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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.

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At least 1,495 records · Page 83
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Effects of 2D filler on rheology of additive manufacturing polymers: Simulation and experiment on polyetherketoneketone-mica composites

Polymeric composites have attracted increasing interest in fundamental studies and industrial applications due to their often-superior characteristics over conventional pure polymers. In this work, we studied the relationship between the rheological properties, critical in processing methods such as additive manufacturing, and the structure of a polymer-2D filler system by experiment and simulation methods. Considering the high performance polymer polyetherketoneketone (PEKK) with 2D filler (mica) composite as an example, the effects of filler size, filler content, surface chemistry and shear rate were systematically investigated. Here, it is demonstrated that the interaction between the polymer and 2D filler brings two different consequences on tuning the viscosity of polymer-filler composite. The stronger interaction increases the shear stress of the polymer-2D filler composite system, leading to higher viscosity. On the other hand, the stronger interaction can promote more absorption of polymer chains on the surface, which makes the local polymer network disentangled and decreases the continuous viscosity from the polymer network. This work provides a fundamental understanding on the relationship between macroscopic rheological properties and the structural properties and energetics at molecular level of polymer-2D filler composite.

36 MATERIALS SCIENCE↗
NASA NTRS2019

Bimetallic Channel Wall Nozzle Development and Hot-Fire Testing Using Additively Manufactured Laser Wire Direct Closeout Technology

NASA has been developing and advancing regeneratively-cooled channel wall nozzle technology for liquid rocket engines to reduce cost and schedules associated with fabrication. One of the primary methods being advanced is Laser Wire Direct Closeout (LWDC). LWDC was developed to provide an additively manufactured laser deposited closeout of the coolant channels that also forms the structural jacket in-situ. This technique has been previously demonstrated through process development and hot-fire testing on a series of subscale nozzles at NASA Marshall Space Flight Center. The hot-fire test articles were fabricated using monolithic alloys to simplify the fabrication process. Ongoing research is being conducted to further expand use of this process for increased scale and bimetallic or multi-alloy options. The use of multi-alloys is desired to fully optimize the combination of materials in the radial and axial directions to reduce overall weight of the nozzle and allow for higher thermal and structural margins on the channel wall nozzle. NASA recently completed process development and hot-fire testing of a series of channel wall nozzles that incorporate a copper-alloy as the hotwall liner material and a superalloy and combination thereof for the structural jacket using the LWDC technique. The fabrication process was further advanced by using a multi-alloy axial joint using explosive bonding integrating a copper-alloy at the forward end of the nozzle hotwall and a stainless-alloy for the remaining length. A third alloy was then used for the channel closeout using the LWDC process. This paper will describe the process development using the LWDC process for channel closeout utilizing the multi-alloys, hardware design and results from hot-fire testing on subscale multi-alloy LWDC channel cooled nozzles.

Gradl, Paul↗
NASA NTRSDate not supplied

In-Situ Alloying of GRCop-42 via Additive Manufacturing: Precipitate Analysis

GRCop-42, a Cu-4at% Cr-2at% Nb alloy, was designed as a high temperature, high strength, high heat flux material for rocket engine combustion chamber liners by NASA Glenn Research Center. In situ alloying of GRCop-42 (ISGRCop-42) using powder bed fusion (PBF) additive manufacturing (AM) takes elemental powders of Cu, Cr, and Nb to be introduced into the PBF environment and develop the GRCop alloy while simultaneously building an AM component. Elemental powders were milled together prior to printing in an effort to facilitate the alloying process. Success of the in situ alloying process may provide lower cost, faster lead times, alloying optimization, and more design freedom in the development of regeneratively-cooled rocket propulsion systems. Evaluation of the ISGRCop-42 was conducted using a phase extraction procedure to isolate the Cr2Nb precipitates from the pure Cu matrix. The isolated precipitates were then examined using x-ray powder diffraction (XRD), scanning electron microscopy (SEM), and energy dispersion spectroscopy (EDS). It was found that ISGRCop-42 successfully and repeatedly formed Cr2Nb at a yield as high as 89% of potential Cr2Nb. Further, it was identified that the preparation of the powder was the most influential factor in alloying success, and the second most influential factor was the laser power.

