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DOE OSTI2025

A Review of the Influence of Processing Parameters on ODS Steels Produced via Additive Manufacturing Techniques

Abstract This paper reviews current observations regarding processing conditions for oxide dispersion-strengthened steels consolidated through additive manufacturing techniques. Variations in ODS steels observed across process parameters include changes in grain size, grain texture, oxide size, density of oxides, porosity, melt pool characteristics, and mechanical properties. These properties were then compared across techniques to understand which techniques and processing conditions lead to the highest strength, ductility, and oxide density. Current literature suggests that a mix of grain types, in the form of either morphology or phase, can significantly increase the strength of printed ODS steels. Meanwhile, the most ductile samples, regardless of consolidation technique or matrix material, were made from feedstock with oxide additions located on the powder surface. Reported grain and oxide sizes were plotted against the ratio of laser power to scan speed, volumetric energy density, and normalized enthalpy. No strong correlation between these values and microstructural features was observed. The plots that were made suggest that a larger data set, more in-depth representative equations, and more defined material properties as a function of specific feedstock used are necessary to determine a value that can be correlated to the printed ODS steel microstructure.

deJong, Matthew↗

DOE OSTI2025

Effect of LPBF Processing Parameters on Inconel 718 Lattice Structures: Geometrical Characteristics, Surface Morphology, and Mechanical Properties

Laser Powder Bed Fusion (LPBF) enables the additive manufacturing of complex lattice structures. However, the fabrication of lattice structures via LPBF poses challenges in achieving the intended geometrical accuracy due to their inherent complexity. This study investigates the effects of LPBF processing parameters, specifically laser power and scanning speed, on the geometrical characteristics, surface quality, and mechanical behavior of Inconel 718 lattices structures. The results reveal that processing parameters required for the fabrication of near-full dense structures do not translate effectively to lattice configurations, as variations in energy input influence lattice geometry and surface quality. In this work, strut thickness, open-pore size, open-cell porosity, and surface roughness were measured, and the mechanical properties of the lattices were evaluated under shear loading. The findings indicate that lower energy inputs, achieved by reducing laser power and increasing scanning speed, yield porous structures but lead to mechanical degradation. In contrast, high energy inputs lead to lattices with enhanced strength but result in undesirable open-pore blockage and dimensional inaccuracies. These findings provide insights into tailoring LPBF parameters for dimensional accuracy in lattices and correlating the processing parameters to mechanical performance and surface roughness.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Dynamic measurements of thermophysical properties of metals and alloys at high temperatures by subsecond pulse heating techniques

Rapid (subsecond) heating techniques developed at the National Institute of Standards and Technology for the measurements of selected thermophysical and related properties of metals and alloys at high temperatures (above 1000 C) are described. The techniques are based on rapid resistive self-heating of the specimen from room temperature to the desired high temperature in short times and measuring the relevant experimental quantities, such as electrical current through the specimen, voltage across the specimen, specimen temperature, length, etc., with appropriate time resolution. The first technique, referred to as the millisecond-resolution technique, is for measurements on solid metals and alloys in the temperature range 1000 C to the melting temperature of the specimen. It utilizes a heavy battery bank for the energy source, and the total heating time of the specimen is typically in the range of 100-1000 ms. Data are recorded digitally every 0.5 ms with a full-scale resolution of about one part in 8000. The properties that can be measured with this system are as follows: specific heat, enthalpy, thermal expansion, electrical resistivity, normal spectral emissivity, hemispherical total emissivity, temperature and energy of solid-solid phase transformations, and melting temperature (solidus). The second technique, referred to as the microsecond-resolution technique, is for measurements on liquid metals and alloys in the temperature range 1200 to 6000 C. It utilizes a capacitor bank for the energy source, and the total heating time of the specimen is typically in the range 50-500 micro-s. Data are recorded digitally every 0.5 micro-s with a full-scale resolution of about one part in 4000. The properties that can be measured with this system are: melting temperature (solidus and liquidus), heat of fusion, specific heat, enthalpy, and electrical resistivity. The third technique is for measurements of the surface tension of liquid metals and alloys at their melting temperature. It utilizes a modified millisecond-resolution heating system designed for use in a microgravity environment.

