Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Manufacturing”

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

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

At least 1,441 records · Page 80
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Overview of Additively Manufactured TPS Proposed Flight Test and Earth Re-Entry Capsule Design

A flight mechanics overview is presented of an Earth flight test designed to investigate a novel, 3D printed thermal protection system (TPS) that is currently in development at NASA as part of the Additive Manufacturing of Thermal Protection Systems project. The project is pioneering a method to print a thermal protection system onto an entry vehicle forebody one layer at a time. This method reduces labor and complexity as compared to traditional manufacturing methods while increasing mission-dependent customization of through-depth materials properties. The flight test has three objectives. First, subject the forebody stagnation point of a capsule equipped with additively manufactured TPS (AMTPS) material to peak heat fluxes in excess of 100 $W/cm^2$. Second, capture in-flight data to enable flight reconstruction and AMTPS material thermal response model improvement. Third, recover the capsule with data storage and forebody AMTPS intact to enable post-flight inspection and analysis of AMTPS performance. The flight test trajectory is designed to achieve a peak stagnation point, cold-wall, entry heat flux of 135~$W/cm^2$. Flight mechanics simulations are performed using the Program to Optimize Simulated Trajectories II (POST2) and Monte-Carlo analysis yields statistical percentiles on vehicle performance at key points along the trajectory. Based on the flight mechanics analysis presented in this paper, a prototype capsule was designed, partially fabricated, and underwent preliminary component stress testing in preparation for fabrication of the flight unit capsule. The capsule outer mold line is a modified version of the heritage Mars Microprobe geometry. The capsule has a 0.356~m diameter, a 30~kg mass, and a hypersonic ballistic coefficient of 300~$kg/m^2$. Sensor selection is guided by flight dynamics simulations with the goal of resolving the re-entry heating pulse. On-board instrumentation include forebody and aftbody pressure sensors and thermocouples, a 9-axis IMU, a GPS receiver, and an Iridium satellite modem, all of which collect and store data throughout flight via on-board avionics systems. A two-stage parachute system is designed to decelerate the capsule to touchdown velocities that will not result in significant fracture or deformation of the charred AMTPS material at ground impact.

Flight Mechanics↗
NASA NTRSDate not supplied

Additive Manufacture of Novel Tungsten Wicking and Heat Transfer Structures

Additive manufacturing (AM) is utilized for fabricating complex geometries from refractory metals, such as tungsten and molybdenum. In this study, plates with ultra-fine and fine lattice structures were manufactured from tungsten to demonstrate printability and the component fabrication advantages of AM. Previous work was completed on individual tungsten lattice structures; this work demonstrates the advantages of printing these structures on tubing and first-wall materials. Initial work using stainless steel demonstrated increased heat transfer properties promoted by these lattice structures. Applications for these structures include wicking structures, heat pipes, and first-wall materials in fusion devices. A major advantage of these designs is the capability to produce a monolithic component with tailored heat transfer and wicking properties. This research helps promote the ability to use liquid lithium in fusion devices since these lattice structures manufactured from tungsten could act as a high temperature first-wall or divertor material and as a wicking structure for liquid lithium. Different lattice structures with varying unit cell sizes and strut thicknesses were printed and the effects of these structures on heat transfer properties were measured. Abrasion resistance of these structures was also investigated. This presentation will discuss the results of these experiments and their implications related to heat transfer applications. This work will help inform the development and implementation of complex geometries made from tungsten for future heat pipe and fusion first-wall or divertor component designs.

Carly J. Romnes↗
NASA NTRS2024

NASA HECC Geometry and Performance Review Part 1: Validation of a Computational Model for the Vaneless Diffuser Configuration with As-Manufactured Impeller Geometry

