictographs. Other tools create input objects; Data Views supports output objects directly, thus output objects are not considered. Finally, a set of utilities for executing, monitoring use, editing, and displaying the content of interfaces is included in the toolkit.

Shoaff, William D.↗
NASA NTRS1991

Cost studies for commercial fuselage crown designs

Studies were conducted to evaluate the cost and weight potential of advanced composite design concepts in the crown region of a commercial transport. Two designs from each of three design families were developed using an integrated design-build team. A range of design concepts and manufacturing processes were included to allow isolation and comparison of cost centers. Detailed manufacturing/assembly plans were developed as the basis for cost estimates. Each of the six designs was found to have advantages over the 1995 aluminum benchmark in cost and weight trade studies. Large quadrant panels and cobonded frames were found to save significant assembly labor costs. Comparisons of high- and intermediate-performance fiber systems were made for skin and stringer applications. Advanced tow placement was found to be an efficient process for skin lay up. Further analysis revealed attractive processes for stringers and frames. Optimized designs were informally developed for each design family, combining the most attractive concepts and processes within that family. A single optimized design was selected as the most promising, and the potential for further optimization was estimated. Technical issues and barriers were identified.

Walker, T. H.↗
NASA NTRS2001

Assessment of the State-of-the-Art in the Design and Manufacturing of Large Composite Structure

This viewgraph presentation gives an assessment of the state-of-the-art in the design and manufacturing of large component structures, including details on the use of continuous fiber reinforced polymer matrix composites (CFRP) in commercial and military aircraft and in space launch vehicles. Project risk mitigation plans must include a building-block test approach to structural design development, manufacturing process scale-up development tests, and pre-flight ground tests to verify structural integrity. The potential benefits of composite structures justifies NASA's investment in developing the technology. Advanced composite structures technology is enabling to virtually every Aero-Space Technology Enterprise Goal.

Harris, C. E.↗
NASA NTRS2007

An Array of Optical Receivers for Deep-Space Communications

An array of small optical receivers is proposed as an alternative to a single large optical receiver for high-data-rate communications in NASA s Deep Space Network (DSN). Because the telescope for a single receiver capable of satisfying DSN requirements must be greater than 10 m in diameter, the design, building, and testing of the telescope would be very difficult and expensive. The proposed array would utilize commercially available telescopes of 1-m or smaller diameter and, therefore, could be developed and verified with considerably less difficulty and expense. The essential difference between a single-aperture optical-communications receiver and an optical-array receiver is that a single-aperture receiver focuses all of the light energy it collects onto the surface of an optical detector, whereas an array receiver focuses portions of the total collected energy onto separate detectors, optically detects each fractional energy component, then combines the electrical signal from the array of detector outputs to form the observable, or "decision statistic," used to decode the transmitted data. A conceptual block diagram identifying the key components of the optical-array receiver suitable for deep-space telemetry reception is shown in the figure. The most conspicuous feature of the receiver is the large number of small- to medium-size telescopes, with individual apertures and number of telescopes selected to make up the desired total collecting area. This array of telescopes is envisioned to be fully computer- controlled via the user interface and prediction-driven to achieve rough pointing and tracking of the desired spacecraft. Fine-pointing and tracking functions then take over to keep each telescope pointed toward the source, despite imperfect pointing predictions, telescope-drive errors, and vibration caused by wind.

Vilnrotter, Chi-Wung↗
NASA NTRS2016

High Temperature Thermoplastic Additive Manufacturing Using Low-Cost, Open-Source Hardware

Additive manufacturing (or 3D printing) via Fused Filament Fabrication (FFF), also known as Fused Deposition Modeling (FDM), is a process where material is placed in specific locations layer-by-layer to create a complete part. Printers designed for FFF build parts by extruding a thermoplastic filament from a nozzle in a predetermined path. Originally developed for commercial printers, 3D printing via FFF has become accessible to a much larger community of users since the introduction of Reprap printers. These low-cost, desktop machines are typically used to print prototype parts or novelty items. As the adoption of desktop sized 3D printers broadens, there is increased demand for these machines to produce functional parts that can withstand harsher conditions such as high temperature and mechanical loads. Materials meeting these requirements tend to possess better mechanical properties and higher glass transition temperatures (Tg), thus requiring printers with high temperature printing capability. This report outlines the problems and solutions, and includes a detailed description of the machine design, printing parameters, and processes specific to high temperature thermoplastic 3D printing.