Cezairliyan, Ared↗

NASA NTRS1987

Opposed jet burner studies of hydrogen combustion with pure and N2, NO-contaminated air

A counterflow diffusion flame formed by an argon-bathed tubular-opposed jet burner (OJB) was used to determine the 'blowoff' and 'restore' combustion characteristics for jets of various H2/N2 mixtures and for jets of air contaminated by NO (which normally occurs in high-enthalpy airflows supplied to hypersonic test facilities for scramjet combustors). Substantial divergence of 'blowoff' and 'restore' limits occurred as H2 mass flux, M(H)2, increased, the H2 jet became richer, and the M(air)/M(H2 + N2) ratio increased from 1 to 3 (molar H2/O2 from 1 to 16). Both OJB limits were sensitive to reactant composition. One to six percent NO in air led to significant N2-corrected decreases in the M(H2) values for 'blowoff' (2-8 percent) and 'restore' (6-12 percent) for mole fractions of H2 ranging from 0.5 to 0.95. However, when H2/O2 was held constant, all N2-corrected changes in M(H2) were negligible.

Guerra, Rosemary↗

NASA NTRS2018

Determination of Uncertainties for Analytically Derived Material Properties to Be Used in Monte Carlo Based Orion Heatshield Sizing

Ablative materials are often used for spacecraft heatshields to protect underlying structures from the extreme environments associated with atmospheric reentry. NASA's Orion EM-1 capsule has been designed to use a molded Avcoat material system. In order to determine the required heatshield thickness, a Monte Carlo approach to the sizing process was proposed. To perform the Monte Carlo simulation, statistical uncertainties on all material property input parameters were required. Obtaining these values for measured properties is straightforward, however input parameters that are derived analytically have historically used uncertainties based on engineering judgment. A MATLAB program was created to use laboratory generated thermogravimetric analysis (TGA) data to calculate uncertainties on the Arrhenius parameters for molded Avcoat. Uncertainties associated with the normalized ablation rate and pyrolysis gas enthalpy were also generated using a wrapper script and the ACE code. These uncertainties could then be tied directly to measured values of individual elemental constituents. The resulting uncertainty values will allow for a probabilistic sizing approach on molded Avcoat with a higher level of confidence in the input parameters.

material property uncertainties↗

NASA NTRS1986

Coupling conditions for integrating boundary layer and rotational inviscid flow

The matching of a boundary layer and a rotational inviscid flow is reexamined by extending the Johnson and Sockol (1979) coupling conditions to include the case where the boundary layer solution includes the second-order effects of the freestream vorticity and the total temperature gradient. It is pointed out that two of the three conditions are not independent. If the boundary layer solution satisfies the appropriate momentum and energy integral equations, it follows that the imposition of the normal mass flux condition insures that the conditions on a normal flux of streamwise momentum and total enthalpy will also be satisfied.

Sockol, P. M.↗

NASA NTRS1976

Table and charts of equilibrium normal shock and shock tube properties for pure argon with velocities to 18 km/sec

Equilibrium thermodynamic and flow properties are presented in tabulated and graphical form for moving, standing, and reflected normal shock waves in pure argon. Properties include pressure, temperature, density, enthalpy, speed of sound, entropy, molecular-weight ratio, isentropic exponent, velocity, and species mole fractions. Incident (moving) shock velocities are varied from 2 to 18 km/sec for a range of initial pressure of 5 N/sq m to 500 kN/sq m. Working charts illustrating shock tube performance with argon test gas and heated helium and hydrogen driver gases are also presented.

Miller, C. G., III↗

NASA NTRS1976

Table and charts of equilibrium normal-shock and shock-tube properties for pure carbon dioxide with velocities from 1 to 16 km/sec

Equilibrium thermodynamic and flow properties are presented in tabulated and graphical form for moving, standing, and reflected normal shock waves in pure CO2. Properties include pressure, temperature, density, enthalpy, speed of sound, entropy, molecular weight ratio, isentropic exponent, velocity, and species mole fractions. Incident (moving) shock velocities are varied from 1 to 16 km/sec for a range of initial pressure of 5 N/sq m to 500 kN/sq m. The present results are applicable to shock tube flows and to freeflight conditions for a blunt body at high velocities. Working charts illustrating idealized shock tube performance with CO2 test gas and heated helium and hydrogen driver gases are also presented.