An investigation of the NASA High Efficiency Centrifugal Compressor (HECC) vaneless diffuser configuration was performed. This multipart investigation presents an extensive validation of the computational model against experimental data. The validated model was then used to explore the effects geometric differences between the as-manufactured and design-intent impellers. Lastly, the validated model was used for comparison against an experimental tip clearance study. Part I of the investigation focused on describing the HECC vaneless computational model and its validation against the experimental data published in GT2023-103128. To generate the model, a verification of the manufactured impeller was performed and was confirmed to match the impeller CAD. Section data from the impeller CAD, referred to as the As-Manufactured geometry, were used for development of the computational model. Steady RANS simulations utilizing the Wilcox K-Omega 98 turbulence model and a multiblock structured mesh were used to conduct a mesh convergence study. The resultant mesh was then used for simulations at both design-speed and off-design speed conditions. The simulations compared well to data in both 1D and 2D terms for the major performance metrics of efficiency, total pressure rise, and total temperature rise. Based on the observed results the model was deemed validated and was used in the latter two parts of the multipart investigation.

centrifugal compressor↗
NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses market needs to advance structural aircraft composite manufacturing technologies to significantly increase production rates. Dry, non-crimp fabric (NCF) carbon materials infused with advanced resin systems offer a promising solution to these manufacturing demands. Northrop Grumman’s Automated Stiffener Forming (ASF) technology has been adapted for ply-by-ply, in-situ processing of NCF materials. The modular ASF process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for NCF materials, heating technologies and roller compaction processes were designed and tested on representative structural aircraft part geometries. Key success criteria for the ASF process with NCF materials is forming quality and preform compaction. Trials were performed with multiple NCF materials: unidirectional up to quad-axial formats. The NCF constituents, veils, stitching, and binders, were evaluated with the ASF process. The material performance in the ASF process and the resulting preform quality are presented.

dry carbon fiber materials↗
NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses market needs to advance structural aircraft composite manufacturing technologies to significantly increase production rates. Dry, non-crimp fabric (NCF) carbon materials infused with advanced resin systems offer a promising solution to these manufacturing demands. Northrop Grumman’s Automated Stiffener Forming (ASF) technology has been adapted for ply-by-ply, in-situ processing of NCF materials. The modular ASF process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for NCF materials, heating technologies and roller compaction processes were designed and tested on representative structural aircraft part geometries. Key success criteria for the ASF process with NCF materials is forming quality and preform compaction. Trials were performed with multiple NCF materials: unidirectional up to quad-axial formats. The NCF constituents, veils, stitching, and binders, were evaluated with the ASF process. The material performance in the ASF process and the resulting preform quality are presented.

dry carbon fiber materials↗
NASA NTRSDate not supplied

NASA HECC Geometry and Performance Review Part 1: Validation of a Computational Model for the Vaneless Diffuser Configuration with As-Manufactured Impeller Geometry

An investigation of the NASA High Efficiency Centrifugal Compressor (HECC) vaneless diffuser configuration was performed. This multipart investigation focused on validating the computational model against experimental data. The validated model was then used to explore the effects of observed geometric differences between the as-manufactured and design-intent impellers. Lastly, the validated model was used for comparison against an experimental tip clearance study. Details regarding each of the parts are detailed below: A multipart investigation of the NASA High Efficiency Centrifugal Compressor (HECC) vaneless diffuser configuration was performed. Part I of the investigation focused on describing the HECC vaneless computational model and its validation against the experimental data published in GT2023-103128. To generate the model, a verification of the manufactured impeller was performed and was confirmed to match the impeller CAD. Section data from the impeller CAD, referred to as As-Manufactured, were used in the model. Steady RANS simulations using a multiblock structured mesh were used to conduct a mesh convergence study. The resultant mesh was then used for simulations at both design-speed and off-design speed conditions. The simulations compared well to data in both 1D and 2D terms. Based on the observed results the model was deemed validated and was used in the latter two parts of the multipart investigation.

centrifugal compressor↗
NASA NTRSDate not supplied

Development of an Additively Manufactured Subscale Secondary Sealed Container for the NASA FROSTE Project

