Method for Fabricating Composite Structures Using Continuous Press Forming

NASA Technical Reports Server (NTRS)

Farley, Gary L. (Inventor)

1997-01-01

A method for fabricating composite structures at a low-cost. moderate-to-high production rate. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform and debulking the partially debulked preform to form a net-shape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length and electron-beam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates. resulting in lower cost and high structural performance.

Advanced high-temperature alloys: Processing and properties; Proceedings of the Nicholas J. Grant Symposium, MIT, Cambridge, MA, June 16-18, 1985

DOE Office of Scientific and Technical Information (OSTI.GOV)

Allen, S.M.; Pelloux, R.M.; Widmer, R.

1986-01-01

Historical and advanced methods of producing, forming and polishing alloys in billets and net shapes are explored. Attention is given to the deficiencies in arc furnace melts and to the benefits which are accruing from rapid solidification processing, powder metallurgy and superplastic forming. The techniques employed in these methods for processing materials to desired shapes, mainly for aircraft gas turbine engines, are described, along with the microstructures and mechanical properties which are obtained. The state of the art in casting and forming techniques which yield the most favorable properties in intermetallic compound-based alloys, superalloys, glasses and metacrystals are identified. Finally,more » research directions being pursued to obtain higher purity, enhanced temperature, longer lifetime, damage resistant alloys which can be formed to net shapes are discussed.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Paranthaman, M. Parans; Sridharan, Niyanth; List, Fred A.

The technical objective of this technical collaboration phase I proposal is to fabricate near net-shaped permanent magnets using alloy powders utilizing direct metal deposition technologies at the ORNL MDF. Direct Manufacturing using the POM laser system was used to consolidate Nd 2Fe 14B (NdFeB) magnet powders into near net-shape parts efficiently and with virtually no wasted material as part of the feasibility study. We fabricated builds based on spherical NdFeB magnet particles. The results show that despite the ability to fabricate highly reactive materials in the laser deposition process, the magnetic coercivity and remanence of the NdFeB hard magnets ismore » significantly reduced. X-ray powder diffraction in conjunction with electron microscopy showed that the material experienced a primary Nd 2Fe 17B x solidification due to the undercooling effect (>60K). Consequently the presence of alpha iron phase resulted in deterioration of the build properties. Further optimization of the processing parameters is needed to maintain the Nd 2Fe 14B phase during fabrication.« less

2D net shape weaving for cost effective manufacture of textile reinforced composites

NASA Astrophysics Data System (ADS)

Vo, D. M. P.; Kern, M.; Hoffmann, G.; Cherif, C.

2017-10-01

Despite significant weight and performance advantages over metal parts, the today’s demand for fibre-reinforced polymer composites (FRPC) has been limited mainly by their large manufacturing cost. The combination of dry textile preforms and low-cost consolidation processes such as resin transfer molding (RTM) has been appointed as a promising approach to low-cost FRPC manufacture. At the current state of the art, tooling and impregnation technology is well understood whereas preform fabrication technology has not been developed effectively. This paper presents an advanced 2D net shape weaving technology developed with the aim to establish a more cost effective system for the manufacture of dry textile preforms for FRPC. 2D net shape weaving is developed based on open reed weave (ORW) technology and enables the manufacture of 2D contoured woven fabrics with firm edge, so that oversize cutting and hand trimming after molding are no longer required. The introduction of 2D net shape woven fabrics helps to reduce material waste, cycle time and preform manufacturing cost significantly. Furthermore, higher grade of automation in preform fabrication can be achieved.

Progress on high-performance rapid prototype aluminum mirrors

NASA Astrophysics Data System (ADS)

Woodard, Kenneth S.; Myrick, Bruce H.

2017-05-01

Near net shape parts can be produced using some very old processes (investment casting) and the relatively new direct metal laser sintering (DMLS) process. These processes have significant advantages for complex blank lightweighting and costs but are not inherently suited for producing high performance mirrors. The DMLS process can provide extremely complex lightweight structures but the high residual stresses left in the material results in unstable mirror figure retention. Although not to the extreme intricacy of DMLS, investment casting can also provide complex lightweight structures at considerably lower costs than DMLS and even conventional wrought mirror blanks but the less than 100% density for casting (and also DMLS) limits finishing quality. This paper will cover the progress that has been made to make both the DMLS and investment casting processes into viable near net shape blank options for high performance aluminum mirrors. Finish and figure results will be presented to show performance commensurate with existing conventional processes.

INEL Spray-forming Research

NASA Technical Reports Server (NTRS)

Mchugh, Kevin M.; Key, James F.

1993-01-01

Spray forming is a near-net-shape fabrication technology in which a spray of finely atomized liquid droplets is deposited onto a suitably shaped substrate or mold to produce a coherent solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g., refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray-forming technology for producing near-net-shape solids and coatings of a variety of metals, polymers, and composite materials. Results from several spray forming programs are presented to illustrate the range of capabilities of the technique as well as the accompanying technical and economic benefits. Low-carbon steel strip greater than 0.75 mm thick and polymer membranes for gas/gas and liquid/liquid separations that were spray formed are discussed; recent advances in spray forming molds, dies, and other tooling using low-melting-point metals are described.

Scale-up of Carbon/Carbon Bipolar Plates

DOE Office of Scientific and Technical Information (OSTI.GOV)

David P. Haack

2009-04-08

This project was focused upon developing a unique material technology for use in PEM fuel cell bipolar plates. The carbon/carbon composite material developed in this program is uniquely suited for use in fuel cell systems, as it is lightweight, highly conductive and corrosion resistant. The project further focused upon developing the manufacturing methodology to cost-effectively produce this material for use in commercial fuel cell systems. United Technology Fuel Cells Corp., a leading fuel cell developer was a subcontractor to the project was interested in the performance and low-cost potential of the material. The accomplishments of the program included the developmentmore » and testing of a low-cost, fully molded, net-shape carbon-carbon bipolar plate. The process to cost-effectively manufacture these carbon-carbon bipolar plates was focused on extensively in this program. Key areas for cost-reduction that received attention in this program was net-shape molding of the detailed flow structures according to end-user design. Correlations between feature detail and process parameters were formed so that mold tooling could be accurately designed to meet a variety of flow field dimensions. A cost model was developed that predicted the cost of manufacture for the product in near-term volumes and long-term volumes (10+ million units per year). Because the roduct uses lowcost raw materials in quantities that are less than competitive tech, it was found that the cost of the product in high volume can be less than with other plate echnologies, and can meet the DOE goal of $4/kW for transportation applications. The excellent performance of the all-carbon plate in net shape was verified in fuel cell testing. Performance equivalent to much higher cost, fully machined graphite plates was found.« less

Enery Efficient Press and Sinter of Titanium Powder for Low-Cost Components in Vehicle Applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Thomas Zwitter; Phillip Nash; Xiaoyan Xu

2011-03-31

This is the final technical report for the Department of Energy NETL project NT01931 Energy Efficient Press and Sinter of Titanium Powder for Low-Cost Components in Vehicle Applications. Titanium has been identified as one of the key materials with the required strength that can reduce the weight of automotive components and thereby reduce fuel consumption. Working with newly developed sources of titanium powder, Webster-Hoff will develop the processing technology to manufacture low cost vehicle components using the single press/single sinter techniques developed for iron based powder metallurgy today. Working with an automotive or truck manufacturer, Webster-Hoff will demonstrate the feasibilitymore » of manufacturing a press and sinter titanium component for a vehicle application. The project objective is two-fold, to develop the technology for manufacturing press and sinter titanium components, and to demonstrate the feasibility of producing a titanium component for a vehicle application. The lowest cost method for converting metal powder into a net shape part is the Powder Metallurgy Press and Sinter Process. The method involves compaction of the metal powder in a tool (usually a die and punches, upper and lower) at a high pressure (up to 60 TSI or 827 MPa) to form a green compact with the net shape of the final component. The powder in the green compact is held together by the compression bonds between the powder particles. The sinter process then converts the green compact to a metallurgically bonded net shape part through the process of solid state diffusion. The goal of this project is to expand the understanding and application of press and sinter technology to Titanium Powder applications, developing techniques to manufacture net shape Titanium components via the press and sinter process. In addition, working with a vehicle manufacturer, demonstrate the feasibility of producing a titanium component for a vehicle. This is not a research program, but rather a project to develop a process for press and sinter of net shape Titanium components. All of these project objectives have been successfully completed.« less

Microgravity Manufacturing Via Fused Deposition

NASA Technical Reports Server (NTRS)

Cooper, K. G.; Griffin, M. R.

2003-01-01

Manufacturing polymer hardware during space flight is currently outside the state of the art. A process called fused deposition modeling (FDM) can make this approach a reality by producing net-shaped components of polymer materials directly from a CAE model. FDM is a rapid prototyping process developed by Stratasys, Inc.. which deposits a fine line of semi-molten polymer onto a substrate while moving via computer control to form the cross-sectional shape of the part it is building. The build platen is then lowered and the process is repeated, building a component directly layer by layer. This method enables direct net-shaped production of polymer components directly from a computer file. The layered manufacturing process allows for the manufacture of complex shapes and internal cavities otherwise impossible to machine. This task demonstrated the benefits of the FDM technique to quickly and inexpensively produce replacement components or repair broken hardware in a Space Shuttle or Space Station environment. The intent of the task was to develop and fabricate an FDM system that was lightweight, compact, and required minimum power consumption to fabricate ABS plastic hardware in microgravity. The final product of the shortened task turned out to be a ground-based breadboard device, demonstrating miniaturization capability of the system.

Hot working behavior of selective laser melted and laser metal deposited Inconel 718

NASA Astrophysics Data System (ADS)

Bambach, Markus; Sizova, Irina

2018-05-01

The production of Nickel-based high-temperature components is of great importance for the transport and energy sector. Forging of high-temperature alloys often requires expensive dies, multiple forming steps and leads to forged parts with tolerances that require machining to create the final shape and a large amount of scrap. Additive manufacturing offers the possibility to print the desired shapes directly as net-shape components, requiring only little additional effort in machining. Especially for high-temperature alloys carrying a large amount of energy per unit mass, additive manufacturing could be more energy-efficient than forging if the energy contained in the machining scrap exceeds the energy needed for powder production and laser processing. However, the microstructure and performance of 3d-printed parts will not reach the level of forged material unless further expensive processes such as hot-isostatic pressing are used. Using the design freedom and possibilities to locally engineer material, additive manufacturing could be combined with forging operations to novel process chains, offering the possibility to reduce the number of forging steps and to create near-net shape forgings with desired local properties. Some innovative process chains combining additive manufacturing and forging have been patented recently, but almost no scientific knowledge on the workability of 3D printed preforms exists. The present study investigates the flow stress and microstructure evolution during hot working of pre-forms produced by laser powder deposition and selective laser melting (Figure 1) and puts forward a model for the flow stress.

Advanced Materials and Fabrication Techniques for the Orion Attitude Control Motor

NASA Technical Reports Server (NTRS)

Gorti, Sridhar; Holmes, Richard; O'Dell, John; McKechnie, Timothy; Shchetkovskiy, Anatoliy

2013-01-01

Rhenium, with its high melting temperature, excellent elevated temperature properties, and lack of a ductile-to-brittle transition temperature (DBTT), is ideally suited for the hot gas components of the ACM (Attitude Control Motor), and other high-temperature applications. However, the high cost of rhenium makes fabricating these components using conventional fabrication techniques prohibitive. Therefore, near-net-shape forming techniques were investigated for producing cost-effective rhenium and rhenium alloy components for the ACM and other propulsion applications. During this investigation, electrochemical forming (EL-Form ) techniques were evaluated for producing the hot gas components. The investigation focused on demonstrating that EL-Form processing techniques could be used to produce the ACM flow distributor. Once the EL-Form processing techniques were established, a representative rhenium flow distributor was fabricated, and samples were harvested for material properties testing at both room and elevated temperatures. As a lower cost and lighter weight alternative to an all-rhenium component, rhenium- coated graphite and carbon-carbon were also evaluated. The rhenium-coated components were thermal-cycle tested to verify that they could withstand the expected thermal loads during service. High-temperature electroforming is based on electrochemical deposition of compact layers of metals onto a mandrel of the desired shape. Mandrels used for electro-deposition of near-net shaped parts are generally fabricated from high-density graphite. The graphite mandrel is easily machined and does not react with the molten electrolyte. For near-net shape components, the inner surface of the electroformed part replicates the polished graphite mandrel. During processing, the mandrel itself becomes the cathode, and scrap or refined refractory metal is the anode. Refractory metal atoms from the anode material are ionized in the molten electrolytic solution, and are deposited onto the cathodic mandrel by electrochemical reduction. Rotation of the mandrel ensures uniform distribution of refractory material. The EL-Form process allows for manufacturing in an inert atmosphere with deposition rates from 0.0004 to 0.002 in./h (10.2 to 50.8 m/h). Thicknesses typically range from microns to greater than 0.5 in. (13 mm). The refractory component produced is fabricated, dependably, to within one micron of the desired tolerances with no shrinkage or distortion as in other refractory metal manufacture techniques. The electroforming process has been used to produce solid, nonporous deposits of rhenium, iridium, niobium, tungsten, and their alloys.

Investigation of the laser engineered net shaping process for nanostructured cermets

NASA Astrophysics Data System (ADS)

Xiong, Yuhong

Laser Engineered Net Shaping (LENSRTM) is a solid freeform fabrication (SFF) technology that combines high power laser deposition and powder metallurgy technologies. The LENSRTM technology has been used to fabricate a number of metallic alloys with improved physical and mechanical material properties. The successful application provides a motivation to also apply this method to fabricate non-metallic alloys, such as tungsten carbide-cobalt (WC-Co) cermets in a timely and easy way. However, reports on this topic are very limited. In this work, the LENSRTM technology was used to investigate its application to nanostructured WC-Co cermets, including processing conditions, microstructural evolution, thermal behavior, mechanical properties, and environmental and economic benefits. Details of the approaches are described as follows. A comprehensive analysis of the relationships between process parameters, microstructural evolution and mechanical properties was conducted through various analytical techniques. Effects of process parameters on sample profiles and microstructures were analyzed. Dissolution, shape change and coarsening of WC particles were investigated to study the mechanisms of microstructural evolution. The thermal features were correlated with the microstructure and mechanical properties. The special thermal behavior during this process and its relevant effects on the microstructure have been experimentally studied and numerically simulated. A high-speed digital camera was applied to study the temperature profile, temperature gradient and cooling rate in and near the molten pool. Numerical modeling was employed for 3D samples using finite element method with ADINA software for the first time. The validated modeling results were used to interpret microstructural evolution and thermal history. In order to fully evaluate the capability of the LENSRTM technology for the fabrication of cermets, material properties of WC-Co cermets produced by different powder metallurgy technologies were compared. In addition, another cermet system, nanostructured titanium/tungsten carbide-nickel ((Ti,W)C-Ni) powder, prepared using high-energy ball milling process, was also deposited by the LENSRTM technology. Because of the near net shape feature of the LENSRTM process, special emphasis was also placed on its potential environmental and economic benefits by applying life cycle assessment (LCA) and technical cost modeling (TCM). Comparisons were conducted between the conventional powder metallurgy processes and the LENSRTM process.

Near-Net Shape Fabrication Using Low-Cost Titanium Alloy Powders

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dr. David M. Bowden; Dr. William H. Peter

2012-03-31

The use of titanium in commercial aircraft production has risen steadily over the last half century. The aerospace industry currently accounts for 58% of the domestic titanium market. The Kroll process, which has been used for over 50 years to produce titanium metal from its mineral form, consumes large quantities of energy. And, methods used to convert the titanium sponge output of the Kroll process into useful mill products also require significant energy resources. These traditional approaches result in product forms that are very expensive, have long lead times of up to a year or more, and require costly operationsmore » to fabricate finished parts. Given the increasing role of titanium in commercial aircraft, new titanium technologies are needed to create a more sustainable manufacturing strategy that consumes less energy, requires less material, and significantly reduces material and fabrication costs. A number of emerging processes are under development which could lead to a breakthrough in extraction technology. Several of these processes produce titanium alloy powder as a product. The availability of low-cost titanium powders may in turn enable a more efficient approach to the manufacture of titanium components using powder metallurgical processing. The objective of this project was to define energy-efficient strategies for manufacturing large-scale titanium structures using these low-cost powders as the starting material. Strategies include approaches to powder consolidation to achieve fully dense mill products, and joining technologies such as friction and laser welding to combine those mill products into near net shape (NNS) preforms for machining. The near net shape approach reduces material and machining requirements providing for improved affordability of titanium structures. Energy and cost modeling was used to define those approaches that offer the largest energy savings together with the economic benefits needed to drive implementation. Technical feasibility studies were performed to identify the most viable approaches to NNS preform fabrication using basic powder metallurgy mill product forms as the building blocks and advanced joining techniques including fusion and solid state joining to assemble these building blocks into efficient machining performs.« less

A study of process parameters on workpiece anisotropy in the laser engineered net shaping (LENSTM) process

NASA Astrophysics Data System (ADS)

Chandra, Shubham; Rao, Balkrishna C.

2017-06-01

The process of laser engineered net shaping (LENSTM) is an additive manufacturing technique that employs the coaxial flow of metallic powders with a high-power laser to form a melt pool and the subsequent deposition of the specimen on a substrate. Although research done over the past decade on the LENSTM processing of alloys of steel, titanium, nickel and other metallic materials typically reports superior mechanical properties in as-deposited specimens, when compared to the bulk material, there is anisotropy in the mechanical properties of the melt deposit. The current study involves the development of a numerical model of the LENSTM process, using the principles of computational fluid dynamics (CFD), and the subsequent prediction of the volume fraction of equiaxed grains to predict process parameters required for the deposition of workpieces with isotropy in their properties. The numerical simulation is carried out on ANSYS-Fluent, whose data on thermal gradient are used to determine the volume fraction of the equiaxed grains present in the deposited specimen. This study has been validated against earlier efforts on the experimental studies of LENSTM for alloys of nickel. Besides being applicable to the wider family of metals and alloys, the results of this study will also facilitate effective process design to improve both product quality and productivity.

Effect of Tooling Material on the Internal Surface Quality of Ti6Al4V Parts Fabricated by Hot Isostatic Pressing

NASA Astrophysics Data System (ADS)

Cai, Chao; Song, Bo; Wei, Qingsong; Yan, Wu; Xue, Pengju; Shi, Yusheng

2017-01-01

For the net-shape hot isostatic pressing (HIP) process, control of the internal surface roughness of as-HIPped parts remains a challenge for practical engineering. To reveal the evolution mechanism of the internal surface of the parts during the HIP process, the effect of different tooling materials (H13, T8, Cr12 steel, and graphite) as internal cores on the interfacial diffusion and surface roughness was systematically studied.

Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing

NASA Technical Reports Server (NTRS)

Hofmann, Douglas C.; Borgonia, John Paul C.; Dillon, Robert P.; Suh, Eric J.; Mulder, jerry L.; Gardner, Paul B.

2013-01-01

Recently, additive manufacturing (AM) techniques have been developed that may shift the paradigm of traditional metal production by allowing complex net-shaped hardware to be built up layer-by-layer, rather than being machined from a billet. The AM process is ubiquitous with polymers due to their low melting temperatures, fast curing, and controllable viscosity, and 3D printers are widely available as commercial or consumer products. 3D printing with metals is inherently more complicated than with polymers due to their higher melting temperatures and reactivity with air, particularly when heated or molten. The process generally requires a high-power laser or other focused heat source, like an electron beam, for precise melting and deposition. Several promising metal AM techniques have been developed, including laser deposition (also called laser engineered net shaping or LENS® and laser deposition technology (LDT)), direct metal laser sintering (DMLS), and electron beam free-form (EBF). These machines typically use powders or wire feedstock that are melted and deposited using a laser or electron beam. Complex net-shape parts have been widely demonstrated using these (and other) AM techniques and the process appears to be a promising alternative to machining in some cases. Rather than simply competing with traditional machining for cost and time savings, the true advantage of AM involves the fabrication of hardware that cannot be produced using other techniques. This could include parts with "blind" features (like foams or trusses), parts that are difficult to machine conventionally, or parts made from materials that do not exist in bulk forms. In this work, the inventors identify that several AM techniques can be used to develop metal parts that change composition from one location in the part to another, allowing for complete control over the mechanical or physical properties. This changes the paradigm for conventional metal fabrication, which relies on an assortment of "post-processing" methods to locally alter properties (such as coating, heat treating, work hardening, shot peening, etching, anodizing, among others). Building the final part in an additive process allows for the development of an entirely new class of metals, so-called "functionally graded metals" or "gradient alloys." By carefully blending feedstock materials with different properties in an AM process, hardware can be developed with properties that cannot be obtained using other techniques but with the added benefit of the net-shaped fabrication that AM allows.

Plastic deformation history in infeed rotary swaging process

NASA Astrophysics Data System (ADS)

Liu, Yang; Herrmann, Marius; Schenck, Christian; Kuhfuss, Bernd

2017-10-01

In bulk forming processes, the net shape of a final product is achieved by plastic deformation as the material flows from the initial shape to the final shape of the workpiece. The material flow during the process is an important issue for its relationship with forging force, heat generation, microstructure transformation and energy consumption. Hence, the final properties of the product are directly influenced. Former researches showed that the material flow in the rotary swaging process is affected by different processing parameters like die angle, feeding velocity and friction condition. Thus, a profound knowledge of detailed material flow during the process is essential for a better understanding of the process. By using FEM, the material flow was investigated by the history of the plastic strain (PEEQ) development. In this study a 2D-axisymmetric model was built by using ABAQUS explicit. Both aluminum alloy (3.3206) and steel (1.0308) are studied with different feeding velocities and coefficients of friction. To achieve the development of PEEQ in different areas, the workpiece was divided into radial layers. The PEEQ history of each layer was tracked during the quasi-static forming process. Based on that, the plastic strain rate (PSR) was calculated and examined in a single stroke of the process. In that way, the material flow in different layers is presented and the material flow on the surface differs from that in the center, just the first 1/4 radial area from the surface is sensitive to different friction conditions.

Life cycle assessment and sustainable engineering in the context of near net shape grown components: striving towards a sustainable way of future production.

PubMed

Kämpfer, Christoph; Seiler, Thomas-Benjamin; Beger, Anna-Lena; Jacobs, Georg; Löwer, Manuel; Moser, Franziska; Reimer, Julia; Trautz, Martin; Usadel, Björn; Wormit, Alexandra; Hollert, Henner

2017-01-01

Technical product harvesting (TEPHA) is a newly developing interdisciplinary approach in which bio-based production is investigated from a technical and ecological perspective. Society's demand for ecologically produced and sustainably operable goods is a key driver for the substitution of conventional materials like metals or plastics through bio-based alternatives. Technical product harvesting of near net shape grown components describes the use of suitable biomass for the production of technical products through influencing the natural shape of plants during their growth period. The use of natural materials may show positive effects on the amount of non-renewable resource consumption. This also increases the product recyclability at the end of its life cycle. Furthermore, through the near net shape growth of biomass, production steps can be reduced. As a consequence such approaches may save energy and the needed resources like crude oil, coal or gas. The derived near net shape grown components are not only considered beneficial from an environmental point of view. They can also have mechanical advantages through an intrinsic topology optimization in contrast to common natural materials, which are influenced in their shape after harvesting. In order to prove these benefits a comprehensive, interdisciplinary scientific strategy is needed. Here, both mechanical investigations and life cycle assessment as a method of environmental evaluation are used.

Collaboration for the Advancement of Indirect 3D Printing Technology

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cordero, Zachary; Elliott, Amy M.

Amorphous powders often possess high hardness values and other useful mechanical properties. However, densifying these powders into complex shapes while retaining their unique properties is a challenge with standard processing routes. Pressureless sintering, for example, can densify intricate green parts composed of rapidly-solidified powders. But this process typically involves long exposures to elevated temperatures, during which the non-equilibrium microstructure of the powder can evolve towards lower energy configurations with inferior properties. Pressure-assisted compaction techniques, by contrast, can consolidate green parts with simple shapes while preserving the microstructure and properties of the powder feedstock. But parts made with these processes generallymore » require additional post-processing, including machining, which introduces new challenges due to the high hardness of these materials. One processing route that can potentially avoid these issues is Indirect 3D Printing (I-3DP; aka Binder Jetting) followed by melt infiltration. In I-3DP, an organic binder is used to join powder feedstock, layer-by-layer, into a green part. In melt infiltration, this green preform is densified by placing it in contact with a molten alloy that wets the preform and wicks into the pores as a result of capillary forces. When these processes are paired together, they offer two key advantages for the densification of rapidly-solidified powders. The first advantage is that the timescale associated with melt infiltration is on the order of seconds for parts with cm-scale dimensions. So in many instances, infiltration requires only a brief thermal excursion that does not degrade the feedstock’s microstructure. The second advantage is that the combination of binder-jet 3D printing and melt infiltration gives fully-dense net shape objects, minimizing the need for subsequent post-processing. In this work, fully-dense, net shape objects have been fabricated from an amorphous powder using I-3DP and molten bronze infiltration while maintaining the amorphous microstructure. X-ray diffraction, scanning electron microscopy, and differential thermal analysis were used to characterize the structural evolution of the powder feedstock during an infiltration heating cycle. Microindentation and bend tests were performed on the infiltrated material to evaluate its mechanical properties. It was found that infiltration improved both the ductility and strength of the sintered preforms by eliminating the stress concentration at the interparticle necks. The infiltrated material had an 11 GPa Vickers hardness and moderate damage tolerance, making it well-suited for applications requiring hard, net shape parts.« less

Radiative and convective properties of 316L Stainless Steel fabricated using the Laser Engineered Net Shaping process

NASA Astrophysics Data System (ADS)

Knopp, Jonathan

Temperature evolution of metallic materials during the additive manufacturing process has direct influence in determining the materials microstructure and resultant characteristics. Through the power of Infrared (IR) thermography it is now possible to monitor thermal trends in a build structure, giving the power to adjust building parameters in real time. The IR camera views radiation in the IR wavelengths and determines temperature of an object by the amount of radiation emitted from the object in those wavelengths. Determining the amount of radiation emitted from the material, known as a materials emissivity, can be difficult in that emissivity is affected by both temperature and surface finish. It has been shown that the use of a micro-blackbody cavity can be used as an accurate reference temperature when the sample is held at thermal equilibrium. A micro-blackbody cavity was created in a sample of 316L Stainless Steel after being fabricated during using the Laser Engineered Net Shaping (LENS) process. Holding the sample at thermal equilibrium and using the micro-blackbody cavity as a reference and thermocouple as a second reference emissivity values were able to be obtained. IR thermography was also used to observe the manufacturing of these samples. When observing the IR thermography, patterns in the thermal history of the build were shown to be present as well as distinct cooling rates of the material. This information can be used to find true temperatures of 316L Stainless Steel during the LENS process for better control of desired material properties as well as future work in determining complete energy balance.

Non-Magnetic, Tough, Corrosion- and Wear-Resistant Knives From Bulk Metallic Glasses and Composites

NASA Technical Reports Server (NTRS)

Hoffman, Douglas C.; Potter, Benjamin

2013-01-01

Quality knives are typically fabricated from high-strength steel alloys. Depending on the application, there are different requirements for mechanical and physical properties that cause problems for steel alloys. For example, diver's knives are generally used in salt water, which causes rust in steel knives. Titanium diver's knives are a popular alternative due to their salt water corrosion resistance, but are too soft to maintain a sharp cutting edge. Steel knives are also magnetic, which is undesirable for military applications where the knives are used as a tactical tool for diffusing magnetic mines. Steel is also significantly denser than titanium (8 g/cu cm vs. 4.5 g/cu cm), which results in heavier knives for the same size. Steel is hard and wear-resistant, compared with titanium, and can keep a sharp edge during service. A major drawback of both steel and titanium knives is that they must be ground or machined into the final knife shape from a billet. Since most knives have a mirrored surface and a complex shape, manufacturing them is complex. It would be more desirable if the knife could be cast into a net or near-net shape in a single step. The solution to the deficiencies of titanium, steel, and ceramic knives is to fabricate them using bulk metallic glasses (or composites). These alloys can be cast into net or near-net shaped knives with a combination of properties that exceed both titanium and steel. A commercially viable BMG (bulk metallic glass) or composite knife is one that exhibits one or all of the following properties: It is based on titanium, has a self-sharpening edge, can retain an edge during service, is hard, is non-magnetic, is corrosion-resistant against a variety of corrosive environments, is tough (to allow for prying), can be cast into a net-shape with a mirror finish and a complex shape, has excellent wear resistance, and is low-density. These properties can be achieved in BMG and composites through alloy chemistry and processing. For each desired property for knife fabrication and performance, there is an alloy development strategy that optimizes behavior. Although BMG knives have been demonstrated as far back as 1995, they never found commercial success because they had to be ground (which presented problems because the alloys contained beryllium), they weren't low cost (because they weren't cast to a net-shape), they were brittle (because they were made with a low-quality commercial material), and they had extremely poor corrosion resistance (because corrosion was not well-understood in these materials). Ultimately, these shortcomings prevented the widespread commercialization. In the current work, the inventors have applied more than a decade of research on BMGs from Caltech and JPL to develop a better understanding of how to make BMG knives that exhibit an optimal combination of properties, processing and cost. Alloys have been developed based in titanium (and other metals), that exhibit high toughness, high hardness, excellent corrosion resistance, no ferromagnetism, edge-retaining selfsharpening, and the ability to be cast like a plastic using commercially available casting techniques (currently used by commercial companies such as Liquidmetal Technologies and Visser Precision Casting). The inventors argue that depending on the application (diving, military, tactical, utility, etc.) there is an optimal combination of design and alloy composition. Moreover, with new casting technologies not available at the inception of these materials, net-shaped knives can be cast into complex shapes that require no aftermarket forming, except for sharpening using water-cooled polishing wheel. These combinations of discoveries seek to make low-cost BMG knives commercially viable products that have no equal among metal or ceramic knives. Current work at JPL focuses on net-shape casting of these alloys and testing their mechanical properties versus commercially available knives to demonstrate their benefits.

Near-Net Forging Technology Demonstration Program

NASA Technical Reports Server (NTRS)

Hall, I. Keith

1996-01-01

Significant advantages in specific mechanical properties, when compared to conventional aluminum (Al) alloys, make aluminum-lithium (Al-Li) alloys attractive candidate materials for use in cryogenic propellant tanks and dry bay structures. However, the cost of Al-Li alloys is typically five times that of 2219 aluminum. If conventional fabrication processes are employed to fabricate launch vehicle structure, the material costs will restrict their utilization. In order to fully exploit the potential cost and performance benefits of Al-Li alloys, it is necessary that near-net manufacturing methods be developed to off-set or reduce raw material costs. Near-net forging is an advanced manufacturing method that uses elevated temperature metal movement (forging) to fabricate a single piece, near-net shape, structure. This process is termed 'near-net' because only a minimal amount of post-forge machining is required. The near-net forging process was developed to reduce the material scrap rate (buy-to-fly ratio) and fabrication costs associated with conventional manufacturing methods. The goal for the near-net forging process, when mature, is to achieve an overall cost reduction of approximately 50 percent compared with conventional manufacturing options for producing structures fabricated from Al-Li alloys. This NASA Marshall Space Flight Center (MSFC) sponsored program has been a part of a unique government / industry partnership, coordinated to develop and demonstrate near-net forging technology. The objective of this program was to demonstrate scale-up of the near-net forging process. This objective was successfully achieved by fabricating four integrally stiffened, 170- inch diameter by 20-inch tall, Al-Li alloy 2195, Y-ring adapters. Initially, two 2195 Al-Li ingots were converted and back extruded to produce four cylindrical blockers. Conventional ring rolling of the blockers was performed to produce ring preforms, which were then contour ring rolled to produce 'contour preforms'. All of the contour preforms on this first-of-a-kind effort were imperfect, and the ingot used to fabricate two of the preforms was of an earlier vintage. As lessons were learned throughout the program, the tooling and procedures evolved, and hence the preform quality. Two of the best contour preforms were near- net forged to produce a process pathfinder Y-ring adapter and a 'mechanical properties pathfinder' Y-ring adapter. At this point, Lockheed Martin Astronautics elected to procure additional 2195 aluminum-lithium ingot of the latest vintage, produce two additional preforms, and substitute them for older vintage material non-perfectly filled preforms already produced on this contract. The existing preforms could have been used to fulfill the requirements of the contract.