Miller, C. G., III↗

NASA NTRS1990

Keyhole and weld shapes for plasma arc welding under normal and zero gravity

A first order study of the interfacial (keyhole) shape between a penetrating argon plasma arc jet and a stationary liquid metal weld pool is presented. The interface is determined using the Young-Laplace equation by assuming that the plasma jet behaves as a one-dimensional ideal gas flow and by neglecting flow within the weld pool. The solution for the keyhole shape allows an approximate determination of the liquid-solid metal phase boundary location based on the assumption that the liquid melt is a stagnant thermal boundary layer. Parametric studies examine the effect of plasma mass flow rate, initial plasma enthalpy, liquid metal surface tension, and jet shear on weldment shape under both normal and zero gravity. Among the more important findings of this study is that keyhole and weld geometries are minimally affected by gravity, suggesting that data gathered under gravity can be used in planning in-space welding.

Keanini, R. G.↗

NASA NTRS2003

Coherent Anti-Stokes Raman Scattering (CARS) as a Probe for Supersonic Hydrogen-Fuel/Air Mixing

The dual-pump coherent anti-Stokes Raman spectroscopy (CARS) method was used to measure temperature and the absolute mole fractions of N2, O2 and H2 in a supersonic non-reacting fuel-air mixing experiment. Experiments were conducted in NASA Langley Research Center s Direct Connect Supersonic Combustion Test Facility. Under normal operation of this facility, hydrogen and air burn to increase the enthalpy of the test gas and O2 is added to simulate air. This gas is expanded through a Mach 2 nozzle and into a combustor model where fuel is then injected, mixes and burns. In the present experiment the O2 of the test gas is replaced by N2. The lack of oxidizer inhibited combustion of the injected H2 fuel jet allowing the fuel/air mixing process to be studied. CARS measurements were performed 427 mm downstream of the nozzle exit and 260 mm downstream of the fuel injector. Maps were obtained of the mean temperature, as well as the N2, O2 and H2 mean mole fraction fields. A map of mean H2O vapor mole fraction was also inferred from these measurements. Correlations between different measured parameters and their fluctuations are presented. The CARS measurements are compared with a preliminary computational prediction of the flow.

Danehy, P. M.↗

NASA NTRS2004

Evaluation of CO2, N2 and He as Fire Suppression Agents in Microgravity

The U.S. modules of the International Space Station use gaseous CO2 as the fire extinguishing agent. This was selected as a result of extensive experience with CO2 as a fire suppressant in terrestrial applications, trade studies on various suppressants, and experiments. The selection of fire suppressants and suppression strategies for NASA s Lunar and Martian exploration missions will be based on the same studies and normal-gravity data unless reduced gravity fire suppression data is obtained. In this study, the suppressant agent concentrations required to extinguish a flame in low velocity convective flows within the 20-sec of low gravity on the KC-135 aircraft were investigated. Suppressant gas mixtures of CO2, N2, and He with the balance being oxygen/nitrogen mixtures with either 21% or 25% O2 were used to suppress flames on a 19-mm diameter PMMA cylinder in reduced gravity. For each of the suppressant mixtures, limiting concentrations were established that would extinguish the flame at any velocity. Similarly, concentrations were established that would not extinguish the flame. The limiting concentrations were generally consistent with previous studies but did suggest that geometry had an effect on the limiting conditions. Between the extinction and non-extinction limits, the suppression characteristics depended on the extinguishing agent, flow velocity, and O2 concentration. The limiting velocity data from the CO2, He, and N2 suppressants were well correlated using an effective mixture enthalpy per mole of O2, indicating that all act via O2 displacement and cooling mechanisms. In reduced gravity, the agent concentration required to suppress the flames increased as the velocity increased, up to approximately 10 cm/s (the maximum velocity evaluated in this experiment). The effective enthalpy required to extinguish flames at velocities of 10 cm/s is approximately the same as the concentrations in normal gravity. A computational study is underway to further evaluate these findings.

Ruff, Gary A.↗

NASA NTRS1974

Tables and charts of equilibrium normal shock and shock tube solutions for pure CO2 with velocities to 16 km/second

Equilibrium thermodynamic and flow properties are presented in tabulated and graphical form for moving, standing, and reflected normal shock waves in pure CO2, representative of Mars and Venus atmospheres. Properties include pressure, temperature, density, enthalpy, speed of sound, entropy, molecular weight ratio, isentropic exponent, velocity and species mole fractions. Incident (moving) shock velocities are varied from 1 to 16 km/sec for a range of initial pressure of 5 Newtons per square meter to 500 kilo Newtons per square meter. The present results are applicable to shock tube flows, and to free-flight conditions for a blunt body at high velocities. Working charts illustrating idealized shock-tube performance with CO2 test gas and heated helium and hydrogen driver gases are also presented.

