Development and Transition of a Computational Materials Framework to Support Qualification of Additively Manufactured Components
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E H Glaessgen↗
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Results for “additively manufactured components”
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NASA's Plans for Development of a Standard for Additive Manufactured Components
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Rick Russell↗
Comparison of NDE techniques for sintered-SiC components
High frequency, bulk-wave ultrasonics detected defects in manufactured SiC components. In addition, gas-turbine blades and vanes were examined by scanning laser acoustic microscopy (SLAM). Comparative results obtained on simple shapes such as disks and bars by microfocus X-ray radiography, ultrasonics, scanning photoacoustic spectroscopy, and SLAM are discussed.
Srinivasan, M.↗
Experimental Characterization of Additively Manufactured Nickel-Titanium Shape Memory Alloy Heat Pipes
Shape memory alloys (SMA) have been identified for use in spacecraft components as replacement for conventional deployment mechanisms. They may be used in thermal management components such as radiators to create self-deploying radiators. One SMA, NiTi, has also been developed for additive manufacturing processes. Heat pipes are a common way to create highly effective and lightweight spaceflight radiators, and heat pipes can also be made from NiTi and related alloys. The wick is the critical element of a functioning heat pipe, and recent progress over the past years has led to the development of additively manufactured heat pipe wicks in various materials. The combination of these efforts is the focus of this project: creating an additively manufactured, shape memory alloy self-deploying heat pipe radiator. This paper will focus on the experimental characterization of these additively manufactured NiTi heat pipes. The heat pipe coupons were additively manufactured by direct metal laser sintering (DMLS), with an integral liquid cooled condenser. Heat is input to the heat pipe via a thin film heater. Thermocouples were spot welded to the heat pipes to measure temperature at several axial locations. The heat pipes were tested with two working fluids: water and ethanol. Ethanol is not an ideal working fluid for heat pipes but is useful in characterizing them because it wets well to a wide variety of surfaces. Water is in general a superior working fluid for heat pipes, but its contact angle and therefore wicking performance strongly depends on the surface chemistry of the surface it is in contact with. A particular measurement of interest in this test is the evaporator to condenser thermal conductance, which will be compared in the full paper to recently published correlations for additively manufactured heat pipes. Experimental results for two straight geometry and one bellows geometry heat pipe will be presented. The bellows geometry is of interest for condenser of the self-deploying radiator design.
Additive manufacturing↗
A Review of Direct Ink Writing of Polymer Derived Ceramics
With the growing demand for materials capable of withstanding extreme temperatures and pressures, ceramic components with exceptional corrosion resistance and reliable mechanical properties have experienced a significant surge in demand. However, traditional ceramic forming methods involve high-temperatures and energy-intensive processes that often struggle to produce complex parts or composites efficiently. Polymer-Derived Ceramics (PDCs) offer a transformative solution by using polymeric precursors that can be converted into a wide variety of silicon-based and non-silicon-based ceramics through heat treatment. The polymeric nature of PDC precursors enables the fabrication of geometrically intricate components using conventional polymer-forming techniques at significantly lower processing temperatures. Furthermore, PDCs are well-suited for additive manufacturing (AM), allowing the production of complex structural and functional components through cost-effective, low-temperature processes. By leveraging the diverse properties of PDC materials – each with unique advantages and limitations – manufacturers can optimise performance for specific applications. This review provides an overview of the types of PDCs developed to date and their broad range of applications. Specifically, it delves into the Direct Ink Writing (DIW) process, exploring its rheological requirements and the critical role of fillers in tailoring the rheological properties of polymeric precursors to meet the specific demands of DIW.
Victoria Bishop↗
A Frank Discussion on Lessons Learned From Adopting and Applying NASA-STD-6030 for Spaceflight Systems
With the advancement and adoption of Additive Manufacturing (AM) for spaceflight systems, numerous lessons have been learned during the qualification and certification of AM components. The lessons learned covered in this presentation will provide an overview of the challenges faced by NASA centers and commercial partners working to design AM hardware that complies with NASA-STD-6030 Additive Manufacturing Requirements (AMR). Topics of interest include tailoring of requirements for specific projects, documentation requirements, and addressing conservative approaches towards mechanical property development and analysis. In addition to that, this presentation aims to impress that these lessons learned will influence the future revisions of the NASA technical standard to facilitate and advance AM technology adoption on NASA projects.