Selecting mirror materials for high-performance optical systems

NASA Astrophysics Data System (ADS)

Parsonage, Thomas B.

1990-11-01

The properties of four candidate mirror materials--beryllium, silicon carbide, a silicon carbide/aluminum iretal-matrix carposite and aluminum--are corrpared. Because of its high specific stiffness and dirrensional stability under changing mschanical and thermal loads , beryllium is the best choice . Berjllium mirrors have been made irore cost-conpetitive by new processing technologies in which mirror blanks are isostatically pressed to near-net shape directly fran beiyllium pc1ers. Isostatic pressing also improves material properties and mskes it possible to develop mirror rraterials with superior properties.

Niobium-Matrix-Composite High-Temperature Turbine Blades

NASA Technical Reports Server (NTRS)

Kaplan, Richard B.; Tuffias, Robert H.; La Ferla, Raffaele; Heng, Sangvavann; Harding, John T.

1995-01-01

High-temperture composite-material turbine blades comprising mainly niobium matrices reinforced with refractory-material fibers being developed. Of refractory fibrous materials investigated, FP-AL(2)0(3), tungsten, and polymer-based SiC fibers most promising. Blade of this type hollow and formed in nearly net shape by wrapping mesh of reinforcing refractory fibers around molybdenum mandrel, then using thermal-gradient chemical-vapor infiltration (CVI) to fill interstices with niobium. CVI process controllable and repeatable, and kinetics of both deposition and infiltration well understood.

Process for making ceramic insulation

DOEpatents

Akash, Akash [Salt Lake City, UT; Balakrishnan, G Nair [Sandy, UT

2009-12-08

A method is provided for producing insulation materials and insulation for high temperature applications using novel castable and powder-based ceramics. The ceramic components produced using the proposed process offers (i) a fine porosity (from nano-to micro scale); (ii) a superior strength-to-weight ratio; and (iii) flexibility in designing multilayered features offering multifunctionality which will increase the service lifetime of insulation and refractory components used in the solid oxide fuel cell, direct carbon fuel cell, furnace, metal melting, glass, chemical, paper/pulp, automobile, industrial heating, coal, and power generation industries. Further, the ceramic components made using this method may have net-shape and/or net-size advantages with minimum post machining requirements.

Low Cost, Net Shape Fabrication of Rhenium and High Temperature Materials for Rocket Engine Components

DTIC Science & Technology

2001-03-01

tungsten thin wall nozzle liner removed from reusable mandrel. b) W and Re rocket, nozzle inserts (2 inserts per mandrel) for Air Force. Rhenium PPI...compares the fabrication time for the VPS nozzles with equivalent carbon / carbon composite (C/C) and forged tungsten materials. Table 5: Comparison of...UNCLASSIFIED Defense Technical Information Center Compilation Part Notice ADPO1 1181 TITLE: Low Cost, Net Shape Fabrication of Rhenium and High

Processing study of injection molding of silicon nitride for engine applications

NASA Technical Reports Server (NTRS)

Rorabaugh, M. E.; Yeh, H. C.

1985-01-01

The high hardness of silicon nitride, which is currently under consideration as a structural material for such hot engine components as turbine blades, renders machining of the material prohibitively costly; the near net shape forming technique of injection molding is accordingly favored as a means for component fabrication. Attention is presently given to the relationships between injection molding processing parameters and the resulting microstructural and mechanical properties of the resulting engine parts. An experimental program has been conducted under NASA sponsorship which tests the quality of injection molded bars of silicon nitride at various stages of processing.

Cryogenic Tank Technology Program (CTTP)

NASA Technical Reports Server (NTRS)

Vaughn, T. P.

2001-01-01

The objectives of the Cryogenic Tank Technology Program were to: (1) determine the feasibility and cost effectiveness of near net shape hardware; (2) demonstrate near net shape processes by fabricating large scale-flight quality hardware; and (3) advance state of current weld processing technologies for aluminum lithium alloys.

Future trends in metal forming—equipment, materials and processes in automotive applications

NASA Astrophysics Data System (ADS)

Hitz, D.; Duggirala, R.

1995-10-01

Global competition in the automotive market has made a significant impact in the materials, processes, tools, and equipment used to make components. Steels are being replaced by other materials, such as aluminum, composites, and plastics, that meet the demand for a higher performance per weight ratio. From a processing viewpoint, the customers demand production of parts to near-net shape with little or no machining. Competition in business depends on understanding the needs of the customer in the coming years in the area of metal forming. A workshop was conducted using a novel approach to address the above issue. This presentation describes the approach and the results of the study.

Evaluation of ceramics for stator application: Gas turbine engine report

NASA Technical Reports Server (NTRS)

Trela, W.; Havstad, P. H.

1978-01-01

Current ceramic materials, component fabrication processes, and reliability prediction capability for ceramic stators in an automotive gas turbine engine environment are assessed. Simulated engine duty cycle testing of stators conducted at temperatures up to 1093 C is discussed. Materials evaluated are SiC and Si3N4 fabricated from two near-net-shape processes: slip casting and injection molding. Stators for durability cycle evaluation and test specimens for material property characterization, and reliability prediction model prepared to predict stator performance in the simulated engine environment are considered. The status and description of the work performed for the reliability prediction modeling, stator fabrication, material property characterization, and ceramic stator evaluation efforts are reported.

Metal Injection Moulding: A Near Net Shape Fabrication Method for the Manufacture of Turbine Engine Component

DTIC Science & Technology

2006-05-01

on the processing and characterization of Inconel 625 LPIM material are presented. In depth microstructural characterization was performed on the...annealing. 1 INTRODUCTION Nickel superalloys such as Inconel 625 were developed to withstand the intense conditions present in gas turbine engines...aeronautic parts. A low- pressure injection moulding process, LPIM, has been developed for the fabrication of parts made of Inconel 625 , which maximizes

Spray forming of NiTi and NiTiPd shape-memory alloys

NASA Astrophysics Data System (ADS)

Smith, Ronald; Mabe, James; Ruggeri, Robert; Noebe, Ronald

2008-03-01

In the work to be presented, vacuum plasma spray forming has been used as a process to deposit and consolidate prealloyed NiTi and NiTiPd powders into near net shape actuators. Testing showed that excellent shape memory behavior could be developed in the deposited materials and the investigation proved that VPS forming could be a means to directly form a wide range of shape memory alloy components. The results of DSC characterization and actual actuation test results will be presented demonstrating the behavior of a Nitinol 55 alloy and a higher transition temperature NiTiPd alloy in the form of torque tube actuators that could be used in aircraft and aerospace controls.

Spray Forming of NiTi and NiTiPd Shape-Memory Alloys

NASA Technical Reports Server (NTRS)

Mabe, James; Ruggeri, Robert; Noebe, Ronald

2008-01-01

In the work to be presented, vacuum plasma spray forming has been used as a process to deposit and consolidate prealloyed NiTi and NiTiPd powders into near net shape actuators. Testing showed that excellent shape memory behavior could be developed in the deposited materials and the investigation proved that VPS forming could be a means to directly form a wide range of shape memory alloy components. The results of DSC characterization and actual actuation test results will be presented demonstrating the behavior of a Nitinol 55 alloy and a higher transition temperature NiTiPd alloy in the form of torque tube actuators that could be used in aircraft and aerospace controls.

Improved silicon nitride for advanced heat engines

NASA Technical Reports Server (NTRS)

Yeh, H. C.; Wimmer, J. M.

1986-01-01

Silicon nitride is a high temperature material currently under consideration for heat engine and other applications. The objective is to improve the net shape fabrication technology of Si3N4 by injection molding. This is to be accomplished by optimizing the process through a series of statistically designed matrix experiments. To provide input to the matrix experiments, a wide range of alternate materials and processing parameters was investigated throughout the whole program. The improvement in the processing is to be demonstrated by a 20 percent increase in strength and a 100 percent increase in the Weibull modulus over that of the baseline material. A full characterization of the baseline process was completed. Material properties were found to be highly dependent on each step of the process. Several important parameters identified thus far are the starting raw materials, sinter/hot isostatic pressing cycle, powder bed, mixing methods, and sintering aid levels.

Density of Spray-Formed Materials

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kevin M. McHugh; Volker Uhlenwinkel; Nils Ellendr

2008-06-01

Spray Forming is an advanced materials processing technology that transforms molten metal into a near-net-shape solid by depositing atomized droplets onto a substrate. Depending on the application, the spray-formed material may be used in the as-deposited condition or it may undergo post-deposition processing. Regardless, the density of the as-deposited material is an important issue. Porosity is detrimental because it can significantly reduce strength, toughness, hardness and other properties. While it is not feasible to achieve fully-dense material in the as-deposited state, density greater than 99% of theoretical density is possible if the atomization and impact conditions are optimized. Thermal conditionsmore » at the deposit surface and droplet impact angle are key processing parameters that influence the density of the material. This paper examines the factors that contribute to porosity formation during spray forming and illustrates that very high as-deposited density is achieved by optimizing processing parameters.« less

Method for Fabricating Composite Structures Using Pultrusion Processing

NASA Technical Reports Server (NTRS)

Farley, Gary L. (Inventor)

2000-01-01

A method for fabricating composite structures at a low-cost, moderate-to-high production rate. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform and debulking the partially debulked preform to form a netshape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length and electronbeam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates, resulting in lower cost and high structural performance.

Post-processing of 3D-printed parts using femtosecond and picosecond laser radiation

NASA Astrophysics Data System (ADS)

Mingareev, Ilya; Gehlich, Nils; Bonhoff, Tobias; Meiners, Wilhelm; Kelbassa, Ingomar; Biermann, Tim; Richardson, Martin C.

2014-03-01

Additive manufacturing, also known as 3D-printing, is a near-net shape manufacturing approach, delivering part geometry that can be considerably affected by various process conditions, heat-induced distortions, solidified melt droplets, partially fused powders, and surface modifications induced by the manufacturing tool motion and processing strategy. High-repetition rate femtosecond and picosecond laser radiation was utilized to improve surface quality of metal parts manufactured by laser additive techniques. Different laser scanning approaches were utilized to increase the ablation efficiency and to reduce the surface roughness while preserving the initial part geometry. We studied post-processing of 3D-shaped parts made of Nickel- and Titanium-base alloys by utilizing Selective Laser Melting (SLM) and Laser Metal Deposition (LMD) as additive manufacturing techniques. Process parameters such as the pulse energy, the number of layers and their spatial separation were varied. Surface processing in several layers was necessary to remove the excessive material, such as individual powder particles, and to reduce the average surface roughness from asdeposited 22-45 μm to a few microns. Due to the ultrafast laser-processing regime and the small heat-affected zone induced in materials, this novel integrated manufacturing approach can be used to post-process parts made of thermally and mechanically sensitive materials, and to attain complex designed shapes with micrometer precision.

Additive manufacturing of near-net-shape bonded magnets: Prospects and challenges

DOE PAGES

Li, Ling; Post, Brian; Kunc, Vlastimil; ...

2017-01-03

Additive manufacturing (AM) or 3D printing is well known for producing arbitrary shaped parts without any tooling required, offering a promising alternative to the conventional injection molding method to fabricate near-net-shaped magnets. In order to determine their applicability in the fabrication of Nd-Fe-B bondedmagnets, we compare two 3D printing technologies, namely binder jetting and material extrusion. Some prospects and challenges of these state-of-the-art technologies for large-scale industrial applications will be discussed.

A net-shaped multicellular formation facilitates the maturation of hPSC-derived cardiomyocytes through mechanical and electrophysiological stimuli

PubMed Central

Liu, Taoyan; Huang, Chengwu; Li, Hongxia; Wu, Fujian; Luo, Jianwen; Lu, Wenjing

2018-01-01

The use of human-induced pluripotent stem cell-derived cardiomyocytes (hiPSC-CMs) is limited in drug discovery and cardiac disease mechanism studies due to cell immaturity. Although many approaches have been reported to improve the maturation of hiPSC-CMs, the elucidation of the process of maturation is crucial. We applied a small-molecule-based differentiation method to generate cardiomyocytes (CMs) with multiple aggregation forms. The motion analysis revealed significant physical differences in the differently shaped CMs, and the net-shaped CMs had larger motion amplitudes and faster velocities than the sheet-shaped CMs. The net-shaped CMs displayed accelerated maturation at the transcriptional level and were more similar to CMs with a prolonged culture time (30 days) than to sheet-d15. Ion channel genes and gap junction proteins were up-regulated in net-shaped CMs, indicating that robust contraction was coupled with enhanced ion channel and connexin expression. The net-shaped CMs also displayed improved myofibril ultrastructure under transmission electron microscopy. In conclusion, different multicellular hPSC-CM structures, such as the net-shaped pattern, are formed using the conditioned induction method, providing a useful tool to improve cardiac maturation. PMID:29661985

Processing and mechanical characterization of alumina laminates

NASA Astrophysics Data System (ADS)

Montgomery, John K.

2002-08-01

Single-phase ceramics that combine property gradients or steps in monolithic bodies are sought as alternatives to ceramic composites made of dissimilar materials. This work describes novel processing methods to produce stepped-density (or laminated) alumina single-phase bodies that maintain their mechanical integrity. One arrangement consists of a stiff, dense bulk material with a thin, flaw tolerant, porous exterior layer. Another configuration consists of a lightweight, low-density bulk material with a thin, hard, wear resistant exterior layer. Alumina laminates with strong interfaces have been successfully produced in this work using two different direct-casting processes. Gelcasting is a useful near-net shape processing technique that has been combined with several techniques, such as reaction bonding of aluminum oxide and the use of starch as a fugative filler, to successfully produced stepped-density alumina laminates. The other direct casting process that has been developed in this work is thermoreversible gelcasting (TRG). This is a reversible gelation process that has been used to produce near-net shape dense ceramic bodies. Also, individual layers can be stacked together and heated to produce laminates. Bilayer laminate samples were produced with varied thickness of porous and dense layers. It was shown that due to the difference in modulus and hardness, transverse cracking is found upon Hertzian contact when the dense layer is on the exterior. In the opposite arrangement, compacted damage zones formed in the porous material and no damage occurred in the underlying dense layer. Flaw tolerant behavior of the porous exterior/dense underlayer was examined by measuring biaxial strength as a function of Vickers indentation load. It was found that the thinnest layer of porous material results in the greatest flaw tolerance. Also, higher strength was exhibited at large indentation loads when compared to dense monoliths. The calculated stresses on the surfaces and interface afforded an explanation of the behavior that failure initiates at the interface between the layers for the thinnest configuration, rather than the sample surface.

Net shaped high performance oxide ceramic parts by selective laser melting

NASA Astrophysics Data System (ADS)

Yves-Christian, Hagedorn; Jan, Wilkes; Wilhelm, Meiners; Konrad, Wissenbach; Reinhart, Poprawe

An additive manufacturing technique (AM) for ceramics, based on Al2O3-ZrO2 powder by means of Selective Laser Melting (SLM) is presented. Pure ceramic powder is completely melted by a laser beam yielding net-shaped specimens of almost 100% densities without any post-processing. Possible crack formation during the build-up process due to thermal stresses is prevented by a high-temperature preheating of above 1600 ∘C. Specimens with fine-grained nano-sized microstructures and flexural strengths of above 500 MPa are produced. The new technology allows for rapid freeform manufacture of complex net-shaped ceramics, thus, exploiting the outstanding mechanical and thermal properties for high-end medical and engineering disciplines.

Improved Net-Level Filling And Finishing Of Large Castings

NASA Technical Reports Server (NTRS)

Johnson, Erik P.; Brown, Richard F.

1995-01-01

Improved method of vacuum casting of large, generally cylindrical objects to net sizes and shapes reduces amount of direct manual labor by workers in proximity to cast material. Original application for which method devised is fabrication of solid rocket-motor segments containing solid propellant, wherein need to minimize exposure of workers to propellant material being cast. Improved method adaptable to other applications involving large castings of toxic, flammable, or otherwise hazardous materials.

Advanced Near Net Shape Technology

NASA Technical Reports Server (NTRS)

Vickers, John

2015-01-01

The objective of the Advanced Near Net Shape Technology (ANNST) project is to radically improve near net shape manufacturing methods from the current Technology/ Manufacturing Readiness Levels (TRL/MRL 3-4) to the point where they are viable candidates (TRL/ MRL-6) for shortening the time and cost for insertion of new aluminum alloys and revolutionary manufacturing methods into the development/improvement of space structures. Conventional cyrotank manufacturing processes require fabrication of multiple pieces welded together to form a complete tank. A variety of near net shape manufacturing processes has demonstrated excellent potential for enabling single-piece construction of components such as domes, barrels, and ring frames. Utilization of such processes can dramatically reduce the extent of welding and joining needed to construct cryogenic tanks and other aerospace structures. The specific focus of this project is to successfully mature the integrally stiffened cylinder (ISC) process in which a single-piece cylinder with integral stiffeners is formed in one spin/flow forming process. Structural launch vehicle components, like cryogenic fuel tanks (e.g., space shuttle external tank), are currently fabricated via multipiece assembly of parts produced through subtractive manufacturing techniques. Stiffened structural panels are heavily machined from thick plate, which results in excessive scrap rates. Multipiece construction requires welds to assemble the structure, which increases the risk for defects and catastrophic failures.

Powder Injection Molding (PIM) for Low Cost Manufacturing of Intricate Parts to Net-Shape

DTIC Science & Technology

2006-05-01

tungsten - or molybdenum-pseudoalloys, which can be net-shape manufactured only by PIM because of the tight dimension tolerances needed for the final...materials. Rhenium metal, for instance, which costs about US$ 800 /lb, offers the advantage of a high melting point. It can maintain reasonable...tubes, valves and thrusters of solid fluid propeller systems. Production of these components is however both expensive and difficult, as rhenium cannot

High Thermal Conductivity NARloy-Z-Diamond Composite Combustion Chamber Liner For Advanced Rocket Engines

NASA Technical Reports Server (NTRS)

Bhat, Biliyar N.; Ellis, David; Singh, Jogender

2014-01-01

Advanced high thermal conductivity materials research conducted at NASA Marshall Space Flight Center (MSFC) with state of the art combustion chamber liner material NARloy-Z showed that its thermal conductivity can be increased significantly by adding diamond particles and sintering it at high temperatures. For instance, NARloy-Z containing 40 vol. percent diamond particles, sintered at 975C to full density by using the Field assisted Sintering Technology (FAST) showed 69 percent higher thermal conductivity than baseline NARloy-Z. Furthermore, NARloy-Z-40vol. percent D is 30 percent lighter than NARloy-Z and hence the density normalized thermal conductivity is 140 percent better. These attributes will improve the performance and life of the advanced rocket engines significantly. By one estimate, increased thermal conductivity will directly translate into increased turbopump power up to 2X and increased chamber pressure for improved thrust and ISP, resulting in an expected 20 percent improvement in engine performance. Follow on research is now being conducted to demonstrate the benefits of this high thermal conductivity NARloy-Z-D composite for combustion chamber liner applications in advanced rocket engines. The work consists of a) Optimizing the chemistry and heat treatment for NARloy-Z-D composite, b) Developing design properties (thermal and mechanical) for the optimized NARloy-Z-D, c) Fabrication of net shape subscale combustion chamber liner, and d) Hot fire testing of the liner for performance. FAST is used for consolidating and sintering NARlo-Z-D. The subscale cylindrical liner with built in channels for coolant flow is also fabricated near net shape using the FAST process. The liner will be assembled into a test rig and hot fire tested in the MSFC test facility to determine performance. This paper describes the development of this novel high thermal conductivity NARloy-Z-D composite material, and the advanced net shape technology to fabricate the combustion chamber liner. Properties of optimized NARloy-Z-D composite material will also be presented.

Study of soft magnetic iron cobalt based alloys processed by powder injection molding

NASA Astrophysics Data System (ADS)

Silva, Aline; Lozano, Jaime A.; Machado, Ricardo; Escobar, Jairo A.; Wendhausen, Paulo A. P.

As a near net shape process, powder injection molding (PIM) opens new possibilities to process Fe-Co alloys for magnetic applications. Due to the fact that PIM does not involve plastic deformation of the material during processing, we envisioned the possibility of eliminating vanadium (V), which is generally added to Fe-Co alloys to improve the ductility in order to enable its further shaping by conventional processes such as forging and cold rolling. In our investigation we have found out two main futures related to the elimination of V, which lead to a cost-benefit gain in manufacturing small magnetic components where high-saturation induction is needed at low frequencies. Firstly, the elimination of V enables the achievement of much better magnetic properties when alloys are processed by PIM. Secondly, a lower sintering temperature can be used when the alloy is processed starting with elemental Fe and Co powders without the addition of V.

Method for Fabricating Composite Structures Including Continuous Press Forming and Pultrusion Processing

NASA Technical Reports Server (NTRS)

Farley, Gary L. (Inventor)

1995-01-01

A method for fabricating composite structures at a low-cost, moderate-to-high production rate is disclosed. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply, and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform, and debulking the partially debulked preform to form a netshape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length, and electron-beam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates, resulting in lower cost and high structural performance.

Mechanism study of biopolymer hair as a coupled thermo-water responsive smart material

NASA Astrophysics Data System (ADS)

Xiao, Xueliang; Zhou, Hongtao; Qian, Kun

2017-03-01

Animal hairs existing broadly in nature are found to be effectively responsive to stimuli of heat and water in sequence for shape deformation and recovery, namely, coupled shape memory function (CSMF). In the paper, the ability of thermo-water sensitive CSMF was first time investigated for animal hairs, the structural and molecular networks for net-points and switches were therefrom identified. Experimentally, animal hair manifested a high ability of shape fixation in thermal processing and good shape recovery by water stimulus. Characterizations of two stimuli (heating and hydration) were performed systematically on hair’s deformation, recovery, viscoelasticity and chemical components (crystalline phase, key bonds inamorphous area). The variations of related chemical components in molecular networks were also explored. A hybrid structural network model was thereafter proposed to interpret the thermo-water sensitive CSMF of hair. This study of two-sequential-stimuli CSMF is original and inspired to explore more complex functions of other smart natural materials and expected to make much smarter synthetic polymers.

Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Paranthaman, M. Parans; Shafer, Christopher S.; Elliott, Amy M.

2016-04-05

Our goal of this research is to fabricate near-net-shape isotropic (Nd) 2Fe 14B-based (NdFeB) bonded magnets using a three dimensional printing process to compete with conventional injection molding techniques used for bonded magnets. Additive manufacturing minimizes the waste of critical materials and allows for the creation of complex shapes and sizes. The binder jetting process works similarly to an inkjet printer. A print-head passes over a bed of NdFeB powder and deposits a polymer binding agent to bind the layer of particles together. The bound powder is then coated with another layer of powder, building the desired shape in successivemore » layers of bonded powder. Upon completion, the green part and surrounding powders are placed in an oven at temperatures between 100°C and 150°C for 4–6 h to cure the binder. After curing, the excess powder can be brushed away to reveal the completed “green” part. Green magnet parts were then infiltrated with a clear urethane resin to achieve the measured density of the magnet of 3.47 g/cm 3 close to 46% relative to the NdFeB single crystal density of 7.6 g/cm 3. Magnetic measurements indicate that there is no degradation in the magnetic properties. In conclusion, this study provides a new pathway for preparing near-net-shape bonded magnets for various magnetic applications.« less

Net Shape Technology in Aerospace Structures. Volume 1.

DTIC Science & Technology

1986-11-01

ofI nIo n- destructive evaluation methods, such a s ult rasonic inspection, in detecting otherwise hidden defects in parts made of the material. Pratt...SCHEDULE 4. PERFORMING ORGANIZATION REPORT NUMBER( S ) 5. MONITORING ORGANIZATION REPORT NUMBER( S ) n/a n/a 6a. NAME OF PERFORMING ORGANIZATION 6b...a n/a n/a 11 TITLE (Include Security Classification) Net Shape Technology in Aerospace Structures, Vol. I (U) 12. PERSONAL AUTHOR( S ) 13a. TYPE OF

Synthesis and processing of composites by reactive metal penetration

DOE Office of Scientific and Technical Information (OSTI.GOV)

Loehman, R.E.; Ewsuk, K.G.; Tomsia, A.P.

1997-04-01

Achieving better performance in commercial products and processes often is dependent on availability of new and improved materials. Ceramic-metal composites have advantages over more conventional materials because of their high stiffness-to-weight ratios, good fracture toughness, and because their electrical and thermal properties can be varied through control of their compositions and microstructures. However, ceramic composites will be more widely used only when their costs are competitive with other materials and when designers have more confidence in their reliability. Over the past four years reactive metal penetration has been shown to be a promising technique for making ceramic and metal-matrix compositesmore » to near-net-shape with control of both composition and microstructure. It appears that, with sufficient development, reactive metal penetration could be an economical process for manufacturing many of the advanced ceramic composites that are needed for light-weight structural and wear applications for transportation and energy conversion devices. Near-net-shape fabrication of parts is a significant advantage because costly and energy intensive grinding and machining operations are substantially reduced, and the waste generated from such finishing operations is minimized. The most promising compositions to date consist of Al and Al{sub 2}O{sub 3}; thus, these composites should be of particular interest to the aluminum industry. The goals of this ceramic-metal composite research and development program are: (1) to identify compositions favorable for making composites by reactive metal penetration; (2) to understand the mechanism(s) by which these composites are formed; (3) to control and optimize the process so that composites and composite coatings can be made economically; and (4) to apply R&D results to problems of interest to the aluminum industry.« less

Data indicating temperature response of Ti-6Al-4V thin-walled structure during its additive manufacture via Laser Engineered Net Shaping.

PubMed

Marshall, Garrett J; Thompson, Scott M; Shamsaei, Nima

2016-06-01

An OPTOMEC Laser Engineered Net Shaping (LENS(™)) 750 system was retrofitted with a melt pool pyrometer and in-chamber infrared (IR) camera for nondestructive thermal inspection of the blown-powder, direct laser deposition (DLD) process. Data indicative of temperature and heat transfer within the melt pool and heat affected zone atop a thin-walled structure of Ti-6Al-4V during its additive manufacture are provided. Melt pool temperature data were collected via the dual-wavelength pyrometer while the dynamic, bulk part temperature distribution was collected using the IR camera. Such data are provided in Comma Separated Values (CSV) file format, containing a 752×480 matrix and a 320×240 matrix of temperatures corresponding to individual pixels of the pyrometer and IR camera, respectively. The IR camera and pyrometer temperature data are provided in blackbody-calibrated, raw forms. Provided thermal data can aid in generating and refining process-property-performance relationships between laser manufacturing and its fabricated materials.

Data indicating temperature response of Ti–6Al–4V thin-walled structure during its additive manufacture via Laser Engineered Net Shaping

PubMed Central

Marshall, Garrett J.; Thompson, Scott M.; Shamsaei, Nima

2016-01-01

An OPTOMEC Laser Engineered Net Shaping (LENS™) 750 system was retrofitted with a melt pool pyrometer and in-chamber infrared (IR) camera for nondestructive thermal inspection of the blown-powder, direct laser deposition (DLD) process. Data indicative of temperature and heat transfer within the melt pool and heat affected zone atop a thin-walled structure of Ti–6Al–4V during its additive manufacture are provided. Melt pool temperature data were collected via the dual-wavelength pyrometer while the dynamic, bulk part temperature distribution was collected using the IR camera. Such data are provided in Comma Separated Values (CSV) file format, containing a 752×480 matrix and a 320×240 matrix of temperatures corresponding to individual pixels of the pyrometer and IR camera, respectively. The IR camera and pyrometer temperature data are provided in blackbody-calibrated, raw forms. Provided thermal data can aid in generating and refining process-property-performance relationships between laser manufacturing and its fabricated materials. PMID:27054180

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.;

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.;

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.;

Animal Hairs as Water-stimulated Shape Memory Materials: Mechanism and Structural Networks in Molecular Assemblies

NASA Astrophysics Data System (ADS)

Xiao, Xueliang; Hu, Jinlian

2016-05-01

Animal hairs consisting of α-keratin biopolymers existing broadly in nature may be responsive to water for recovery to the innate shape from their fixed deformation, thus possess smart behavior, namely shape memory effect (SME). In this article, three typical animal hair fibers were first time investigated for their water-stimulated SME, and therefrom to identify the corresponding net-points and switches in their molecular and morphological structures. Experimentally, the SME manifested a good stability of high shape fixation ratio and reasonable recovery rate after many cycles of deformation programming under water stimulation. The effects of hydration on hair lateral size, recovery kinetics, dynamic mechanical behaviors and structural components (crystal, disulfide and hydrogen bonds) were then systematically studied. SME mechanisms were explored based on the variations of structural components in molecular assemblies of such smart fibers. A hybrid structural network model with single-switch and twin-net-points was thereafter proposed to interpret the water-stimulated shape memory mechanism of animal hairs. This original work is expected to provide inspiration for exploring other natural materials to reveal their smart functions and natural laws in animals including human as well as making more remarkable synthetic smart materials.

Animal Hairs as Water-stimulated Shape Memory Materials: Mechanism and Structural Networks in Molecular Assemblies

PubMed Central

Xiao, Xueliang; Hu, Jinlian

2016-01-01

Animal hairs consisting of α-keratin biopolymers existing broadly in nature may be responsive to water for recovery to the innate shape from their fixed deformation, thus possess smart behavior, namely shape memory effect (SME). In this article, three typical animal hair fibers were first time investigated for their water-stimulated SME, and therefrom to identify the corresponding net-points and switches in their molecular and morphological structures. Experimentally, the SME manifested a good stability of high shape fixation ratio and reasonable recovery rate after many cycles of deformation programming under water stimulation. The effects of hydration on hair lateral size, recovery kinetics, dynamic mechanical behaviors and structural components (crystal, disulfide and hydrogen bonds) were then systematically studied. SME mechanisms were explored based on the variations of structural components in molecular assemblies of such smart fibers. A hybrid structural network model with single-switch and twin-net-points was thereafter proposed to interpret the water-stimulated shape memory mechanism of animal hairs. This original work is expected to provide inspiration for exploring other natural materials to reveal their smart functions and natural laws in animals including human as well as making more remarkable synthetic smart materials. PMID:27230823

CRADA/NFE-15-05761 Report: Additive Manufacturing of Isotropic NdFeB Bonded Permanent Magnets

DOE Office of Scientific and Technical Information (OSTI.GOV)

Paranthaman, M. Parans

2016-07-18

The technical objective of this technical collaboration phase I proposal is to fabricate net shape isotropic NdFeB bonded magnets utilizing additive manufacturing technologies at the ORNL MDF. The goal is to form complex shapes of thermoplastic and/or thermoset bonded magnets without expensive tooling and with minimal wasted material. Two additive manufacturing methods; the binder jet process; and big area additive manufacturing (BAAM) were used. Binder jetting produced magnets with the measured density of the magnet of 3.47 g/cm 3, close to 46% relative to the NdFeB single crystal density of 7.6 g/cm 3 were demonstrated. Magnetic measurements indicate that theremore » is no degradation in the magnetic properties. In addition, BAAM was used to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm 3, and the room temperature magnetic properties are: Intrinsic coercivity Hci = 8.65 kOe, Remanence Br = 5.07 kG, and energy product (BH) max = 5.47 MGOe (43.50 kJ/m 3). This study provides a new pathway for preparing near-net shape bonded magnets for various magnetic applications.« less

Characterization of the Fe-Co-1.5V soft ferromagnetic alloy processed by Laser Engineered Net Shaping (LENS)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kustas, Andrew B.; Susan, Donald F.; Johnson, Kyle L.

