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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Nitriding kinetics of Si-SiC powder mixtures as simulations of reaction bonded Si3N4-SiC composites

The nitriding kinetics of Si and Si plus SiC powder mixtures were studied to simulate the fabrication of RBSN-SiC ceramic matrix composites. Very clean, assynthesized, and solvent-exposed powders were studied; C-rich and Si-rich SiC 0.04-0.05 micron diameter powders were mixed in varying concentrations with SiH4-derived 0.2-0.3 micron diameter Si powder. Complete nitridation is achieved with C-rich SiC powders in 140 min at 1250 C, and in the centers of Si-rich SiC powders in 15 min. The effects on the incubation periods, fast reaction periods, and slow reaction periods that characterize these nitriding processes were studied to explain unusual reverse reaction gradients and other effects of contamination.

Lightfoot, A.↗
NASA NTRS1990

The development of an alternative thermoplastic powder prepregging technique

Discussed is a novel powder prepregging technique that is based on the deposition of the powder onto fibers that have been moistened using an ultrasonic humidifier. The moisture acts as an initial binding agent for the powder until the powder can be melted onto the fiber in a subsequent heating step. LaRC-TPI powder, produced by Mitsui Toastsu, and Hercules AS-4 fiber served as the process development material system. The influence of powder particle size on this process, and the quality of the resulting composite are discussed.

Ogden, A. L.↗
NASA NTRS1995

Powder-Coated Towpreg: Avenues to Near Net Shape Fabrication of High Performance Composites

Near net shape parts were fabricated from powder-coated preforms. Key issues including powder loss during weaving and tow/tow friction during braiding were addressed, respectively, by fusing the powder to the fiber prior to weaving and applying a water-based gel to the towpreg prior to braiding. A 4:1 debulking of a complex 3-D woven powder-coated preform was achieved in a single step utilizing expansion rubber molding. Also, a process was developed for using powder-coated towpreg to fabricate consolidated ribbon having good dimensional integrity and low voids. Such ribbon will be required for in situ fabrication of structural components via heated head advanced tow placement. To implement process control and ensure high quality ribbon, the ribbonizer heat transfer and pulling force were modeled from fundamental principles. Most of the new ribbons were fabricated from dry polyarylene ether and polymide powders.

Johnston, N. J.↗
NASA NTRS2005

Pods: a Powder Delivery System for Mars In-situ Organic, Mineralogic and Isotopic Analysis Instruments

Many Mars in situ instruments require fine-grained high-fidelity samples of rocks or soil. Included are instruments for the determination of mineralogy as well as organic and isotopic chemistry. Powder can be obtained as a primary objective of a sample collection system (e.g., by collecting powder as a surface is abraded by a rotary abrasion tool (RAT)), or as a secondary objective (e.g, by collecting drill powder as a core is drilled). In the latter case, a properly designed system could be used to monitor drilling in real time as well as to deliver powder to analytical instruments which would perform complementary analyses to those later performed on the intact core. In addition, once a core or other sample is collected, a system that could transfer intelligently collected subsamples of power from the intact core to a suite of analytical instruments would be highly desirable. We have conceptualized, developed and tested a breadboard Powder Delivery System (PoDS) intended to satisfy the collection, processing and distribution requirements of powder samples for Mars in-situ mineralogic, organic and isotopic measurement instruments.

Saha, C. P.↗
NASA NTRSDate not supplied

Quick and Correlative TOF-SIMS Analysis of Dispersoid Content in Powder Feedstock and Printed Oxide Dispersion Strengthened Alloys

Oxide dispersion strengthening (ODS) of metal alloys, when combined with additive manufacturing (AM), can be used to solve high-temperature material application problems. The performance of ODS materials is dependent on nano-scale oxide being distributed uniformly throughout the metal matrix; a homogenous distribution is critical to the creep and yield strength. Therefore, quantifying and analyzing these oxide nanoparticles is essential for ODS alloy development. Assessing the chemistry and morphology of dispersoids in a material can be conducted using a variety of X-ray and electron-based methods. Time of Flight Secondary Ion Mass Spectrometry (TOF-SIMS), which assesses chemical concentrations from ion masses, provides the necessary spatial resolution and avoids potential spectral overlap of all elements present. In this work, preparing ODS powder feedstock and Laser Powder Bed Fusion AM was conducted with a NiCoCr alloy and yttria dispersoid, mixed with a Resodyn resonance mixer and printed on an EOS M100 3D printer at NASA Glenn. TOF-SIMS was performed on a Physical Electronics NanoTOF TRIFT V TOF-SIMS at Case Western Reserve University. The TOF-SIMS results collected on the feedstock powder samples correspond to the qualitative interpretation of the homogeneity of the oxide coating on the metal powder from SEM images. This provides quantitative support to the qualitative microscopy images collected earlier in the process design phase. The variance in the yttrium distribution on the powder feedstock samples also correlated with the variance of the yttrium distribution detected in the printed samples. This correlation supported the hypothesis that an even coating of yttria on the metal powders contributes to an even distribution of yttria in the printed material.