In Situ alloying↗
DOE OSTI2021

Data Mining for Faster, Interpretable Solutions to Inverse Problems:A Case Study Using Additive Manufacturing

Solving inverse problems, where we nd the input values that result in desired values of outputs, can be challenging. The solution process is often computationally expensive and it can be di cult to interpret the solution in high-dimensional input spaces. In this paper, we use a problem from additive manufacturing to address these two issues with the intent of making it easier to solve inverse problems and exploit their results. First, focusing on Gaussian process surrogates that are used to solve inverse problems, we describe how a simple modi cation to the idea of tapering can substantially speed up the surrogate without losing accuracy in prediction. Second, we demonstrate that Kohonen self-organizing maps can be used to visualize and interpret the solution to the inverse problem in the high-dimensional input space. For our data set, as not all input dimensions are equally important, we show that using weighted distances results in a better organized map that makes the relationships among the inputs obvious

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Thermal tomography 3D imaging of additively manufactured metallic structures

Thermal tomography is a computational method for heat diffusion-based imaging of solids, which provides 3D visualization of data from flash thermography measurements. We investigate thermal tomography imaging and nondestructive evaluation of stainless steel and nickel super alloy metallic structures produced with the laser powder bed fusion (LPBF) additive manufacturing (AM) process. Metallic structures produced with LPBF contain defects, and there are limited capabilities to evaluate these structures non-destructively. Thermal tomography reconstruction of 3D apparent spatial effusivity provides information about AM structure geometry and internal material flaws. We study performance of thermal tomography in imaging of metallic structures through COMSOL computer simulations of transient heat transfer and through reconstruction of data obtained from experimental measurements. Thermal tomography reconstructions of structure shape and dimensions are shown for the Inconel 718 AM structure which has variations in the horizontal plane but is uniform along the depth dimension. Reconstruction of internal defects is investigated using a stainless steel 316L specimen with flat bottom hole (FBH) indentations, and the Inconel 718 plate is produced with the LPBF method, which contains imprinted hemispherical shape low density regions containing non-sintered metallic powder. The FBHs have the same sizes as the imprinted defects in the LPBF specimens but offer better imaging contrast. Thermal tomography reconstructions provide visualizations of internal defects and allow for estimation of their sizes and locations. Results of this study demonstrate that thermal tomography can be used for visualization and quality control in AM.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Rapid Optimization of Total Variation with Applications in Imaging, Additive Manufacturing, and Qualification

Total Variation optimization penalizes the gradient of a control variable or state. While this work focuses on image processing in particular, it has also found applications in inverse problems and topology optimization. In image processing, the goal is to maintain faithfulness to the original image while denoising and/or deblurring. Additionally, bilevel optimization over the spatially varying regularization weights can illuminate interfaces such as damage regions and other anomalies. We will address two fundamental challenges with TV-optimization: (i) the typical slow convergence of existing TV-optimization methods, and (ii) the selection of spatially varying TV parameters to promote interface detection. Additionally, we will apply such techniques to image data collected in additive manufacturing. In said context, stochasticity in build events induces flaws in the manufactured piece, compromising the integrity of said part. There is a critical need for in-situ monitoring to spot anomalies once they form, and in this setting we apply our total variation and hyperparameter solvers. We will develop a customized algorithm based on for extreme-scale TV-optimization that achieves super-linear or quadratic-convergence, a critical property for real-time, image-by-image analysis. A worst-case outcome is a preprocessing step that enhances image quality in-situ, specifically for out-of-focus and noisy images.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Metallic Powder Core Tubular Wire Development for Additive Manufacturing