Processing of the low workability Fe-Co-1.5V (Hiperco® equivalent) alloy is demonstrated using the Laser Engineered Net Shaping (LENS) metals additive manufacturing technique. As an innovative and highly localized solidification process, LENS is shown to overcome workability issues that arise during conventional thermomechanical processing, enabling the production of bulk, near net-shape forms of the Fe-Co alloy. Bulk LENS structures appeared to be ductile with no significant macroscopic defects. Atomic ordering was evaluated and significantly reduced in as-built LENS specimens relative to an annealed condition, tailorable through selection of processing parameters. Fine equiaxed grain structures were observed in as-built specimens following solidification,more » which then evolved toward a highly heterogeneous bimodal grain structure after annealing. The microstructure evolution in Fe-Co is discussed in the context of classical solidification theory and selective grain boundary pinning processes. In conclusion, magnetic properties were also assessed and shown to fall within the extremes of conventionally processed Hiperco® alloys.« less

Characterization of the Fe-Co-1.5V soft ferromagnetic alloy processed by Laser Engineered Net Shaping (LENS)

DOE PAGES

Kustas, Andrew B.; Susan, Donald F.; Johnson, Kyle L.; ...

2018-02-21

Processing of the low workability Fe-Co-1.5V (Hiperco® equivalent) alloy is demonstrated using the Laser Engineered Net Shaping (LENS) metals additive manufacturing technique. As an innovative and highly localized solidification process, LENS is shown to overcome workability issues that arise during conventional thermomechanical processing, enabling the production of bulk, near net-shape forms of the Fe-Co alloy. Bulk LENS structures appeared to be ductile with no significant macroscopic defects. Atomic ordering was evaluated and significantly reduced in as-built LENS specimens relative to an annealed condition, tailorable through selection of processing parameters. Fine equiaxed grain structures were observed in as-built specimens following solidification,more » which then evolved toward a highly heterogeneous bimodal grain structure after annealing. The microstructure evolution in Fe-Co is discussed in the context of classical solidification theory and selective grain boundary pinning processes. In conclusion, magnetic properties were also assessed and shown to fall within the extremes of conventionally processed Hiperco® alloys.« less

Carbon Fiber Reinforced Carbon Composite Valve for an Internal Combustion Engine

NASA Technical Reports Server (NTRS)

Rivers, H. Kevin (Inventor); Ransone, Philip O. (Inventor); Northam, G. Burton (Inventor)

1999-01-01

A carbon fiber reinforced carbon composite valve for internal combustion engines and the like formed of continuous carbon fibers throughout the valve's stem and head is disclosed. The valve includes braided carbon fiber material over axially aligned unidirectional carbon fibers forming a valve stem; the braided and unidirectional carbon fibers being broomed out at one end of the valve stem forming the shape of the valve head; the valve-shaped structure being densified and rigidized with a matrix of carbon containing discontinuous carbon fibers: and the finished valve being treated to resist oxidation. Also disclosed is a carbon matrix plug containing continuous and discontinuous carbon fibers and forming a net-shape valve head acting as a mandrel over which the unidirectional and braided carbon fibers are formed according to textile processes. Also disclosed are various preform valves and processes for making finished and preform carbon fiber reinforced carbon composite valves.

Bulk combinatorial synthesis and high throughput characterization for rapid assessment of magnetic materials: Application of laser engineered net shaping (LENS)

DOE PAGES

Geng, J.; Nlebedim, I. C.; Besser, M. F.; ...

2016-04-15

A bulk combinatorial approach for synthesizing alloy libraries using laser engineered net shaping (LENS; i.e., 3D printing) was utilized to rapidly assess material systems for magnetic applications. The LENS system feeds powders in different ratios into a melt pool created by a laser to synthesize samples with bulk (millimeters) dimensions. By analyzing these libraries with autosampler differential scanning calorimeter/thermal gravimetric analysis and vibrating sample magnetometry, we are able to rapidly characterize the thermodynamic and magnetic properties of the libraries. Furthermore, the Fe-Co binary alloy was used as a model system and the results were compared with data in the literature.

Reactive processing and mechanical properties of polymer derived silicon nitride matrix composites and their use in coating and joining ceramics and ceramic matrix composites

NASA Astrophysics Data System (ADS)

Stackpoole, Margaret Mary

Use of preceramic polymers offers many advantages over conventional ceramic processing routes. Advantages include being able to plastically form the part, form a pyrolized ceramic material at lower temperatures and form high purity microstructures which are tailorable depending on property requirements. To date preceramic polymers are mostly utilized in the production of low dimensional products such as fibers since loss of volatiles during pyrolysis leads to porosity and large shrinkage (in excess of 30%). These problems have been partially solved by use of active fillers (e.g. Ti, Cr, B). The reactive filler converts to a ceramic material with a volume expansion and this increases the density and reduces shrinkage and porosity. The expansion of the reactive filler thus compensates for the polymer shrinkage if the appropriate volume fraction of filler is present in a reactive atmosphere (e.g. N2 or NH3). This approach has resulted in structural composites with limited success. The present research investigates the possibility of using filled preceramic polymers to form net shaped ceramic composite materials and to investigate the use of these unique composite materials to join and coat ceramics and ceramic composites. The initial research focused on phase and microstructural development of bulk composites from the filled polymer/ceramic systems. A processing technique was developed to insure consistency between different samples and the most promising filler/polymer choices for this application have been determined. The processing temperatures and atmospheres have also been optimized. The work covers processing and characterization of bulk composites, joints and coatings. With careful control of processing near net shape bulk composites were fabricated. Both ambient and high temperature strength and fracture toughness was obtained for these composite systems. The potential of using reactively filled preceramic polymers to process joints and coatings was also investigated. A critical thickness below which crack free joints/coatings could be processed was determined. Finally, mechanical properties of the joints and coatings at ambient and elevated temperatures (including oxidation studies) have been evaluated. The interfacial fracture behavior of the joints and coatings was also evaluated.

Process for preparing energetic materials

DOEpatents

Simpson, Randall L [Livermore, CA; Lee, Ronald S [Livermore, CA; Tillotson, Thomas M [Tracy, CA; Hrubesh, Lawrence W [Pleasanton, CA; Swansiger, Rosalind W [Livermore, CA; Fox, Glenn A [Livermore, CA

2011-12-13

Sol-gel chemistry is used for the preparation of energetic materials (explosives, propellants and pyrotechnics) with improved homogeneity, and/or which can be cast to near-net shape, and/or made into precision molding powders. The sol-gel method is a synthetic chemical process where reactive monomers are mixed into a solution, polymerization occurs leading to a highly cross-linked three dimensional solid network resulting in a gel. The energetic materials can be incorporated during the formation of the solution or during the gel stage of the process. The composition, pore, and primary particle sizes, gel time, surface areas, and density may be tailored and controlled by the solution chemistry. The gel is then dried using supercritical extraction to produce a highly porous low density aerogel or by controlled slow evaporation to produce a xerogel. Applying stress during the extraction phase can result in high density materials. Thus, the sol-gel method can be used for precision detonator explosive manufacturing as well as producing precision explosives, propellants, and pyrotechnics, along with high power composite energetic materials.

Laser Consolidation - A Novel One-Step Manufacturing Process for Making Net-Shape Functional Components

DTIC Science & Technology

2006-05-01

dies. This process uses a laser beam to melt a controlled amount of injected powder on a base plate to deposit the first layer and on previous passes...Consolidation” to build functional net-shape components directly from metallic powder in one step [1-3]. The laser consolidation is a one-step computer-aided...A focused laser beam is irradiated on the substrate to create a molten pool, while metallic powder is injected simultaneously into the pool. A

Spray forming process for producing molds, dies and related tooling

DOEpatents

McHugh, Kevin M.; Key, James F.

1998-01-01

A method for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers.

Spray forming process for producing molds, dies and related tooling

DOEpatents

McHugh, K.M.; Key, J.F.

1998-02-17

A method is disclosed for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers. 17 figs.

Investigation of Friction Stir Welding and Laser Engineered Net Shaping of Metal Matrix Composite Materials

NASA Technical Reports Server (NTRS)

Diwan, Ravinder M.

2002-01-01

The improvement in weld quality by the friction stir welding (FSW) process invented by TWI of Cambridge, England, patented in 1991, has prompted investigation of this process for advanced structural materials including Al metal matrix composite (Al-MMC) materials. Such materials can have high specific stiffness and other potential beneficial properties for the extreme environments in space. Developments of discontinuous reinforced Al-MMCs have found potential space applications and the future for such applications is quite promising. The space industry has recognized advantages of the FSW process over conventional welding processes such as the absence of a melt zone, reduced distortion, elimination of the need for shielding gases, and ease of automation. The process has been well proven for aluminum alloys, and work is being carried out for ferrous materials, magnesium alloys and copper alloys. Development work in the FSW welding process for joining of Al-MMCs is relatively recent and some of this and related work can be found in referenced research publications. NASA engineers have undertaken to spear head this research development work for FSW process investigation of Al-MMCs. Some of the reported related work has pointed out the difficulty in fusion welding of particulate reinforced MMCs where liquid Al will react with SiC to precipitate aluminum carbide (Al4C3). Advantages of no such reaction and no need for joint preparation for the FSW process is anticipated in the welding of Al-MMCs. The FSW process has been best described as a combination of extrusion and forging of metals. This is carried out as the pin tool rotates and is slowly plunged into the bond line of the joint as the pin tool's shoulder is in intimate contact with the work piece. The material is friction-stirred into a quality weld. Al-MMCs, 4 in. x 12 in. plates of 0.25 in. (6.35mm) thickness, procured from MMCC, Inc. were butt welded using FSW process at Marshall Space Flight Center (MSFC) using prior set of operating conditions. Weld quality was evaluated using radiography and standard metallography techniques. Another aspect of the MMCs centered around the use of the laser engineered net shaping (LENS) processing of selected Narloy-Z composites. Such an approach has been earlier studied for fabrication of stainless steels. In the present study, attempts were made to fabricate straight cylindrical specimens using LENS process of Narloy-Z and Narloy-Z with 20 vol. % Al2O3 MMCs using the direct metal deposition Optomec LENS-750 system.

Metal injection molding of titanium for medical and aerospace applications

NASA Astrophysics Data System (ADS)

Scharvogel, Matthias; Winkelmueller, Wendelin

2011-02-01

Mixing of titanium powder and thermoplastic binders creates a feedstock that is injection molded similar to plastic, has a chemical and thermal debinding process, and then is sintered to form a net-shape or near-net shape part. TiJet Medizintechnik GmbH (TiJet) developed and uses its own feedstock and powder processing technology to achieve desired mechanical properties. This paper explains the theory of the process and the possibilities that result from the development of this new powder processing technology, such as new alloys, design possibilities, etc. Discussed will be the microstructure, chemical composition, and mechanical properties of the manufactured parts.

Propagation characteristic of THz wave in camouflage net material

NASA Astrophysics Data System (ADS)

Dong, Hailong; Wang, Jiachun; Chen, Zongsheng; Lin, Zhidan; Zhao, Dapeng; Liu, Ruihuang

2017-10-01

Terahertz (THz) radar system, with excellent potentials such as high-resolution and strong penetration capability, is promising in the field of anti-camouflage. Camouflage net is processed by cutting the camouflage net material, which is fabricated on pre-processing substrate by depositing coatings with camouflage abilities in different bands, such as visible, infrared and radar. In this paper, we concentrate on the propagation characteristic of THz wave in camouflage net material. Firstly, function and structure of camouflage net were analyzed. Then the advantage and appliance of terahertz time-domain spectroscopy (THz-TDS) was introduced. And the relevant experiments were conducted by utilizing THz-TDS. The results obtained indicate that THz wave has better penetration capacity in camouflage net material, which demonstrates the feasibility of using THz radar to detect those targets covered with camouflage net.

A novel restraint spraying-Conform process for manufacturing hypereutectic Al-Si alloy with enhanced properties

NASA Astrophysics Data System (ADS)

Chen, Y. G.; Yang, H.; Zhang, B. Q.; Liu, Y. L.; Yin, J. C.; Wei, W.; Zhong, Y.

2017-02-01

A novel restraint spraying-Conform (RS-C) process, which directly combines spraying with Conform to process metals in one step, has been proposed. Al-20Si alloy selected as experimental material was successfully fabricated by the RS-C process. The microstructures were dominated with fine and uniform primary silicon phases. The tensile strength and elongation to failure of the Al-20Si alloy were 204 MPa and 7.2% respectively after the RS-C process. The wear resistance of the processed Al-20Si alloy was increased significantly, about 1.7 times over the as-cast ingot. The experimental results indicate that RS-C is a promising near net shape forming technology.

Fast-Response-Time Shape-Memory-Effect Foam Actuators

NASA Technical Reports Server (NTRS)

Jardine, Peter

2010-01-01

Bulk shape memory alloys, such as Nitinol or CuAlZn, display strong recovery forces undergoing a phase transformation after being strained in their martensitic state. These recovery forces are used for actuation. As the phase transformation is thermally driven, the response time of the actuation can be slow, as the heat must be passively inserted or removed from the alloy. Shape memory alloy TiNi torque tubes have been investigated for at least 20 years and have demonstrated high actuation forces [3,000 in.-lb (approximately equal to 340 N-m) torques] and are very lightweight. However, they are not easy to attach to existing structures. Adhesives will fail in shear at low-torque loads and the TiNi is not weldable, so that mechanical crimp fits have been generally used. These are not reliable, especially in vibratory environments. The TiNi is also slow to heat up, as it can only be heated indirectly using heater and cooling must be done passively. This has restricted their use to on-off actuators where cycle times of approximately one minute is acceptable. Self-propagating high-temperature synthesis (SHS) has been used in the past to make porous TiNi metal foams. Shape Change Technologies has been able to train SHS derived TiNi to exhibit the shape memory effect. As it is an open-celled material, fast response times were observed when the material was heated using hot and cold fluids. A methodology was developed to make the open-celled porous TiNi foams as a tube with integrated hexagonal ends, which then becomes a torsional actuator with fast response times. Under processing developed independently, researchers were able to verify torques of 84 in.-lb (approximately equal to 9.5 Nm) using an actuator weighing 1.3 oz (approximately equal to 37 g) with very fast (less than 1/16th of a second) initial response times when hot and cold fluids were used to facilitate heat transfer. Integrated structural connections were added as part of the net shape process, eliminating the need for welding, adhesives, or mechanical crimping. Inexpensive net-shape processing was used, which reduces the cost of the actuator by over a factor of 10 over nonporous TiNi made by hot drawing of tube or electrical discharge machining. By forming the alloy as an open-celled foam, the surface area for heat transfer is dramatically increased, allowing for much faster response times. The technology also allows for netshape fabrication of the actuator, which allows for structural connections to be integrated into the actuator material, making these actuators significantly less expensive. Commercial applications include actuators for concepts such as the variable area chevron and nozzle in jet aircraft. Lightweight tube or rod components can be supplied to interested parties.

Net shape fabrication of Alpha Silicon Carbide turbine components

NASA Technical Reports Server (NTRS)

Storm, R. S.

1982-01-01

Development of Alpha Silicon Carbide components by net shape fabrication techniques has continued in conjunction with several turbine engine programs. Progress in injection molding of simple parts has been extended to much larger components. Turbine rotors fabricated by a one piece molding have been successfully spin tested above design speeds. Static components weighing up to 4.5 kg and 33 cc in diameter have also been produced using this technique. Use of sintering fixtures significantly improves dimensional control. A new Si-SiC composite material has also been developed with average strengths up to 1000 MPa (150 ksi) at 1200 C.

Aluminum-Alloy-Matrix/Alumina-Reinforcement Composites

NASA Technical Reports Server (NTRS)

Kashalikar, Uday; Rozenoyer, Boris

2004-01-01

Isotropic composites of aluminum-alloy matrices reinforced with particulate alumina have been developed as lightweight, high-specific-strength, less-expensive alternatives to nickel-base and ferrous superalloys. These composites feature a specific gravity of about 3.45 grams per cubic centimeter and specific strengths of about 200 MPa/(grams per cubic centimeter). The room-temperature tensile strength is 100 ksi (689 MPa) and stiffness is 30 Msi (206 GPa). At 500 F (260 C), these composites have shown 80 percent retention in strength and 95 percent retention in stiffness. These materials also have excellent fatigue tolerance and tribological properties. They can be fabricated in net (or nearly net) sizes and shapes to make housings, pistons, valves, and ducts in turbomachinery, and to make structural components of such diverse systems as diesel engines, automotive brake systems, and power-generation, mining, and oil-drilling equipment. Separately, incorporation of these metal matrix composites within aluminum gravity castings for localized reinforcement has been demonstrated. A composite part of this type can be fabricated in a pressure infiltration casting process. The process begins with the placement of a mold with alumina particulate preform of net or nearly net size and shape in a crucible in a vacuum furnace. A charge of the alloy is placed in the crucible with the preform. The interior of the furnace is evacuated, then the furnace heaters are turned on to heat the alloy above its liquidus temperature. Next, the interior of the furnace is filled with argon gas at a pressure about 900 psi (approximately equal to 6.2 MPa) to force the molten alloy to infiltrate the preform. Once infiltrated, the entire contents of the crucible can be allowed to cool in place, and the composite part recovered from the mold.

Sol-Gel Manufactured Energetic Materials

DOEpatents

Simpson, Randall L.; Lee, Ronald S.; Tillotson, Thomas M.; Hrubesh, Lawrence W.; Swansiger, Rosalind W.; Fox, Glenn A.

2005-05-17

Sol-gel chemistry is used for the preparation of energetic materials (explosives, propellants and pyrotechnics) with improved homogeneity, and/or which can be cast to near-net shape, and/or made into precision molding powders. The sol-gel method is a synthetic chemical process where reactive monomers are mixed into a solution, polymerization occurs leading to a highly cross-linked three dimensional solid network resulting in a gel. The energetic materials can be incorporated during the formation of the solution or during the gel stage of the process. The composition, pore, and primary particle sizes, gel time, surface areas, and density may be tailored and controlled by the solution chemistry. The gel is then dried using supercritical extraction to produce a highly porous low density aerogel or by controlled slow evaporation to produce a xerogel. Applying stress during the extraction phase can result in high density materials. Thus, the sol-gel method can be used for precision detonator explosive manufacturing as well as producing precision explosives, propellants, and pyrotechnics, along with high power composite energetic materials.

Sol-gel manufactured energetic materials

DOEpatents

Simpson, Randall L.; Lee, Ronald S.; Tillotson, Thomas M.; Hrubesh, Lawrence W.; Swansiger, Rosalind W.; Fox, Glenn A.

2003-12-23

Sol-gel chemistry is used for the preparation of energetic materials (explosives, propellants and pyrotechnics) with improved homogeneity, and/or which can be cast to near-net shape, and/or made into precision molding powders. The sol-gel method is a synthetic chemical process where reactive monomers are mixed into a solution, polymerization occurs leading to a highly cross-linked three dimensional solid network resulting in a gel. The energetic materials can be incorporated during the formation of the solution or during the gel stage of the process. The composition, pore, and primary particle sizes, gel time, surface areas, and density may be tailored and controlled by the solution chemistry. The gel is then dried using supercritical extraction to produce a highly porous low density aerogel or by controlled slow evaporation to produce a xerogel. Applying stress during the extraction phase can result in high density materials. Thus, the sol-gel method can be used for precision detonator explosive manufacturing as well as producing precision explosives, propellants, and pyrotechnics, along with high power composite energetic materials.

Microstructure and Mechanical Properties of Vacuum Plasma Sprayed Cu-8Cr-4Nb

NASA Technical Reports Server (NTRS)

Holmes, Richard; Ellis, David; McKechnie, Timothy; Hickman, Robert

1997-01-01

This paper compares the tensile properties of Cu-8Cr-4Nb material produced by VPS to material previously produced by extrusion. The microstructure of the VPS material is also presented. The combustion chamber liner of rocket motors represents an extreme materials application. The liner hot wall is exposed to a 2760 C (5000 F) flame while the cold side is exposed to cryogenic hydrogen liquid. Materials for use in the combustion chamber liner require a combination of high temperature strength, creep resistance, and low cycle fatigue resistance along with high thermal conductivity. The hot side is also subject to localized cycles between reducing and oxidizing environments that degrade the liner by a process called blanching. A new Cu-8 at.% Cr-4 at% Nb (Cu-8Cr-4Nb) alloy has been developed at NASA Lewis Research Center as a replacement for the currently used alloy, NARloy-z (Cu-3 wt.% Ag-0.5 wt.% Zr). The alloy is strengthened by a fine dispersion of Cr2Nb particles. The alloy has better mechanical properties than NARloy-Z while retaining most of the thermal conductivity of pure copper. The alloy has been successfully consolidated by extrusion and hot isostatic pressing (HIPing). However, vacuum plasma spraying (VPS) offers several advantages over prior consolidation methods. VPS can produce a near net shape piece with the profile of the liner. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the liner hot wall during the VPS deposition. The low oxygen VPS Cu-8Cr-4Nb exhibits a higher strength than Cu-8Cr-4Nb produced by extrusion at elevated temperatures and a comparable strength at room temperature. Moduli and ductility were not significantly different. However, the ability to produce parts to near-net shape and maintain the good elevated temperature tensile properties of the extruded Cu-8Cr-4Nb makes VPS an attractive processing method for fabricating rocket engine combustion liners.

Effect Of Gravity On Porous Tricalcium Phosphate And Nonstoichiometric Titanium Carbide Produced Via Combustion Synthesis

NASA Technical Reports Server (NTRS)

Castillo, M.; Moore, J. J.; Schowengerdt, F. D.; Ayers, R. A.

2003-01-01

Novel processing techniques, such as self-propagating high temperature synthesis (SHS), have the capability to rapidly produce advanced porous materials that are difficult to fabricate by other methods. This processing technique is also capable of near net shape synthesis, while variable gravity allows the manipulation of the structure and composition of the material. The creation of porous tricalcium phosphate (TCP) is advantageous in the biomaterials field, since it is both a biocompatible material and an osteoconductive material. Porous tricalcium phosphate produced via SHS is an excellent candidate for bone scaffold material in the bone regeneration process. The porosity allows for great vascularization and ingrowth of tissue. Titanium Carbide is a nonstoichiometric biocompatible material that can be incorporated into a TiC-Ti composite system using combustion synthesis. The TiC-Ti composite exhibits a wide range of mechanical and chemical properties. Both of these material systems (TCP and TiC-Ti) can be used to advantage in designing novel bone replacement materials. Gravity plays an important role in both the pore structure and the chemical uniformity of these composite systems and offers considerable potential in advanced bone engineering.

Microstructural and Mechanical Property Characterization of Shear Formed Aerospace Aluminum Alloys

NASA Technical Reports Server (NTRS)

Troeger, Lillianne P.; Domack, Marcia S.; Wagner, John A.

2000-01-01

Advanced manufacturing processes such as near-net-shape forming can reduce production costs and increase the reliability of launch vehicle and airframe structural components through the reduction of material scrap and part count and the minimization of joints. The current research is an investigation of the processing-microstructure-property relationships for shear formed cylinders of the Al-Cu-Li-Mg-Ag alloy 2195 for space applications and the Al-Cu-Mg-Ag alloy C415 for airframe applications. Cylinders which had undergone various amounts of shear-forming strain were studied to correlate the grain structure, texture, and mechanical properties developed during and after shear forming.

Microstructural and Mechanical Characterization of Shear Formed Aluminum Alloys for Airframe and Space Applications

NASA Technical Reports Server (NTRS)

Troeger, L. P.; Domack, M. S.; Wagner, J. A.

1998-01-01

Advanced manufacturing processes such as near-net-shape forming can reduce production costs and increase the reliability of launch vehicle and airframe structural components through the reduction of material scrap and part count and the minimization of joints. The current research is an investigation of the processing-microstructure-property relationship for shear formed cylinders of the Al-Cu-Li-Mg-Ag alloy 2195 for space applications and the Al-Cu-Mg-Ag alloy C415 for airframe applications. Cylinders which have undergone various amounts of shear-forming strain have been studied to assess the microstructure and mechanical properties developed during and after shear forming.

Activated carbon fiber composite material and method of making

DOEpatents

Burchell, Timothy D.; Weaver, Charles E.; Chilcoat, Bill R.; Derbyshire, Frank; Jagtoyen, Marit

2000-01-01

An activated carbon fiber composite for separation and purification, or catalytic processing of fluids is described. The activated composite comprises carbon fibers rigidly bonded to form an open, permeable, rigid monolith capable of being formed to near-net-shape. Separation and purification of gases are effected by means of a controlled pore structure that is developed in the carbon fibers contained in the composite. The open, permeable structure allows the free flow of gases through the monolith accompanied by high rates of adsorption. By modification of the pore structure and bulk density the composite can be rendered suitable for applications such as gas storage, catalysis, and liquid phase processing.

Activated carbon fiber composite material and method of making

DOEpatents

Burchell, Timothy D.; Weaver, Charles E.; Chilcoat, Bill R.; Derbyshire, Frank; Jagtoyen, Marit

2001-01-01

An activated carbon fiber composite for separation and purification, or catalytic processing of fluids is described. The activated composite comprises carbon fibers rigidly bonded to form an open, permeable, rigid monolith capable of being formed to near-net-shape. Separation and purification of gases are effected by means of a controlled pore structure that is developed in the carbon fibers contained in the composite. The open, permeable structure allows the free flow of gases through the monolith accompanied by high rates of adsorption. By modification of the pore structure and bulk density the composite can be rendered suitable for applications such as gas storage, catalysis, and liquid phase processing.

Rapid solidification processing system for producing molds, dies and related tooling

DOEpatents

McHugh, Kevin M.

2004-06-08

A system for the spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the in-flight atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as powders, whiskers or fibers.

Materials and processes for aircraft environmental controls in the 1990's

NASA Astrophysics Data System (ADS)

Delgrosso, E. J.; Zajac, T.; Tseka, J.

1980-10-01

Changes in materials and processes expected to be used in aircraft environmental control systems (ECS) in the 1990s are analyzed, and a forecast is presented. Results of the study show that the most advanced development would be in the use of a cast high strength alloy steel, i.e., a steel with below 8% alloy content, and a 225 KSI annealed tensile strength. To assure complete densification and enhancement of properties, the casting would be HIP, and modification of its surface chemistry could be achieved through ion implantation. As candidate methods for imparting surface protection, laser glazing and chemical vapor deposition are mentioned. The anticipated changes in the materials and techniques used for construction of ECS components are: the development of rapid solidification rate powders for the production of some alloy systems such as Al-Mg-Li, bearing alloy CRB-7, and titanium alloys, 'near-net-shape' processing, and the use of advanced fiber-reinforced plastics.

Propulsion Systems Panel

NASA Technical Reports Server (NTRS)

Bianca, Carmelo J.; Miner, Robert; Johnston, Lawrence M.; Bruce, R.; Dennies, Daniel P.; Dickenson, W.; Dreshfield, Robert; Karakulko, Walt; Mcgaw, Mike; Munafo, Paul M.

1993-01-01

Topics addressed are: (1) cryogenic tankage; (2) launch vehicle TPS/insulation; (3) durable passive thermal control devices and/or coatings; (4) development and characterization of processing methods to reduce anisotropy of material properties in Al-Li; (5) durable thermal protection system (TPS); (6) unpressurized Al-Li structures (interstages, thrust structures); (7) near net shape sections; (8) pressurized structures; (9) welding and joining; (10) micrometeoroid and debris hypervelocity shields; (11) state-of-the-art shell buckling structure optimizer program to serve as a rapid design tool; (12) test philosophy; (13) reduced load cycle time; (14) structural analysis methods; (15) optimization of structural criteria; and (16) develop an engineering approach to properly trade material and structural concepts selection, fabrication, facilities, and cost.

Propulsion Systems Panel

NASA Astrophysics Data System (ADS)

Bianca, Carmelo J.; Miner, Robert; Johnston, Lawrence M.; Bruce, R.; Dennies, Daniel P.; Dickenson, W.; Dreshfield, Robert; Karakulko, Walt; McGaw, Mike; Munafo, Paul M.

1993-02-01

Topics addressed are: (1) cryogenic tankage; (2) launch vehicle TPS/insulation; (3) durable passive thermal control devices and/or coatings; (4) development and characterization of processing methods to reduce anisotropy of material properties in Al-Li; (5) durable thermal protection system (TPS); (6) unpressurized Al-Li structures (interstages, thrust structures); (7) near net shape sections; (8) pressurized structures; (9) welding and joining; (10) micrometeoroid and debris hypervelocity shields; (11) state-of-the-art shell buckling structure optimizer program to serve as a rapid design tool; (12) test philosophy; (13) reduced load cycle time; (14) structural analysis methods; (15) optimization of structural criteria; and (16) develop an engineering approach to properly trade material and structural concepts selection, fabrication, facilities, and cost.

One-step manufacturing of innovative flat-knitted 3D net-shape preforms for composite applications

NASA Astrophysics Data System (ADS)

Bollengier, Quentin; Wieczorek, Florian; Hellmann, Sven; Trümper, Wolfgang; Cherif, Chokri

2017-10-01

Mostly due to the cost-intensive manually performed processing operations, the production of complex-shaped fibre reinforced plastic composites (FRPC) is currently very expensive and therefore either restricted to sectors with high added value or for small batch applications (e.g. in the aerospace or automotive industry). Previous works suggest that the successful integration of conventional textile manufacturing processes in the FRPC-process chain is the key to a cost-efficient manufacturing of complex three-dimensional (3D) FRPC-components with stress-oriented fibre arrangement. Therefore, this work focuses on the development of the multilayer weft knitting technology for the one-step manufacturing of complex 3D net-shaped preforms for high performance FRPC applications. In order to highlight the advantages of net-shaped multilayer weft knitted fabrics for the production of complex FRPC parts, seamless preforms such as 3D skin-stringer structures and tubular fabrics with load oriented fibre arrangement are realised. In this paper, the development of the textile bindings and performed technical modifications on flat knitting machines are presented. The results show that the multilayer weft knitting technology meets perfectly the requirements for a fully automated and reproducible manufacturing of complex 3D textile preforms with stress-oriented fibre arrangement.

Fabrication of High Thermal Conductivity NARloy-Z-Diamond Composite Combustion Chamber Liner for Advanced Rocket Engines

NASA Technical Reports Server (NTRS)

Bhat, Biliyar N.; Greene, Sandra E.; Singh, Jogender

2016-01-01

NARloy-Z alloy (Cu-3 percent, Ag-0.5 percent, Zr) is a state of the art alloy currently used for fabricating rocket engine combustion chamber liners. Research conducted at NASA-MSFC and Penn State – Applied Research Laboratory has shown that thermal conductivity of NARloy-Z can be increased significantly by adding diamonds to form a composite (NARloy-Z-D). NARloy-Z-D is also lighter than NARloy-Z. These attributes make this advanced composite material an ideal candidate for fabricating combustion chamber liner for an advanced rocket engine. Increased thermal conductivity will directly translate into increased turbopump power and increased chamber pressure for improved thrust and specific impulse. This paper describes the process development for fabricating a subscale high thermal conductivity NARloy-Z-D combustion chamber liner using Field Assisted Sintering Technology (FAST). The FAST process uses a mixture of NARloy-Z and diamond powders which is sintered under pressure at elevated temperatures. Several challenges were encountered, i.e., segregation of diamonds, machining the super hard NARloy-Z-D composite, net shape fabrication and nondestructive examination. The paper describes how these challenges were addressed. Diamonds coated with copper (CuD) appear to give the best results. A near net shape subscale combustion chamber liner is being fabricated by diffusion bonding cylindrical rings of NARloy-Z-CuD using the FAST process.

Powder Injection Molding of Ceramic Engine Components for Transportation

NASA Astrophysics Data System (ADS)

Lenz, Juergen; Enneti, Ravi K.; Onbattuvelli, Valmikanathan; Kate, Kunal; Martin, Renee; Atre, Sundar

2012-03-01

Silicon nitride has been the favored material for manufacturing high-efficiency engine components for transportation due to its high temperature stability, good wear resistance, excellent corrosion resistance, thermal shock resistance, and low density. The use of silicon nitride in engine components greatly depends on the ability to fabricate near net-shape components economically. The absence of a material database for design and simulation has further restricted the engineering community in developing parts from silicon nitride. In this paper, the design and manufacturability of silicon nitride engine rotors for unmanned aerial vehicles by the injection molding process are discussed. The feedstock material property data obtained from experiments were used to simulate the flow of the material during injection molding. The areas susceptible to the formation of defects during the injection molding process of the engine component were identified from the simulations. A test sample was successfully injection molded using the feedstock and sintered to 99% density without formation of significant observable defects.