Additive Manufacturing↗
Sikorsky interactive graphics surface design/manufacturing system
An interactive graphics system conceived to be used in the design, analysis, and manufacturing of aircraft components with free form surfaces was described. In addition to the basic surface definition and viewing capabilities inherent in such a system, numerous other features are present: surface editing, automated smoothing of control curves, variable milling patch boundary definitions, surface intersection definition and viewing, automatic creation of true offset surfaces, digitizer and drafting machine interfaces, and cutter path optimization. Documented costs and time savings of better than six to one are being realized with this system. The system was written in FORTRAN and GSP for use on IBM 2250 CRT's in conjunction with an IBM 370/158 computer.
Robbins, R.↗
A Dispersion-Strengthened Low-Density Niobium Alloy and Its Elevated Temperature Mechanical Performance
In response to the elevated-temperature and weight-reduction demands of modern aerospace applications, a novel oxide-dispersion-strengthened low-density niobium alloy (LDNb-ODS) was fabricated using laser powder bed fusion (L-PBF). To overcome powder procurement barriers, L-PBF feedstock was produced by blending commercial Nb521, Ti64, and Cr powder with Y2O3 nanoparticles via resonant acoustic mixing. Following L-PBF and a 1400°C vacuum heat treatment, the alloy achieved a density of 6.73 g/cc and a fine mean grain size of 4.62 µm stabilized by uniform ~30 nm yttria dispersoids. Microstructural analysis revealed a chemically inhomogeneous build with lack-of-fusion defects and a titanium (Ti) shift from a nominal 31.5 wt% in the starting powder blend to 24.8 wt% in the printed part due to preferential Ti loss during printing. Elevated-temperature tensile testing demonstrated that LDNb-ODS maintained a superior specific yield strength of 60-85 MPa/(g/cc) up to 800°C, outperforming nickel-based alloys Ni625, Ni230, and GRX-810. Between 870°C and 950°C, its specific strength surpassed both Ni718 and Ni625. In rapid stress-rupture testing at 1093°C and 20.7 MPa, uncoated LDNb-ODS survived 21.4 hours (a tenfold increase over legacy C-103) while an R512E silicide coating extended rupture life to 84.8 hours, confirming that oxidation accelerates low-stress failure. These findings demonstrate that additive manufacturing of LDNb-ODS provides a viable, lightweight alternative to nickel-based superalloys for high-temperature (>850°C) aerospace components.
Low Density Niobium Alloy↗
Evaluations of Additively Manufactured Superalloy Lattice Blocks
Cast lattice block structures made up of high-temperature superalloys were previously shown to offer advantages in density, efficiency, and tailored properties. However, inconsistencies in casting die-fill, composition, and microstructure were identified as persistent issues with the casting process path. Three candidate lattice designs were screened through additive manufacturing of a superalloy. Laser powder bed fusion was applied with superalloy powder to produce lattice blocks for three-dimensional octahedral unit-cell designs of three heights. Properties of the structural designs versus additively manufactured lattices were compared, including structural dimensions, densities, defects, grain structures, crystallographic texture, and surface residual stresses. Findings indicate this concept could produce useful superalloy structures for high-temperature-capable static components requiring tailored density, and thermophysical and mechanical properties.
superalloy↗
Greases
The characteristics and applications of greases are discussed. The basic components of greases are analyzed to show the types of additives used and the basis for grease classification. Manufacturing methods for soap base and nonsoap base greases are described. The tests which are conducted to determine the properties of greases are reported.