NASA Langley Research Center (LaRC) in Hampton, VA, and the Center for Welding, Joining, and Coating Research (CWJCR) in the Department of Metallurgical and Materials Engineering at the Colorado School of Mines (CSM) in Golden, CO, have collaborated for nearly fifteen years to develop metallic powder core tubular wire (PCTW) feedstock for additive manufacturing (AM) using electron beam deposition. The motivation for this development was to offset dealloying observed during deposition of titanium and aluminum alloy solid wire feedstock in the LaRC electron beam freeform fabrication (EBF3) system and to explore novel alloy compositions by tailoring the powder fill. EBF3 is a fusion-based AM process that is performed under vacuum and is consequently prone to vaporization loss of low vapor pressure alloying elements. Research spanning four graduate student research projects succeeded in developing the basic methodology to fabricate PCTW, the mass balance equations used to define the powder fill, microstructure control through particulate inoculation, and the feasibility of producing metal matrix composite materials.

powder core tubular wire (PCTW)↗
NASA NTRSDate not supplied

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultra-fine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray micro-focus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗
NASA NTRS2020

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultrafine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray microfocus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗
DOE OSTI2025

Overall Cooling Effectiveness of Internally Cooled Additively Manufactured Blades

Power generation gas turbine blades must utilize highly effective cooling schemes to withstand moderate heat loads for long operating times. Prior work indicates that gas turbines in the 5-10 MW range primarily utilize internal cooling to prevent further increase of aerodynamic losses that result from film cooling, but few studies focus solely on internal cooling. In this study, three additively manufactured internal cooling designs were tested in the 50 percent span section of the National Experimental Turbine (NExT) blade: a baseline cooling design with pin-fin arrays and rib turbulators, a double wall design with impingement jets and serpentine channels, and an incremental impingement design. The designs were tested in a high-speed linear cascade at exit Reynolds numbers ranging from 700,000 to 1,400,000 at an exit Mach of 0.8. In addition, freestream turbulence and build angle effects on cooling performance were studied.

gas turbine blades↗
DOE OSTI2022

Closed-loop additive manufacturing of upcycled commodity plastic through dynamic cross-linking

A sustainable closed-loop manufacturing would become reality if commodity plastics can be upcycled into higher-performance materials with facile processability. Such circularity will be realized when the upcycled plastics can be (re)processed into custom-designed structures through energy/resource-efficient additive manufacturing methods, especially by approachable and scalable fused filament fabrication (FFF). Here, we introduce a circular model epitomized by upcycling a prominent thermoplastic, acrylonitrile butadiene styrene (ABS) into a recyclable, robust adaptive dynamic covalent network (ABS-vitrimer) (re)printable via FFF. The full FFF processing of ABS-vitrimer overcomes the major challenge of (re)printing cross-linked materials and produces stronger, tougher, solvent-resistant three-dimensional objects directly reprintable and separable from unsorted plastic waste. This study thus offers an imminently adoptable approach for advanced manufacturing toward the circular plastics economy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Computer-aided design file format for additive manufacturing and methods of file generation

A method of generating a tessellated output file comprising receiving a computer-aided design (CAD) model file defining a CAD model including a plurality of vertices, a plurality of curves, a plurality of surfaces, and at least one volume; generating base polygon data defining the CAD model for additive manufacturing, the base polygon data including a plurality of connected polygons, each polygon including a plurality of nodes, a plurality of edges, and a face; generating data for a vertex metadata container including a listing of CAD model vertices and one polygon node associated with each CAD model vertex; generating data for a curve metadata container including a listing of CAD model curves and at least one polygon edge associated with each CAD model curve; and generating data for a surface metadata container including a listing of CAD model surfaces and at least one polygon face associated with each CAD model surface.

Vernon, Gregory John↗
DOE OSTI2025

Design and Analysis of an Integrated Additively Manufactured Test Article for Plasma-Facing Components

Current plasma-facing components (PFCs) used in helium-cooled divertor modules are complex structures with tungsten tile, steel sleeve components, and cartridges, all assembled in a helium-cooled multiple jet (HEMJ) structure. The goal of this project is to simplify the complex PFC design using additive manufacturing techniques to create a single integrated tungsten test article. Apart from the flexibility this opens up in exploring a wide array of geometries for the article, having a single integrated article significantly reduces the number of joints and parts in the article, thus reducing chances of leaks. A process called electron beam melting has shown to produce very high-density samples and unique geometries, enabling HEMJ or similar designs. To validate and optimize this novel design, the model underwent a series of computational fluid dynamics and finite element analysis simulations to replicate steady-state heat flux in the divertors. The simulations presented in this study consider a steady-state base heat flux of 5 MW/m 2 , with water serving as the coolant. Future research will explore the use of helium as a coolant, simulate edge-localized-mode conditions, and include experimental validation. Since 3D-printed tungsten is anisotropic, the build direction versus build plane of the article are taken into consideration for the test article strength. Because of the high operating temperatures and low ductility of tungsten, thermal creep and brittle fracture are important failure mechanisms to consider. In conclusion, the cap is evaluated with various flow velocities and nozzle diameters, and an optimal design choice is made for which this cap will survive the divertor conditions with a conservative safety margin.