Miller, C. G., III↗

NASA NTRSDate not supplied

Development of a Composite Material Aerodynamic Demise Model for the Object Reentry Survival Analysis Tool (ORSAT)

The reentry demise of fiber-reinforced polymer (FRP) composites is an increasing concern for modern spacecraft at end of life. Unlike traditional materials such as metals, shredding of the material by aerodynamic forces appears to be a major component of the reentry demise mechanism. This paper will describe a new mechanical, strength-based, material demise model for the Object Reentry Survival Analysis Tool (ORSAT) Version 7.1. The model is based on laboratory in-situ and residual strength tests of several FRP materials performed during the NASA Orbital Debris Program Office’s Phase II Composite Material Demise test campaign. To test the residual strength of partially charred FRP materials, the authors tested 107 rectangular shaped samples of different thicknesses that were previously exposed to high-enthalpy flow at the University of Texas at Austin’s Inductively Coupled Plasma Torch facility. Tests were performed under normal atmospheric conditions at NASA Johnson Space Center’s Experimental Impact Laboratory using a Chatillon TCD1000 tensile test machine configured with a three-point bending jig. Mean fracture load, residual strength, delamination, and flexural modulus were measured for each test. An engineering model of aeromechanical demise for each material was developed by correlating the measured residual strength of the samples with the duration and magnitude of the applied heat flux and the mass loss and char progression. This model has been implemented in ORSAT 7.1 for the built-in, charring carbon fiber/epoxy and charring glass fiber/epoxy material models. The new model was verified by calculating the demise of hundreds of FRP composite fragments of various shapes and sizes and checking the calculations for consistency, with specific focus on material characterization in one-dimension. Further tests are planned in hypersonic flow facilities to validate the assumptions used in the model.

Priscilla A. Mendoza↗

NASA NTRSDate not supplied

Development of a Composite Material Aerodynamic Demise Model for the Object Reentry Survival Analysis Tool (ORSAT)

Priscilla A. Mendoza↗

NASA NTRS1986

Application of a Runge-Kutta scheme for high-speed inviscid internal flows

A multi-stage Runge-Kutta method is analyzed for solving the two-dimensional Euler equations for external and internal flow problems. Subsonic, supersonic and, highly supersonic flows are studied. Various techniques for accelerating the convergence to a steady state are described and analyzed. Effects of the grid aspect ratio on the rate of convergence are evaluated. An enthalpy damping technique applicable to supersonic flows is described in detail. Numerical results for supersonic flows containing both oblique and normal shocks are presented confirming the efficiency of the method.

Moitra, A.↗

NASA NTRS1986

Application of Runge-Kutta scheme for high-speed inviscid internal flows

Moitra, A.↗

NASA NTRS1993

Comparison of Numerical Model Results with Diffusion Flames in Microgravity

The effects of gravity on methane diffusion flames were studied using a finite difference numerical model. Variables under consideration included velocity, pressure, temperature, enthalpy, reactive species, and inert carrier gas. Results obtained showed that flames in zero gravity were wider and taller than those in normal gravity. The use of a six reaction scheme produced similar predictions of flame width and height compared to those of the single reaction case. The numerical models predicted a considerable difference in the flame base region between normal gravity and low gravity. This region is considered to be beyond the boundaries of current analytical models.

Hyer, Paul V.↗

NASA NTRS1976

Table and charts of equilibrium normal-shock properties for hydrogen-helium mixtures with velocities to 70 km/sec. Volume 1: 0.95 H2-0.05 He (by volume)

Equilibrium thermodynamic and flow properties are presented in tabulated and graphical form for moving, standing, and reflected normal shock waves into hydrogen-helium mixtures representative of postulated outer planet atmospheres. These results are presented in four volumes and the volmetric compositions of the mixtures are 0.95H2-0.05He in Volume 1, 0.90H2-0.10He in Volume 2, 0.85H2-0.15He in Volume 3, and 0.75H2-0.25He in Volume 4. Properties include pressure, temperature, density, enthalpy, speed of sound, entropy, molecular-weight ratio, isentropic exponent, velocity, and species mole fractions. Incident (moving) shock velocities are varied from 4 to 70 km/sec for a range of initial pressure of 5 N/sq m to 100 kN/sq m. Results are applicable to shock-tube flows and for determining flow conditions behind the normal portion of the bow shock about a blunt body at high velocities in postulated outer planet atmospheres. The document is a revised version of the original edition of NASA SP-3085 published in 1974.

Miller, C. G., III↗