Additive Manufacturing at NASA/MSFC. Hybrid Manufacturing of Bi-Metallic Liquid Rocket Engine Igniter
No abstract available
Burlingame, Steven↗
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Results for “Hybrid manufacturing”
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Transforming Manufacturing: Transitioning from Rapid Prototyping to Hybrid Manufacturing
No abstract available
Bagg, Stacey↗
Dry Process for Manufacturing Hybridized Boron Fiber/Carbon Fiber Thermoplastic Composite Materials from a Solution Coated Precursor
An apparatus for producing a hybrid boron reinforced polymer matrix composite from precursor tape and a linear array of boron fibers. The boron fibers are applied onto the precursor tapes and the precursor tape processed within a processing component having an impregnation bar assembly. After passing through variable-dimension forming nip-rollers, the precursor tape with the boron fibers becomes a hybrid boron reinforced polymer matrix composite. A driving mechanism is used to pulled the precursor tape through the method and a take-up spool is used to collect the formed hybrid boron reinforced polymer matrix composite.
Harry L Belvin↗
Radiation Heating Effects on Oxidizer-to-Fuel Ratio of Additively Manufactured Hybrid Rocket Fuels
Explore the source record for details and available documents.
S. A. Whitmore↗
Manufacture of Hybrid Standard-Ply/Thin-Ply Carbon/Epoxy Panels for Notched Test Specimens
Weight is a critical metric for aerospace structures, and one possible way to reduce weight is to improve performance using hybrid standard-ply/thin-ply laminates from a single material system. Previous studies showed benefits for stiffness, strength, reduced damage after impact, and increased compression-after-impact strength for these hybrid laminates. Another study suggested that performance of compression-loaded notched hybrid laminate specimens performed better than standard-ply laminates under compression, but the standard-ply laminates performed better under tension loading. However, analysis predicted the failure load and mode better for the hybrid laminates. An analytical study determined several hybrid laminate designs to use in a follow-on testing regiment that is planned to further study the notched hybrid composite performance under compression and tension load. Described herein is a manufacturing method to efficiently manufacture hybrid laminates using automated fiber placement using a 16-tow head where 8 tows are standard-ply and 8 tows are thin-ply. The method saves time in that it eliminates the need to change spools of material when switching from standard-ply to thin-ply lamina, and reduces the waste associated with changing of spools. The method is ideal for small manufacturing operations or research facilities that have only a single head, and the method was successfully applied at the NASA Langley Research Center (LaRC) Integrated Structural Assembly of Advanced Composites (ISAAC) facility to manufacture nine panels that will be used for the follow-on notched specimen testing of hybrid and standard laminates.
composite↗
Manufacture of Hybrid Standard-Ply/Thin-Ply Carbon/Epoxy Panels for Notched Test Specimens
Weight is a critical metric for aerospace structures, and one possible way to reduce weight is to improve performance using hybrid standard-ply/thin-ply laminates from a single material system. Previous studies showed benefits for stiffness, strength, reduced damage after impact, and increased compression-after-impact strength for these hybrid laminates. Another study suggested that performance of compression-loaded notched hybrid laminate specimens performed better than standard-ply laminates under compression, but the standard-ply laminates performed better under tension loading. However, analysis predicted the failure load and mode better for the hybrid laminates. An analytical study determined several hybrid laminate designs to use in a follow-on testing regiment that is planned to further study the notched hybrid composite performance under compression and tension load. Described herein is a manufacturing method to efficiently manufacture hybrid laminates using automated fiber placement using a 16-tow head where 8 tows are standard-ply and 8 tows are thin-ply. The method saves time in that it eliminates the need to change spools of material when switching from standard-ply to thin-ply lamina, and reduces the waste associated with changing of spools. The method is ideal for small manufacturing operations or research facilities that have only a single head, and the method was successfully applied at the NASA Langley Research Center (LaRC) Integrated Structural Assembly of Advanced Composites (ISAAC) facility to manufacture nine panels that will be used for the follow-on notched specimen testing of hybrid and standard laminates.
composite↗
Hybrid Additive Manufacturing Deposition and Selective Laser Melting Techniques Applied to Copper-Alloy Liquid Rocket Engine Combustion Chambers
Virgin Orbit and the NASA Marshall Space Flight Center have partnered to fabricate a small, multi-metallic, regeneratively cooled thrust chamber by leveraging the strengths of two different types of additive manufacturing: Direct Metal Laser Sintering (DMLS) for the copper alloy liner and blown powder Directed Energy Deposition (DED) for the Inconel structural jacket. The DED is being developed using Virgin Orbit's DMG Mori Seiki hybrid additive/subtractive machining center to further enable unique processing and further cost savings. The materials chosen are preferred for high performance thrust chamber applications, representing a significant advancement from the compromises typically made in the production of metal 3D printed thrust chambers for rocket engines. The 1.2K-lbf thrust article is a 16" tall, 3" diameter design modified for this effort to be regeneratively cooled with water and hot fired using a RP-1/LOX pintle-style development injector from Virgin Orbit's NewtonFour upper stage engine. The thrust chamber was tested at Virgin Orbit's Necker test site in Mojave, California. Results from this test campaign are reported in addition to information characterizing the liner, jacket, and bimetallic diffusion layer materials. This paper will also highlight some of the future bimetallic thrust chamber developments that MSFC and Virgin Orbit will complete under a recently awarded NASA contract.