Electrohydraulic Forming of Near-Net Shape Automotive Panels

DOE Office of Scientific and Technical Information (OSTI.GOV)

Golovaschenko, Sergey F.

2013-09-26

The objective of this project was to develop the electrohydraulic forming (EHF) process as a near-net shape automotive panel manufacturing technology that simultaneously reduces the energy embedded in vehicles and the energy consumed while producing automotive structures. Pulsed pressure is created via a shockwave generated by the discharge of high voltage capacitors through a pair of electrodes in a liquid-filled chamber. The shockwave in the liquid initiated by the expansion of the plasma channel formed between two electrodes propagates towards the blank and causes the blank to be deformed into a one-sided die cavity. The numerical model of the EHFmore » process was validated experimentally and was successfully applied to the design of the electrode system and to a multi-electrode EHF chamber for full scale validation of the process. The numerical model was able to predict stresses in the dies during pulsed forming and was validated by the experimental study of the die insert failure mode for corner filling operations. The electrohydraulic forming process and its major subsystems, including durable electrodes, an EHF chamber, a water/air management system, a pulse generator and integrated process controls, were validated to be capable to operate in a fully automated, computer controlled mode for forming of a portion of a full-scale sheet metal component in laboratory conditions. Additionally, the novel processes of electrohydraulic trimming and electrohydraulic calibration were demonstrated at a reduced-scale component level. Furthermore, a hybrid process combining conventional stamping with EHF was demonstrated as a laboratory process for a full-scale automotive panel formed out of AHSS material. The economic feasibility of the developed EHF processes was defined by developing a cost model of the EHF process in comparison to the conventional stamping process.« less

Particle morphology influence on mechanical and biocompatibility properties of injection molded Ti alloy powder.

PubMed

Gülsoy, H Özkan; Gülsoy, Nagihan; Calışıcı, Rahmi

2014-01-01

Titanium and Titanium alloys exhibits properties that are excellent for various bio-applications. Metal injection molding is a processing route that offers reduction in costs, with the added advantage of near net-shape components. Different physical properties of Titanium alloy powders, shaped and processed via injection molding can achieve high complexity of part geometry with mechanical and bioactivity properties, similar or superior to wrought material. This study describes that the effect of particle morphology on the microstructural, mechanical and biocompatibility properties of injection molded Ti-6Al-4V (Ti64) alloy powder for biomaterials applications. Ti64 powders irregular and spherical in shape were injection molded with wax based binder. Binder debinding was performed in solvent and thermal method. After debinding the samples were sintered under high vacuum. Metallographic studies were determined to densification and the corresponding microstructural changes. Sintered samples were immersed in a simulated body fluid (SBF) with elemental concentrations that were comparable to those of human blood plasma for a total period of 15 days. Both materials were implanted in fibroblast culture for biocompatibility evaluations were carried out. The results show that spherical and irregular powder could be sintered to a maximum theoretical density. Maximum tensile strength was obtained for spherical shape powder sintered. The tensile strength of the irregular shape powder sintered at the same temperature was lower due to higher porosity. Finally, mechanical tests show that the irregular shape powder has lower mechanical properties than spherical shape powder. The sintered irregular Ti64 powder exhibited better biocompatibility than sintered spherical Ti64 powder. Results of study showed that sintered spherical and irregular Ti64 powders exhibited high mechanical properties and good biocompatibility properties.

Spray-formed tooling

NASA Astrophysics Data System (ADS)

McHugh, K. M.; Key, J. F.

The United States Council for Automotive Research (USCAR) has formed a partnership with the Idaho National Engineering Laboratory (INEL) to develop a process for the rapid production of low-cost tooling based on spray forming technology developed at the INEL. Phase 1 of the program will involve bench-scale system development, materials characterization, and process optimization. In Phase 2, prototype systems will be designed, constructed, evaluated, and optimized. Process control and other issues that influence commercialization will be addressed during this phase of the project. Technology transfer to USCAR, or a tooling vendor selected by USCAR, will be accomplished during Phase 3. The approach INEL is using to produce tooling, such as plastic injection molds and stamping dies, combines rapid solidification processing and net-shape materials processing into a single step. A bulk liquid metal is pressure-fed into a de Laval spray nozzle transporting a high velocity, high temperature inert gas. The gas jet disintegrates the metal into fine droplets and deposits them onto a tool pattern made from materials such as plastic, wax, clay, ceramics, and metals. The approach is compatible with solid freeform fabrication techniques such as stereolithography, selective laser sintering, and laminated object manufacturing. Heat is extracted rapidly, in-flight, by convection as the spray jet entrains cool inert gas to produce undercooled and semi-solid droplets. At the pattern, the droplets weld together while replicating the shape and surface features of the pattern. Tool formation is rapid; deposition rates in excess of 1 ton/h have been demonstrated for bench-scale nozzles.

Future requirements for advanced materials

NASA Technical Reports Server (NTRS)

Olstad, W. B.

1980-01-01

Recent advances and future trends in aerospace materials technology are reviewed with reference to metal alloys, high-temperature composites and adhesives, tungsten fiber-reinforced superalloys, hybrid materials, ceramics, new ablative materials, such as carbon-carbon composite and silica tiles used in the Shuttle Orbiter. The technologies of powder metallurgy coupled with hot isostatic pressing, near net forging, complex large shape casting, chopped fiber molding, superplastic forming, and computer-aided design and manufacture are emphasized.

Effects Of Thermal Exchange On Material Flow During Steel Thixoextrusion Process

NASA Astrophysics Data System (ADS)

Eric, Becker; Guochao, Gu; Laurent, Langlois; Raphaël, Pesci; Régis, Bigot

2011-01-01

Semisolid processing is an innovative technology for near net-shape production of components, where the metallic alloys are processed in the semisolid state. Taking advantage of the thixotropic behavior of alloys in the semisolid state, significant progress has been made in semisolid processing. However, the consequences of such behavior on the flow during thixoforming are still not completely understood. To explore and better understand the influence of the different parameters on material flow during thixoextrusion process, thixoextrusion experiments were performed using the low carbon steel C38. The billet was partially melted at high solid fraction. Effects of various process parameters including the initial billet temperature, the temperature of die, the punch speed during process and the presence of a Ceraspray layer at the interface of tool and billet were investigated through experiments and simulation. After analyzing the results thus obtained, it was identified that the aforementioned parameters mainly affect thermal exchanges between die and part. The Ceraspray layer not only plays a lubricant role, but also acts as a thermal barrier at the interface of tool and billet. Furthermore, the thermal effects can affect the material flow which is composed of various distinct zones.

Near-Net-Shape Processing of Sintered Fibrous Ceramics Achieved

NASA Technical Reports Server (NTRS)

Angel, Paul W.

2000-01-01

A variety of sintered fibrous ceramic (SFC) materials have been developed over the last 50 years as thermal barrier materials for reentry applications. SFC materials typically exhibit very low thermal conductivities combined with low densities and good thermal stability up to 2500 F. These materials have flown successfully on the space shuttle orbiters since the 1960's. More recently, the McDonnell Douglas Corporation successfully used SFC tiles as a heat shield on the underside of its DC X test vehicle. For both of these applications, tiles are machined from blocks of a specific type of SFC called an alumina-enhanced thermal barrier (AETB). The sizes of these blocks have been limited by the manufacturing process. In addition, as much as 80 to 90 percent of the material can be lost during the machining of tiles with significant amounts of curvature. To address these problems, the NASA Glenn Research Center at Lewis Field entered a cooperative contract with the Boeing Company to develop a vacuum-assisted forming process that can produce large (approximately 4 square feet), severely contoured panels of AETB while saving costs in comparison to the conventional cast-and-machine billet process. For shuttle use, AETB is slurry cast, drained, and fired to form square billets conforming to the shape of the filtration box. The billets are then cut into tiles of the appropriate size for thermally protecting the space shuttle. Processing techniques have limited the maximum size of AETB billets to 21.5 square inches by 6.5-in. thick, but the space shuttles use discrete heat shield tiles no more than 8 to 12 square inches. However, in other applications, large, complex shapes are needed, and the tiling approach is undesirable. For such applications, vacuum-assisted forming can produce large parts with complex shapes while reducing machining waste and eliminating cemented joints between bonded billets. Because it allows contoured shapes to be formed, material utilization is inherently high. Initial estimates show that the amount of material lost during machining can be reduced by 50 percent or more. In addition, a fiber alignment favorable for minimum heat transfer is maintained for all panel shapes since the fibers are aligned parallel to the contoured surface of the forming tool or mold. The vacuum-assisted forming process can complete the entire forming operation in a matter of minutes and can produce multiple parts whose size is limited only by the size of the forming tool. To date, panels as large as 2 square feet have been demonstrated The vacuum-assisted forming process starts with the fabrication of a permeable forming tool, or mold, with the proper part contour. This reusable tool is mounted over an internal rib support structure, as depicted in the diagram, such that a vacuum can be pulled on the bottom portion of the tool. AETB slurry is then poured over and around the tool, liquid is drawn from the slurry, and the part forms over the tool surface. The part is then dried, fired, and finished machined. Future plans include an evaluation of the need for additional coatings and surface-toughness treatments to extend the durability and performance of this material.

Net Shape Spin Formed Cryogenic Aluminum Lithium Cryogenic Tank Domes for Lower Cost Higher Performance Launch Vehicles

NASA Technical Reports Server (NTRS)

Curreri, Peter A.; Hoffman, Eric; Domack, Marcia; Brewster, Jeb; Russell, Carolyn

2013-01-01

With the goal of lower cost (simplified manufacturing and lower part count) and higher performance (higher strength to weight alloys) the NASA Technical Maturation Program in 2006 funded a proposal to investigate spin forming of space launch vehicle cryogenic tank domes. The project funding continued under the NASA Exploration Technology Development Program through completion in FY12. The first phase of the project involved spin forming of eight, 1 meter diameter "path finder" domes. Half of these were processed using a concave spin form process (MT Aerospace, Augsburg Germany) and the other half using a convex process (Spincraft, Boston MA). The convex process has been used to produce the Ares Common Bulkhead and the concave process has been used to produce dome caps for the Space Shuttle light weight external tank and domes for the NASDA H2. Aluminum Lithium material was chosen because of its higher strength to weight ratio than the Aluminum 2219 baseline. Aluminum lithium, in order to obtain the desired temper (T8), requires a cold stretch after the solution heat treatment and quench. This requirement favors the concave spin form process which was selected for scale up. This paper describes the results of processing four, 5.5 meter diameter (upper stage scale) net shaped spin formed Aluminum Lithium domes. In order to allow scalability beyond the limits of foundry and rolling mills (about 12 foot width) the circular blank contained one friction stir weld (heavy lifter scales require a flat blank containing two welds). Mechanical properties data (tensile, fracture toughness, stress corrosion, and simulated service testing) for the parent metal and weld will also be discussed.

Laser Additive Manufacturing of Magnetic Materials

NASA Astrophysics Data System (ADS)

Mikler, C. V.; Chaudhary, V.; Borkar, T.; Soni, V.; Jaeger, D.; Chen, X.; Contieri, R.; Ramanujan, R. V.; Banerjee, R.

2017-03-01

While laser additive manufacturing is becoming increasingly important in the context of next-generation manufacturing technologies, most current research efforts focus on optimizing process parameters for the processing of mature alloys for structural applications (primarily stainless steels, titanium base, and nickel base alloys) from pre-alloyed powder feedstocks to achieve properties superior to conventionally processed counterparts. However, laser additive manufacturing or processing can also be applied to functional materials. This article focuses on the use of directed energy deposition-based additive manufacturing technologies, such as the laser engineered net shaping (LENS™) process, to deposit magnetic alloys. Three case studies are presented: Fe-30 at.%Ni, permalloys of the type Ni-Fe-V and Ni-Fe-Mo, and Fe-Si-B-Cu-Nb (derived from Finemet) alloys. All these alloys have been processed from a blend of elemental powders used as the feedstock, and their resultant microstructures, phase formation, and magnetic properties are discussed in this paper. Although these alloys were produced from a blend of elemental powders, they exhibited relatively uniform microstructures and comparable magnetic properties to those of their conventionally processed counterparts.

How small bugs tie down big rocks: Measuring and modeling the forces acting between nets spun by Caddisfly larvae (Hydropsychidae) and gravel particles at the onset of motion

NASA Astrophysics Data System (ADS)

Mclaughlin, M. K.; Tumolo, B.; Sklar, L. S.; Albertson, L.; Daniels, M.

2017-12-01

The influence of life on geomorphic processes is commonly inferred from correlations between the size and abundance of individual organisms and the change in process thresholds and rates from abiotic conditions. However, to understand and model the underlying mechanisms, it is helpful to make direct measurements of the forces acting between organisms and the earth materials they inhabit. For example, flume studies have found that the presence of net-spinning caddisfly larvae (Trichoptera: Hydropsychidae) can increase the shear stress required to initiate particle motion by more than a factor of two, with potentially significant implications for the timing and magnitude of bedload sediment transport in gravel-bedded rivers. To explore the underlying mechanics we conducted flume experiments at the Stroud Water Research center in Avonadale, Pennsylvania, using strain gages to measure the forces acting between caddisfly nets and sediment particles of various sizes, during the process of initial particle motion. We combine these measurements with high-speed video images to document for the first time, the three dimensional dynamics of net stretching, tearing, and detachment that govern the magnitude of the increase in critical shear stress. We are using these data and insights to substantially improve a previously published theoretical model for the mechanics of sediment stabilization by caddisfly larvae. In particular, we seek to constrain the range of particle sizes potentially stabilized by caddisfly larvae and explain mechanistically why the effect of caddisfly nets varies with particle size. These predictions have implications for understanding feedbacks between bed stabilization by caddisflies, insect density, inter-specific niche partitioning, and the movement of sediment that shapes gravel-bed channels.

Thermo-mechanical performance of precision C/SiC mounts

NASA Astrophysics Data System (ADS)

Goodman, William A.; Mueller, Claus E.; Jacoby, Marc T.; Wells, Jim D.

2001-12-01

For complex shaped, lightweight, high precision opto- mechanical structures that must operate in adverse environments and over wide ranges of temperature, we consider IABG's optical grade silicon carbide composite ceramic (C/SiC) as the material of choice. C/SiC employs conventional NC machining/milling equipment to rapidly fabricate near-net shape parts, providing substantial schedule, cost, and risk savings for high precision components. Unlike powder based SiC ceramics, C/SiC does not experience significant shrinkage during processing, nor does it suffer from incomplete densification. If required, e.g. for large-size components, a fully-monolithic ceramic joining technique can be applied. Generally, the thermal and mechanical properties of C/SiC are tunable in certain ranges by modifying certain process steps. This paper focuses on the thermo-mechanical performance of new, high precision mounts designed by Schafer Corporation and manufactured by IABG. The mounts were manufactured using standard optical grade C/SiC (formulation internally called A-3). The A-3 formulation has a near-perfect CTE match with silicon, making it the ideal material to athermally support Schafer produced Silicon Lightweight Mirrors (SLMs) that will operate in a cryogenic environment. Corresponding thermo- mechanical testing and analysis is presented in this manuscript.

Development Study of Cartridge/Crucible Tube Materials

NASA Technical Reports Server (NTRS)

McKechnie, Timothy N.; ODell, Scott J.

1998-01-01

The limitations of traditional alloys and the desire for improved performance for components is driving the increased utilization of refractory metals in tile space industry. From advanced propulsion systems to high temperature furnace components for microgravity processing, refractory metals are being used for their high melting temperatures and inherent chemical stability. Techniques have been developed to produce near net shape refractory metal components utilizing vacuum plasma spraying. Material utilization is very high, and laborious machining can be avoided. As-spray formed components have been tested and found to perform adequately. However, increased mechanical and thermal properties are needed. To improve these properties, post processing thermal treatments such as hydrogen sintering and vacuum annealing have been performed. Components formed from alloys of tungsten, rhenium, tantalum, niobium, and molybdenum are discussed and a metallurgical analyses detailing the results are presented. A qualitative comparison of mechanical properties is also included.

Development and Demonstration of Adanced Tooling Alloys for Molds and Dies

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kevin M. McHugh; Enrique J. Lavernia

2006-01-01

This report summarizes research results in the project Development and Demonstration of Advanced Tooling Alloys for Molds and Dies. Molds, dies and related tooling are used to manufacture most of the plastic and metal products we use every day. Conventional fabrication of molds and dies involves a multiplicity of machining, benching and heat treatment unit operations. This approach is very expensive and time consuming. Rapid Solidifcation Process (RSP) Tooling is a spray-forming technology tailored for producing molds and dies. The appraoch combines rapid solidifcation processing and net-shape materials processing in a single step. An atomized spray of a tool-forming alloy,more » typically a tool steel, is deposited onto an easy-to-form tool pattern to replicate the pattern's shape and surface features. By so doing, the approach eliminates many machining operations in conventional mold making, significantly reducing cost, lead time and energy. Moreover, rapid solidification creates unique microstructural features by suppressing carbide precipitation and growth, and creating metastable phases. This can result in unique material properties following heat treatment. Spray-formed and aged tool steel dies have exhibited extended life compared to conventional dies in many forming operations such as forging, extrusion and die casting. RSP Tooling technolocy was commercialized with the formation of RSP Tooling, LLC in Solon, Oh.« less

Evaluation of Braided Stiffener Concepts for Transport Aircraft Wing Structure Applications

NASA Technical Reports Server (NTRS)

Deaton, Jerry W.; Dexter, H. Benson (Editor); Markus, Alan; Rohwer, Kim

1995-01-01

Braided composite materials have potential for application in aircraft structures. Stiffeners, wing spars, floor beams, and fuselage frames are examples where braided composites could find application if cost effective processing and damage requirements are met. Braiding is an automated process for obtaining near-net shape preforms for fabrication of components for structural applications. Previous test results on braided composite materials obtained at NASA Langley indicate that damage tolerance requirements can be met for some applications. In addition, the braiding industry is taking steps to increase the material through-put to be more competitive with other preform fabrication processes. Data are presented on the compressive behavior of three braided stiffener preform fabric constructions as determined from individual stiffener crippling test and three stiffener wide panel tests. Stiffener and panel fabrication are described and compression data presented for specimens tested with and without impact damage. In addition, data are also presented on the compressive behavior of the stitched stiffener preform construction currently being used by McDonnell Douglas Aerospace in the NASA ACT wing development program.

Electron Beam Freeform Fabrication for Cost Effective Near-Net Shape Manufacturing

NASA Technical Reports Server (NTRS)

Taminger, Karen M.; Hafley, Robert A.

2006-01-01

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cm3/hr (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Electron Beam Freeform Fabrication (EBF3) for Cost Effective Near-Net Shape Manufacturing

NASA Technical Reports Server (NTRS)

Taminger, Karen M.; Hafley, Robert A.

2006-01-01

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cubic centimeters per hour (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Improved silicon nitride for advanced heat engines

NASA Technical Reports Server (NTRS)

Yeh, Hun C.; Fang, Ho T.

1987-01-01

The technology base required to fabricate silicon nitride components with the strength, reliability, and reproducibility necessary for actual heat engine applications is presented. Task 2 was set up to develop test bars with high Weibull slope and greater high temperature strength, and to conduct an initial net shape component fabrication evaluation. Screening experiments were performed in Task 7 on advanced materials and processing for input to Task 2. The technical efforts performed in the second year of a 5-yr program are covered. The first iteration of Task 2 was completed as planned. Two half-replicated, fractional factorial (2 sup 5), statistically designed matrix experiments were conducted. These experiments have identified Denka 9FW Si3N4 as an alternate raw material to GTE SN502 Si3N4 for subsequent process evaluation. A detailed statistical analysis was conducted to correlate processing conditions with as-processed test bar properties. One processing condition produced a material with a 97 ksi average room temperature MOR (100 percent of goal) with 13.2 Weibull slope (83 percent of goal); another condition produced 86 ksi (6 percent over baseline) room temperature strength with a Weibull slope of 20 (125 percent of goal).

Modeling of Ti-W Solidification Microstructures Under Additive Manufacturing Conditions

NASA Astrophysics Data System (ADS)

Rolchigo, Matthew R.; Mendoza, Michael Y.; Samimi, Peyman; Brice, David A.; Martin, Brian; Collins, Peter C.; LeSar, Richard

2017-07-01

Additive manufacturing (AM) processes have many benefits for the fabrication of alloy parts, including the potential for greater microstructural control and targeted properties than traditional metallurgy processes. To accelerate utilization of this process to produce such parts, an effective computational modeling approach to identify the relationships between material and process parameters, microstructure, and part properties is essential. Development of such a model requires accounting for the many factors in play during this process, including laser absorption, material addition and melting, fluid flow, various modes of heat transport, and solidification. In this paper, we start with a more modest goal, to create a multiscale model for a specific AM process, Laser Engineered Net Shaping (LENS™), which couples a continuum-level description of a simplified beam melting problem (coupling heat absorption, heat transport, and fluid flow) with a Lattice Boltzmann-cellular automata (LB-CA) microscale model of combined fluid flow, solute transport, and solidification. We apply this model to a binary Ti-5.5 wt pct W alloy and compare calculated quantities, such as dendrite arm spacing, with experimental results reported in a companion paper.

Pull-Up Nets

ERIC Educational Resources Information Center

Meenan, Liz

2008-01-01

When the author began teaching, she always hit a problem when it came to 3D shapes. She wanted the pupils to get a feel for them, and she would get them to make the shapes from their nets. The pupils would first try to visualize how the 2D nets could become 3D shapes and then they would physically fold the nets into the shapes for themselves.…

Method for making carbon super capacitor electrode materials

DOEpatents

Firsich, D.W.; Ingersoll, D.; Delnick, F.M.

1998-07-07

A method is described for making near-net-shape, monolithic carbon electrodes for energy storage devices. The method includes the controlled pyrolysis and activation of a pressed shape of methyl cellulose powder with pyrolysis being carried out in two stages; pre-oxidation, preferably in air at a temperature between 200--250 C, followed by carbonization under an inert atmosphere. An activation step to adjust the surface area of the carbon shape to a value desirable for the application being considered, including heating the carbon shape in an oxidizing atmosphere to a temperature of at least 300 C, follows carbonization. 1 fig.

Method for making carbon super capacitor electrode materials

DOEpatents

Firsich, David W.; Ingersoll, David; Delnick, Frank M.

1998-01-01

A method for making near-net-shape, monolithic carbon electrodes for energy storage devices. The method includes the controlled pyrolysis and activation of a pressed shape of methyl cellulose powder with pyrolysis being carried out in two stages; pre-oxidation, preferably in air at a temperature between 200.degree.-250.degree. C., followed by carbonization under an inert atmosphere. An activation step to adjust the surface area of the carbon shape to a value desirable for the application being considered, including heating the carbon shape in an oxidizing atmosphere to a temperature of at least 300.degree. C., follows carbonization.

Fabrication of sinterable silicon nitride by injection molding

NASA Technical Reports Server (NTRS)

Quackenbush, C. L.; French, K.; Neil, J. T.

1982-01-01

Transformation of structural ceramics from the laboratory to production requires development of near net shape fabrication techniques which minimize finish grinding. One potential technique for producing large quantities of complex-shaped parts at a low cost, and microstructure of sintered silicon nitride fabricated by injection molding is discussed and compared to data generated from isostatically dry-pressed material. Binder selection methodology, compounding of ceramic and binder components, injection molding techniques, and problems in binder removal are discussed. Strength, oxidation resistance, and microstructure of sintered silicon nitride fabricated by injection molding is discussed and compared to data generated from isostatically dry-pressed material.

Advanced resin systems and 3D textile preforms for low cost composite structures

NASA Technical Reports Server (NTRS)

Shukla, J. G.; Bayha, T. D.

1993-01-01

Advanced resin systems and 3D textile preforms are being evaluated at Lockheed Aeronautical Systems Company (LASC) under NASA's Advanced Composites Technology (ACT) Program. This work is aimed towards the development of low-cost, damage-tolerant composite fuselage structures. Resin systems for resin transfer molding and powder epoxy towpreg materials are being evaluated for processability, performance and cost. Three developmental epoxy resin systems for resin transfer molding (RTM) and three resin systems for powder towpregging are being investigated. Various 3D textile preform architectures using advanced weaving and braiding processes are also being evaluated. Trials are being conducted with powdered towpreg, in 2D weaving and 3D braiding processes for their textile processability and their potential for fabrication in 'net shape' fuselage structures. The progress in advanced resin screening and textile preform development is reviewed here.

Magnetic and microstructural investigation of high-coercivity net-shape Nd-Fe-B-type magnets produced from spark-plasma-sintered melt-spun ribbons blended with DyF3

NASA Astrophysics Data System (ADS)

Žagar, Kristina; Kocjan, Andraž; Kobe, Spomenka

2016-04-01

Nanostructured Nd-Fe-B-type materials produced by melt-spinning (MS) are used in a variety of applications in the electronics, automotive, and sensor industries. The very rapid MS process leads to flake-like powders with metastable, nanoscale, Nd2Fe14B grains. These powders are then formed into net-shaped, isotropic, polymer-bonded magnets, or they are hot formed into fully dense, metallic magnets that are isotropic and anisotropic. These fully dense magnets are usually produced with a conventional hot press without the inclusion of additives prior to the hot pressing. As a result, their properties, particularly the coercivity (Hci), are insufficient at automotive-relevant temperatures of 100-150 °C since the material Hci has a large temperature coefficient. In this study, we instead add a thin layer of DyF3 to the melt-spun ribbons prior to their hot consolidation in order to enhance the coercivity through a diffusion-based, partial substitution of the Nd by Dy. This is accomplished by applying extremely rapid, spark-plasma sintering to minimize any growth of the nanoscale Nd2Fe14B grains during consolidation. The result is a very high-coercivity magnet with drastically reduced amounts of heavy rare earths that is suitable for high-temperature applications. This work clearly demonstrates how rapidly formed, metastable states can provide us with properties that are unobtainable with conventional techniques.

Effect of Surface Treatments on Electron Beam Freeform Fabricated Aluminum Structures

NASA Technical Reports Server (NTRS)

Taminger, Karen M. B.; Hafley, Robert A.; Fahringer, David T.; Martin, Richard E.

2004-01-01

Electron beam freeform fabrication (EBF3) parts exhibit a ridged surface finish typical of many layer-additive processes. This, post-processing is required to produce a net shape with a smooth surface finish. High speed milling wire electrical discharge machining (EDM), electron beam glazing, and glass bead blasting were performed on EBF3-build 2219 aluminum alloy parts to reduce or eliminate the ridged surface features. Surface roughness, surface residual stress state, and microstructural characteristics were examined for each of the different surface treatment to assess the quality and effect of the surface treatments on the underlying material. The analysis evaluated the effectivenes of the different surface finishing techniques for achieving a smooth surface finish on an electron beam freeform fabricated part.

Physico-chemical characterization of functionalized polypropylenic fibers for prosthetic applications

NASA Astrophysics Data System (ADS)

Nisticò, Roberto; Faga, Maria Giulia; Gautier, Giovanna; Magnacca, Giuliana; D'Angelo, Domenico; Ciancio, Emanuele; Piacenza, Giacomo; Lamberti, Roberta; Martorana, Selanna

2012-08-01

Polypropylene (PP) fibers can be manufactured to form nets which can find application as prosthesis in hernioplasty. One of the most important problem to deal with when nets are applied in vivo consists in the reproduction of bacteria within the net fibers intersections. This occurs right after the application of the prosthesis, and causes infections, thus it is fundamental to remove bacteria in the very early stage of the nets application. This paper deals with the physico-chemical characterization of such nets, pre-treated by atmospheric pressure plasma dielectric barrier discharge apparatus (APP-DBD) and functionalized with an antibiotic drug such as chitosan. The physico-chemical characterization of sterilized nets, before and after the functionalization with chitosan, was carried out by means of scanning electron microscopy (SEM) coupled with EDS spectroscopy, FTIR spectroscopy, drop shape analysis (DSA), X-ray diffraction and thermal analyses (TGA and DSC). The aim of the work is to individuate a good strategy to characterize this kind of materials, to understand the effects of polypropylene pre-treatment on functionalization efficiency, to follow the materials ageing in order to study the effects of the surface treatment for in vivo applications.

Near-Net-Shape Production of Hollow Titanium Alloy Components via Electrochemical Reduction of Metal Oxide Precursors in Molten Salts

NASA Astrophysics Data System (ADS)

Hu, Di; Xiao, Wei; Chen, George Z.

2013-04-01

Metal oxide precursors (ca. 90 wt pct Ti, 6 wt pct Al, and 4 wt pct V) were prepared with a hollow structure in various shapes such as a sphere, miniature golf club head, and cup using a one-step solid slip-casting process. The precursors were then electro-deoxidized in molten calcium chloride [3.2 V, 1173 K (900 °C)] against a graphite anode. After 24 hours of electrolysis, the near-net-shape Ti-6Al-4V product maintained its original shape with controlled shrinkage. Oxygen contents in the Ti-6Al-4V components were typically below 2000 ppm. The maximum compressive stress and modulus of electrolytic products obtained in this work were approximately 243 MPa and 14 GPa, respectively, matching with the requirement for medical implants. Further research directions are discussed for mechanical improvement of the products via densification during or after electrolysis. This simple, fast, and energy-efficient near-net-shape manufacturing method could allow titanium alloy components with desired geometries to be prepared directly from a mixture of metal oxides, promising an innovative technology for the low-cost production of titanium alloy components.

Production of aluminum-lithium near net shape extruded cylinders

NASA Technical Reports Server (NTRS)

Hartley, Paula J.

1995-01-01

In the late 1980's, under funding from the Advanced Launch System Program, numerous near net shape technologies were investigated as a means for producing high quality, low cost Aluminum-Lithium (Al-Li) hardware. Once such option was to extrude near net shape barrel panels instead of producing panels by machining thick plate into a final tee-stiffened configuration (which produced up to 90% scrap). This method offers a reduction in the volume of scrap and consequently reduces the buy-to-fly cost. Investigation into this technology continued under Shuttle-C funding where four Al alloys 2219, 2195, 2096, and RX 818 were extruded. Presented herein are the results of that program. Each alloy was successfully extruded at Wyman Gordon, opened and flattened at Ticorm, and solution heat treated and stretched at Reynolds Metals Company. The first two processes were quite successful while the stretching process did offer some challenges. Due to the configuration of the panels and the stretch press set-up, it was difficult to induce a consistent percentage of cold work throughout the length and width of each panel. The effects of this variation will be assessed in the test program to be conducted at a future date.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, Ling; Post, Brian; Kunc, Vlastimil

Additive manufacturing (AM) or 3D printing is well known for producing arbitrary shaped parts without any tooling required, offering a promising alternative to the conventional injection molding method to fabricate near-net-shaped magnets. In order to determine their applicability in the fabrication of Nd-Fe-B bondedmagnets, we compare two 3D printing technologies, namely binder jetting and material extrusion. Some prospects and challenges of these state-of-the-art technologies for large-scale industrial applications will be discussed.

Review of selective laser melting: Materials and applications

NASA Astrophysics Data System (ADS)

Yap, C. Y.; Chua, C. K.; Dong, Z. L.; Liu, Z. H.; Zhang, D. Q.; Loh, L. E.; Sing, S. L.

2015-12-01

Selective Laser Melting (SLM) is a particular rapid prototyping, 3D printing, or Additive Manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders. A component is built by selectively melting and fusing powders within and between layers. The SLM technique is also commonly known as direct selective laser sintering, LaserCusing, and direct metal laser sintering, and this technique has been proven to produce near net-shape parts up to 99.9% relative density. This enables the process to build near full density functional parts and has viable economic benefits. Recent developments of fibre optics and high-power laser have also enabled SLM to process different metallic materials, such as copper, aluminium, and tungsten. Similarly, this has also opened up research opportunities in SLM of ceramic and composite materials. The review presents the SLM process and some of the common physical phenomena associated with this AM technology. It then focuses on the following areas: (a) applications of SLM materials and (b) mechanical properties of SLM parts achieved in research publications. The review is not meant to put a ceiling on the capabilities of the SLM process but to enable readers to have an overview on the material properties achieved by the SLM process so far. Trends in research of SLM are also elaborated in the last section.

