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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 1,603 records · Page 89
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Two-dimensional stitching interferometry for self-calibration of high-order additive systematic errors

Stitching interferometry is performed by collecting interferometric data from overlapped sub-apertures and stitching these data together to provide a full surface map. The propagation of the systematic error in the measured subset data is one of the main error sources in stitching interferometry for accurate reconstruction of the surface topography. In this work, we propose, using the redundancy of the captured subset data, two types of two-dimensional (2D) self-calibration stitching algorithms to overcome this issue by in situ estimating the repeatable high-order additive systematic errors, especially for the application of measuring X-ray mirrors. The first algorithm, called CS short for “Calibrate, and then Stitch”, calibrates the high-order terms of the reference by minimizing the de-tilted discrepancies of the overlapped subsets and then stitches the reference-subtracted subsets. The second algorithm, called SC short for “Stitch, and then Calibrate”, stitches a temporarily result and then calibrates the reference from the de-tilted discrepancies of the measured subsets and the temporarily stitched result. In the implementation of 2D scans in $x$- and y -directions, step randomization is introduced to generate nonuniformly spaced subsets which can diminish the periodic stitching errors commonly observed in evenly spaced subsets. The regularization on low-order terms enables a highly flexible option to add the curvature and twist acquired by another system. Both numerical simulations and experiments are carried out to verify the proposed method. All the results indicate that 2D high-order repeatable additive systematic errors can be retrieved from the 2D redundant overlapped data in stitching interferometry.

42 ENGINEERING↗
DOE OSTI2022

Latent image volumetric additive manufacturing

We report volumetric additive manufacturing (VAM) enables rapid printing into a wide range of materials, offering significant advantages over other printing technologies, with a lack of inherent layering of particular note. However, VAM suffers from striations, similar in appearance to layers, and similarly limiting applications due to mechanical and refractive index inhomogeneity, surface roughness, etc. We hypothesize that these striations are caused by a self-written waveguide effect, driven by the gelation material nonlinearity upon which VAM relies, and that they are not a direct recording of non-uniform patterning beams. We demonstrate a simple and effective method of mitigating striations via a uniform optical exposure added to the end of any VAM printing process. We show this step to additionally shorten the period from initial gelation to print completion, mitigating the problem of partially gelled parts sinking before print completion, and expanding the range of resins printable in any VAM printer.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Additive manufacturing and processing of architected materials

Architected materials are a unique and emerging class of materials where performance is fundamentally controlled by geometry at multiple length scales, from the nano- to the macroscale, rather than chemical composition alone. As a result, the realization of these remarkable materials is contingent upon the ability to faithfully reproduce the designed architecture. Furthermore, this presents fundamental challenges in fabrication due to the required three-dimensional complexity, multiple length scales, range of material constituents, possibility of multiple materials in a single architecture, and overall manufacturing throughput. Additive manufacturing (AM) processes can provide solutions to some of these challenges and are discussed in this article. Specifically, light-based and extrusion-based processes and associated materials are presented with an emphasis on recent developments, including volumetric additive manufacturing, and on-the-fly mixing of materials in extrusion-based printing systems. While remarkable advancements have been made in AM for architected materials, bringing these materials and processes to industrial realization remains a significant challenge.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Deformation and fracture characteristics of zirconium plate produced via ultrasonic additive manufacturing

Abstract The microstructural evolution, deformation modes, and fracture mechanisms of zirconium plate produced using ultrasonic additive manufacturing (UAM) are presented. In addition to conventional tensile testing techniques, digital image correlation captured highly variable strain accumulation in specimens loaded perpendicular or parallel to the build height (Z). When tested in parallel to Z, delamination at prior foil/foil interfaces creates strain localization noticeable in strain rate maps, whereas specimens loaded perpendicular to Z illustrate conventional strain hardening until necking accelerates delamination. Although bond strengths are statistically and spatially variable, in situ electron backscattering diffraction tests illustrate the ability for grains near interfaces to accommodate strain with twinning and slip modes consistent with conventionally produced zirconium alloys. Finally, mixtures of ductile and delamination-induced fracture highlight the interface-driven failure modes of UAM zirconium plate in the as-built condition. Graphic abstract