Mccarthy, P. R.↗
Electric utility acid fuel cell stack technology advancement
The principal effort under this program was directed at the fuel cell stack technology required to accomplish the initial feasibility demonstrations of increased cell stack operating pressures and temperatures, increased cell active area, incorporation of the ribbed substrate cell configuration at the bove conditions, and the introduction of higher performance electrocatalysts. The program results were successful with the primary accomplishments being: (1) fabrication of 10 sq ft ribbed substrate, cell components including higher performing electrocatalysts; (2) assembly of a 10 sq ft, 30-cell short stack; and (3) initial test of this stack at 120 psia and 405 F. These accomplishments demonstrate the feasibility of fabricating and handling large area cells using materials and processes that are oriented to low cost manufacture. An additional accomplishment under the program was the testing of two 3.7 sq ft short stacks at 12 psia/405 F to 5400 and 4500 hours respectively. These tests demonstrate the durability of the components and the cell stack configuration to a nominal 5000 hours at the higher pressure and temperature condition planned for the next electric utility power plant.
Congdon, J. V.↗
Environmental effects on composites for aircraft
The influence of the operational environment on the behavior of composite materials and aircraft components fabricated with these composite materials was considered. Structural weight savings, manufacturing cost savings, and long-term environmental durability are among the factors examined. The flight service experience to date of composite components is evaluated. In addition, the influence of a number of worldwide, ground based outdoor exposures on the physical and mechanical properties of six composite materials is discussed. In particular, the current extent of the ultraviolet surface degradation and the moisture gained by diffusion is shown.
Pride, R. A.↗
Evaluation of Superalloy 718 Additively Manufactured Lattice Blocks
Lattice block structures made up of high temperature superalloys could offer advantages in density, efficiency, and tailored properties. Three candidate lattice designs were screened through additive manufacturing of superalloy 718. Laser powder bed fusion was applied with 718 powder to produce lattice blocks for three-dimensional octahedral unit cell designs of three heights. As-designed versus additively manufactured 718 lattices were compared, including structural dimensions, densities, defects, grain structures, crystallographic texture, and surface residual stresses. Manufactured lattice I diverged the most from its design, with both corner and center nodes merged into continuous columns. Manufactured lattice III came closest to its design, though the actual nodes and struts were still larger in cross section than in the design. Only modest grain coarsening and negligible chemical segregation were observed for all three designs, suggesting uniform thermo-physical and mechanical properties are possible. Significant tensile residual stresses were present at the surface of the manufactured blocks, with highest stresses in the building direction. Current findings indicate this concept could produce useful superalloy structures for high-temperature-capable static components requiring tailored density, and thermo-physical/mechanical properties.
super alloys↗
A common geometric data-base approach for computer-aided manufacturing of wind-tunnel models and theoretical aerodynamic analysis
A more automated process to produce wind tunnel models using existing facilities is discussed. A process was sought to more rapidly determine the aerodynamic characteristics of advanced aircraft configurations. Such aerodynamic characteristics are determined from theoretical analyses and wind tunnel tests of the configurations. Computers are used to perform the theoretical analyses, and a computer aided manufacturing system is used to fabricate the wind tunnel models. In the past a separate set of input data describing the aircraft geometry had to be generated for each process. This process establishes a common data base by enabling the computer aided manufacturing system to use, via a software interface, the geometric input data generated for the theoretical analysis. Thus, only one set of geometric data needs to be generated. Tests reveal that the process can reduce by several weeks the time needed to produce a wind tunnel model component. In addition, this process increases the similarity of the wind tunnel model to the mathematical model used by the theoretical aerodynamic analysis programs. Specifically, the wind tunnel model can be machined to within 0.008 in. of the original mathematical model. However, the software interface is highly complex and cumbersome to operate, making it unsuitable for routine use. The procurement of an independent computer aided design/computer aided manufacturing system with the capability to support both the theoretical analysis and the manufacturing tasks was recommended.