Gardner, John M.↗
NASA NTRSDate not supplied

Addressing the High-Rate Deep Space Communications Shortfall in NASA’s Space Technology Mission Directorate's Envisioned Future

NASA’s Space Technology Mission Directorate (STMD) has identified key technologies needed for future crewed and robotic exploration and science missions. STMD is helping to build the civilian technology base by working with other NASA Mission Directorates, other United States government agencies, commercial industry, and academia to identify technology shortfalls and to develop plans to address them. One critical area of shortfalls lies with deep space communications and navigation. While NASA had huge success to date with the Deep Space Network (DSN), recent studies have shown that without enhancements to current systems, the DSN will be unable to support the anticipated increases in the pace of space exploration or the expected higher data rates from deep space needed soon without severely impacting other missions. High-rate communications from the Moon and beyond is needed to enable future exploration and science missions currently being developed or under consideration. For example, a robust communications infrastructure will be needed to support a sustained human presence on the Moon and its eventual industrialization. High data rate trunk lines between the Earth and the Moon are needed to reduce the number of individual links. The human exploration of Mars will also require high-rate communications between Earth and Mars. Return data rates to Earth from Mars for a single link, for example, are anticipated to be greater than 100 Mb/s; forward data rates to Mars, based on experience from the International Space Station, are anticipated to be greater than 20 Mb/s. Future deep space science missions will also require higher data rates than possible with today’s technology and the current capabilities of the DSN. To support future exploration and science needs, it will be necessary to upgrade the DSN to enhance its radio frequency (RF) capabilities. In addition, it is envisioned that NASA will gradually introduce optical communications to augment its RF systems. Optical communications will enable new science and exploration missions by providing high data rates and better navigation over long distances. This paper will briefly describe STMD’s envisioned future for deep space communications in the 2030+ timeframe and the technology roadmaps being developed for both radio frequency and optical systems.

Bernard Edwards↗
DOE OSTI2024

ACCELERATING MICROREACTOR DEVELOPMENT AND DEPLOYMENT THROUGH JOINT PUBLIC TEST BEDS AND PRIVATE ADVANCED REACTOR DEVELOPMENT

The United States Department of Energy (DOE) has funded the National Reactor Innovation Center (NRIC) to accelerate the development and commercialization of small modular reactors and other advanced reactor technologies. As part of this effort NIRC is building two strategic assets at the Idaho National Laboratory (INL) to facilitate public-private partnerships for the development and testing of advanced nuclear microreactors and Small Modular Reactors (SMR). One will provide a safe, secure, and affordable location for High-Assay Low Enriched Uranium (HALEU) fueled reactors and a second for Highly Enriched Uranium (HEU) fueled reactors. Together these testbeds fill a nuclear testing infrastructure gap. The availability of such comprehensive testing facilities at the national labs eliminates the significant financial and operational burdens associated with each developer building and licensing their own test facilities. Consequently, this approach will not only accelerate technological innovation and reduce time-to-market for advanced nuclear solutions but it also underscores the DOE's commitment to fostering an ecosystem where nuclear energy will thrive as a clean, reliable, and efficient source of power. The Demonstration of Microreactor Experiments (DOME) and Laboratory for Operations and Testing in the United States (LOTUS) have planned availability in 2026, and 2027 respectively.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Build-To-Replace Strategy to Reduce O&M Costs of Advanced Reactors

This paper targets the goal of reducing fixed operations and maintenance (O&M) costs to $2/MWh for advanced reactor (AR) designs, an order of magnitude reduction from current nuclear fleets. Such goal will be severely constrained if the underlying assumptions of O&M approaches and practices are not questioned and reexamined, especially today when changes can be implemented effectively and efficiently. Achieving a 90% reduction in AR O&M costs requires a completely new way of thinking – a paradigm shift – not through incremental, technology-focused approaches alone. Here, we address this challenge by evaluating the impact of moving to shorter design life for major structures, systems and components (SSCs) and shorter, more predictable refurbishment cycles as modeled by the commercial airline industry. This paper provides a brief overview of this different mindset to O&M applied to ARs: the build-to-replace approach. We provide a direct example of analysis of a build-to-replace scenario by identifying and evaluating scenarios for reduced system and component lifetimes and associated replacement and refurbishment schedules to evaluate impacts on O&M costs and other lifecycle elements such as SSC reliability.

97 - MATHEMATICS AND COMPUTING↗
NASA NTRS1999

Low Earth Orbiter: Terminal

In response to the current government budgetary environment that requires the National Aeronautics and Space Administration (NASA) to do more with less, NASA/Goddard Space Flight Center's Wallops Flight Facility has developed and implemented a class of ground stations known as a Low Earth Orbiter-Terminal (LEO-T). This development thus provides a low-cost autonomous ground tracking service for NASA's customers. More importantly, this accomplishment provides a commercial source to spacecraft customers around the world to purchase directly from the company awarded the NASA contract to build these systems. A few years ago, NASA was driven to provide more ground station capacity for spacecraft telemetry, tracking, and command (TT&C) services with a decreasing budget. NASA also made a decision to develop many smaller, cheaper satellites rather than a few large spacecraft as done in the past. In addition, university class missions were being driven to provide their own TT&C services due to the increasing load on the NASA ground-tracking network. NASA's solution for this ever increasing load was to use the existing large aperture systems to support those missions requiring that level of performance and to support the remainder of the missions with the autonomous LEO-T systems. The LEO-T antenna system is a smaller, cheaper, and fully autonomous unstaffed system that can operate without the existing NASA support infrastructure. The LEO-T provides a low-cost, reliable space communications service to the expanding number of low-earth orbiting missions around the world. The system is also fostering developments that improve cost-effectiveness of autonomous-class capabilities for NASA and commercial space use. NASA has installed three LEO-T systems. One station is at the University of Puerto Rico, the second system is installed at the Poker Flat Research Range near Fairbanks, Alaska, and the third system is installed at NASA's Wallops Flight Facility in Virginia. This paper will describe the current NASA implementation of the LEO-T network of antenna systems, the customers now being supported, and the services NASA can now offer with this new breed of autonomous ground stations. In addition, the paper will define the technical capabilities of the system and the cost effectiveness of using the systems including the capital costs of installation.