Zagorski, Kevin↗
Investigation of low cost, high reliability sealing techniques for hybrid microcircuits, phase 1
A preliminary investigation was made to determine the feasibility of using adhesive package sealing for hybrid microcircuits. Major effort consisted of: (1) surveying representative hybrid manufacturers to assess the current use of adhesives for package sealing; (2) making a cost comparison of metallurgical versus adhesive package sealing; (3) determining the seal integrity of gold plated flatpack type packages sealed with selected adhesives, thermal shock, temperature cycling, mechanical shock, and constant acceleration test environments; and (4) defining a more comprehensive study to continue the evaluation of adhesives for package sealing. Results showed that 1.27 cm square gold plated flatpack type packages sealed with the film adhesives and the paste adhesive retained their seal integrity after all tests, and that similarly prepared 2.54 cm square packages retained their seal integrity after all tests except the 10,000 g's constant acceleration test. It is concluded that these results are encouraging, but by no means sufficient to establish the suitability of adhesives for sealing high reliability hybrid microcircuits.
Perkins, K. L.↗
Additive Manufacturing of Multi-Material Systems for Aerospace Applications
Additive manufacturing methods for producing single materials are rapidly improving. The resulting material properties and microstructures are becoming more comparable to those of conventionally fabricated materials. However, the need for multi-functional and complex structures and components requires additional innovations in manufacturing such as multi-material and hybrid additive manufacturing approaches. Additive manufacturing machines with multiple print capabilities and combinations of AM, machining, and conventional processing methods will further open up design spaces and possibilities. In this presentation, several examples of the needs and methods for multi-material fabrication will be discussed with a focus on aerospace applications. Direct printing of silver coils in conjunction with fused deposition modeling, machined parts, and, binder jetting is being developed for innovative stator designs. Binder jetting of silicon-based materials with powder bed additions is being developed for heat exchanger applications. Additive manufacturing of bi-material systems is being pursued to fabricate lightweight, integrated, multifunctional structures.
multi-materials↗
Integrated automation for manufacturing of electronic assemblies
Since 1985, the Naval Ocean Systems Center has been identifying and developing needed technology for flexible manufacturing of hybrid microelectronic assemblies. Specific projects have been accomplished through contracts with manufacturing companies, equipment suppliers, and joint efforts with other government agencies. The resulting technology has been shared through semi-annual meetings with government, industry, and academic representatives who form an ad hoc advisory panel. More than 70 major technical capabilities have been identified for which new development is needed. Several of these developments have been completed and are being shared with industry.
Sampite, T. Joseph↗
Specification guidelines for hybrid microcircuits
Guidelines establishing manufacturing and control procedures for hybrid microcircuits used in aerospace programs may have possible commercial and industrial applications. Guidelines encompass parts, materials, and process controls, as well as assembly, packaging methods, screening, and inspection procedures for procurement of custom packaged, high reliability microcircuits.
Caruso, S. V.↗
Strength of adhesive-bonded hybrid structures
Structures prepared from materials with different thermal and mechanical properties by means of fiber-strengthened binders can fail in a number of ways. The present lecture is focused on failures through debonding at the metal or at the fiber-reinforced plastic. A method for calculating the stress distribution in adhesive layers as a function of the load is outlined, and its usefulness in providing insight into the behavior of bonds in hybrid structures is noted. Means of eliminating the unfavorable effects of temperature, humidity, creep and relaxation on the bonds in the manufacture of hybrid structures are examined, along with test methods developed for such structures.
Kirschke, L.↗
Additive Manufacturing of Aerospace Propulsion Components
The presentation will provide an overview of ongoing activities on additive manufacturing of aerospace propulsion components, which included rocket propulsion and gas turbine engines. Future opportunities on additive manufacturing of hybrid electric propulsion components will be discussed.
Additive Manufacturing↗
Hybrid Propulsion Demonstration Program 250K Hybrid Motor
The Hybrid Propulsion Demonstration Program (HPDP) program was formed to mature hybrid propulsion technology to a readiness level sufficient to enable commercialization for various space launch applications. The goal of the HPDP was to develop and test a 250,000 pound vacuum thrust hybrid booster in order to demonstrate hybrid propulsion technology and enable manufacturing of large hybrid boosters for current and future space launch vehicles. The HPDP has successfully conducted four tests of the 250,000 pound thrust hybrid rocket motor at NASA's Stennis Space Center. This paper documents the test series.
Story, George↗
Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition
Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.
Gradl, Paul R.↗
Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition
Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.
Gradl, Paul↗
Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology
Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary toolless pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.
Shah, Sandeep↗
Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology
Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.
Shah, Sandeep↗