36 MATERIALS SCIENCE↗
DOE OSTI2022

Design of crack-free laser additive manufactured Inconel 939 alloy driven by computational thermodynamics method

Abstract This paper examined the effect of Si addition on the cracking resistance of Inconel 939 alloy after laser additive manufacturing (AM) process. With the help of CALculation of PHAse Diagrams (CALPHAD) software Thermo-Calc, the amounts of specific elements (C, B, and Zr) in liquid phase during solidification, cracking susceptibility coefficients (CSC) and cracking criterion based on $$\left| {{\text{d}}T/{\text{d}}f_{{\text{s}}}^{1/2} } \right|$$ d T / d f s 1 / 2 values ( T : solidification temperature, f s : mass fraction of solid during solidification) were evaluated as the indicators for composition optimization. It was found that CSC together with $$\left| {{\text{d}}T/{\text{d}}f_{{\text{s}}}^{1/2} } \right|$$ d T / d f s 1 / 2 values provided a better prediction for cracking resistance. Graphical abstract

Zeng, Congyuan (ORCID:0000000214764277)↗
DOE OSTI2026

Wire-arc Additive Manufacturing Benchmark

This is the dataset associated with the 2022 SRP Additive Manufacturing Prediction Challenge, originally hosted on Github at https://github.com/SRP-AM/SRP_AM_Prediction_Challenge. The benchmark was designed for validating prediction for the temperature history, residual stress, and distortion of an additively manufactured metal part with relatively simple geometry. A calibration problem with the same as-built geometry is provided with measured quantities of interest; including temperature histories at selective locations, post-build residual stress at selective locations, and overall distortion measurements. The challenge problem is presented with a different build sequence (i.e. thermal history). In this dataset, we include the actual recorded calibration and challenge measurements, as well as benchmark template files for testing predictions without incorporating the challenge data. Supplementary files around the materials and setup are available for transparency and reproducibility.

Bachus, Nicholas [UC Davis, Davis, CA]↗
DOE OSTI2023

Characterization of Additive Manufacturing Materials for String Assembly in Cleanroom

Beamline components, such as superconducting radio frequency cavities and focusing lenses, need to be assembled together in a string while in a cleanroom environment. The present contribution identifies and characterizes materials for additive manufacturing that can be used in a cleanroom. The well known advantages of additive manufacturing processes would highly benefit the design and development of tooling needed for the mechanical support and alignment of string components. Cleanliness, mechanical properties, and leak tightness of the chosen materials are the main focus of this contribution, which also paves the way for the integration of such materials in cryomodule assemblies. Results reported here were obtained in the framework of the PIP-II project at Fermilab.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

AdditiveFOAM: A Continuum Multiphysics Code for Additive Manufacturing

AdditiveFOAM is a computational framework that simulates transport phenomena in Additive Manufacturing (AM) processes. It is built on OpenFOAM (Weller et al., 1998), the leading free, open-source software package for computational fluid dynamics (CFD). OpenFOAM offers an extensible platform for solving complex multiphysics problems using state-of-the-art finite volume methods. AdditiveFOAM leverages these capabilities to develop specialized tools aimed at addressing challenges in AM processing. Metal additive manufacturing, also known as metal 3D printing, is an advanced manufacturing technique that creates physical parts from a three-dimensional (3D) digital model by melting metal powder or wire feedstock. A significant area of research in metal AM focuses on process planning to mitigate anomalous features during printing that are deleterious to part performance (e.g., porosity and cracking), as well as controlling localized microstructure and material properties. Given the high costs and substantial time requirements associated with experimental methods for qualifying new materials and processes, there is a compelling incentive for researchers to utilize advanced computational simulations. In this context, AdditiveFOAM offers a simulation framework to better understand undesirable features in printing, thereby enhancing process planning and reducing the reliance on labor-intensive experimental campaigns.