Review of selective laser melting: Materials and applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yap, C. Y., E-mail: cyap001@e.ntu.edu.sg; Energy Research Institute @ NTU, Interdisciplinary Graduate School, Nanyang Technological University, 50 Nanyang Avenue, Block S2 - B3a - 01, Singapore 639798; Chua, C. K., E-mail: mckchua@ntu.edu.sg

Selective Laser Melting (SLM) is a particular rapid prototyping, 3D printing, or Additive Manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders. A component is built by selectively melting and fusing powders within and between layers. The SLM technique is also commonly known as direct selective laser sintering, LaserCusing, and direct metal laser sintering, and this technique has been proven to produce near net-shape parts up to 99.9% relative density. This enables the process to build near full density functional parts and has viable economic benefits. Recent developments of fibre optics and high-power lasermore » have also enabled SLM to process different metallic materials, such as copper, aluminium, and tungsten. Similarly, this has also opened up research opportunities in SLM of ceramic and composite materials. The review presents the SLM process and some of the common physical phenomena associated with this AM technology. It then focuses on the following areas: (a) applications of SLM materials and (b) mechanical properties of SLM parts achieved in research publications. The review is not meant to put a ceiling on the capabilities of the SLM process but to enable readers to have an overview on the material properties achieved by the SLM process so far. Trends in research of SLM are also elaborated in the last section.« less

Netcast™ Shape Casting Technology: A Technological Breakthrough that Enhances the Cost Effectiveness of Aluminum Forgings

NASA Astrophysics Data System (ADS)

Anderson, Mark; Bruski, Richard; Groszkiewicz, Daniel; Wagstaff, Bob

A new Direct Chill (DC) casting process is introduced to semi-continuous casting where near net shaped ingots are solidified. This process is currently being used at Alcan Engineered Cast Products (ECP) facility in Jonquiere, Canada, sectioned, then forged at Alcoa Automotive, Kentucky Casting Center (KCC). Finished forgings are machined and assembled into the Ford D/EW98 platform as suspension components. A brief description of the process and the implications on the forging process are presented.

Ceramic Near-Net Shaped Processing Using Highly-Loaded Aqueous Suspensions

NASA Astrophysics Data System (ADS)

Rueschhoff, Lisa

Ceramic materials offer great advantages over their metal counterparts, due to their lower density, higher hardness and wear resistance, and higher melting temperatures. However, the use of ceramics in applications where their properties would offer tremendous advantages are often limited due to the difficulty of forming them into complex and near-net shaped parts. Methods that have been developed to injection-mold or cast ceramics into more complicated shapes often use significant volume fractions of a carrier (often greater than 35 vol.% polymer), elevated temperature processing, or less-than-environmentally friendly chemicals where a complex chemical synthesis reaction must be timed perfectly for the approach to work. Furthermore, the continuing maturation of additive manufacturing methods requires a new approach for flowing/placing ceramic powders into useful designs. This thesis addresses the limitations of the current ceramic forming approaches by developing highly-stabilized and therefore high solids loading ceramic suspensions, with the requisite rheology for a variety of complex and near-net shaped forming techniques. Silicon nitride was chosen as a material of focus due to its high fracture toughness compared to other ceramic materials. Designing ceramic suspensions that are flowable at room temperature greatly simplifies processing as neither heating nor cooling are required during forming. Highly-loaded suspensions (>40 vol.%) are desired because all formed ceramic bodies have to be sintered to remove pores. Finally, using aqueous-based suspensions reduces any detrimental effect on the environment and tooling. The preparation of highly-loaded suspensions requires the development of a suitable dispersant through which particle-particle interactions are controlled. However, silicon nitride is difficult to stabilize in water due to complex surface and solution chemistry. In this study, aqueous silicon nitride suspensions up to 45 vol.% solids loading were dispersed using commercially available comb-type copolymer. These copolymers are used as superplasticizers in the concrete industry and are referred to as water-reducing admixtures (WRAs). Four different WRA dispersants were examined and chemical analysis determined that each was made up of a sodium salt of polyacrylic acid (PAA-Na) backbone with neutral polyethylene oxide (PEO) side chains that afford steric stabilization. The general structures of the WRAs were compared to each other by measuring the relative areas of their prominent FTIR peaks and calculating a PAA-Na/PEO peak ratio. Suspensions were made with as-received silicon nitride powders with 5 wt.% aluminum oxide and 5 wt.% yttrium oxide added as sintering aids. Three of the four WRA dispersants studied were able to produce suspensions with 43 vol.% solids loading and 5 vol.% polymer dispersant, while exhibiting a yield-pseudoplastic behavior for shear rates up to 30 s-1. At higher solids loading (45 to 47 vol.%), a shift to shear thickening behavior was observed at a critical shear rate for these WRAs. Those WRAs with a lower PAA-Na/PEO peak ratio displayed better stabilization and diminished shear thickening behavior. The vol.% of the dispersant was optimized, producing yield-pseudoplastic suspensions containing 45 vol.% solids loading with yield stresses less than 75 Pa, no shear thickening behavior, and viscosities less than 75 Pa-s for shear rates in the range of 1 to 30 s-1. Using suspensions prepared with two of the WRAs investigated in this work, silicon nitride near-net shaped parts were formed via a novel injection molding process by loading each suspension in a syringe and injecting them at a controlled rate into a mold. Each suspensions had carefully tailored yield-pseudoplastic rheology such that they can be injection molded at room temperature and low pressures (< 150 kPa). Four suspensions were studied; two different commercially available concrete water-reducing admixtures (WRAs) were used as dispersants with and without a polymer binder (Polyvinylprolidone, PVP) added for rheological modification and improved green body strength. Test bars formed via this process were sintered to high densities (up to 97% TD) without the use of external pressure, and had complete conversion to the desirable beta-Si3N4 phase with high flexural strengths up to 700 MPa. The specimen sets with the smallest average pore size on the fracture surface (77 mum) had the highest average flexural strengths of 573 MPa. The hardness of all specimens was approximately 16 GPa. The water-based suspensions, ease and low cost of processing, and robust mechanical properties obtained demonstrate this as a viable process for the economical and environmentally friendly production of Si3N4 parts. Finally, additive manufacturing was also used as a method to overcome ceramic forming difficulties and to create near-net shaped dense components via room-temperature direct ink writing. In this processes, highly loaded aqueous alumina suspensions were extruded in a layer-by-layer fashion using a low-cost syringe style 3D printer. With alumina as a model material, the effect of solids loading on rheology, specimen uniformity, density, microstructure, and mechanical properties was studied. All suspensions contained a polymer binder ( 5 vol.%), dispersant, and 51 to 58 vol.% alumina powder. Rheological measurements indicated all suspensions to be yield-pseudoplastic, and both yield stress and viscosity were found to increase with increasing alumina solids loading. Shear rates ranging from 19.5 to 24.2 s-1, corresponding to viscosities of 9.8 to 17.2 Pa·s, for the 53 - 56 vol.% alumina suspensions were found to produce the best results for the 1.25 mm tip employed during writing. All parts were sintered to greater than 98% of true density, with grain sizes ranging from 3.2 to 3.7 mum. The average flexure strength, which ranged from 134 to 157 MPa, was not influenced by the alumina solids loading. In limited study, additive manufacturing of silicon nitride suspensions stabilized with a WRA has been established. These processing routes have been proven as low-cost and viable means for producing robust ceramic parts, both of which can be tailored to many systems to expand the use of ceramics materials. Further studies on utilizing the flow stress behavior during both injection molding and direct ink writing could be beneficial in creating ceramic materials with carefully tailored microstructure to increase mechanical performance.

Fast Response Shape Memory Effect Titanium Nickel (TiNi) Foam Torque Tubes

NASA Technical Reports Server (NTRS)

Jardine, Peter

2014-01-01

Shape Change Technologies has developed a process to manufacture net-shaped TiNi foam torque tubes that demonstrate the shape memory effect. The torque tubes dramatically reduce response time by a factor of 10. This Phase II project matured the actuator technology by rigorously characterizing the process to optimize the quality of the TiNi and developing a set of metrics to provide ISO 9002 quality assurance. A laboratory virtual instrument engineering workbench (LabVIEW'TM')-based, real-time control of the torsional actuators was developed. These actuators were developed with The Boeing Company for aerospace applications.

Study of silicon carbide formation by liquid silicon infiltration of porous carbon structures

NASA Astrophysics Data System (ADS)

Margiotta, Jesse C.

Silicon carbide (SiC) materials are prime candidates for high temperature heat exchangers for next generation nuclear reactors due to their refractory nature and high thermal conductivity at elevated temperatures. This research has focused on demonstrating the potential of liquid silicon infiltration (LSI) for making SiC to achieve this goal. The major advantage of this method over other ceramic processing techniques is the enhanced capability of making fully dense, high purity SiC materials in complex net shapes. For successful formation of net shape SiC using LSI techniques, the carbon preform reactivity and pore structure must be controlled to allow the complete infiltration of the porous carbon structure followed by conversion of this carbon to SiC. We have established a procedure for achieving desirable carbon properties by using carbon precursors consisting of two readily available high purity organic materials, crystalline cellulose and phenolic resin. Phenolic resin yields a glassy carbon with low reactivity and porosity, and cellulose carbon is highly reactive and porous. By adjusting the ratio of these two materials in the precursor mixtures, the properties of the carbons produced can be controlled. We have identified the most favorable carbon precursor composition to be a cellulose:resin mass ratio of 6:4 for LSI formation of SiC. The optimum reaction conditions are a temperature of 1800°C, a pressure of 0.5 Torr of argon, and a time of 120 minutes. The fully dense net shape SiC material produced has a density of 2.96 g cm-3 (about 92% of pure SiC) and a SiC volume fraction of over 0.82. Kinetics of the LSI SiC formation process were studied by optical microscopy and quantitative digital image analysis. This study identified six reaction stages and provided important understanding of the process. Such knowledge can be used to further refine the LSI technique. Although the thermal conductivity of pure SiC at elevated temperatures is very high, thermal conductivities of most commercial SiC materials are much lower due to phonon scattering by impurities (e.g., sintering aids located at the grain boundaries of these materials). The thermal conductivity of our SiC was determined using the laser flash method and it is 214 W/mK at 373 K and 64 W/mK at 1273 K. These values are very close to those of pure SiC and are much higher than those of SiC materials made by industrial processes. Thus, SiC made by our LSI process is an ideally suited material for use in high temperature heat exchanger applications. Electron probe microanalysis (EPMA) and Auger electron spectroscopy (AES) were used to study the chemical composition of LSI SiC materials. Optimized low voltage microanalysis conditions for EPMA of SiC were theoretically determined. EPMA and AES measurements indicate that the SiC phase in our materials is slightly carbon rich. Carbon contamination was identified as a possible source of error during EPMA of SiC, and this error was corrected by using high purity SiC standards. Cellulose and phenolic resin carbons lack the well-defined atomic structures associated with common carbon allotropes. Atomic-scale structure was studied using high resolution transmission electron microscopy (HRTEM), nitrogen gas adsorption and helium gas pycnometry. These studies revealed that cellulose carbon exhibits a very high degree of atomic disorder and angstrom-scale porosity. It has a density of only 93% of that of pure graphite, with primarily sp2 bonding character and a low concentration of graphene clusters. Phenolic resin carbon shows more structural order and substantially less angstrom-scale porosity. Its density is 98% of that of pure graphite, and Fourier transform analysis of its TEM micrographs has revealed high concentrations of sp3 diamond and sp 2 graphene nano-clusters. This is the first time that diamond nano-clusters have been observed in carbons produced from phenolic resin.

Space Shuttle inflatable training articles

NASA Technical Reports Server (NTRS)

West, M. L.

1984-01-01

The design, development, construction, and testing of the Long Duration Exposure Facility inflatable and the space telescope training articles are discussed. While these articles are of similar nature, materials, and construction, they vary in size and present different problems with regards to size, shape, gross/net lift, and balance.

A peek into the history of sapphire crystal growth

NASA Astrophysics Data System (ADS)

Harris, Daniel C.

2003-09-01

After the chemical compositions of sapphire and ruby were unraveled in the middle of the 19th century, chemists set out to grow artificial crystals of these valuable gemstones. In 1885 a dealer in Geneva began to sell ruby that is now believed to have been created by flame fusion. Gemnologists rapidly concluded that the stones were artificial, but the Geneva ruby stimulated A. V. L. Verneuil in Paris to develop a flame fusion process to produce higher quality ruby and sapphire. By 1900 there was brisk demand for ruby manufactured by Verneuil's method, even though Verneuil did not publicly announce his work until 1902 and did not publish details until 1904. The Verneuil process was used with little alteration for the next 50 years. From 1932-1953, S. K. Popov in the Soviet Union established a capability for manufacturing high quality sapphire by the Verneuil process. In the U.S., under government contract, Linde Air Products Co. implemented the Verneuil process for ruby and sapphire when European sources were cut off during World War II. These materials were essential to the war effort for jewel bearings in precision instruments. In the 1960s and 1970s, the Czochralski process was implemented by Linde and its successor, Union Carbide, to make higher crystal quality material for ruby lasers. Stimulated by a government contract for structural fibers in 1966, H. LaBelle invented edge-defined film-fed growth (EFG). The Saphikon company, which is currently owned by Saint-Gobain, evolved from this effort. Independently and simultaneously, Stepanov developed edge-defined film-fed growth in the Soviet Union. In 1967 F. Schmid and D. Viechnicki at the Army Materials Research Lab grew sapphire by the heat exchanger method (HEM). Schmid went on to establish Crystal Systems, Inc. around this technology. Rotem Industries, founded in Israel in 1969, perfected the growth of sapphire hemispheres and near-net-shape domes by gradient solidification. In the U.S., growth of near-net-shape sapphire domes was demonstrated by both the EFG and HEM methods in the 1980s under government contract, but neither method entered commercial production. Today, domes in the U.S. are made by "scooping" sapphire boules with diamond-impregnated cutting tools. Commercial markets for sapphire, especially in the semiconductor industry, are healthy and growing at the dawn of the 21st century.

Condensed phase conversion and growth of nanorods and other materials instead of from vapor

DOEpatents

Geohegan, David B.; Seals, Roland D.; Puretzky, Alex A.; Fan, Xudong

2010-10-19

Compositions, systems and methods are described for condensed phase conversion and growth of nanorods and other materials. A method includes providing a condensed phase matrix material; and activating the condensed phase matrix material to produce a plurality of nanorods by condensed phase conversion and growth from the condensed phase matrix material instead of from vapor. The compositions are very strong. The compositions and methods provide advantages because they allow (1) formation rates of nanostructures necessary for reasonable production rates, and (2) the near net shaped production of component structures.

Effect of Layer Thickness in Selective Laser Melting on Microstructure of Al/5 wt.%Fe2O3 Powder Consolidated Parts

PubMed Central

Hao, Liang

2014-01-01

In situ reaction was activated in the powder mixture of Al/5 wt.%Fe2O3 by using selective laser melting (SLM) to directly fabricate aluminium metal matrix composite parts. The microstructural characteristics of these in situ consolidated parts through SLM were investigated under the influence of thick powder bed, 75 μm layer thickness, and 50 μm layer thickness in various laser powers and scanning speeds. It was found that the layer thickness has a strong influence on microstructural outcome, mainly attributed to its impact on oxygen content of the matrix. Various microstructural features (such as granular, coralline-like, and particulate appearance) were observed depending on the layer thickness, laser power, and scanning speed. This was associated with various material combinations such as pure Al, Al-Fe intermetallics, and Al(-Fe) oxide phases formed after in situ reaction and laser rapid solidification. Uniformly distributed very fine particles could be consolidated in net-shape Al composite parts by using lower layer thickness, higher laser power, and lower scanning speed. The findings contribute to the new development of advanced net-shape manufacture of Al composites by combining SLM and in situ reaction process. PMID:24526879

Material forming apparatus using a directed droplet stream

DOEpatents

Holcomb, David E.; Viswanathan, Srinath; Blue, Craig A.; Wilgen, John B.

2000-01-01

Systems and methods are described for rapidly forming precision metallic and intermetallic alloy net shape parts directly from liquid metal droplets. A directed droplet deposition apparatus includes a crucible with an orifice for producing a jet of material, a jet destabilizer, a charging structure, a deflector system, and an impact zone. The systems and methods provide advantages in that fully dense, microstructurally controlled parts can be fabricated at moderate cost.

Neural-Net Processed Characteristic Patterns for Measurement of Structural Integrity of Pressure Cycled Components

NASA Technical Reports Server (NTRS)

Decker, A. J.

2001-01-01

A neural-net inspection process has been combined with a bootstrap training procedure and electronic holography to detect changes or damage in a pressure-cycled International Space Station cold plate to be used for cooling instrumentation. The cold plate was excited to vibrate in a normal mode at low amplitude, and the neural net was trained by example to flag small changes in the mode shape. The NDE (nondestructive-evaluation) technique is straightforward but in its infancy; its applications are ad-hoc and uncalibrated. Nevertheless previous research has shown that the neural net can detect displacement changes to better than 1/100 the maximum displacement amplitude. Development efforts that support the NDE technique are mentioned briefly, followed by descriptions of electronic holography and neural-net processing. The bootstrap training procedure and its application to detection of damage in a pressure-cycled cold plate are discussed. Suggestions for calibrating and quantifying the NDE procedure are presented.

Shaped Charge Liner Materials: Resources, Processes, Properties, Costs, and Applications

DTIC Science & Technology

1991-02-01

SUBTITLE 5. FUNDING NUMBERS Shaped Charge Liner Materials: Resources, Processes, Properties, Costs, and Applications 2 6. AUTHOC Steven M. Buc 7...summaries of the mineral availability, Cq prmarymetal refinement processeb, material costs in raw form and as finished shaped charge liners , relevant... liner materials. 94-11479 gI 14, SUBJECT TERMS iSt NUMBER OF PAGIS 13chrg wrhad :xplosively formed penetrators material R. PRCE COEV" processing

The implementation of microstructural and heat treatment models to development of forming technology of critical aluminum-alloy parts

NASA Astrophysics Data System (ADS)

Biba, Nikolay; Alimov, Artem; Shitikov, Andrey; Stebunov, Sergei

2018-05-01

The demand for high performance and energy efficient transportation systems have boosted interest in lightweight design solutions. To achieve maximum weight reductions, it is not enough just to replace steel parts by their aluminium analogues, but it is necessary to change the entire concept of vehicle design. In this case we must develop methods for manufacturing a variety of critical parts with unusual and difficult to produce shapes. The mechanical properties of the material in these parts must also be optimised and tightly controlled to provide the best distribution within the part volume. The only way to achieve these goals is to implement technology development methods based on simulation of the entire manufacturing chain from preparing a billet through the forming operations and heat treatment of the product. The paper presents an approach to such technology development. The simulation of the technological chain starts with extruding a round billet. Depending on the extrusion process parameters, the billet can have different levels of material workout and variation of grain size throughout the volume. After extrusion, the billet gets formed into the required shape in a forging process. The main requirements at this stage are to get the near net shape of the product without defects and to provide proper configuration of grain flow that strengthens the product in the most critical direction. Then the product undergoes solution treatment, quenching and ageing. The simulation of all these stages are performed by QForm FEM code that provides thermo-mechanical coupled deformation of the material during extrusion and forging. To provide microstructure and heat treatment simulation, special subroutines has been developed by the authors. The proposed approach is illustrated by an industrial case study.

Condensed phase conversion and growth of nanorods instead of from vapor

DOEpatents

Geohegan, David B.; Seals, Roland D.; Puretzky, Alex A.; Fan, Xudong

2005-08-02

Compositions, systems and methods are described for condensed phase conversion and growth of nanorods and other materials. A method includes providing a condensed phase matrix material; and activating the condensed phase matrix material to produce a plurality of nanorods by condensed phase conversion and growth from the condensed chase matrix material instead of from vacor. The compositions are very strong. The compositions and methods provide advantages because they allow (1) formation rates of nanostructures necessary for reasonable production rates, and (2) the near net shaped production of component structures.

Modeling and Simulation of Metallurgical Process Based on Hybrid Petri Net

NASA Astrophysics Data System (ADS)

Ren, Yujuan; Bao, Hong

2016-11-01

In order to achieve the goals of energy saving and emission reduction of iron and steel enterprises, an increasing number of modeling and simulation technologies are used to research and analyse metallurgical production process. In this paper, the basic principle of Hybrid Petri net is used to model and analyse the Metallurgical Process. Firstly, the definition of Hybrid Petri Net System of Metallurgical Process (MPHPNS) and its modeling theory are proposed. Secondly, the model of MPHPNS based on material flow is constructed. The dynamic flow of materials and the real-time change of each technological state in metallurgical process are simulated vividly by using this model. The simulation process can implement interaction between the continuous event dynamic system and the discrete event dynamic system at the same level, and play a positive role in the production decision.

The Effect of the Traverse Feed Rate on the Microstructure and Mechanical Properties of Laser Deposited Fe₃Al (Zr,B) Intermetallic Alloy.

PubMed

Łazińska, Magdalena; Durejko, Tomasz; Czujko, Tomasz; Bojar, Zbigniew

2018-05-14

The results of the fabrication of components made with Fe-30%Al-0.35%Zr-0.1%B alloy powder using the Laser Engineered Net Shaping (LENS TM ) system operated at different traverse feed rates are described in this paper. The temperature of the molten metal pool was recorded during this process. Depending on the assumed feed rate, the formation of Zr⁻based precipitates with various morphologies and distributions was observed in the structure of the investigated material. It was found that as the traverse speed increased, spheroidization, refinement, and a more homogeneous distribution of these precipitates occurred.

IPMC-driven thrust generation: a new conceptual design (Conference Presentation)

NASA Astrophysics Data System (ADS)

Olsen, Zakai; Kim, Kwang Jin

2017-04-01

Ionic Polymer-Metal Composites (IPMC) are highly functional actuators that find many uses in the field of soft robotics due to their low actuation voltage and ability to operate in aquatic environments. The actuation of an IPMC relies on the swelling of the negatively charged side when a potential is applied, due to the free-moving cations and water molecules migrating to that half. While this bending type actuation can be utilized to perform many tasks, it is ill suited for the primary propulsion mechanism in certain soft robotic applications. Here, a new conceptual design is presented which utilizes the bending of IPMC materials to achieve complex actuation motion in an attempt to generate a non-zero net thrust for propulsion of soft robots. The design capitalizes on advances in the manufacturing processes of electroactive polymer materials, which now allow for more complex shapes and thus new and unique modes of actuation. By utilizing the consistent bending deformation of IPMC actuators, in conjunction with carefully considered geometry, an IPMC driven body may serve as a primary mode of propulsion through a positive net thrust generation. This work consists of the initial feasibility study, concept testing, and optimization for such an actuator through computer modeling and simulation. COMSOL will be used for the finite element analysis to design the most efficient and optimized design for a positive net thrust generation. Such an IPMC design may find a great deal of applications, and the potential of future integration into other soft robotic systems is considered.

Using compression calorimetry to characterize powder compaction behavior of pharmaceutical materials.

PubMed

Buckner, Ira S; Friedman, Ross A; Wurster, Dale Eric

2010-02-01

The process by which pharmaceutical powders are compressed into cohesive compacts or tablets has been studied using a compression calorimeter. Relating the various thermodynamic results to relevant physical processes has been emphasized. Work, heat, and internal energy change values have been determined with the compression calorimeter for common pharmaceutical materials. A framework of equations has been proposed relating the physical processes of friction, reversible deformation, irreversible deformation, and inter-particle bonding to the compression calorimetry values. The results indicate that irreversible deformation dominated many of the thermodynamic values, especially the net internal energy change following the compression-decompression cycle. The relationships between the net work and the net heat from the complete cycle were very clear indicators of predominating deformation mechanisms. Likewise, the ratio of energy stored as internal energy to the initial work input distinguished the materials according to their brittle or plastic deformation tendencies. (c) 2009 Wiley-Liss, Inc. and the American Pharmacists Association.

Microstructural investigation of D2 tool steel during rapid solidification

NASA Astrophysics Data System (ADS)

Delshad Khatibi, Pooya

Solidification is considered as a key processing step in developing the microstructure of most metallic materials. It is, therefore, important that the solidification process can be designed and controlled in such a way so as to obtain the desirable properties in the final product. Rapid solidification refers to the system's high undercooling and high cooling rate, which can yield a microstructure with unique chemical composition and mechanical properties. An area of interest in rapid solidification application is high-chromium, high-carbon tool steels which experience considerable segregation of alloying elements during their solidification in a casting process. In this dissertation, the effect of rapid solidification (undercooling and cooling rate) of D2 tool steel on the microstructure and carbide precipitation during annealing was explored. A methodology is described to estimate the eutectic and primary phase undercooling of solidifying droplets. The estimate of primary phase undercooling was confirmed using an online measurement device that measured the radiation energy of the droplets. The results showed that with increasing primary phase and eutectic undercooling and higher cooling rate, the amount of supersaturation of alloying element in metastable retained austenite phase also increases. In the case of powders, the optimum hardness after heat treatment is achieved at different temperatures for constant periods of time. Higher supersaturation of austenite results in obtaining secondary hardness at higher annealing temperature. D2 steel ingots generated using spray deposition have high eutectic undercooling and, as a result, high supersaturation of alloying elements. This can yield near net shape D2 tool steel components with good mechanical properties (specifically hardness). The data developed in this work would assist in better understanding and development of near net shape D2 steel spray deposit products with good mechanical properties.

Feasibility Assessment for Pressure Casting of Ceramic-Aluminum Composites for NASA's Propulsion Applications

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.

2005-01-01

Feasibility assessment of pressure casting of ceramic-aluminum composites for NASA% propulsion applications is summarized. A combination of several demonstration projects to produce three unique components for liquid hydrogen-oxygen rocket engine% flanges, valves and turbo-pump housing are conducted. These components are made from boron carbide, silicon carbide and alumina powders fabricated into complex net shaped parts using dry green powder compaction, slip casting or a novel 3D ink-jet printing process, followed by sintering to produce performs that can be pressure cast by infiltration with molten aluminum. I n addition, joining techniques are also explored to insure that these components can be assembled into a structure without degrading their highly tailored properties. The feasibility assessment was made to determine if these new materials could provide a significant weight savings, thereby reducing vehicle launch costs, while being durable materials to increase safety and performance for propulsion system.

Low cost fabrication development for oxide dispersion strengthened alloy vanes

NASA Technical Reports Server (NTRS)

Perkins, R. J.; Bailey, P. G.

1978-01-01

Viable processes were developed for secondary working of oxide dispersion strengthened (ODS) alloys to near-net shapes (NNS) for aircraft turbine vanes. These processes were shown capable of producing required microstructure and properties for vane applications. Material cost savings of 40 to 50% are projected for the NNS process over the current procedures which involve machining from rectangular bar. Additional machining cost savings are projected. Of three secondary working processes evaluated, directional forging and plate bending were determined to be viable NNS processes for ODS vanes. Directional forging was deemed most applicable to high pressure turbine (HPT) vanes with their large thickness variations while plate bending was determined to be most cost effective for low pressure turbine (LPT) vanes because of their limited thickness variations. Since the F101 LPT vane was selected for study in this program, development of plate bending was carried through to establishment of a preliminary process. Preparation of ODS alloy plate for bending was found to be a straight forward process using currently available bar stock, providing that the capability for reheating between roll passes is available. Advanced ODS-NiCrAl and ODS-FeCrAl alloys were utilized on this program. Workability of all alloys was adequate for directional forging and plate bending, but only the ODS-FeCrAl had adequate workability for shaped preform extrustion.

Ultra low density biodegradable shape memory polymer foams with tunable physical properties

DOE Office of Scientific and Technical Information (OSTI.GOV)

Singhal, Pooja; Wilson, Thomas S.; Cosgriff-Hernandez, Elizabeth

Compositions and/or structures of degradable shape memory polymers (SMPs) ranging in form from neat/unfoamed to ultra low density materials of down to 0.005 g/cc density. These materials show controllable degradation rate, actuation temperature and breadth of transitions along with high modulus and excellent shape memory behavior. A method of m ly low density foams (up to 0.005 g/cc) via use of combined chemical and physical aking extreme blowing agents, where the physical blowing agents may be a single compound or mixtures of two or more compounds, and other related methods, including of using multiple co-blowing agents of successively higher boilingmore » points in order to achieve a large range of densities for a fixed net chemical composition. Methods of optimization of the physical properties of the foams such as porosity, cell size and distribution, cell openness etc. of these materials, to further expand their uses and improve their performance.« less

Laser Engineered Net Shaping of Nickel-Based Superalloy Inconel 718 Powders onto AISI 4140 Alloy Steel Substrates: Interface Bond and Fracture Failure Mechanism

PubMed Central

Kim, Hoyeol; Cong, Weilong; Zhang, Hong-Chao; Liu, Zhichao

2017-01-01

As a prospective candidate material for surface coating and repair applications, nickel-based superalloy Inconel 718 (IN718) was deposited on American Iron and Steel Institute (AISI) 4140 alloy steel substrate by laser engineered net shaping (LENS) to investigate the compatibility between two dissimilar materials with a focus on interface bonding and fracture behavior of the hybrid specimens. The results show that the interface between the two dissimilar materials exhibits good metallurgical bonding. Through the tensile test, all the fractures occurred in the as-deposited IN718 section rather than the interface or the substrate, implying that the as-deposited interlayer bond strength is weaker than the interfacial bond strength. From the fractography using scanning electron microscopy (SEM) and energy disperse X-ray spectrometry (EDS), three major factors affecting the tensile fracture failure of the as-deposited part are (i) metallurgical defects such as incompletely melted powder particles, lack-of-fusion porosity, and micropores; (ii) elemental segregation and Laves phase, and (iii) oxide formation. The fracture failure mechanism is a combination of all these factors which are detrimental to the mechanical properties and structural integrity by causing premature fracture failure of the as-deposited IN718. PMID:28772702

Laser Engineered Net Shaping of Nickel-Based Superalloy Inconel 718 Powders onto AISI 4140 Alloy Steel Substrates: Interface Bond and Fracture Failure Mechanism.

PubMed

Kim, Hoyeol; Cong, Weilong; Zhang, Hong-Chao; Liu, Zhichao

2017-03-25

As a prospective candidate material for surface coating and repair applications, nickel-based superalloy Inconel 718 (IN718) was deposited on American Iron and Steel Institute (AISI) 4140 alloy steel substrate by laser engineered net shaping (LENS) to investigate the compatibility between two dissimilar materials with a focus on interface bonding and fracture behavior of the hybrid specimens. The results show that the interface between the two dissimilar materials exhibits good metallurgical bonding. Through the tensile test, all the fractures occurred in the as-deposited IN718 section rather than the interface or the substrate, implying that the as-deposited interlayer bond strength is weaker than the interfacial bond strength. From the fractography using scanning electron microscopy (SEM) and energy disperse X-ray spectrometry (EDS), three major factors affecting the tensile fracture failure of the as-deposited part are (i) metallurgical defects such as incompletely melted powder particles, lack-of-fusion porosity, and micropores; (ii) elemental segregation and Laves phase, and (iii) oxide formation. The fracture failure mechanism is a combination of all these factors which are detrimental to the mechanical properties and structural integrity by causing premature fracture failure of the as-deposited IN718.

Influence of processing factors on the physical metallurgy of LENS deposited 316L stainless steel.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yang, Nancy Y. C.; Yee, Joshua Keng; Zheng, Baolong

2015-12-01

Directed energy deposition (DED) is a type of additive manufacturing (AM) process; Laser Engineered Net Shaping (LENS) is a commercial DED process. We are developing LENS technology for printing 316L stainless steel components for structural applications. It is widely known that material properties of AM components are process dependent, attributed to different molten metal incorporation and thermal transport mechanisms. This investigation focuses on process-structure-property relationships for LENS deposits for enabling the process development and optimization to control material property. We observed interactions among powder melting, directional molten metal flow, and the molten metal solidification. The resultant LENS induced microstructure foundmore » to be dictated by the process-related characteristics, i.e., interpass boundaries from multi-layer deposition, molten metal flow lines, and solidification dendrite cells. Each characteristic bears the signature of the unique localized thermal history during deposition. Correlation observed between localized thermal transport, resultant microstructure, and its subsequent impact on the mechanical behavior of the current 316L is discussed. We also discuss how the structures of interpass boundaries are susceptible to localized recrystallization, grain growth and/or defect formation, and therefore, heterogeneous mechanical properties due to the adverse presence of unmelted powder inclusions.« less

Catalogue of X-Ray Texture Data for Al-Cu-Li Alloy 1460, 2090, 2096 and 2195 Near-Net-Shape Extrusions, Sheet and Plate

NASA Technical Reports Server (NTRS)

Hales, Stephen J.; Hafley, Robert A.; Alexa, Joel A.