This presentation details the development of an additively manufactured (AM) subscale test article for the secondary sealed container (SSC) as part of the NASA FROSTE project. FROSTE is focused on the collection of regolith samples from shadowed regions of the Moon and the preservation of those samples at cryogenic temperatures for return to Earth. Our team was integrated into the FROSTE program to leverage innovative design approaches and additive manufacturing capabilities in support of a scalable development strategy, where the subscale configuration serves as the development path toward a full-scale SSC. Scalmalloy was selected as the primary material for all AM components due to its favorable strength-to-weight ratio, thermal conductivity, and demonstrated performance in aerospace applications. Its aluminum-based composition supports robust mechanical behavior at cryogenic temperatures while enabling efficient heat transfer and control of thermal gradients within the containment system. The SSC architecture consists of an outer container assembly that houses a phase change material (PCM) tank, which in turn contains primary containers holding the regolith. Thermal management relies on controlled conductive and radiative heat transfer, including a thermal connection assembly that interfaces the PCM tank to an external cryocooler via a thermal strap, and IMLI surrounding the PCM tank to inhibit radiative heat transfer. The outer container assembly incorporates sealing interfaces, thermal connection ports, and I/O feedthroughs, with PTFE spring seals used at critical interfaces to maintain containment integrity. The PCM tank is manufactured as a single monolithic Scalmalloy component and incorporates an integral lattice structure to minimize thermal gradients, internal channels for thermocouple routing, and interface features for thermal connection assembly integration. The tank is centrally suspended within the outer container using support rings, with G10 insulating components employed to inhibit thermal leaks. This work describes the design methodology, AM approach, and key considerations used to inform the design.

regolith↗
DOE OSTI2013

The Present, Mid-Term, and Long-Term Supply Curves for Tellurium; and Updates in the Results from NREL's CdTe PV Module Manufacturing Cost Model (Presentation)

For those PV technologies that rely upon Te, In, and Ga, first-order observations and calculations hint that there may be resource constraints that could inhibit their successful deployment at a SunShot level. These are only first-order approximations, however, and the possibility for an expansion in global Te, In, and Ga supplies needs to be considered in the event that there are upward revisions in their demand and prices.In this study, we examine the current, mid-term, and long-term prospects of Tellurium (Te) for use in PV. We find that the current global supply base of Te would support <10 GW of annual traditional CdTe PV manufacturing production. But as for the possibility that the supply base for Te might be expanded, after compiling several preliminary cumulative availability curves we find that there may be significant upside potential in the supply base for this element - principally vis a vis increasing demand and higher prices. Primarily by reducing the Tellurium intensity in manufacturing and by increasing the recovery efficiency of Te in Cu refining processes, we calculate that it may prove affordable to PV manufacturers to expand the supply base for Te such that 100 GW, or greater, of annual CdTe PV production is possible in the 2030 - 2050 timeframe.

14 SOLAR ENERGY↗
DOE OSTI2015

Industrial Assessment Centers - Small Manufacturers Reduce Energy & Increase Productivity

Since 1976, the Industrial Assessment Centers (IACs), administered by the US Department of Energy, have supported small and medium-sized American manufacturers to reduce energy use and increase their productivity and competitiveness. The 24 IACs, located at premier engineering universities around the country (see below), send faculty and engineering students to local small and medium-sized manufacturers to provide no-cost assessments of energy use, process performance and waste and water flows. Under the direction of experienced professors, IAC engineering students analyze the manufacturer’s facilities, energy bills and energy, waste and water systems, including compressed air, motors/pumps, lighting, process heat and steam. The IACs then follow up with written energy-saving and productivity improvement recommendations, with estimates of related costs and payback periods.

Success, Alumni, Sign Up, Industrial, Assessment, ↗
DOE OSTI2016

Effusion plate using additive manufacturing methods

Additive manufacturing techniques may be utilized to construct effusion plates. Such additive manufacturing techniques may include defining a configuration for an effusion plate having one or more internal cooling channels. The manufacturing techniques may further include depositing a powder into a chamber, applying an energy source to the deposited powder, and consolidating the powder into a cross-sectional shape corresponding to the defined configuration. Such methods may be implemented to construct an effusion plate having one or more channels with a curved cross-sectional geometry.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2015

Bandwidth Study on Energy Use and Potential Energy Saving Opportunities in U.S. Chemical Manufacturing

Energy bandwidth studies of U.S. manufacturing sectors can serve as foundational references in framing the range (or bandwidth) of potential energy savings opportunities. This bandwidth study examines energy consumption and potential energy savings opportunities in U.S. chemical manufacturing. The study relies on multiple sources to estimate the energy used in the production of 74 individual chemicals, representing 57% of sector-wide energy consumption. Energy savings opportunities for individual chemicals and for 15 subsectors of chemicals manufacturing are based on technologies currently in use or under development; these potential savings are then extrapolated to estimate sector-wide energy savings opportunity.