Kremer, Steven E.↗
NASA NTRS2001

Extraction of Airport Features from High Resolution Satellite Imagery for Design and Risk Assessment

The LPA Group, consisting of 17 offices located throughout the eastern and central United States is an architectural, engineering and planning firm specializing in the development of Airports, Roads and Bridges. The primary focus of this ARC project is concerned with assisting their aviation specialists who work in the areas of Airport Planning, Airfield Design, Landside Design, Terminal Building Planning and design, and various other construction services. The LPA Group wanted to test the utility of high-resolution commercial satellite imagery for the purpose of extracting airport elevation features in the glide path areas surrounding the Columbia Metropolitan Airport. By incorporating remote sensing techniques into their airport planning process, LPA wanted to investigate whether or not it is possible to save time and money while achieving the equivalent accuracy as traditional planning methods. The Affiliate Research Center (ARC) at the University of South Carolina investigated the use of remotely sensed imagery for the extraction of feature elevations in the glide path zone. A stereo pair of IKONOS panchromatic satellite images, which has a spatial resolution of 1 x 1 m, was used to determine elevations of aviation obstructions such as buildings, trees, towers and fence-lines. A validation dataset was provided by the LPA Group to assess the accuracy of the measurements derived from the IKONOS imagery. The initial goal of this project was to test the utility of IKONOS imagery in feature extraction using ERDAS Stereo Analyst. This goal was never achieved due to problems with ERDAS software support of the IKONOS sensor model and the unavailability of imperative sensor model information from Space Imaging. The obstacles encountered in this project pertaining to ERDAS Stereo Analyst and IKONOS imagery will be reviewed in more detail later in this report. As a result of the technical difficulties with Stereo Analyst, ERDAS OrthoBASE was used to derive aviation obstruction measurements for this project. After collecting ancillary data such as GPS locations, South Carolina Geodetic Survey and Aero Dynamics ground survey points to set up the OrthoBASE Block File, measurements were taken of the various glide path obstructions and compared to the validation dataset. This process yielded the following conclusions: The IKONOS stereo model in conjunction with Imagine OrthoBASE can provide The LPA Group with a fast and cost efficient method for assessing aviation obstructions. Also, by creating our own stereo model we achieved any accuracy better currently available commercial products.

Robinson, Chris↗
NASA NTRS1985

The blackboard model - A framework for integrating multiple cooperating expert systems

The use of an artificial intelligence (AI) architecture known as the blackboard model is examined as a framework for designing and building distributed systems requiring the integration of multiple cooperating expert systems (MCXS). Aerospace vehicles provide many examples of potential systems, ranging from commercial and military aircraft to spacecraft such as satellites, the Space Shuttle, and the Space Station. One such system, free-flying, spaceborne telerobots to be used in construction, servicing, inspection, and repair tasks around NASA's Space Station, is examined. The major difficulties found in designing and integrating the individual expert system components necessary to implement such a robot are outlined. The blackboard model, a general expert system architecture which seems to address many of the problems found in designing and building such a system, is discussed. A progress report on a prototype system under development called DBB (Distributed BlackBoard model) is given. The prototype will act as a testbed for investigating the feasibility, utility, and efficiency of MCXS-based designs developed under the blackboard model.

Erickson, W. K.↗
DOE OSTI2022

It's All About the Envelope: Prioritizing Envelope Upgrades for Electrification of Cold Climate Homes

Building decarbonization via electrification on a clean grid is the most promising climate solution proposed to date for the building sector. In cold climate zones, building electrification will be driven in large part by moving from natural gas space heating to cold climate heat pumps (CCHPs). CCHPs are commercially available today, including economical cold climate air source heat pumps (ccASHPs). But there's one big problem - wide-scale adoption of ccASHPs will dramatically increase winter peak electricity demand, even with the highest efficiency ccASHP products. Furthermore, cold climate space heating loads will drive unprecedented electric system peaks during the lowest periods of renewable generation and are likely to overwhelm existing distribution systems. This scenario is avoidable by coupling electrification with building envelope upgrades to reduce peak heating loads. This paper presents a model, built from home energy audit and research data sets, that quantifies the above challenges. Results demonstrate how weatherization efforts coupled with additional high-performance envelope upgrade measures can prepare the building stock for electrification and show the benefit these measures can bring to future utility operations. Much of this envelope upgrade work is cost-effective, according to conservative cost-benefit testing and program successes to date, and is coupled with substantial non-energy benefits. However, persistent market barriers have made scaling of envelope retrofit work challenging for decades, suggesting additional policy support is required. Lessons learned from previous policy experience, combined with new technology and administrative support, create exciting potential for this decarbonization climate solution.

air sealing↗
NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