Laura G. Wilson↗
DOE OSTI2022

Method for nano powder loading into micro-capillary mold

A method loading powder into a mold can include immersing the mold comprising one or more microchannels into a suspension comprising the powder and a surfactant suspended in a dispersant, wherein the powder comprises particles having an average particle size of less than 100 μm, wherein the mold is substantially entirely covered by the suspension; heating the suspension having the mold immersed therein under a temperature condition suitable to lower the stability of the particles of the powder in the suspension such that the particles settle out of solution and into the one or more microchannels; and applying an ultrasonic wave to the heated suspension to further settle the particles of the powder into the one or more microchannels thereby filling the one or more microchannels of the mold with the powder.

Yacout, Abdellatif M.↗
DOE OSTI2023

Tailored particles for powder-based additive manufacturing

The present disclosure relates to a plurality of powder particles configured to be joined in an additive manufacturing process to form a part. Each one of the powder particles has a determined three dimensional, non-spherical shape. The plurality of powder particles are further of dimensions enabling fitting individual ones of the powder particles in abutting relationship with one another. At least a subplurality of the powder particles each have a functionalized surface feature to enhance at least one of clustering or separation of the subplurality of powder particles.

Watts, Seth Evan↗
DOE OSTI2021

Comparison of active impurity control between lithium and boron powder real-time injection in EAST

The lithium and boron powder have been successfully real-time injected into Experimental Advanced Superconducting Tokamak (EAST) high-confinement (H-) mode discharges, showing good wall conditioning effects, especially on the impurities control. Both of lithium and boron powder particles are gravitationally accelerated into the upper edge of a upper single null discharge. The lithium powder real-time injection effectively reduced the tungsten impurity content both in the plasma edge and core. Contrary to the lithium injection, the boron injection mainly reduced the impurities content in the plasma core, while the impurities increased in the edge. Furthermore, this mainly due to that there was an edge harmonic mode stimulated by boron injection, providing sufficient particles transport. Moreover, the impurities control through boron injection has much wider operation windows than lithium powder injection. Furthermore, there was accumulative wall conditioning effects after sequential boron powder injection discharges.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Laser pre-sintering for denudation reduction in the laser powder bed fusion additive manufacturing of Ti-6Al-4V alloy

As a fundamentally different process for creation of complex parts, laser powder bed fusion (LPBF) additive manufacturing exhibits complex behavior at the melt pool that has a direct influence on the macroscopic properties of the final material. Powder denudation, a previously studied deleterious phenomenon, is the displacement of powder due to entrainment in a jet of rapidly vaporized metal created by the process laser. To minimize the effect of denudation and inspired by methods in adjacent fields, a laser pre-sintering (LPS) method was studied in an effort to reduce denudation. LPS was found to be most effective in the 1–4 J/mm3 volumetric energy density processing regimes, minimizing the common experimentally observed problems with the LPBF process. Scanning electron microscopy of the LPS-treated powder bed revealed insight into the accelerating effect morphological irregularities along the powder particle surface have in the pre-sintering process. To further understand the process, an estimation of the sintered neck sizes necessary to eliminate denudation in LPS is made, qualitatively affirming the low energy densities needed to prevent denudation. Here, the results presented in this work represent an initial step towards understanding and implementing LPS as a quality-enhancing step in LPBF.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

The laser powder bed fusion (LPBF) process utilizing a focused Gaussian-shaped beam faces challenges, including pore formation, melt pool fluctuation and liquid spattering. While beam shaping technology has been explored as a potential approach for defect mitigation, the beam-matter interaction dynamics during melting with shaped beams remain unclear. Here, we report the direct observation of ring-shaped beam-matter interaction dynamics, including pore formation, melt pool fluctuation and liquid spattering, and unveil defect mitigation mechanisms in ring-shaped beam laser powder bed fusion process. Here, we find that, by spatially manipulating incident laser rays, the ring-shaped beam controls keyhole morphology, thereby managing the distribution of the reflected rays. This manipulation can effectively eliminate the formation of an unstable cavity at the keyhole tip, stabilizing the keyhole and mitigating keyhole pores. This enhanced keyhole stability effectively reduces the melt pool fluctuation, the formation of liquid breakup induced spatters and liquid droplet colliding induced large spatters in the laser powder bed fusion process. Additionally, the high-energy forefront of the ring-shaped beam effectively melts the powder bed, reducing agglomeration liquid spatter in the laser powder bed fusion process. The discovered defect mitigation mechanisms may guide the design of beam shaping strategies for simultaneously increasing the quality and productivity of metal additive manufacturing.