Coleman, John [Oak Ridge National Laboratory (ORNL↗
DOE OSTI2016

The Frontiers of Additive Manufacturing

Additive manufacturing, more commonly known as 3-D printing, has become a ubiquitous tool in science for its precise control over mechanical design. For additive manufacturing to work, a 3-D structure is split into thin 2D slices, and then different physical properties, such as photo-polymerization or melting, are used to grow the sequential layers. The level of control allows not only for devices to be made with a variety of materials: e.g. plastics, metals, and quantum dots, but to also have finely controlled structures leading to other novel properties. While 3-D printing is widely used by hobbyists for making models, it also has industrial applications in structural engineering, biological tissue scaffolding, customized electric circuitry, fuel cells, security, and more.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Diamond field emitter array cathodes and possibilities for employing additive manufacturing for dielectric laser accelerating structures

These are slides for a presentation at Stanford University. The outline is as follows: Motivation: customers for compact accelerators, LANL's technologies for laser acceleration, DFEA cathodes, and additive manufacturing of micron-size structures. Among the stated conclusions are the following: preliminary study identified DFEA cathodes as promising sources for DLAs--high beam current and small emittance; additive manufacturing with Nanoscribe Professional GT can produce structures with the right scale features for a DLA operating at micron wavelengths (fabrication tolerances need to be studied, DLAs require new materials). Future plans include DLA experiment with a beam produced by the DFEA cathode with field emission, demonstration of photoemission from DFEAs, and new structures to print and test.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Report From BPTCS Project Team On Evaluation Of Additive Manufacturing For Pressure Retaining Equipment

ASME is evaluating the use of additive manufacturing (AM) for the construction of pressure equipment. The information in this report assesses available AM technologies for direct metal fabrication of pressure equipment. Background information is included in the report to provide context for those not experienced in AM technology. Only commercially available technologies for direct metal fabrication are addressed in the report because these AM methods are the only viable approaches for the construction of pressure equipment. Metal AM technologies can produce near-net shape parts by using multiple layers of material from a three dimensional (3D) design model of the geometry. Additive manufacturing of metal components was developed from polymer based rapid prototyping or 3D printing. At the current maturity level, AM application for pressure equipment has the potential to reduce delivery times and costs for complex shapes. AM will also lead to a reduction in the use of high cost materials, since parts can be created with corrosion resistant layers of high alloy material and structural layers of lower cost materials.

42 ENGINEERING↗
DOE OSTI2016

Feasibility and Testing of Additive Manufactured Components

This project focused on demonstrating the ability to fabricate two parts with different geometry: an arc flash interrupter and a hydraulic manifold. Eaton Corporation provided ORNL solid models, information related to tolerances and sensitive parameters of the parts and provided testing and evaluation. ORNL successfully manufactured both components, provided cost models of the manufacturing (materials, labor, time and post processing) and delivered test components for Eaton evaluation. The arc flash suppressor was fabricated using the Renishaw laser powder bed technology in CoCrMo while the manifold was produced from Ti-6Al-4V using the Arcam electron beam melting technology. These manufacturing techniques were selected based on the design and geometrical tolerances required. A full-scale manifold was produced on the Arcam A2 system (nearly 12 inches tall). A portion of the manifold was also produced in the Arcam Q10 system. Although a full scale manifold could not be produced in the system, a full scale manifold is expected to have similar material properties, geometric accuracy, and surface finish as could be fabricated on an Arcam Q20 system that is capable of producing four full scale manifolds in a production environment. In addition to the manifold, mechanical test specimens, geometric tolerance artifacts, and microstructure samples were produced alongside the manifold. The development and demonstration of these two key components helped Eaton understand the impact additive manufacturing can have on many of their existing products. By working within the MDF and leveraging ORNL’s manufacturing and characterization capabilities, the work will ensure the rapid insertion and commercialization of this technology.