1998-01-01

The effect of crystallographic texture on the mechanical properties of near-net-shape extrusions is of major interest ff these products are to find application in launch vehicle or aircraft structures. The objective of this research was to produce a catalogue containing quantitative texture information for extruded product, sheet and plate. The material characterized was extracted from wide, integrally stiffened panels fabricated from the Al-Cu-Li alloys 1460, 2090, 2096 and 2195. The textural characteristics of sheet and plate products of the same alloys were determined for comparison purposes. The approach involved using X-ray diffraction to generate pole figures in combination with orientation distribution function analysis. The data were compiled as a function of location in the extruded cross-sections and the variation in the major deformation- and recrystallization-related texture components was identified.

Laser Metal Deposition as Repair Technology for a Gas Turbine Burner Made of Inconel 718

NASA Astrophysics Data System (ADS)

Petrat, Torsten; Graf, Benjamin; Gumenyuk, Andrey; Rethmeier, Michael

Maintenance, repair and overhaul of components are of increasing interest for parts of high complexity and expensive manufacturing costs. In this paper a production process for laser metal deposition is presented, and used to repair a gas turbine burner of Inconel 718. Different parameters for defined track geometries were determined to attain a near net shape deposition with consistent build-up rate for changing wall thicknesses over the manufacturing process. Spot diameter, powder feed rate, welding velocity and laser power were changed as main parameters for a different track size. An optimal overlap rate for a constant layer height was used to calculate the best track size for a fitting layer width similar to the part dimension. Deviations in width and height over the whole build-up process were detected and customized build-up strategies for the 3D sequences were designed. The results show the possibility of a near net shape repair by using different track geometries with laser metal deposition.

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

NASA Technical Reports Server (NTRS)

Johnston, N. J.; Cano, R. J.; Marchello, J. M.; Sandusky, D. A.

1995-01-01

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.

Formation of amorphous metal alloys by chemical vapor deposition

DOEpatents

Mullendore, Arthur W.

1990-01-01

Amorphous alloys are deposited by a process of thermal dissociation of mixtures or organometallic compounds and metalloid hydrides, e.g., transition metal carbonyl such as nickel carbonyl, and diborane. Various sizes and shapes of deposits can be achieved, including near-net-shape free standing articles, multilayer deposits, and the like. Manipulation or absence of a magnetic field affects the nature and the structure of the deposit.

Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets

NASA Astrophysics Data System (ADS)

Li, Ling; Tirado, Angelica; Nlebedim, I. C.; Rios, Orlando; Post, Brian; Kunc, Vlastimil; Lowden, R. R.; Lara-Curzio, Edgar; Fredette, Robert; Ormerod, John; Lograsso, Thomas A.; Paranthaman, M. Parans

2016-10-01

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic properties are: intrinsic coercivity Hci = 688.4 kA/m, remanence Br = 0.51 T, and energy product (BH)max = 43.49 kJ/m3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. The present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.

Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets

PubMed Central

Li, Ling; Tirado, Angelica; Nlebedim, I. C.; Rios, Orlando; Post, Brian; Kunc, Vlastimil; Lowden, R. R.; Lara-Curzio, Edgar; Fredette, Robert; Ormerod, John; Lograsso, Thomas A.; Paranthaman, M. Parans

2016-01-01

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic properties are: intrinsic coercivity Hci = 688.4 kA/m, remanence Br = 0.51 T, and energy product (BH)max = 43.49 kJ/m3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. The present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials. PMID:27796339

Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets.

PubMed

Li, Ling; Tirado, Angelica; Nlebedim, I C; Rios, Orlando; Post, Brian; Kunc, Vlastimil; Lowden, R R; Lara-Curzio, Edgar; Fredette, Robert; Ormerod, John; Lograsso, Thomas A; Paranthaman, M Parans

2016-10-31

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm 3 , and the room temperature magnetic properties are: intrinsic coercivity H ci  = 688.4 kA/m, remanence B r  = 0.51 T, and energy product (BH) max  = 43.49 kJ/m 3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. The present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.

Big area additive manufacturing of high performance bonded NdFeB magnets

DOE PAGES

Li, Ling; Tirado, Angelica; Nlebedim, I. C.; ...

2016-10-31

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic propertiesmore » are: intrinsic coercivity Hci = 688.4 kA/m, remanence B r = 0.51 T, and energy product (BH) max = 43.49 kJ/m 3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. As a result, the present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.« less

Big area additive manufacturing of high performance bonded NdFeB magnets

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, Ling; Tirado, Angelica; Nlebedim, I. C.

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic propertiesmore » are: intrinsic coercivity Hci = 688.4 kA/m, remanence B r = 0.51 T, and energy product (BH) max = 43.49 kJ/m 3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. As a result, the present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.« less

Optical and optomechanical ultralightweight C/SiC components

NASA Astrophysics Data System (ADS)

Papenburg, Ulrich; Pfrang, Wilhelm; Kutter, G. S.; Mueller, Claus E.; Kunkel, Bernd P.; Deyerler, Michael; Bauereisen, Stefan

1999-11-01

Optical and optomechanical structures based on silicon carbide (SiC) ceramics are becoming increasingly important for ultra- lightweight optical systems that must work in adverse environments. At IABG and Dornier Satellite Systems (DSS) in Munich, a special form of SiC ceramics carbon fiber reinforced silicon carbide (C/SiCR) has been developed partly under ESA and NASA contracts. C/SiCR is a light-weight, high- strength engineering material that features tunable mechanical and thermal properties. It offers exceptional design freedom due to its reduced brittleness and negligible volume shrinkage during processing in comparison to traditional, powder-based ceramics. Furthermore, its rapid fabrication process produces near-net-shape components using conventional NC machining/milling equipment and, thus, provides substantial schedule, cost, and risk savings. These characteristics allow C/SiCR to overcome many of the problems associated with more traditional optical materials. To date, C/SiCR has been used to produce ultra-lightweight mirrors and reflectors, antennas, optical benches, and monolithic and integrated reference structures for a variety of space and terrestrial applications. This paper describes the material properties, optical system and structural design aspects, the forming and manufacturing process including high-temperature joining technology, precision grinding and cladding techniques, and the performance results of a number of C/SiCR optical components we have built.

Preliminary Investigation on Life Cycle Inventory of Powder Bed Fusion of Stainless Steel

NASA Astrophysics Data System (ADS)

Nyamekye, Patricia; Piili, Heidi; Leino, Maija; Salminen, Antti

Manufacturing of work pieces from stainless steel with laser additive manufacturing, known also as laser sintering or 3D printing may increase energy and material efficiency. The use of powder bed fusion offers advantages to make parts for dynamic applications of light weight and near-net-shape products. Due to these advantages among others, PBF may also reduce emissions and operational cost in various applications. However, there are only few life cycle assessment studies examining this subject despite its prospect to business opportunity. The application of Life Cycle Inventory (LCI) in Powder Bed Fusion (PBF) provides a distinct evaluation of material and energy consumption. LCI offers a possibility to improve knowledge of process efficiency. This study investigates effect of process sustainability in terms of raw material, energy and time consumption with PBF and CNC machining. The results of the experimental study indicated lower energy efficiency in the production process with PBF. This study revealed that specific energy consumption in PBF decreased when several components are built simultaneously than if they would be built individually. This is due to fact that energy consumption per part is lower. On the contrary, amount of energy needed to machine on part in case of CNC machining is lower when parts are done separately.

Laser materials processing facility

NASA Technical Reports Server (NTRS)

Haggerty, J. S.

1982-01-01

The laser materials processing facility and its capabilities are described. A CO2 laser with continuous wave, repetitive pulse, and shaped power-time cycles is employed. The laser heated crystal growth station was used to produce metal and metal oxide single crystals and for cutting and shaping experiments using Si3N4 to displace diamond shaping processes.

Lightweight Aluminum/Nano composites for Automotive Drive Train Applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chelluri, Bhanumathi; Knoth, Edward A.; Schumaker, Edward J.

2012-12-14

During Phase I, we successfully processed air atomized aluminum powders via Dynamic Magnetic Compaction (DMC) pressing and subsequent sintering to produce parts with properties similar to wrought aluminum. We have also showed for the first time that aluminum powders can be processed without lubes via press and sintering to 100 % density. This will preclude a delube cycle in sintering and promote environmentally friendly P/M processing. Processing aluminum powders via press and sintering with minimum shrinkage will enable net shape fabrication. Aluminum powders processed via a conventional powder metallurgy process produce too large a shrinkage. Because of this, sinter partsmore » have to be machined into specific net shape. This results in increased scrap and cost. Fully sintered aluminum alloy under this Phase I project has shown good particle-to-particle bonding and mechanical properties. We have also shown the feasibility of preparing nano composite powders and processing via pressing and sintering. This was accomplished by dispersing nano silicon carbide (SiC) powders into aluminum matrix comprising micron-sized powders (<100 microns) using a proprietary process. These composite powders of Al with nano SiC were processed using DMC press and sinter process to sinter density of 85-90%. The process optimization along with sintering needs to be carried out to produce full density composites.« less

Preventing Clogging In A Vacuum Plasma Spray Gun

NASA Technical Reports Server (NTRS)

Krotz, Phillip D.; Daniel, Ronald L., Jr.; Davis, William M.

1994-01-01

Modification of powder-injection ports enables lengthy, high-temperature deposition operations. Graphite inserts prevent clogging of ports through which copper powder injected into vacuum plasma spray (VPS) gun. Graphite liners eliminate need to spend production time refurbishing VPS gun, reducing cost of production and increasing productivity. Concept also applied to other material systems used for net-shape fabrication via VPS.

Formation of amorphous metal alloys by chemical vapor deposition

DOEpatents

Mullendore, A.W.

1988-03-18

Amorphous alloys are deposited by a process of thermal dissociation of mixtures of organometallic compounds and metalloid hydrides,e.g., transition metal carbonyl, such as nickel carbonyl and diborane. Various sizes and shapes of deposits can be achieved, including near-net-shape free standing articles, multilayer deposits, and the like. Manipulation or absence of a magnetic field affects the nature and the structure of the deposit. 1 fig.

Electroacoustics modeling of piezoelectric welders for ultrasonic additive manufacturing processes

NASA Astrophysics Data System (ADS)

Hehr, Adam; Dapino, Marcelo J.

2016-04-01

Ultrasonic additive manufacturing (UAM) is a recent 3D metal printing technology which utilizes ultrasonic vibrations from high power piezoelectric transducers to additively weld similar and dissimilar metal foils. CNC machining is used intermittent of welding to create internal channels, embed temperature sensitive components, sensors, and materials, and for net shaping parts. Structural dynamics of the welder and work piece influence the performance of the welder and part quality. To understand the impact of structural dynamics on UAM, a linear time-invariant model is used to relate system shear force and electric current inputs to the system outputs of welder velocity and voltage. Frequency response measurements are combined with in-situ operating measurements of the welder to identify model parameters and to verify model assumptions. The proposed LTI model can enhance process consistency, performance, and guide the development of improved quality monitoring and control strategies.

Evaluation of Double-Vacuum-Bag Process For Composite Fabrication

NASA Technical Reports Server (NTRS)

Hou, T. H.; Jensen, B. J.

2004-01-01

A non-autoclave vacuum bag process using atmospheric pressure alone that eliminates the need for external pressure normally supplied by an autoclave or a press is an attractive method for composite fabrication. This type of process does not require large capital expenditures for tooling and processing equipment. In the molding cycle (temperature/pressure profile) for a given composite system, the vacuum application point has to be carefully selected to achieve the final consolidated laminate net shape and resin content without excessive resin squeeze-out. The traditional single-vacuum- bag (SVB) process is best suited for molding epoxy matrix based composites because of their superior flow and the absence of reaction by-products or other volatiles. Other classes of materials, such as polyimides and phenolics, generate water during cure. In addition, these materials are commonly synthesized as oligomers using solvents to facilitate processability. Volatiles (solvents and reaction byproducts) management therefore becomes a critical issue. SVB molding, without additional pressure, normally fails to yield void-free quality composites for these classes of resin systems. A double-vacuum- bag (DVB) process for volatile management was envisioned, designed and built at the NASA Langley Research Center. This experimental DVB process affords superior volatiles management compared to the traditional SVB process. Void-free composites are consistently fabricated as measured by C-scan and optical photomicroscopy for high performance polyimide and phenolic resins.

Engineering fluid flow using sequenced microstructures

NASA Astrophysics Data System (ADS)

Amini, Hamed; Sollier, Elodie; Masaeli, Mahdokht; Xie, Yu; Ganapathysubramanian, Baskar; Stone, Howard A.; di Carlo, Dino

2013-05-01

Controlling the shape of fluid streams is important across scales: from industrial processing to control of biomolecular interactions. Previous approaches to control fluid streams have focused mainly on creating chaotic flows to enhance mixing. Here we develop an approach to apply order using sequences of fluid transformations rather than enhancing chaos. We investigate the inertial flow deformations around a library of single cylindrical pillars within a microfluidic channel and assemble these net fluid transformations to engineer fluid streams. As these transformations provide a deterministic mapping of fluid elements from upstream to downstream of a pillar, we can sequentially arrange pillars to apply the associated nested maps and, therefore, create complex fluid structures without additional numerical simulation. To show the range of capabilities, we present sequences that sculpt the cross-sectional shape of a stream into complex geometries, move and split a fluid stream, perform solution exchange and achieve particle separation. A general strategy to engineer fluid streams into a broad class of defined configurations in which the complexity of the nonlinear equations of fluid motion are abstracted from the user is a first step to programming streams of any desired shape, which would be useful for biological, chemical and materials automation.

Replication of microchannel structures in WC-Co feedstock using elastomeric replica moulds by hot embossing process.

PubMed

Sahli, M; Gelin, J-C; Barrière, T

2015-10-01

Hot embossing is a net shaping process that is able to produce the micro-components of polymers with intrinsic and complex shapes at lower cost compared with machining and injection moulding. However, the emboss of hard metals, such as WC-Co, is more challenging due to their high thermal conductivity and ease of agglomeration. Thus, a WC-Co alloy mixed with a wax-based binder feedstock was selected. The formed feedstock exhibited pseudo-plastic flow and was successfully embossed (green part). Here, we developed a novel process that is used to replicate polymer microfluidic chips while simultaneously reducing the channel surface roughness of the mould insert, yielding optical-grade (less than 100 nm surface roughness) channels and reservoirs. This paper concerns the replication of metallic microfluidic mould inserts in WC-Co and the parameters associated with feedstock formation via a hot embossing process. A suitable formulation for micro-powder hot embossing has been established and characterised by thermogravimetric analyses and measurements of mixing torques to verify and quantify the homogeneity of the proposed feedstocks. The relative density of the samples increased with processing temperature, and almost fully dense materials were obtained. In this work, the effects of the sintering temperature on the physical properties were systematically analysed. The evolution of the metal surface morphology during the hot embossing process was also investigated. The results indicate that the feedstock can be used to manufacture micro-fluidic die mould cavities with a low roughness, proper dimensions and good shape retention. The shrinkage of the sintered part was approximately 19-24% compared with that of the brown part. Copyright © 2015 Elsevier B.V. All rights reserved.

Energy Implications of Materials Processing

ERIC Educational Resources Information Center

Hayes, Earl T.

1976-01-01

Processing of materials could become energy-limited rather than resource-limited. Methods to extract metals, industrial minerals, and energy materials and convert them to useful states requires more than one-fifth of the United States energy budget. Energy accounting by industries must include a total systems analysis of costs to insure net energy…

Mechanism of concave ``tafoni'' and convex ``domal shape'' formation on TRIASSIC red sandstone of some old buildings, Chester City, UK, Case study

NASA Astrophysics Data System (ADS)

Kamh, G. M. E.

2005-08-01

The weathering factors act on the recent and archaeological sites through different processes based on the dominant environmental conditions. The net result of weathering is deformation of the original form of construction rock. In the current case study, the main aim is to find out the mechanism of formation of two different weathering forms recorded on many old buildings taking Chester City as a case study. The construction rock in the case study is arenitic sandstone with carbonate content ranging from 0.0 to 15.6%. The sandstone blocks are cemented together by hydraulic lime mortar that can easily be altered chemically to salts by acid rain that dominates at the study area. In case of mortar with worse geotechnical limits than the sandstone blocks, the net result is convex “domal” shape blocks, but in case of mortar with better geotechnical limits than the construction sandstone, the net result of weathering is tafoni “concave” weathering form.

Application specific beam profiles: new surface and thin-film refinement processes using beam shaping technologies

NASA Astrophysics Data System (ADS)

Hauschild, Dirk

2017-02-01

Today, the use of laser photons for materials processing is a key technology in nearly all industries. Most of the applications use circular beam shapes with Gaussian intensity distribution that is given by the resonator of the laser or by the power delivery via optical fibre. These beam shapes can be typically used for material removal with cutting or drilling and for selective removal of material layers with ablation processes. In addition to the removal of materials, it is possible to modify and improve the material properties in case the dose of laser photons and the resulting light-material interaction addresses a defined window of energy and dwell-time. These process windows have typically dwell-times between µs and s because of using sintering, melting, thermal diffusion or photon induced chemical and physical reaction mechanisms. Using beam shaping technologies the laser beam profiles can be adapted to the material properties and time-temperature and the space-temperature envelopes can be modified to enable selective annealing or crystallization of layers or surfaces. Especially the control of the process energy inside the beam and at its edges opens a large area of laser applications that can be addressed only with an optimized spatial and angular beam profile with down to sub-percent intensity variation used in e.g. immersion lithography tools with ArF laser sources. LIMO will present examples for new beam shapes and related material refinement processes even on large surfaces and give an overview about new mechanisms in laser material processing for current and coming industrial applications.

Reactive Melt Infiltration Of Silicon Into Porous Carbon

NASA Technical Reports Server (NTRS)

Behrendt, Donald R.; Singh, Mrityunjay

1994-01-01

Report describes study of synthesis of silicon carbide and related ceramics by reactive melt infiltration of silicon and silicon/molybdenum alloys into porous carbon preforms. Reactive melt infiltration has potential for making components in nearly net shape, performed in less time and at lower temperature. Object of study to determine effect of initial pore volume fraction, pore size, and infiltration material on quality of resultant product.

Near Net Shape Rapid Manufacture & Repair by LENS(registered trademark)

DTIC Science & Technology

2006-05-01

J. Vlcek, “Property Investigation of Laser Cladded , Laser Sintered and Electron Beam Sintered Ti 6Al 4V”, AVT-139 Specialists Meeting on Cost...manufactured from advanced materials such as titanium alloys, superalloys or special steels are critical to the performance of the armed forces...10 years, CAD driven, additive manufacturing technologies have been developed. The leading technology for defence applications is Laser Engineered

In situ reactive multi-material Ti6Al4V-calcium phosphate-nitride coatings for bio-tribological applications.

PubMed

Sahasrabudhe, Himanshu; Bandyopadhyay, Amit

2018-05-24

To reduce the wear related damage of medical grade Ti-6Al-4V alloy, laser engineered net shaping (LENS™) based in situ reactive multi-material additive manufacturing was employed to process a mixed coating of Ti-6Al-4V powder and calcium phosphate (CaP) in an oxygen free, nitrogen-argon environment. The resultant coatings were composite materials of titanium nitrides and calcium titanate in an α-Ti matrix. Hardness was increased by up to ~148% to 868 ± 9 HV as compared to the untreated Ti-6Al-4V substrate. Similarly, when tribological properties were evaluated in deionized (DI) water medium against alumina counter material, the wear damage was reduced by ~91% as compared to the untreated Ti-6Al-4V substrate. Furthermore, the untreated Ti-6Al-4V substrate released Ti ions of ~12.45 ppm concentration during wear whereas the Ti6Al4V-5%CaP coating processed in an argon-nitrogen environment released ions of ~3.17 ppm concentration under similar testing conditions. The overall coefficient of friction was also found to decrease due to the addition of CaP and processing the Ti6Al4V-CaP mixture in an argon-nitrogen environment. Our results indicate that this reactive multi-material additive manufacturing of metal-ceramic composites is an effective way of enhancing the tribological performance of metallic materials. Copyright © 2018 Elsevier Ltd. All rights reserved.

Tuning the sapphire EFG process to the growth of Al2O3/YAG/ZrO2:Y eutectic

NASA Astrophysics Data System (ADS)

Carroz, L.; Duffar, T.

2018-05-01

In this work, a model is proposed, in order to analytically study the working point of the Edge defined Film-fed Growth (EFG) pulling of crystal plates. The model takes into account the heat equilibrium at the interface and the pressure equilibrium across the meniscus. It is validated on an industrial device dedicated to the pulling of sapphire ribbons. Then, the model is applied to pulling ceramic alloy plates, of the ternary eutectic Al2O3/YAG/ZrO2:Y. This allowed understanding the experimental difficulties of pulling this new material and suggested improvements of the control software. From these results, pulling net shaped ceramic alloy plates was successful in the same industrial equipment as used for sapphire.

Supportability Technologies for Future Exploration Missions

NASA Technical Reports Server (NTRS)

Watson, Kevin; Thompson, Karen

2007-01-01

Future long-duration human exploration missions will be challenged by resupply limitations and mass and volume constraints. Consequently, it will be essential that the logistics footprint required to support these missions be minimized and that capabilities be provided to make them highly autonomous from a logistics perspective. Strategies to achieve these objectives include broad implementation of commonality and standardization at all hardware levels and across all systems, repair of failed hardware at the lowest possible hardware level, and manufacture of structural and mechanical replacement components as needed. Repair at the lowest hardware levels will require the availability of compact, portable systems for diagnosis of failures in electronic systems and verification of system functionality following repair. Rework systems will be required that enable the removal and replacement of microelectronic components with minimal human intervention to minimize skill requirements and training demand for crews. Materials used in the assembly of electronic systems (e.g. solders, fluxes, conformal coatings) must be compatible with the available repair methods and the spacecraft environment. Manufacturing of replacement parts for structural and mechanical applications will require additive manufacturing systems that can generate near-net-shape parts from the range of engineering alloys employed in the spacecraft structure and in the parts utilized in other surface systems. These additive manufacturing processes will need to be supported by real-time non-destructive evaluation during layer-additive processing for on-the-fly quality control. This will provide capabilities for quality control and may serve as an input for closed-loop process control. Additionally, non-destructive methods should be available for material property determination. These nondestructive evaluation processes should be incorporated with the additive manufacturing process - providing an in-process capability to ensure that material deposited during layer-additive processing meets required material property criteria.

Productivity is a poor predictor of plant species richness

USDA-ARS?s Scientific Manuscript database

For 30 years, the relationship between net primary productivity and species richness has generated intense debate in ecology about the processes regulating fine-scale species richness. The true relationship was thought to be hump-shaped, with richness peaking at intermediate levels of productivity, ...

Fabrication of near-net shape graphite/magnesium composites for large mirrors

NASA Astrophysics Data System (ADS)

Wendt, Robert; Misra, Mohan

1990-10-01

Successful development of space-based surveillance and laser systems will require large precision mirrors which are dimensionally stable under thermal, static, and dynamic (i.e., structural vibrations and retargeting) loading conditions. Among the advanced composites under consideration for large space mirrors, graphite fiber reinforced magnesium (Gr/Mg) is an ideal candidate material that can be tailored to obtain an optimum combination of properties, including a high modulus of elasticity, zero coefficient of thermal expansion, low density, and high thermal conductivity. In addition, an innovative technique, combining conventional filament winding and vacuum casting has been developed to produce near-net shape Gr/Mg composites. This approach can significantly reduce the cost of fabricating large mirrors by decreasing required machining. However, since Gr/Mg cannot be polished to a reflective surface, plating is required. This paper will review research at Martin Marietta Astronautics Group on Gr/Mg mirror blank fabrication and measured mechanical and thermal properties. Also, copper plating and polishing methods, and optical surface characteristics will be presented.

Powder Injection Molding for mass production of He-cooled divertor parts

NASA Astrophysics Data System (ADS)

Antusch, S.; Norajitra, P.; Piotter, V.; Ritzhaupt-Kleissl, H.-J.

2011-10-01

A He-cooled divertor for future fusion power plants has been developed at KIT. Tungsten and tungsten alloys are presently considered the most promising materials for functional and structural divertor components. The advantages of tungsten materials lie, e.g. in the high melting point, and low activation, the disadvantages are high hardness and brittleness. The machinig of tungsten, e.g. milling, is very complex and cost-intensive. Powder Injection Molding (PIM) is a method for cost effective mass production of near-net-shape parts with high precision. The complete W-PIM process route is outlined and, results of product examination discussed. A binary tungsten powder feedstock with a grain size distribution in the range 0.7-1.7 μm FSSS, and a solid load of 50 vol.% was developed. After heat treatment, the successfully finished samples showed promising results, i.e. 97.6% theoretical density, a grain size of approximately 5 μm, and a hardness of 457 HV0.1.

Fundamentals of Mold Free Casting: Experimental and Computational Studies

NASA Technical Reports Server (NTRS)

Tryggvason, Gretar; Ceccio, Steven

1997-01-01

Researchers are developing the technology of 'Ballistic Particle Manufacturing' (BPM) in which individual drops are precisely layered onto a substrate, and the drops are deposited so as to prevent splatting. These individual drops will ultimately be combined to form a net-shape, three-dimensional object. Our understanding of controlled drop deposition as applied to BPM is far from complete. Process parameters include the size and temperature of the liquid metal drop, its impact velocity and trajectory, and the condition and temperature of the substrate. Quantitative knowledge of the fluid mechanics and heat transfer of drop deposition and solidification are necessary to fully optimize the manufacturing process and to control the material microstructure of the final part. The object of this study is to examine the dynamics of liquid metal drops as they impinge upon a solid surface and solidify under conditions consistent with BPM (i.e. conditions which produce non-splatting drops). A program of both numerical simulations and experiments will be conducted. Questions this study will address include the following: How do the deformation and solidification of the drop depend on the properties of the fluid drop and the solid substrate? How does the presence of previously deposited drops affect the impingement and solidification process? How does the impingement of the new drop affect already deposited material? How does the cooling rate and solidification of the drops influence the material microstructure?

Classification of pulmonary neuroendocrine tumors: new insights.

PubMed

Pelosi, Giuseppe; Sonzogni, Angelica; Harari, Sergio; Albini, Adriana; Bresaola, Enrica; Marchiò, Caterina; Massa, Federica; Righi, Luisella; Gatti, Gaia; Papanikolaou, Nikolaos; Vijayvergia, Namrata; Calabrese, Fiorella; Papotti, Mauro

2017-10-01

Neuroendocrine tumors of the lung (Lu-NETs) embrace a heterogeneous family of neoplasms classified into four histological variants, namely typical carcinoid (TC), atypical carcinoid (AC), large cell neuroendocrine carcinoma (LCNEC) and small cell lung carcinoma (SCLC). Defining criteria on resection specimens include mitotic count in 2 mm 2 and the presence or absence of necrosis, alongside a constellation of cytological and histological traits including cell size and shape, nuclear features and overall architecture. Clinically, TC are low-grade malignant tumors, AC intermediate-grade malignant tumors and SCLC/LCNEC high-grade malignant full-blown carcinomas with no significant differences in survival between them. Homologous tumors arise in the thymus that occasionally have some difficulties in differentiating from the lung counterparts when presented with large unresectable or metastatic lesions. Immunohistochemistry (IHC) helps refine NE diagnosis at various anatomical sites, particularly on small-sized tissue material, in which only TC and small cell carcinoma categories can be recognized easily on hematoxylin & eosin stain, while AC and LCNEC can only be suggested on such material. The Ki-67 labeling index effectively separates carcinoids from small cell carcinoma and may prove useful for the clinical management of a metastatic disease to help the therapeutic decision-making process. Although carcinoids and high-grade neuroendocrine carcinomas in the lung and elsewhere make up separate tumor categories on molecular grounds, emerging data supports the concept of secondary high-grade NETs arising in the preexisting carcinoids, whose clinical and biological relevance will have to be placed into the proper context for the optimal management of these patients. In this review, we will discuss the selected, recent literature with a focus on current issues regarding Lu-NET nosology, i.e., classification, derivation and tumor evolution.

Evaluation of ceramics for stator applications: Gas turbine engines interim report. Stator fabrication and evaluation

NASA Technical Reports Server (NTRS)

Arnon, N.; Trela, W.

1983-01-01

The objective was to assess current ceramic materials, fabrication processes, reliability prediction, and stator durability when subjected to simulated automotive gas turbine engine operating conditions. Ceramic one-piece stators were fabricated of two materials, silicon nitride and silicon carbide, using two near-net-shape processes, slip casting and injection molding. Non-destructive evaluation tests were conducted on all stators identifying irregularities which could contribute to failures under durability testing. Development of the test rig and automatic control system for repeatably controlling air flow rate and temperature over a highly transient durability duty cycle is discussed. Durability results are presented for repeated thermal cycle testing of the ceramic one-piece stators. Two duty cycles were used, encompassing the temperature ranges of 704 to 1204 C (1300 to 2200 F) and 871 to 1371 C (1600 to 2500 F). Tests were conducted on 28 stators, accumulating 135,551 cycles in 2441 hours of hot testing. Cyclic durability for the ceramic one-piece stator was demonstrated to be in excess of 500 hours, accumulating over 28,850 thermal cycles. Ceramic interface forces were found to be the significant factor in limiting stator life rather than the scatter in material strength properties or the variation in component defects encountered.

Microstructure and mechanical behavior of metal injection molded Ti-Nb binary alloys as biomedical material.

PubMed

Zhao, Dapeng; Chang, Keke; Ebel, Thomas; Qian, Ma; Willumeit, Regine; Yan, Ming; Pyczak, Florian

2013-12-01

The application of titanium (Ti) based biomedical materials which are widely used at present, such as commercially pure titanium (CP-Ti) and Ti-6Al-4V, are limited by the mismatch of Young's modulus between the implant and the bones, the high costs of products, and the difficulty of producing complex shapes of materials by conventional methods. Niobium (Nb) is a non-toxic element with strong β stabilizing effect in Ti alloys, which makes Ti-Nb based alloys attractive for implant application. Metal injection molding (MIM) is a cost-efficient near-net shape process. Thus, it attracts growing interest for the processing of Ti and Ti alloys as biomaterial. In this investigation, metal injection molding was applied to the fabrication of a series of Ti-Nb binary alloys with niobium content ranging from 10wt% to 22wt%, and CP-Ti for comparison. Specimens were characterized by melt extraction, optical microscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and transmission electron microscopy (TEM). Titanium carbide formation was observed in all the as-sintered Ti-Nb binary alloys but not in the as-sintered CP-Ti. Selected area electron diffraction (SAED) patterns revealed that the carbides are Ti2C. It was found that with increasing niobium content from 0% to 22%, the porosity increased from about 1.6% to 5.8%, and the carbide area fraction increased from 0% to about 1.8% in the as-sintered samples. The effects of niobium content, porosity and titanium carbides on mechanical properties have been discussed. The as-sintered Ti-Nb specimens exhibited an excellent combination of high tensile strength and low Young's modulus, but relatively low ductility. © 2013 Elsevier Ltd. All rights reserved.