Beam shaping↗
DOE OSTI2022

Manufacture aluminum alloy tube from powder with a single-step extrusion via ShAPE

Mechanical performance of aluminum in terms of strength, wear and corrosion resistance, especially high-temperature strength has been shown to improve with the addition of transition metal (TM) elements of Fe, Cr, and Ti. However, these feedstock materials occur as powders. As such, the traditional fabrication process is complex and expensive because it requires multiple procedures and consumes considerable energy. This study developed Shear Assisted Processing and Extrusion (ShAPE) as a single-step process that manufactures tubes directly from Al-TM powders obtained via gas atomization. Meter-long Al-TM alloy tubes are extruded from powders with different processing conditions. The ShAPE tubes have very low porosity and the average density is 2.94 kg/cm 3 , which is equal to or higher than parts fabricated by hot extrusion and sintering. The powder-to-tube fabrication process was revealed and discussed by examining the microstructural evolution. The Vickers hardness of ShAPE tubes ranges from 110 to 140 HV through wall thickness and at different extrusion speeds. The variation in hardness was correlated with the extent of refinement of intermetallics and attributed to the shear deformation per unit extrusion length. Energy cost analysis shows that ShAPE save ~60% energy compared to the conventional sintering and extrusion processes. Results indicate ShAPE is a low-cost, high-efficiency manufacturing process for producing tubes from metallic powders.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Determining processing behaviour of pure Cu in laser powder bed fusion using direct micro-calorimetry

We report copper is challenging to process by laser powder bed fusion (LPBF) given its high reflectivity at common infrared laser diode wavelengths and high thermal conductivity. Successful deposition of copper in a predictable and repeatable fashion relies on understanding the development of the keyhole melting regime, as well as heating, melting, boiling and vapour formation behaviour when interacting with a laser beam within an LPBF environment. In this study, in situ optical absorptivity measurements are used to clarify the complex physics of the laser material interaction. Absorptivity of laser energy is measured using direct micro-calorimetry and compared to melt pool depth in correlation to processing parameters. The measured absorptivity for a 100 μm layer thickness of powder was found to be approximately four times higher than that of the bare polished discs. It was also shown that high laser power above 500 W and scan speed up to 150 mm/s are appropriate for effective melting of the powder layer, with these parameters overcoming the threshold required to achieve keyhole melting. This is explained by multiple reflections withing the powder particles and the lower thermal conductivity of packed powder in comparison to bare discs. Melt pool formation was found to be highly unstable and an explosive behavior was observed when in the keyhole regime, caused by high fluctuations in absorptivity values. This work demonstrates calorimetry can be used to monitor melting behaviour in a real-time fashion during processing for this challenging to process material, thereby avoiding unnecessary parametric optimisation. In addition, the parametric window for optimum processing revealed here can inform future work.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Increased damping through captured powder in additive manufacturing

This paper describes the retention of metal powder within additively manufactured structures to achieve increased damping. In this work, solid and hollow (powder filled) aluminum cylinders were fabricated in using laser powder bed fusion where the internal, captured powder in the hollow cylinders served as an energy dissipation mechanism. Impact testing was completed to compare the frequency response functions of three cylinder geometries: one solid cross-section and two hollow cross-sections with different inner diameters and, therefore, different powder volumes. Increased damping with larger inner diameter was observed. The damping was quantified using a structural damping model.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Biologically-inspired rib designs for captured powder damping in additive manufacturing

This paper describes the design and impact testing of laser powder bed fusion 316L stainless steel walls with captured powder cores. The purpose is to determine the effect of biologically-inspired internal ribs on the mode shapes and damping ratios. Comparison is made between five designs: solid and powder core with {no ribs, vertical ribs, hatched ribs, and bat wing ribs}. The powder core increases damping ratios by factors of 2 to 58 depending on the mode number and design. Mode shape and modal parameter evaluations show that the ribbed powder core designs enable tailored dynamics relative to the solid wall.