AMO, 2015↗
DOE OSTI2015

Control of microstructure in soldered, brazed, welded, plated, cast or vapor deposited manufactured components

Disclosed are methods and systems for controlling of the microstructures of a soldered, brazed, welded, plated, cast, or vapor deposited manufactured component. The systems typically use relatively weak magnetic fields of either constant or varying flux to affect material properties within a manufactured component, typically without modifying the alloy, or changing the chemical composition of materials or altering the time, temperature, or transformation parameters of a manufacturing process. Such systems and processes may be used with components consisting of only materials that are conventionally characterized as be uninfluenced by magnetic forces.

36 MATERIALS SCIENCE↗
DOE OSTI2016

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↗
DOE OSTI2016

CHARACTERIZATION OF ADDITIVE MANUFACTURING FOR PROCESS TUBING

Additive Manufacturing has garnered significant levels of interest in recent years as a primary manufacturing method. While the general technology has been around for over 20 years, with increased computing capacity, higher powered directed energy sources, e.g., lasers and electron beams, it is coming of age as a viable technique for high value added, low production quantity components. The Savannah River National Laboratory is interested in AM as a technique to build hydrogen isotope separation components called Thermal Cycling Absorption Process (TCAP) columns. The TCAP operates from cryogenic to moderate temperatures in a cyclic manner and is a pressure boundary. The current technique for fabricating TCAP columns is to form a flat coil of 0.375 to 0.5 inch diameter tube and braze two coils together. During the brazing operation, the two nested coils often move and this movement results in gaps between the coils. Since one coil contains the working fluid, i.e., liquid nitrogen, and the other the process fluid, hydrogen isotopes, these gaps result in poor heat transfer. Additive manufacturing is being explored as a replacement technology since the adjacent tubes can be fabricated simultaneously and in intimate contact and they can also share a common wall to improve heat transfer. AM allows designers to develop unique tube structures that overcome several of the shortcomings of the coil and braze technique, such as the braze gap in fabrication and slow cooling during operation. Simple test samples with various internal geometries were designed and built from Type 316L stainless steel using a laser powder bed process. Three test article geometries that were built include a simple tube, a pair of stacked tubes, and a tube partially surrounded by two kidney shaped tubes with cooling fins that would extend into the process fluid, these tube sections incorporated thermowells or heat trace channels, selectively. The test samples will be subjected to heat transfer testing and burst testing. The samples were inspected using X-ray, computed tomography, and metallography. The results of the testing conducted on these samples are described in this paper.

Korinko, John S.↗
DOE OSTI2018

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↗
DOE OSTI2018

Additive Manufacturing: The Rise of a Technology and the Need for Quality Control and Inspection Techniques

Additive manufacturing (AM) technology, also known as three-dimensional (3D) printing, rapid prototyping (RP), or solid free forms (SFF), was developed back in the early 1980s. The technology was quickly commercialized in the late 1980s, and since then, the technology has been widely used in different applications at several industrial sectors. AM offers distinct advantages from traditional, subtractive manufacturing techniques. Traditional subtractive manufacturing techniques, including milling, drilling, and turning, are techniques that start with a large block of stock material, which is then subtracted from until the final desired product is reached, leaving much of the initial block as wasted scrap. In the AM process, the part is constructed by depositing material layer by layer in the Z-direction until the final product is produced, leaving little to no waste. The process starts with a computer-aided design (CAD) model that gets sliced into individual layers using software that generates instructions, known as G-code, which are sent to the AM machine. Here, this process allows complex geometry construction that traditional methods would have diffi-culty accomplishing or fail completely. In some cases, a secondary finishing process is needed such as polishing, sintering, curing, sanding, powder removal, or painting.

36 MATERIALS SCIENCE↗
DOE OSTI2018

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↗
DOE OSTI2018

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↗