Measurement and analysis of flow in 3D preforms for aerospace composites

NASA Astrophysics Data System (ADS)

Stewart, Andrew Lawrence

Composite materials have become viable alternatives to traditional engineering materials for many different product categories. Liquid transfer moulding (LTM) processes, specifically resin transfer moulding (RTM), is a cost-effective manufacturing technique for creating high performance composite parts. These parts can be tailor-made to their specific application by optimizing the properties of the textile preform. Preforms which require little or no further assembly work and are close to the shape of the final part are critical to obtaining high quality parts while simultaneously reducing labour and costs associated with other composite manufacturing techniques. One type of fabric which is well suited for near-net- shape preforms is stitched non-crimp fabrics. These fabrics offer very high in-plane strength and stiffness while also having increased resistance to delamination. Manufacturing parts from these dry preforms typically involves long-scale fluid flow through both open channels and porous fibre bundles. This thesis documents and analyzes the flow of fluid through preforms manufactured from non-crimp fabrics featuring through-thickness stitches. The objective of this research is to determine the effect of this type of stitch on the RTM injection process. All of the tests used preforms with fibre volume fractions representative of primary and secondary structural parts. A series of trials was conducted using different fibre materials, flow rates, fibre volumes fractions, and degrees of fibre consolidation. All of the trials were conducted for cases similar to RTM. Consolidation of the fibres showed improvements to both the thoroughness of the filling and to the fibre volume fraction. Experimentally determined permeability data was shown to trend well with simple models and precision of the permeability data was comparable to values presented by other authors who studied fabrics which did not feature the through-thickness stitches.

Shape Memory Characteristics of Ti(sub 49.5)Ni(sub 25)Pd(sub 25)Sc(sub 0.5) High-Temperature Shape Memory Alloy After Severe Plastic Deformation

NASA Technical Reports Server (NTRS)

Atli, K. C.; Karaman, I.; Noebe, R. D.; Garg, A.; Chumlyakov, Y. I.; Kireeva, I. V.

2011-01-01

A Ti(49.5)Ni25Pd25Sc(0.5) high-temperature shape memory alloy is thermomechanically processed to obtain enhanced shape-memory characteristics: in particular, dimensional stability upon repeated thermal cycles under constant loads. This is accomplished using severe plastic deformation via equal channel angular extrusion (ECAE) and post-processing annealing heat treatments. The results of the thermomechanical experiments reveal that the processed materials display enhanced shape memory response, exhibiting higher recoverable transformation and reduced irrecoverable strain levels upon thermal cycling compared with the unprocessed material. This improvement is attributed to the increased strength and resistance of the material against defect generation upon phase transformation as a result of the microstructural refinement due to the ECAE process, as supported by the electron microscopy observations.

Energy Saving Melting and Revert Reduction Technology: Innovative Semi-Solid Metal (SSM) Processing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Diran Apelian

2012-08-15

Semi-solid metal (SSM) processing has emerged as an attractive method for near-net-shape manufacturing due to the distinct advantages it holds over conventional near-net-shape forming technologies. These advantages include lower cycle time, increased die life, reduced porosity, reduced solidification shrinkage, improved mechanical properties, etc. SSM processing techniques can not only produce the complex dimensional details (e.g. thin-walled sections) associated with conventional high-pressure die castings, but also can produce high integrity castings currently attainable only with squeeze and low-pressure permanent mold casting processes. There are two primary semi-solid processing routes, (a) thixocasting and (b) rheocasting. In the thixocasting route, one starts frommore » a non-dendritic solid precursor material that is specially prepared by a primary aluminum manufacturer, using continuous casting methods. Upon reheating this material into the mushy (a.k.a. "two-phase") zone, a thixotropic slurry is formed, which becomes the feed for the casting operation. In the rheocasting route (a.k.a. "slurry-on-demand" or "SoD"), one starts from the liquid state, and the thixotropic slurry is formed directly from the melt via careful thermal management of the system; the slurry is subsequently fed into the die cavity. Of these two routes, rheocasting is favored in that there is no premium added to the billet cost, and the scrap recycling issues are alleviated. The CRP (Trade Marked) is a process where the molten metal flows through a reactor prior to casting. The role of the reactor is to ensure that copious nucleation takes place and that the nuclei are well distributed throughout the system prior to entering the casting cavity. The CRP (Trade Marked) has been successfully applied in hyper-eutectic Al-Si alloys (i.e., 390 alloy) where two liquids of equal or different compositions and temperatures are mixed in the reactor and creating a SSM slurry. The process has been mostly used for hypo-eutectic Al-Si alloys (i.e., 356, 357, etc.) where a single melt passes through the reactor. In addition, the CRP (Trade Marked) was designed to be flexible for thixocasting or rheocasting applications as well as batch or continuous casting. Variable heat extraction rates can be obtained by controlling either the superheat of the melt, the temperature of the channel system, or the temperature of the reactor. This program had four main objectives all of which were focused on a mechanistic understanding of the process in order to be able to scale it up, to develop it into a robust process,and for SSM processing to be commercially used.« less

Improved resolution of 3D printed scaffolds by shrinking.

PubMed

Chia, Helena N; Wu, Benjamin M

2015-10-01

Three-dimensional printing (3DP) uses inkjet printheads to selectively deposit liquid binder to adjoin powder particles in a layer-by-layer fashion to create a computer-modeled 3D object. Two general approaches for 3DP have been described for biomedical applications (direct and indirect 3DP). The two approaches offer competing advantages, and both are limited by print resolution. This study describes a materials processing strategy to enhance 3DP resolution by controlled shrinking net-shape scaffolds. Briefly, porogen preforms are printed and infused with the desired monomer or polymer solution. After solidification or polymerization, the porogen is leached and the polymer is allowed to shrink by controlled drying. Heat treatment is performed to retain the dimensions against swelling forces. The main objective of this study is to determine the effects of polymer content and post-processing on dimension, microstructure, and thermomechanical properties of the scaffold. For polyethylene glycol diacrylate (PEG-DA), reducing polymer content corresponded with greater shrinkage with maximum shrinkage of ∼80 vol% at 20% vol% PEG-DA. The secondary heat treatment retains the microarchitecture and new dimensions of the scaffolds, even when the heat-treated scaffolds are immersed into water. To demonstrate shrinkage predictability, 3D components with interlocking positive and negative features were printed, processed, and fitted. This material processing strategy provides an alternative method to enhance the resolution of 3D scaffolds, for a wide range of polymers, without optimizing the binder-powder interaction physics to print each material combination. © 2014 Wiley Periodicals, Inc.

[Application of individual light-curing resin tray as edge plastic material in complete denture modulo].

PubMed

Chai, Mei; Tang, Xuyan; Liang, Guangku

2015-12-01

To investigate clinical effect of individual light-curing resin tray as edge plastic material in complete denture modulo.
 A total of 30 patients with poor condition for alveolar ridge of mandible were chosen individual tray with individual light-curing resin tray for material edge shaping or traditional individual impression tray for edge shaping cream to produce complete denture. The operability, questionnaire about denture retention, comfort, mucosal cases and chewing function in the process of shaping the edge were investigated three months later after wearing dentures.
 There was no significant difference in retention, comfort, mucosa and the chewing function between the two mandibular denture impression methods. However, the patients with individual light-curing resin tray as edge shaping material felt better in the process than that in the patients with die-cream as the edge shaping material (P<0.05). Furthermore, the manipulation with individual light-curing resin tray as edge shaping material is easy for doctor.
 Although the clinical effect of Individual light-curing resin tray material as the edge shaping material is equal to that of impression cream, it saves time and human resource. Moreover, it is more acceptable for the patients and thus it can be spread in clinics.

Form finding in elastic gridshells.

PubMed

Baek, Changyeob; Sageman-Furnas, Andrew O; Jawed, Mohammad K; Reis, Pedro M

2018-01-02

Elastic gridshells comprise an initially planar network of elastic rods that are actuated into a shell-like structure by loading their extremities. The resulting actuated form derives from the elastic buckling of the rods subjected to inextensibility. We study elastic gridshells with a focus on the rational design of the final shapes. Our precision desktop experiments exhibit complex geometries, even from seemingly simple initial configurations and actuation processes. The numerical simulations capture this nonintuitive behavior with excellent quantitative agreement, allowing for an exploration of parameter space that reveals multistable states. We then turn to the theory of smooth Chebyshev nets to address the inverse design of hemispherical elastic gridshells. The results suggest that rod inextensibility, not elastic response, dictates the zeroth-order shape of an actuated elastic gridshell. As it turns out, this is the shape of a common household strainer. Therefore, the geometry of Chebyshev nets can be further used to understand elastic gridshells. In particular, we introduce a way to quantify the intrinsic shape of the empty, but enclosed regions, which we then use to rationalize the nonlocal deformation of elastic gridshells to point loading. This justifies the observed difficulty in form finding. Nevertheless, we close with an exploration of concatenating multiple elastic gridshell building blocks.

Form finding in elastic gridshells

NASA Astrophysics Data System (ADS)

Baek, Changyeob; Sageman-Furnas, Andrew O.; Jawed, Mohammad K.; Reis, Pedro M.

2018-01-01

Elastic gridshells comprise an initially planar network of elastic rods that are actuated into a shell-like structure by loading their extremities. The resulting actuated form derives from the elastic buckling of the rods subjected to inextensibility. We study elastic gridshells with a focus on the rational design of the final shapes. Our precision desktop experiments exhibit complex geometries, even from seemingly simple initial configurations and actuation processes. The numerical simulations capture this nonintuitive behavior with excellent quantitative agreement, allowing for an exploration of parameter space that reveals multistable states. We then turn to the theory of smooth Chebyshev nets to address the inverse design of hemispherical elastic gridshells. The results suggest that rod inextensibility, not elastic response, dictates the zeroth-order shape of an actuated elastic gridshell. As it turns out, this is the shape of a common household strainer. Therefore, the geometry of Chebyshev nets can be further used to understand elastic gridshells. In particular, we introduce a way to quantify the intrinsic shape of the empty, but enclosed regions, which we then use to rationalize the nonlocal deformation of elastic gridshells to point loading. This justifies the observed difficulty in form finding. Nevertheless, we close with an exploration of concatenating multiple elastic gridshell building blocks.

Development of materials for the rapid manufacture of die cast tooling

NASA Astrophysics Data System (ADS)

Hardro, Peter Jason

The focus of this research is to develop a material composition that can be processed by rapid prototyping (RP) in order to produce tooling for the die casting process. Where these rapidly produced tools will be superior to traditional tooling production methods by offering one or more of the following advantages: reduced tooling cost, shortened tooling creation time, reduced man-hours for tool creation, increased tool life, and shortened die casting cycle time. By utilizing RP's additive build process and vast material selection, there was a prospect that die cast tooling may be produced quicker and with superior material properties. To this end, the material properties that influence die life and cycle time were determined, and a list of materials that fulfill these "optimal" properties were highlighted. Physical testing was conducted in order to grade the processability of each of the material systems and to optimize the manufacturing process for the downselected material system. Sample specimens were produced and microscopy techniques were utilized to determine a number of physical properties of the material system. Additionally, a benchmark geometry was selected and die casting dies were produced from traditional tool materials (H13 steel) and techniques (machining) and from the newly developed materials and RP techniques (selective laser sintering (SLS) and laser engineered net shaping (LENS)). Once the tools were created, a die cast alloy was selected and a preset number of parts were shot into each tool. During tool creation, the manufacturing time and cost was closely monitored and an economic model was developed to compare traditional tooling to RP tooling. This model allows one to determine, in the early design stages, when it is advantageous to implement RP tooling and when traditional tooling would be best. The results of the physical testing and economic analysis has shown that RP tooling is able to achieve a number of the research objectives, namely, reduce tooling cost, shorten tooling creation time, and reduce the man-hours needed for tool creation. Though identifying the appropriate time to use RP tooling appears to be the most important aspect in achieving successful implementation.

Neural-net Processed Electronic Holography for Rotating Machines

NASA Technical Reports Server (NTRS)

Decker, Arthur J.

2003-01-01

This report presents the results of an R&D effort to apply neural-net processed electronic holography to NDE of rotors. Electronic holography was used to generate characteristic patterns or mode shapes of vibrating rotors and rotor components. Artificial neural networks were trained to identify damage-induced changes in the characteristic patterns. The development and optimization of a neural-net training method were the most significant contributions of this work, and the training method and its optimization are discussed in detail. A second positive result was the assembly and testing of a fiber-optic holocamera. A major disappointment was the inadequacy of the high-speed-holography hardware selected for this effort, but the use of scaled holograms to match the low effective resolution of an image intensifier was one interesting attempt to compensate. This report also discusses in some detail the physics and environmental requirements for rotor electronic holography. The major conclusions were that neural-net and electronic-holography inspections of stationary components in the laboratory and the field are quite practical and worthy of continuing development, but that electronic holography of moving rotors is still an expensive high-risk endeavor.

Ceramics in Restorative and Prosthetic DENTISTRY1

NASA Astrophysics Data System (ADS)

Kelly, J. Robert

1997-08-01

This review is intended to provide the ceramic engineer with information about the history and current use of ceramics in dentistry, contemporary research topics, and potential research agenda. Background material includes intra-oral design considerations, descriptions of ceramic dental components, and the origin, composition, and microstructure of current dental ceramics. Attention is paid to efforts involving net-shape processing, machining as a forming method, and the analysis of clinical failure. A rationale is presented for the further development of all-ceramic restorative systems. Current research topics receiving attention include microstructure/processing/property relationships, clinical failure mechanisms and in vitro testing, wear damage and wear testing, surface treatments, and microstructural modifications. The status of the field is critically reviewed with an eye toward future work. Significant improvements seem possible in the clinical use of ceramics based on engineering solutions derived from the study of clinically failed restorations, on the incorporation of higher levels of "biomimicry" in new systems, and on the synergistic developments in dental cements and adhesive dentin bonding.

An Investigation into the Comparative Costs of Additive Manufacture vs. Machine from Solid for Aero Engine Parts

DTIC Science & Technology

2006-05-01

welding power sources are not totally efficient at converting power drawn from the wall into heat energy used for the welding process . TIG sources are...Powder bed + Laser • Wire + Laser • Wire + Electron Beam • Wire + TIG Each system has its own unique attributes in terms of process variables...relative economics of producing a near net shape by Additive Manufacturing (AM) processes compared with traditional machine from solid processes (MFS

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rawls, G.

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.more » 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.« less

Poly(Capro-Lactone) Networks as Actively Moving Polymers

NASA Astrophysics Data System (ADS)

Meng, Yuan

Shape-memory polymers (SMPs), as a subset of actively moving polymers, form an exciting class of materials that can store and recover elastic deformation energy upon application of an external stimulus. Although engineering of SMPs nowadays has lead to robust materials that can memorize multiple temporary shapes, and can be triggered by various stimuli such as heat, light, moisture, or applied magnetic fields, further commercialization of SMPs is still constrained by the material's incapability to store large elastic energy, as well as its inherent one-way shape-change nature. This thesis develops a series of model semi-crystalline shape-memory networks that exhibit ultra-high energy storage capacity, with accurately tunable triggering temperature; by introducing a second competing network, or reconfiguring the existing network under strained state, configurational chain bias can be effectively locked-in, and give rise to two-way shape-actuators that, in the absence of an external load, elongates upon cooling and reversibly contracts upon heating. We found that well-defined network architecture plays essential role on strain-induced crystallization and on the performance of cold-drawn shape-memory polymers. Model networks with uniform molecular weight between crosslinks, and specified functionality of each net-point, results in tougher, more elastic materials with a high degree of crystallinity and outstanding shape-memory properties. The thermal behavior of the model networks can be finely modified by introducing non-crystalline small molecule linkers that effectively frustrates the crystallization of the network strands. This resulted in shape-memory networks that are ultra-sensitive to heat, as deformed materials can be efficiently triggered to revert to its permanent state upon only exposure to body temperature. We also coupled the same reaction adopted to create the model network with conventional free-radical polymerization to prepare a dual-cure "double network" that behaves as a real thermal "actuator". This approach places sub-chains under different degrees of configurational bias within the network to utilize the material's propensity to undergo stress-induced crystallization. Reconfiguration of model shape-memory networks containing photo-sensitive linkages can also be employed to program two-way actuator. Chain reshuffling of a partially reconfigurable network is initiated upon exposure to light under specific strains. Interesting photo-induced creep and stress relaxation behaviors were demonstrated and understood based on a novel transient network model we derived. In summary, delicate manipulation of shape-memory network architectures addressed critical issues constraining the application of this type of functional polymer material. Strategies developed in this thesis may provide new opportunity to the field of shape-memory polymers.

Method and apparatus for making articles from particle based materials

DOEpatents

Moorhead, Arthur J.; Menchhofer, Paul A.

1995-01-01

A method and apparatus for the production of articles made of a particle-based material; e.g., ceramics and sintered metals. In accordance with the invention, a thermally settable slurry containing a relatively high concentration of the particles is conveyed through an elongate flow area having a desired cross-sectional configuration. The slurry is heated as it is advanced through the flow area causing the slurry to set or harden in a shape which conforms to the cross-sectional configuration of the flow area. The material discharges from the flow area as a self-supporting solid of near net final dimensions. The article may then be sintered to consolidate the particles and provide a high density product.

Investigation of plasma arc welding as a method for the additive manufacturing of titanium-(6)aluminum-(4)vanadium alloy components

NASA Astrophysics Data System (ADS)

Stavinoha, Joe N.

The process of producing near net-shape components by material deposition is known as additive manufacturing. All additive manufacturing processes are based on the addition of material with the main driving forces being cost reduction and flexibility in both manufacturing and product design. With wire metal deposition, metal is deposited as beads side-by-side and layer-by-layer in a desired pattern to build a complete component or add features on a part. There are minimal waste products, low consumables, and an efficient use of energy and feedstock associated with additive manufacturing processes. Titanium and titanium alloys are useful engineering materials that possess an extraordinary combination of properties. Some of the properties that make titanium advantageous for structural applications are its high strength-to-weight ratio, low density, low coefficient of thermal expansion, and good corrosion resistance. The most commonly used titanium alloy, Ti-6Al-4V, is typically used in aerospace applications, pressure vessels, aircraft gas turbine disks, cases and compressor blades, and surgical implants. Because of the high material prices associated with titanium alloys, the production of near net-shape components by additive manufacturing is an attractive option for the manufacturing of Ti-6Al-4V alloy components. In this thesis, the manufacturing of cylindrical Ti-6Al-4V alloy specimens by wire metal deposition utilizing the plasma arc welding process was demonstrated. Plasma arc welding is a cost effective additive manufacturing technique when compared to other current additive manufacturing methods such as laser beam welding and electron beam welding. Plasma arc welding is considered a high-energy-density welding processes which is desirable for the successful welding of titanium. Metal deposition was performed using a constant current plasma arc welding power supply, flow-purged welding chamber, argon shielding and orifice gas, ERTi-5 filler metal, and Ti-6Al-4V alloy substrates. Cylindrical weld metal deposits were built by employing an automatic wire feeder, turntable positioner, and vertical torch positioner. A total of four cylindrical weld metal specimens were built with various combinations of essential plasma arc welding process parameters. The temperature of the weld metal deposit was taken with a thermocouple after allowing a specified amount of time to pass before depositing the next weld track. An analytical heat flow model was created that estimated the temperature of the weld metal deposit in relation to the number of tracks deposited. The analytical heat flow model was adjusted to match the experimental data that was obtained and revealed that the rate of production could be increased if the rate of thermal energy losses from the deposit were increased. Cross-sections of the weld metal deposits were examined to observe the effects of thermal energy input on the weld metal macrostructure, microstructure, and grain size. Results from the metallographic inspections revealed an increase in grain size and coarsening of the structure as the number of weld tracks in the deposit increased.

Structural Integrity of an Electron Beam Melted Titanium Alloy.

PubMed

Lancaster, Robert; Davies, Gareth; Illsley, Henry; Jeffs, Spencer; Baxter, Gavin

2016-06-14

Advanced manufacturing encompasses the wide range of processes that consist of "3D printing" of metallic materials. One such method is Electron Beam Melting (EBM), a modern build technology that offers significant potential for lean manufacture and a capability to produce fully dense near-net shaped components. However, the manufacture of intricate geometries will result in variable thermal cycles and thus a transient microstructure throughout, leading to a highly textured structure. As such, successful implementation of these technologies requires a comprehensive assessment of the relationships of the key process variables, geometries, resultant microstructures and mechanical properties. The nature of this process suggests that it is often difficult to produce representative test specimens necessary to achieve a full mechanical property characterisation. Therefore, the use of small scale test techniques may be exploited, specifically the small punch (SP) test. The SP test offers a capability for sampling miniaturised test specimens from various discrete locations in a thin-walled component, allowing a full characterisation across a complex geometry. This paper provides support in working towards development and validation strategies in order for advanced manufactured components to be safely implemented into future gas turbine applications. This has been achieved by applying the SP test to a series of Ti-6Al-4V variants that have been manufactured through a variety of processing routes including EBM and investigating the structural integrity of each material and how this controls the mechanical response.

Demand and willingness-to-pay for bed nets in Tanzania: results from a choice experiment.

PubMed

Gingrich, Chris D; Ricotta, Emily; Kahwa, Amos; Kahabuka, Catherine; Koenker, Hannah

2017-07-14

Universal coverage campaigns for long-lasting insecticide-treated nets do not always reach the goal of one net for every two household members, and even when ownership of at least one net per household is high, many households may not own enough nets. The retail market provides these households options for replacing or increasing the number of nets they own with products that best fit their needs since a variety of net shapes, sizes, and colours are available. Hence, it is important to understand the factors affecting private net demand. This study explores private demand for nets in Tanzania using a discrete choice experiment. The experiment provides participants the option to buy nets with their own money, and thus should prove more accurate than a hypothetical survey of net preferences. Nearly 800 participants sampled in two regions showed an overall strong demand for nets, with 40% choosing to buy a net across all seven combinations of net prices and characteristics such as size, shape, and insecticide treatment. Only 8% of all participants chose not to buy a single net. A key factor influencing demand was whether a participant's household currently owned sufficient nets for all members, with rural participants showing lower net coverage and greater demand than urban participants. Both poor and less poor households showed strong evidence of making purchase decisions based on more than price alone. Mean willingness-to-pay values for a net started at US$1.10 and grew by US$0.50-1.40 for various attributes such as rectangular shape, large size, and insecticide treatment. The impact of price on demand was negative but small, with elasticity values between -0.25 and -0.45. The results suggest that private demand for nets in Tanzania could potentially supplement future coverage campaigns. Net manufacturers and retailers should advertise and promote consumers' preferred net attributes to improve sales and further expand net access and coverage. To overcome household liquidity concerns and best replicate the experiment results, policy makers should consider making credit available for interested buyers.

Productivity is a poor predictor of plant species richness

Treesearch

P.B. Adler; E.T. Borer; H. Hillebrand; Y. Hautier; A. Hector; S. Harpole; L.R. O’Halloran; J.B. Grace; M. Anderson; J.D. Bakker; L.A. Biederman; C.S. Brown; Y.M. Buckley; L.B. Calabrese; C.-J. Chu; E.E. Cleland; S.L. Collins; K.L. Cottingham; M.J. Crawley; E.I. Damschen; K.W. Davies; N.M. DeCrappeo; P.A. Fay; J. Firn; P. Frater; E.I. Gasarch; D.S. Gruner; N. Hagenah; J. Hille Ris Lambers

2011-01-01

For more than 30 years, the relationship between net primary productivity and species richness has generated intense debate in ecology about the processes regulating local diversity. The original view, which is still widely accepted, holds that the relationship is hump-shaped, with richness first rising and then declining with increasing productivity. Although recent...

Near Net Manufacturing Using Thin Gage Friction Stir Welding

NASA Technical Reports Server (NTRS)

Takeshita, Jennifer; Potter, David; Holquin, Michael

2006-01-01

Friction Stir Welding (FSW) and near net spin forming of FSW aluminumn blanks were investigated for large-scale pressure vessel applications. With a specific focus on very thin gage 2xxx and 7xxx aluminum alloys, the program concentrated on the following: the criteria used for material selection, a potential manufacturing flow, and the effectiveness and associated risks of near net spin forming. Discussion will include the mechanical properties of the friction stir welds and the parent material from before and after the spin forming process. This effort was performed under a NASA Space Exploration initiative focused on increasing the affordability, reliability and performance of pressure vessels larger than 10 ft. diameter.

Synthesis and evaluation of rare-earth doped glasses and crystals for optical refrigeration

NASA Astrophysics Data System (ADS)

Patterson, Wendy

This research focused on developing and characterizing rare-earth doped, solid-state materials for laser cooling. In particular, the work targeted the optimization of the lasercooling efficiency in Yb3+ and Tm3+ doped fluorides. The first instance of laser-induced cooling in a Tm3+-doped crystal, BaY2F8 was reported. Cooling by 3 degrees Kelvin below ambient temperature was obtained in a single-pass pump geometry at lambda = 1855 nm. Protocols were developed for materials synthesis and purification which can be applied to each component of ZBLANI:Yb 3+/Tm3+ (ZrF4 -- BaF2 -- LaF3 -- AlF3 -- NaF -- InF3: YbF3/TmF3) glass to enable a material with significantly reduced transition-metal impurities. A method for OH- impurity removal and ultra-drying of the metal fluorides was also improved upon. Several characterization tools were used to quantitatively and qualitatively verify purity, including inductively-coupled plasma mass spectrometry (ICP-MS). Here we found a more than 600-fold reduction in transition-metal impurities in a ZrCl2O solution. A non-contact spectroscopic technique for the measurement of laser-induced temperature changes in solids was developed. Two-band differential luminescence thermometry (TBDLT) achieved a sensitivity of ˜7 mK and enabled precise measurement of the zero-crossing temperature and net quantum efficiency. Several Yb3+-doped ZBLANI glasses fabricated from precursors of varying purity and by different processes were analyzed in detail by TBDLT. Laser-induced cooling was observed at room temperature for several of the materials. A net quantum efficiency of 97.39+/-0.01% at 238 K was found for the best ZBLANI:1%Yb 3+ laser-cooling sample produced from purified metal-fluoride precursors, and proved competitive with the best commercially procured material. The TBDLT technique enabled rapid and sensitive benchmarking of laser-cooling materials and provided critical feedback to the development and optimization of high-performance optical cryocooler materials. Also presented is an efficient and numerically stable method to calculate time-dependent, laser-induced temperature distributions in solids, including a detailed description of the computational procedure and its implementation. The model accurately predicted the zero-crossing temperature, the net quantum efficiency, and the functional shape of the transients, based on input parameters such as luminescence spectra, dopant concentration, pump properties, and several well-characterized material properties.

Effect of Al Addition on Microstructure of AZ91D

NASA Astrophysics Data System (ADS)

Joshi, Utsavi; Babu, Nadendla Hari

Casting is a net shape or near net shape forming process so work-hardening will not be applicable for improving properties of magnesium cast alloys. Grain refinement, solid-solution strengthening, precipitation hardening and specially designed heat treatment are the techniques used to enhance the properties of these alloys. This research focusses on grain refinement of magnesium alloy AZ91D, which is a widely used commercial cast alloy. Recently, Al-B based master alloys have shown potential in grain refining AZ91D. A comparative study of the grain refinement of AZ91D by addition of 0.02wt%B, 0.04wt%B, 0.1wt%B, 0.5wt%B and 1.0wt%B of A1-5B master alloy and equivalent amount of solute element aluminium is described in this paper. Hardness profile of AZ91D alloyed with boron and aluminium is compared.

Casting of weldable graphite/magnesium metal matrix composites with built-in metallic inserts

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.; Kashalikar, Uday; Majkowski, Patricia

1994-01-01

Technology innovations directed at the advanced development of a potentially low cost and weldable graphite/magnesium metal matrix composites (MMC) through near net shape pressure casting are described. These MMC components uniquely have built-in metallic inserts to provide an innovative approach for joining or connecting other MMC components through conventional joining techniques such as welding, brazing, mechanical fasteners, etc. Moreover, the metallic inserts trapped within the MMC components can be made to transfer the imposed load efficiently to the continuous graphite fiber reinforcement thus producing stronger, stiffer, and more reliable MMC components. The use of low pressure near net shape casting is economical compared to other MMC fabrication processes. These castable and potentially weldable MMC components can provide great payoffs in terms of high strength, high stiffness, low thermal expansion, lightweight, and easily joinable MMC components for several future NASA space structural, industrial, and commercial applications.

Development of a thermally-assisted piercing (TAP) process for introducing holes into thermoplastic composites

NASA Astrophysics Data System (ADS)

Brown, Nicholas W. A.

Composite parts can be manufactured to near-net shape with minimum wastage of material; however, there is almost always a need for further machining. The most common post-manufacture machining operations for composite materials are to create holes for assembly. This thesis presents and discusses a thermally-assisted piercing process that can be used as a technique for introducing holes into thermoplastic composites. The thermally-assisted piercing process heats up, and locally melts, thermoplastic composites to allow material to be displaced around a hole, rather than cutting them out from the structure. This investigation was concerned with how the variation of piercing process parameters (such as the size of the heated area, the temperature of the laminate prior to piercing and the geometry of the piercing spike) changed the material microstructure within carbon fibre/Polyetheretherketone (PEEK) laminates. The variation of process parameters was found to significantly affect the formation of resin rich regions, voids and the fibre volume fraction in the material surrounding the hole. Mechanical testing (using open-hole tension, open-hole compression, plain-pin bearing and bolted bearing tests) showed that the microstructural features created during piercing were having significant influence over the resulting mechanical performance of specimens. By optimising the process parameters strength improvements of up to 11% and 21% were found for pierced specimens when compared with drilled specimens for open-hole tension and compression loading, respectively. For plain-pin and bolted bearing tests, maximum strengths of 77% and 85%, respectively, were achieved when compared with drilled holes. Improvements in first failure force (by 10%) and the stress at 4% hole elongation (by 18%), however, were measured for the bolted bearing tests when compared to drilled specimens. The overall performance of pierced specimens in an industrially relevant application ultimately depends on the properties required for that specific scenario. The results within this thesis show that the piercing technique could be used as a direct replacement to drilling depending on this application.

Low Cost Fabrication of Silicon Carbide Based Ceramics and Fiber Reinforced Composites

NASA Technical Reports Server (NTRS)

Singh, M.; Levine, S. R.

1995-01-01

A low cost processing technique called reaction forming for the fabrication of near-net and complex shaped components of silicon carbide based ceramics and composites is presented. This process consists of the production of a microporous carbon preform and subsequent infiltration with liquid silicon or silicon-refractory metal alloys. The microporous preforms are made by the pyrolysis of a polymerized resin mixture with very good control of pore volume and pore size thereby yielding materials with tailorable microstructure and composition. Mechanical properties (elastic modulus, flexural strength, and fracture toughness) of reaction-formed silicon carbide ceramics are presented. This processing approach is suitable for various kinds of reinforcements such as whiskers, particulates, fibers (tows, weaves, and filaments), and 3-D architectures. This approach has also been used to fabricate continuous silicon carbide fiber reinforced ceramic composites (CFCC's) with silicon carbide based matrices. Strong and tough composites with tailorable matrix microstructure and composition have been obtained. Microstructure and thermomechanical properties of a silicon carbide (SCS-6) fiber reinforced reaction-formed silicon carbide matrix composites are discussed.

Microstructure and tensile properties after thermohydrogen processing of Ti-6 Al-4V.

PubMed

Guitar, A; Vigna, G; Luppo, M I

2009-04-01

Thermohydrogen processing (THP), a technique in which hydrogen is used as a temporary alloying element, can refine the microstructure and improve the final mechanical properties of the Ti-6 Al-4V alloy. THP allows microstructural modification of titanium alloys near net shape such as biomaterial components obtained by powder metallurgy and castings, since it does not require mechanical working. Two THP, called THP-A and THP-B, have been evaluated in samples of Ti-6Al-4V with a coarse and lamellar microstructure typical of castings and powder metallurgy. The THP-A is based in the eutectoid decomposition of the beta(H) phase to alpha phase and hydride phase. The THP-B is based in the isothermal decomposition of alpha('') martensite phase, obtained by quenching of hydrogenated samples. The refinement of the microstructure due to THP has been evaluated by means of optical and electron microscopy. Tensile tests showed that while both processes were able to increase the strength of the alloy as compared with the starting material, the ductility in samples subjected to THP-B was severely reduced.

A novel frequency tuned wireless actuator with snake-like motion

NASA Astrophysics Data System (ADS)

Zhang, Kewei; Zhu, Qianke; Chai, Yuesheng

2016-07-01

In this work, we propose a novel wireless actuator which is composed of magnetostrictive material/copper bi-layer film. The actuator can be controlled to move like a snake bi-directionally along a pipe by tuning the frequency of external magnetic field near its first order resonant frequency. The governing equation for the actuator is established and the vibration mode shape function is derived. Theoretical analysis shows that motion of the actuator is achieved by asymmetric vibration mode shape, specific vibration bending deformation, and effective net total impacting force. The simulation and experimental results well confirm the theoretical analysis. This work provides contribution to the development of wireless micro robots and autonomous magnetostrictive sensors.