42 ENGINEERING↗
DOE OSTI2023

SA508 low alloy steel to 316L stainless steel dissimilar metal joint made by powder metallurgy hot isostatic pressing

Joining ferritic SA508 low alloy steel (LAS) and austenitic 316 L stainless steel (SS) via powder metallurgy hot isostatic pressing (PM-HIP) was evaluated as an alternative method to welding. This study investigated the mechanical and microstructural evolutions of the bimetallic interface under different joint designs and heat treatments. Here, the direct joining of dissimilar metal alloys by PM-HIP method resulted in two designs: 1) powder SA508 to solid bar 316 L (P508–B316L) and 2) powder 316 L solid bar SA508 (P316L-B508). In both cases, P508–B316L and P316L-demonstrated satisfactory tensile strength, however, high hardness and severe depreciation in toughness were located on the bimetallic interface. The mechanisms responsible for the detrimental mechanical properties were verified. Large oxides were observed in P508–B316L due to the prior powder boundary (PPB) oxides present in SA508 powder. The intense sensitization occurred from the formation of M 23 C 6 carbides, consequently from the slow cooling after PM-HIP in P316L-B508. Post-HIP heat treatments were explored to reduce the distance of carbide formation; however, the heat treatment could not eliminate the carbides. The experimental results were compared to the diffusion couple simulation as a function of carbide formation with distance. The analysis also showed the high hardness at the bimetallic interface was primarily contributed by solid solution strengthening. In conclusion, the direct joining of P316L-B508 and P508–B316L via PM-HIP was deemed to be unfeasible, and a transitional material is necessary to impede the diffusion of carbon.

316L stainless Steel↗
DOE OSTI2025

Packing fraction control during additive manufacturing of powder green bodies

The demand for high performance ceramic and metal components with complex geometry necessitates developments in powder handling and green body shaping. Here, in this study, vibrational powder deposition is adapted to three-dimensional printing with the ability to modulate packing fraction during printing. Boron carbide powder with sub-micron primary particle size is printed over a packing fraction range of 25.0 % to 46.5 % (below the poured density to above the tapped density). Solid metal powders are printed at 67.5 %, which enables novel freestanding, vertical-walled features without binder. These capabilities introduce opportunities for more complex geometries in high-performance materials, e.g. large-scale uniaxial hot-pressing of ceramic ballistic armor components with graded thickness and three-dimensional curved or stepped features (by compensating for displacement differences during compaction). This technology also enables multi-material patterning of additive manufacturing powder beds with reduced feedstock quantity requirements and wastage.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Interpretive modelling of boron transport in the boundary plasma of WEST experiments with the impurity powder dropper

Abstract Boron (B) powder injection is a potential alternative to glow discharge boronization as a wall conditioning method for tokamaks. This technique is currently being studied in WEST experiments, during which B powder is injected by an Impurity Powder Dropper developed by PPPL. In order to interpret and analyse experimental trends, and to help develop future experiments, a modelling workflow using a boundary plasma simulation (SOLEDGE-EIRENE) and powder ablation simulation (Dust Injection Simulator) was developed and tested. The effect of adding a B neutral source to simulated deuterium + oxygen (D + O) plasmas was compared to experimental data from the WEST C5 campaign, where B powder was injected in a dedicated experiment. While the impact of B injection on radiated power P rad measurements at the upper divertor was similar, there were significant differences in measurements of P rad , outer strike point electron temperature T e OSP and O-II line intensity at the lower divertor between experiment and simulation. This discrepancy suggests that those parameters were affected by phenomena not present in the simulations, with the most likely candidates being reduced D recycling and a reduced O sourcing from the divertor.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

First impurity powder injection experiments in LHD

Injection of impurities in the form of sub-millimeter powder grains is performed for the first time in the Large Helical Device (LHD) plasma, employing the Impurity Powder Dropper (IPD) [A. Nagy et al., RSI 2018], developed and built by PPPL. Controlled amounts of boron (B) and boron nitride (BN) powder are injected into the helical plasma. Visible camera imaging, UV and charge exchange spectroscopy measurements show that the injected impurities effectively penetrate into the plasma in two different magnetic configurations.The prompt effects of the impurities on the plasma are characterized as the injection rate is scanned. The injected impurities provide a supplemental electron source, causing the plasma density to increase, together with the radiated power. Beneficial effects on the confined plasma temperature are observed at low plasma densities, due to an increased efficiency in NBI power absorption. For $n_{e,av}<10^{19}m^{-3}$ the powder grains penetrate deeper into the plasma, as they can be less effectively deflected by the plasma flow in the divertor leg, which they have to cross first as they are injected from the top of the machine.In this case, the created B ions are observed to move outwards from UV spectroscopy and charge exchange measurements, due to the outwards direction of the radial electric field. This makes low density plasmas a better candidate for powder boronization techniques.

Boron↗