Divertor↗
NASA NTRSDate not supplied

Additive Manufacture of Ultra-Fine Lattice Structures of Green Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultrafine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray microfocus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar Mireles↗
DOE OSTI2024

High-Temperature Oxidation Behavior of Wrought and Additive Manufactured H282 in Direct-Fired Supercritical CO2 Power Cycle Environments

Materials selection is a key concern for corrosion resistance in high temperature and pressure direct-fired supercritical CO2 power cycles. The effect of elevated pressure on corrosion resistance can be critical, as impurities within the supercritical fluid such as H2O and O2 can result in additional corrosion behaviors. Utilizing additive manufacturing (AM) methods for construction of power cycle components requiring both compact and complex designs could be advantageous. AM H282 produced by laser powder bed fusion was exposed to direct-fired conditions (95CO2 – 4H2O – 1 O2) at 750 °C at both atmospheric pressure and supercritical conditions (20 MPa) for up to 4,000 hours. Oxidation behavior, sub-surface carbide formation, and chromia scale volatilization was dependent upon AM preparation techniques and surface modifications. These results are discussed in terms of the potential compatibility issues that may arise when using AM alloys in high temperature regions of direct-fired sCO2 power cycles, particularly for thin-walled components.

Carney, Casey↗
DOE OSTI2026

Volumetric Additive Manufacturing of Gradient Composition Glass

Advanced optics, such as lasers or cameras, are currently limited by geometric or compositional restrictions on the silica glass components that act as focusing or refracting lenses. Currently, these glass components must be made of one homogenous material in a range of shapes and sizes limited by a few specialized vendors. However, additional flexibility and customization of these optical components could significantly improve the performance of these devices and expand the design space available to optics engineers, as would the capability to locally change the optical properties of these glass components by changing the composition of the glass as a function of location. To this end, we have developed a method to print and process gradient composition glass, using volumetric additive manufacturing (VAM) and direct ink writing (DIW), on-site at Lawrence Livermore National Lab.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High-Temperature Oxidation Behavior of Wrought and Additive Manufactured Alloys in Direct-Fired Supercritical CO2 Power Cycle Environments

Materials selection is a key concern for corrosion resistance in elevated temperature and pressure direct-fired supercritical CO2 (sCO2) power cycles. The effect of elevated pressure on corrosion resistance can be critical, as impurities within the supercritical fluid such as H2O and O2 can have additional corrosion effects than found at ambient pressure conditions. Several wrought nickel-based commercial alloys (230, 263, 282, 617, 625, 740H) were exposed to direct-fired conditions (95CO2 – 4H2O – 1 O2) at 750 °C at both atmospheric pressure (0.1 MPa) and supercritical conditions (20 MPa) for over 2,000 h. Additionally, additive manufactured (AM) 282 produced by laser powder bed fusion (LPBF) were also included in the exposures. Supercritical conditions affected the oxidation behavior of several alloys. Most notably, water-vapor assisted Cr-oxide volatilization was observed at 750 °C supercritical conditions. Many alloys did not form sufficient protective Cr-oxide scales at supercritical conditions, leading to increased oxidation at elevated pressure. Differences in oxidation behavior were also observed for 282 AM samples compared to their wrought counterparts, with the differences also dependent on the LPBF build parameters and post-production treatments (heat treatment and surface finishing procedures). The AM samples formed Mo-rich carbides in the alloy beneath the oxide following sCO2 exposure, implying potentially higher levels of carbon uptake relative to the wrought

Carney, Casey↗