See, M. J.↗
Feasibility Study 30 Watts per Pound Rollup Solar Array
Principal efforts in this reporting period were applied to preparation of the detail design of the array structure and mechanisms and to manufacturing drawings for a demonstration model of the selected design concept. Analytical support focused on substantiation of the detail design. Additional studies were performed of dynamic criteron effects on components of the wrap drum. Thermal studies were extended to evaluate another thin film (preferred) material for the substrate and its influence on solar cell temperatures. Electrical design considerations included feasibility studies and ramifications of using a new, larger size, solar cell and a new coverglass application concept. Preliminary evaluations suggest improvement in the array power to weight characteristic and net savings in the estimated cost of cell installation. Weight estimates have been up-dated in keeping with refinements in detail design. Performance of this contractor's rollout solar array design is now projected as capable of producing 31.6 watts per pound of weight; excludes estimated improvements from use of new solar cell design.
Source record↗
Abradable compressor and turbine seals, volume 1
The application and advantages of abradable coatings as gas-path seals in a general aviation turbine engine were evaluated for use on the high-pressure compressor, the high-pressure turbine, and the low-pressure turbine shrouds. Topics covered include: (1) the initial selection of candidate materials for interim full-scale engine testing; (2) interim engine testing of the initially selected materials and additional candidate materials; (3) the design of the component required to adapt the hardware to permit full-scale engine testing of the most promising materials; (4) finalization of the fabrication methods used in the manufacture of engine test hardware; and (5) the manufacture of the hardware necessary to support the final full-scale engine tests.
Sundberg, D. V.↗
Computational Materials for Qualification and Certification (CM4QC) Strategy Document: Maturation of Computational Materials Methods for Aviation-Focused Qualification and Certification of Metal Additive Manufacturing (as an Example of Process-Intensive Materials)
Although considerable scientific and technological advances have been made in recent years in additive manufacturing (AM) processes, these advances have not translated into significant market penetration of AM parts within the aviation industry. It is broadly acknowledged that using traditional qualification and certification (Q&C) approaches for AM components is one of the most significant barriers to broader adoption of AM, resulting in high costs, long product development and certification timelines, and complex design iterations during the product development cycle. A new approach is urgently needed. This document lays out a vision for a new Q&C paradigm with increased use of computational materials (CM) methods aimed at decreasing the time and cost of Q&C of process-intensive material (PIM) approaches in the aviation industry, with AM as the immediate use case. This vision was developed with substantial input from industry, regulatory agencies, government research organizations, and academia.
Edward H Glaessgen↗
Development of an Additively Manufactured Subscale Secondary Sealed Container for the NASA FROSTE Project
This presentation details the development of an additively manufactured (AM) subscale test article for the secondary sealed container (SSC) as part of the NASA FROSTE project. FROSTE is focused on the collection of regolith samples from shadowed regions of the Moon and the preservation of those samples at cryogenic temperatures for return to Earth. Our team was integrated into the FROSTE program to leverage innovative design approaches and additive manufacturing capabilities in support of a scalable development strategy, where the subscale configuration serves as the development path toward a full-scale SSC. Scalmalloy was selected as the primary material for all AM components due to its favorable strength-to-weight ratio, thermal conductivity, and demonstrated performance in aerospace applications. Its aluminum-based composition supports robust mechanical behavior at cryogenic temperatures while enabling efficient heat transfer and control of thermal gradients within the containment system. The SSC architecture consists of an outer container assembly that houses a phase change material (PCM) tank, which in turn contains primary containers holding the regolith. Thermal management relies on controlled conductive and radiative heat transfer, including a thermal connection assembly that interfaces the PCM tank to an external cryocooler via a thermal strap, and IMLI surrounding the PCM tank to inhibit radiative heat transfer. The outer container assembly incorporates sealing interfaces, thermal connection ports, and I/O feedthroughs, with PTFE spring seals used at critical interfaces to maintain containment integrity. The PCM tank is manufactured as a single monolithic Scalmalloy component and incorporates an integral lattice structure to minimize thermal gradients, internal channels for thermocouple routing, and interface features for thermal connection assembly integration. The tank is centrally suspended within the outer container using support rings, with G10 insulating components employed to inhibit thermal leaks. This work describes the design methodology, AM approach, and key considerations used to inform the design.
regolith↗