42 ENGINEERING↗
DOE OSTI2016

Evaluation of Additive Manufacturing for Stainless Steel Components

This collaboration between Oak Ridge National Laboratory and General Electric Company aimed to evaluate the mechanical properties, microstructure, and porosity of the additively manufactured 316L stainless steel by ORNL’s Renishaw AM250 machine for nuclear application. The program also evaluated the stress corrosion cracking and corrosion fatigue crack growth rate of the same material in high temperature water environments. Results show the properties of this material to be similar to the properties of 316L stainless steel fabricated additively with equipment from other manufacturers with slightly higher porosity. The stress corrosion crack growth rate is similar to that for wrought 316L stainless steel for an oxygenated high temperature water environment and slightly higher for a hydrogenated high temperature water environment. Optimized heat treatment of this material is expected to improve performance in high temperature water environments.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Report on July 2015 Additional Protocol Coordinators Best Practices Workshop

After 10 years of implementation experience, the Office of Nonproliferation and Arms Control (NPAC) within the Department of Energy/National Nuclear Security Administration (DOE/NNSA) conducted the Additional Protocol (AP) Coordinators Best Practices Workshop at Oak Ridge National Laboratory from July 29-30, 2015. The goal of this workshop was to identify implementation best practices, lessons learned, and compliance challenges from the various Additional Protocol Coordinators (APCs) at each laboratory in the DOE/NNSA complex and associated sites. The workshop provided the opportunity for participants to share their insights and establish networks that APCs can utilize to continue to discuss challenges (new and old), identify best practices, and enhance communication and coordination for reporting multi-lab research projects during review activities. Workshop participants included DOE/NNSA HQ, laboratory and site APCs, seasoned experts, members of the original implementation outreach team, and Field Element and site security representatives.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2017

ORNL-GM: Development of Ionic Liquid-Additized, GF-5/6 Compatible Low-Viscosity Oils for Automotive Engine and Rear Axle Lubrication for 4% Improved Fuel Economy

The overall objective of this project are as follows: Further develop ionic liquid (IL)-additized lowviscosity engine oils meeting the GF-5/6 specifications and possessing superior lubricating characteristics; Expand the IL additive technology to rear axle lubricants; and Seek a combined improvement in the vehicle fuel economy

10 SYNTHETIC FUELS↗
DOE OSTI2016

Ni and Cr addition to alloy waste forms to reduce radionuclide environmental releases

Reference alloy waste forms (RAW) were fabricated and underwent hybrid corrosion/immersion testing to parameterize the ANL analytical oxidative-dissolution model to enable the calculation of fractional release rates and to determine the effectiveness of Ni and Cr trim additions in reducing release rates of radionuclide surrogates. Figure 1 shows the prototypical multiphase microstructure of the alloys with each phase type contributing about equally to the exposed surface area. The waste forms tested at SRNL were variations of the RAW-6 formulation that uses HT9 as the main alloy component, and are meant to enable evaluation of the impact of Ni and Cr trim additions on the release rates of actinides and Tc-99. The test solutions were deaerated alkaline and acidic brines, ranging in pH 3 to pH 10, representing potential repositories with those conditions. The testing approach consisted of 4 major steps; 1) bare surface corrosion measurements at pH values of 3, 5, 8, and 10, 2) hybrid potentiostatic hold/exposure measurements at pH 3, 3) measurement of radionuclide concentrations and relations to anodic current from potentiostatic holds, and 4) identification of corroding phases using SEM/EDS of electrodes.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Additive Manufacturing of Dense Hexagonal Boron Nitride Objects

The feasibility of manufacturing hexagonal boron nitride objects via additive manufacturing techniques was investigated. It was demonstrated that it is possible to hot-extrude thermoplastic filaments containing uniformly distributed boron nitride particles with a volume concentration as high as 60% and that these thermoplastic filaments can be used as feedstock for 3D-printing objects using a fused deposition system. Objects 3D-printed by fused deposition were subsequently sintered at high temperature to obtain dense ceramic products. In a parallel study the behavior of hexagonal boron nitride in aqueous solutions was investigated. It was shown that the addition of a cationic dispersant to an azeotrope enabled the formulation of slurries with a volume concentration of boron nitride as high as 33%. Although these slurries exhibited complex rheological behavior, the results from this study are encouraging and provide a pathway for manufacturing hexagonal boron nitride objects via robocasting.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Additive Manufacturing for Low Volume Bearings

ORNL worked with the Schaeffler Group USA to explore additive manufacturing techniques that might be appropriate for prototyping of bearing cages. Multiple additive manufacturing techniques were investigated, including e-beam, binder jet and multiple laser based processes. The binder jet process worked best for the thin, detailed cages printed.

36 MATERIALS SCIENCE↗