Comparative shock response of additively manufactured versus conventionally wrought 304L stainless steel

NASA Astrophysics Data System (ADS)

Wise, J. L.; Adams, D. P.; Nishida, E. E.; Song, B.; Maguire, M. C.; Carroll, J.; Reedlunn, B.; Bishop, J. E.; Palmer, T. A.

2017-01-01

Gas-gun experiments have probed the compression and release behavior of impact-loaded 304L stainless steel specimens that were machined from additively manufactured (AM) blocks as well as baseline ingot-derived bar stock. The AM technology permits direct fabrication of net- or near-net-shape metal parts. For the present investigation, velocity interferometer (VISAR) diagnostics provided time-resolved measurements of sample response for one-dimensional (i.e., uniaxial strain) shock compression to peak stresses ranging from 0.2 to 7.0 GPa. The acquired wave-profile data have been analyzed to determine the comparative Hugoniot Elastic Limit (HEL), Hugoniot equation of state, spall strength, and high-pressure yield strength of the AM and conventional materials. The possible contributions of various factors, such as composition, porosity, microstructure (e.g., grain size and morphology), residual stress, and/or sample axis orientation relative to the additive manufacturing deposition trajectory, are considered to explain differences between the AM and baseline 304L dynamic material results.

A mobile ferromagnetic shape detection sensor using a Hall sensor array and magnetic imaging.

PubMed

Misron, Norhisam; Shin, Ng Wei; Shafie, Suhaidi; Marhaban, Mohd Hamiruce; Mailah, Nashiren Farzilah

2011-01-01

This paper presents a mobile Hall sensor array system for the shape detection of ferromagnetic materials that are embedded in walls or floors. The operation of the mobile Hall sensor array system is based on the principle of magnetic flux leakage to describe the shape of the ferromagnetic material. Two permanent magnets are used to generate the magnetic flux flow. The distribution of magnetic flux is perturbed as the ferromagnetic material is brought near the permanent magnets and the changes in magnetic flux distribution are detected by the 1-D array of the Hall sensor array setup. The process for magnetic imaging of the magnetic flux distribution is done by a signal processing unit before it displays the real time images using a netbook. A signal processing application software is developed for the 1-D Hall sensor array signal acquisition and processing to construct a 2-D array matrix. The processed 1-D Hall sensor array signals are later used to construct the magnetic image of ferromagnetic material based on the voltage signal and the magnetic flux distribution. The experimental results illustrate how the shape of specimens such as square, round and triangle shapes is determined through magnetic images based on the voltage signal and magnetic flux distribution of the specimen. In addition, the magnetic images of actual ferromagnetic objects are also illustrated to prove the functionality of mobile Hall sensor array system for actual shape detection. The results prove that the mobile Hall sensor array system is able to perform magnetic imaging in identifying various ferromagnetic materials.

A Mobile Ferromagnetic Shape Detection Sensor Using a Hall Sensor Array and Magnetic Imaging

PubMed Central

Misron, Norhisam; Shin, Ng Wei; Shafie, Suhaidi; Marhaban, Mohd Hamiruce; Mailah, Nashiren Farzilah

2011-01-01

This paper presents a Mobile Hall Sensor Array system for the shape detection of ferromagnetic materials that are embedded in walls or floors. The operation of the Mobile Hall Sensor Array system is based on the principle of magnetic flux leakage to describe the shape of the ferromagnetic material. Two permanent magnets are used to generate the magnetic flux flow. The distribution of magnetic flux is perturbed as the ferromagnetic material is brought near the permanent magnets and the changes in magnetic flux distribution are detected by the 1-D array of the Hall sensor array setup. The process for magnetic imaging of the magnetic flux distribution is done by a signal processing unit before it displays the real time images using a netbook. A signal processing application software is developed for the 1-D Hall sensor array signal acquisition and processing to construct a 2-D array matrix. The processed 1-D Hall sensor array signals are later used to construct the magnetic image of ferromagnetic material based on the voltage signal and the magnetic flux distribution. The experimental results illustrate how the shape of specimens such as square, round and triangle shapes is determined through magnetic images based on the voltage signal and magnetic flux distribution of the specimen. In addition, the magnetic images of actual ferromagnetic objects are also illustrated to prove the functionality of Mobile Hall Sensor Array system for actual shape detection. The results prove that the Mobile Hall Sensor Array system is able to perform magnetic imaging in identifying various ferromagnetic materials. PMID:22346653

Extending the Performance of Net Shape Molded Fiber Reinforced Polymer Composite Valves for Use in Internal Combustion Engines

DTIC Science & Technology

2007-06-01

management has been of increasingly significant importance. The combination of conventional materials and heat pipes have been applied in designs to take...chemical heat exchangers 87. In another spacecraft application, a carbon fiber face sheets with aluminum heat pipes embedded in an aluminum honeycomb...core were developed to replace an older all aluminum design. The heat pipes use ammonia as the working fluid. The new design improved thermal performance

Ultrasonic assessment of additive manufactured Ti-6Al-4V

NASA Astrophysics Data System (ADS)

Schehl, Norman; Kramb, Vicki; Dierken, Josiah; Aldrin, John; Schwalbach, Edwin; John, Reji

2018-04-01

Additive Manufacturing (AM) processes offer the potential for manufacturing cost savings and rapid insertion into service through production of near net shape components for complicated structures. Use of these parts in high reliability applications such as those in the aerospace industry will require nondestructive characterization methods to ensure post-process material quality in as-built condition. Ultrasonic methods can be used for this quality verification. Depending on the application, the service life of AM components can be sensitive to the part surface condition. The surface roughness and layered structure inherent to the electron-beam powder-bed fusion process necessitates new approaches to evaluate subsurface material integrity in its presence. Experimental methods and data analytics may improve the evaluation of as-built additively manufactured materials. This paper discusses the assessment of additively manufactured EBM Ti-6Al-4V panels using ultrasonic methods and the data analytics applied to evaluate material integrity. The assessment was done as an exploratory study as the discontinuities of interest in these test samples were not known when the measurements were performed. Water immersion ultrasonic techniques, including pulse-echo and through transmission with 10 MHz focused transducers, were used to explore the material integrity of as-built plates. Subsequent destructive mechanical tests of specimens extracted from the plates provided fracture locations indicating critical flaws. To further understand the effect of surface-roughness, an evaluation of ultrasonic response in the presence of as-built surfaces and with the surface removed was performed. The assessment of additive manufactured EBM Ti-6Al-4V panels with ultrasonic techniques indicated that ultrasonic energy was attenuated by the as-built surface roughness. In addition, feature detection was shown to be sensitive to experimental ultrasonic parameters and flaw morphology.

Shuttle Net, Tuna Net

NASA Technical Reports Server (NTRS)

1983-01-01

Rockwell International, NASA's prime contractor for the Space Shuttle, asked West Coast Netting (WCN) to develop a safety net for personnel working on the Shuttle Orbiter. This could not be an ordinary net, it had to be relatively small, yet have extraordinary tensile strength. It also had to be fire resistant and resistant to ultraviolet (UV) light. After six months, WCN found the requisite fiber, a polyester-like material called NOMEX. The company was forced to invent a more sophisticated twisting process since conventional methods did not approach specified breaking strength. The resulting product, the Hyperester net, sinks faster and fishes deeper, making it attractive to fishing fleets. A patented treatment for UV protection and greater abrasion resistance make Hyperester nets last longer, and the no-shrink feature is an economic bonus.

Apparatus and process for freeform fabrication of composite reinforcement preforms

NASA Technical Reports Server (NTRS)

Yang, Junsheng (Inventor); Wu, Liangwei (Inventor); Liu, Junhai (Inventor); Jang, Bor Z. (Inventor)

2001-01-01

A solid freeform fabrication process and apparatus for making a three-dimensional reinforcement shape. The process comprises the steps of (1) operating a multiple-channel material deposition device for dispensing a liquid adhesive composition and selected reinforcement materials at predetermined proportions onto a work surface; (2) during the material deposition process, moving the deposition device and the work surface relative to each other in an X-Y plane defined by first and second directions and in a Z direction orthogonal to the X-Y plane so that the materials are deposited to form a first layer of the shape; (3) repeating these steps to deposit multiple layers for forming a three-dimensional preform shape; and (4) periodically hardening the adhesive to rigidize individual layers of the preform. These steps are preferably executed under the control of a computer system by taking additional steps of (5) creating a geometry of the shape on the computer with the geometry including a plurality of segments defining the preform shape and each segment being preferably coded with a reinforcement composition defining a specific proportion of different reinforcement materials; (6) generating programmed signals corresponding to each of the segments in a predetermined sequence; and (7) moving the deposition device and the work surface relative to each other in response to these programmed signals. Preferably, the system is also operated to generate a support structure for any un-supported feature of the 3-D preform shape.

High Temperature Deformation Mechanisms in a DLD Nickel Superalloy

PubMed Central

Davies, Sean; Jeffs, Spencer; Lancaster, Robert; Baxter, Gavin

2017-01-01

The realisation of employing Additive Layer Manufacturing (ALM) technologies to produce components in the aerospace industry is significantly increasing. This can be attributed to their ability to offer the near-net shape fabrication of fully dense components with a high potential for geometrical optimisation, all of which contribute to subsequent reductions in material wastage and component weight. However, the influence of this manufacturing route on the properties of aerospace alloys must first be fully understood before being actively applied in-service. Specimens from the nickel superalloy C263 have been manufactured using Powder Bed Direct Laser Deposition (PB-DLD), each with unique post-processing conditions. These variables include two build orientations, vertical and horizontal, and two different heat treatments. The effects of build orientation and post-process heat treatments on the materials’ mechanical properties have been assessed with the Small Punch Tensile (SPT) test technique, a practical test method given the limited availability of PB-DLD consolidated material. SPT testing was also conducted on a cast C263 variant to compare with PB-DLD derivatives. At both room and elevated temperature conditions, differences in mechanical performances arose between each material variant. This was found to be instigated by microstructural variations exposed through microscopic and Energy Dispersive X-ray Spectroscopy (EDS) analysis. SPT results were also compared with available uniaxial tensile data in terms of SPT peak and yield load against uniaxial ultimate tensile and yield strength. PMID:28772817

Near-Net Shape Powder Metallurgy Rhenium Thruster

NASA Technical Reports Server (NTRS)

Leonhardt, Todd; Hamister, Mark; Carlen, Jan C.; Biaglow, James; Reed, Brian

2001-01-01

This paper describes the development of a method to produce a near-net shape (NNS) powder metallurgy (PM) rhenium combustion chamber of the size 445 N (100 lbf) used in a high performance liquid apogee engine. These engines are used in low earth Orbit and geostationary orbit for satellite positioning systems. The developments in near-net shape powder metallurgy rhenium combustion chambers reported in this paper will reduce manufacturing cost of the rhenium chambers by 25 percent, and reduce the manufacturing time by 30 to 40 percent. The quantity of rhenium metal powder used to produce a rhenium chamber is reduced by approximately 70 percent and the subsequent reduction in machining schedule and costs is nearly 50 percent.

Properties of open-cell porous metals and alloys for orthopaedic applications.

PubMed

Lewis, Gladius

2013-10-01

One shortcoming of metals and alloys used to fabricate various components of orthopaedic systems, such as the femoral stem of a total hip joint replacement and the tibial plate of a total knee joint replacement, is well-recognized. This is that the material modulus of elasticity (E') is substantially larger than that of the contiguous cancellous bone, a consequence of which is stress shielding which, in turn, has been postulated to be implicated in a cascade of events that culminates in the principal life-limiting phenomenon of these systems, namely, aseptic loosening. Thus, over the years, a host of research programs have focused on the synthesis of metallic biomaterials whose E' can be tailored to match that of cancellous bone. The present work is a review of the extant large volume of literature on these materials, which are called open-cell porous metals/alloys (or, sometimes, metal foams or cellular materials). As such, its range is wide, covering myriad aspects such as production methods, characterization studies, in vitro evaluations, and in vivo performance. The review also includes discussion of seven areas for future research, such as parametric studies of the influence of an assortment of process variables (such as the space holder material and the laser power in the space holder method and the laser-engineered net-shaping process, respectively) on various properties (notably, permeability, fatigue strength, and corrosion resistance) of a given porous metal/alloy, innovative methods of determining fatigue strength, and modeling of corrosion behavior.

Characterization of mechanical properties of pseudoelastic shape memory alloys under harmonic excitation

NASA Astrophysics Data System (ADS)

Böttcher, J.; Jahn, M.; Tatzko, S.

2017-12-01

Pseudoelastic shape memory alloys exhibit a stress-induced phase transformation which leads to high strains during deformation of the material. The stress-strain characteristic during this thermomechanical process is hysteretic and results in the conversion of mechanical energy into thermal energy. This energy conversion allows for the use of shape memory alloys in vibration reduction. For the application of shape memory alloys as vibration damping devices a dynamic modeling of the material behavior is necessary. In this context experimentally determined material parameters which accurately represent the material behavior are essential for a reliable material model. Subject of this publication is the declaration of suitable material parameters for pseudoelastic shape memory alloys and the methodology of their identification from experimental investigations. The used test rig was specifically designed for the characterization of pseudoelastic shape memory alloys.

Method for Forming Fiber Reinforced Composite Bodies with Graded Composition and Stress Zones

NASA Technical Reports Server (NTRS)

Singh, Mrityunjay (Inventor); Levine, Stanley R. (Inventor); Smialek, James A. (Inventor)

1999-01-01

A near-net, complex shaped ceramic fiber reinforced silicon carbide based composite bodies with graded compositions and stress zones is disclosed. To provide the composite a fiber preform is first fabricated and an interphase is applied by chemical vapor infiltration, sol-gel or polymer processes. This first body is further infiltrated with a polymer mixture containing carbon, and/or silicon carbide, and additional oxide, carbide, or nitride phases forming a second body. One side of the second body is spray coated or infiltrated with slurries containing high thermal expansion and oxidation resistant. crack sealant phases and the other side of this second body is coated with low expansion phase materials to form a third body. This third body consisting of porous carbonaceous matrix surrounding the previously applied interphase materials, is then infiltrated with molten silicon or molten silicon-refractory metal alloys to form a fourth body. The resulting fourth body comprises dense composites consisting of fibers with the desired interphase which are surrounded by silicon carbide and other second phases materials at the outer and inner surfaces comprising material of silicon, germanium, refractory metal suicides, borides, carbides, oxides, and combinations thereof The resulting composite fourth body has different compositional patterns from one side to the other.

Networks of myelin covariance

PubMed Central

Slater, David; Ruef, Anne; Sanabria‐Diaz, Gretel; Preisig, Martin; Kherif, Ferath; Draganski, Bogdan; Lutti, Antoine

2017-01-01

Abstract Networks of anatomical covariance have been widely used to study connectivity patterns in both normal and pathological brains based on the concurrent changes of morphometric measures (i.e., cortical thickness) between brain structures across subjects (Evans, 2013). However, the existence of networks of microstructural changes within brain tissue has been largely unexplored so far. In this article, we studied in vivo the concurrent myelination processes among brain anatomical structures that gathered together emerge to form nonrandom networks. We name these “networks of myelin covariance” (Myelin‐Nets). The Myelin‐Nets were built from quantitative Magnetization Transfer data—an in‐vivo magnetic resonance imaging (MRI) marker of myelin content. The synchronicity of the variations in myelin content between anatomical regions was measured by computing the Pearson's correlation coefficient. We were especially interested in elucidating the effect of age on the topological organization of the Myelin‐Nets. We therefore selected two age groups: Young‐Age (20–31 years old) and Old‐Age (60–71 years old) and a pool of participants from 48 to 87 years old for a Myelin‐Nets aging trajectory study. We found that the topological organization of the Myelin‐Nets is strongly shaped by aging processes. The global myelin correlation strength, between homologous regions and locally in different brain lobes, showed a significant dependence on age. Interestingly, we also showed that the aging process modulates the resilience of the Myelin‐Nets to damage of principal network structures. In summary, this work sheds light on the organizational principles driving myelination and myelin degeneration in brain gray matter and how such patterns are modulated by aging. PMID:29271053

Predicting shrinkage and warpage in injection molding: Towards automatized mold design

NASA Astrophysics Data System (ADS)

Zwicke, Florian; Behr, Marek; Elgeti, Stefanie

2017-10-01

It is an inevitable part of any plastics molding process that the material undergoes some shrinkage during solidification. Mainly due to unavoidable inhomogeneities in the cooling process, the overall shrinkage cannot be assumed as homogeneous in all volumetric directions. The direct consequence is warpage. The accurate prediction of such shrinkage and warpage effects has been the subject of a considerable amount of research, but it is important to note that this behavior depends greatly on the type of material that is used as well as the process details. Without limiting ourselves to any specific properties of certain materials or process designs, we aim to develop a method for the automatized design of a mold cavity that will produce correctly shaped moldings after solidification. Essentially, this can be stated as a shape optimization problem, where the cavity shape is optimized to fulfill some objective function that measures defects in the molding shape. In order to be able to develop and evaluate such a method, we first require simulation methods for the diffierent steps involved in the injection molding process that can represent the phenomena responsible for shrinkage and warpage ina sufficiently accurate manner. As a starting point, we consider the solidification of purely amorphous materials. In this case, the material slowly transitions from fluid-like to solid-like behavior as it cools down. This behavior is modeled using adjusted viscoelastic material models. Once the material has passed a certain temperature threshold during cooling, any viscous effects are neglected and the behavior is assumed to be fully elastic. Non-linear elastic laws are used to predict shrinkage and warpage that occur after this point. We will present the current state of these simulation methods and show some first approaches towards optimizing the mold cavity shape based on these methods.

Process Control and Development for Ultrasonic Additive Manufacturing with Embedded Fibers

NASA Astrophysics Data System (ADS)

Hehr, Adam J.

Ultrasonic additive manufacturing (UAM) is a recent additive manufacturing technology which combines ultrasonic metal welding, CNC machining, and mechanized foil layering to create large gapless near net-shape metallic parts. The process has been attracting much attention lately due to its low formation temperature, the capability to join dissimilar metals, and the ability to create complex design features not possible with traditional subtractive processes alone. These process attributes enable light-weighting of structures and components in an unprecedented way. However, UAM is currently limited to niche areas due to the lack of quality tracking and inadequate scientific understanding of the process. As a result, this thesis work is focused on improving both component quality tracking and process understanding through the use of average electrical power input to the welder. Additionally, the understanding and application space of embedding fibers into metals using UAM is investigated, with particular focus on NiTi shape memory alloy fibers.

Strengthening of ferrous binder jet 3D printed components through bronze infiltration

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cordero, Zachary C.; Siddel, Derek H.; Peter, William H.

Fully-dense, net shape objects have been fabricated from a rapidly-solidified ferrous powder using binder-jet 3D printing and molten bronze infiltration. X-ray diffraction, scanning electron microscopy, and differential thermal analysis were used to characterize the structural evolution of the powder feedstock during an infiltration heating cycle. Microindentation and bend tests were performed on the infiltrated material to evaluate its mechanical properties. The infiltrated material had an 11 GPa hardness and moderate damage tolerance. It was found that infiltration improved both the ductility and strength of the sintered preforms by eliminating the stress concentration at the interparticle necks.

Strengthening of ferrous binder jet 3D printed components through bronze infiltration

DOE PAGES

Cordero, Zachary C.; Siddel, Derek H.; Peter, William H.; ...

2017-04-08

Fully-dense, net shape objects have been fabricated from a rapidly-solidified ferrous powder using binder-jet 3D printing and molten bronze infiltration. X-ray diffraction, scanning electron microscopy, and differential thermal analysis were used to characterize the structural evolution of the powder feedstock during an infiltration heating cycle. Microindentation and bend tests were performed on the infiltrated material to evaluate its mechanical properties. The infiltrated material had an 11 GPa hardness and moderate damage tolerance. It was found that infiltration improved both the ductility and strength of the sintered preforms by eliminating the stress concentration at the interparticle necks.

Uniform-droplet spray forming

DOE Office of Scientific and Technical Information (OSTI.GOV)

Blue, C.A.; Sikka, V.K.; Chun, Jung-Hoon

1997-04-01

The uniform-droplet process is a new method of liquid-metal atomization that results in single droplets that can be used to produce mono-size powders or sprayed-on to substrates to produce near-net shapes with tailored microstructure. The mono-sized powder-production capability of the uniform-droplet process also has the potential of permitting engineered powder blends to produce components of controlled porosity. Metal and alloy powders are commercially produced by at least three different methods: gas atomization, water atomization, and rotating disk. All three methods produce powders of a broad range in size with a very small yield of fine powders with single-sized droplets thatmore » can be used to produce mono-size powders or sprayed-on substrates to produce near-net shapes with tailored microstructures. The economical analysis has shown the process to have the potential of reducing capital cost by 50% and operating cost by 37.5% when applied to powder making. For the spray-forming process, a 25% savings is expected in both the capital and operating costs. The project is jointly carried out at Massachusetts Institute of Technology (MIT), Tuffs University, and Oak Ridge National Laboratory (ORNL). Preliminary interactions with both finished parts and powder producers have shown a strong interest in the uniform-droplet process. Systematic studies are being conducted to optimize the process parameters, understand the solidification of droplets and spray deposits, and develop a uniform-droplet-system (UDS) apparatus appropriate for processing engineering alloys.« less

Studies on Automated Manufacturing of High Performance Composites

NASA Technical Reports Server (NTRS)

Cano, R. J.; Belvin, H. L.; Hulcher, A. B.; Grenoble, R. W.

2001-01-01

The NASA Langley Research Center fiber placement facility has proven to be a valuable asset for obtaining data, experience, and insights into the automated fabrication of high performance composites. The facility consists of two automated devices: an Asea Brown Boveri (ABB) robotic arm with a modified heated head capable of hot gas and focused infrared heating and a 7' x 17' gantry containing a feeder head, rotating platform, focused infrared lamp and e-beam gun. While uncured thermoset tow and tape, e.g., epoxy and cyanate prepreg, can be placed with a robot, the placement facility s most powerful attribute is the ability to place thermoplastic and e-beam curable material to net shape. In recent years, ribbonizing techniques have been developed to make high quality thermoplastic and thermoset dry material forms to the standards required for robotic placement. A variety of composites have been fabricated from these ribbons by heated head tow and tape placement including both flat plates and cylinders. Composite mechanical property values of the former were between 85 and 100 percent of those obtained by hand lay-up/autoclave processing.

Modeling of the flow behavior of SAE 8620H combing microstructure evolution in hot forming

NASA Astrophysics Data System (ADS)

Fu, Xiaobin; Wang, Baoyu; Tang, Xuefeng

2017-10-01

With the development of net-shape forming technology, hot forming process is widely applied to manufacturing gear parts, during which, materials suffer severe plastic distortion and microstructure changes continually. In this paper, to understand and model the flow behavior and microstructure evolution, SAE 8620H, a widely used gear steel, is selected as the object and the flow behavior and microstructure evolution are observed by an isothermal hot compression tests at 1273-1373 K with a strain rate of 0.1-10 s-1. Depending on the results of the compression test, a set of internal-state-variable based unified constitutive equations is put forward to describe the flow behavior and microstructure evaluation of SAE 8620H. Moreover, the evaluation of the dislocation density and the fraction of dynamic recrystallization based on the theory of thermal activation is modeled and reincorporated into the constitutive law. The material parameters in the constitutive model are calculated based on the measured flow stress and dynamic recrystallization fraction. The predicted flow stress under different deformation conditions has a good agreement with the measured results.

Automated Fabrication of High Performance Composites: An Overview of Research at the Langley Research Center

NASA Technical Reports Server (NTRS)

Johnston, N. J.; Towell, T. W.; Marchello, J. M.; Grenoble, R. W.

1997-01-01

Automated heated placement of consolidated fiber reinforced polymer ribbon/tape is a rapid, cost effective technique for net shape fabrication of high performance composites. Several research efforts in the United States are developing the heated head robotic hardware and associated software needed to bring this technology into widespread use for building aircraft parts. These efforts emphasize the use of pre-consolidated thermoplastic ribbon or tape which is thermally welded on-the-fly . The approach provides in-situ consolidation and obviates the need for autoclave processing and massive debulking, thereby reducing costs. Addressed in this paper are some key issues being pursued at NASA Langley related to this technology. These include: (a) preparation of high quality intermediate materials forms such as thermoplastic powders, powder-coated towpreg and consolidated ribbon/tape and (b) achievement of precise control of the following: robot head positioning on the tool; material placement; heat delivery to the lay-down zone; and cut/add, start/stop capability. Heated head development has dealt with the use of hot gases alone and in combination with focused infrared radiation as heat sources.

Homogenization and texture development in rapidly solidified AZ91E consolidated by Shear Assisted Processing and Extrusion (ShAPE)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Overman, N. R.; Whalen, S. A.; Bowden, M. E.

Shear Assisted Processing and Extrusion (ShAPE) -a novel processing route that combines high shear and extrusion conditions- was evaluated as a processing method to densify melt spun magnesium alloy (AZ91E) flake materials. This study illustrates the microstructural regimes and transitions in crystallographic texture that occur as a result of applying simultaneous linear and rotational shear during extrusion. Characterization of the flake precursor and extruded tube was performed using scanning and transmission electron microscopy, x-ray diffraction and microindentation techniques. Results show a unique transition in the orientation of basal texture development. Despite the high temperatures involved during processing, uniform grain refinementmore » and material homogenization are observed. These results forecast the ability to implement the ShAPE processing approach for a broader range of materials with novel microstructures and high performance.« less

Development of a Scale to Explore Technology Literacy Skills of Turkish 8th Graders

ERIC Educational Resources Information Center

Misirli, Zeynel A.; Akbulut, Yavuz

2013-01-01

The use of emerging technologies shape learners' knowledge creation and transformation processes. In this regard, this study aimed to develop a scale to investigate 8 th graders' competencies regarding the educational technology standards based on ISTE-NETS. After a review of relevant literature, an item pool was prepared. The pool was improved…

Optics-Only Calibration of a Neural-Net Based Optical NDE Method for Structural Health Monitoring

NASA Technical Reports Server (NTRS)

Decker, Arthur J.

2004-01-01

A calibration process is presented that uses optical measurements alone to calibrate a neural-net based NDE method. The method itself detects small changes in the vibration mode shapes of structures. The optics-only calibration process confirms previous work that the sensitivity to vibration-amplitude changes can be as small as 10 nanometers. A more practical value in an NDE service laboratory is shown to be 50 nanometers. Both model-generated and experimental calibrations are demonstrated using two implementations of the calibration technique. The implementations are based on previously published demonstrations of the NDE method and an alternative calibration procedure that depends on comparing neural-net and point sensor measurements. The optics-only calibration method, unlike the alternative method, does not require modifications of the structure being tested or the creation of calibration objects. The calibration process can be used to test improvements in the NDE process and to develop a vibration-mode-independence of damagedetection sensitivity. The calibration effort was intended to support NASA s objective to promote safety in the operations of ground test facilities or aviation safety, in general, by allowing the detection of the gradual onset of structural changes and damage.

A Winning Cast

NASA Technical Reports Server (NTRS)

2001-01-01

Howmet Research Corporation was the first to commercialize an innovative cast metal technology developed at Auburn University, Auburn, Alabama. With funding assistance from NASA's Marshall Space Flight Center, Auburn University's Solidification Design Center (a NASA Commercial Space Center), developed accurate nickel-based superalloy data for casting molten metals. Through a contract agreement, Howmet used the data to develop computer model predictions of molten metals and molding materials in cast metal manufacturing. Howmet Metal Mold (HMM), part of Howmet Corporation Specialty Products, of Whitehall, Michigan, utilizes metal molds to manufacture net shape castings in various alloys and amorphous metal (metallic glass). By implementing the thermophysical property data from by Auburn researchers, Howmet employs its newly developed computer model predictions to offer customers high-quality, low-cost, products with significantly improved mechanical properties. Components fabricated with this new process replace components originally made from forgings or billet. Compared with products manufactured through traditional casting methods, Howmet's computer-modeled castings come out on top.

Plasma Chamber Design and Fabrication Activities

NASA Astrophysics Data System (ADS)

Parodi, B.; Bianchi, A.; Cucchiaro, A.; Coletti, A.; Frosi, P.; Mazzone, G.; Pizzuto, A.; Ramogida, G.; Coppi, B.

2006-10-01

A fabrication procedure for a typical Plasma Chamber (PC) sector has been developed to cover all the manufacturing phases, from the raw materials specification (including metallurgical processes) to the machining operations, acceptance procedures and vacuum tests. Basically, the sector is made of shaped elements (forged or rolled) welded together using special fixtures and then machined to achieve the final dimensional accuracy. An upgraded design of the plasma chamber's vertical support that can withstand the estimated electromagnetic loads (Eddy and Halo current plus horizontal net force resulting from the worst plasma disruption scenario VDE, Vertical Displacement Event) has been completed. The maintenance of the radial support can take place hands-on with a direct access from outside the cryostat. With the present design, vacuum tightness is achieved by welding conducted with automatic welding heads. On the outer surface of the PC a dedicated duct system, filled by helium gas, is included to cool down the PC to room temperature when needed.

Quantitative characterization of porosity in stainless steel LENS powders and deposits

DOE Office of Scientific and Technical Information (OSTI.GOV)

Susan, D.F.; Puskar, J.D.; Brooks, J.A.

2006-07-15

Laser Engineered Net Shaping (LENS) utilizes a laser beam to melt fine powders to produce three-dimensional engineering structures line by line and layer by layer. When building these structures, defects including lack-of-fusion (LOF) at interlayer boundaries and intralayer porosity are sometimes observed. LOF defects can be minimized by adjusting processing parameters, but the sources of intralayer porosity are less apparent. In this paper, the amount and size distributions of 17-4PH and 304L powders and pores within the powder were characterized in parallel with the intralayer porosity in LENS deposits fabricated from the same materials. Intralayer porosity increased with increased powdermore » porosity; but was not well correlated with deposition parameters. The results demonstrate the importance of careful characterization and specification of starting powders on the quality of the final LENS deposits.« less

Dysprosium-free melt-spun permanent magnets.

PubMed

Brown, D N; Wu, Z; He, F; Miller, D J; Herchenroeder, J W

2014-02-12

Melt-spun NdFeB powders can be formed into a number of different types of permanent magnet for a variety of applications in electronics, automotive and clean technology industries. The melt-spinning process produces flake powder with a fine uniform array of nanoscale Nd2Fe14B grains. These powders can be net-shape formed into isotropic polymer-bonded magnets or hot formed into fully dense magnets. This paper discusses the influence of heavy rare earth elements and microstructure on the magnetic performance, thermal stability and material cost of NdFeB magnets. Evidence indicates that melt-spun nanocrystalline NdFeB magnets are less dependent on heavy rare earth elements for high-temperature performance than the alternative coarser-grained sintered NdFeB magnets. In particular, hot-pressed melt-spun magnets are an attractive low-cost solution for applications that require thermal stability up to 175-200 °C.

Graphite fiber textile preform/copper matrix composites

NASA Technical Reports Server (NTRS)

Gilatovs, G. J.; Lee, Bruce; Bass, Lowell

1995-01-01

Graphite fiber reinforced/copper matrix composites have sufficiently high thermal conduction to make them candidate materials for critical heat transmitting and rejection components. The term textile composites arises because the preform is braided from fiber tows, conferring three-dimensional reinforcement and near net shape. The principal issues investigated in the past two years have centered on developing methods to characterize the preform and fabricated composite and on braidability. It is necessary to have an analytic structural description for both processing and final property modeling. The structure of the true 3-D braids used is complex and has required considerable effort to model. A structural mapping has been developed as a foundation for analytic models for thermal conduction and mechanical properties. The conductivity has contributions both from the copper and the reinforcement. The latter is accomplished by graphitization of the fibers, the higher the amount of graphitization the greater the conduction. This is accompanied by an increase in the fiber modulus, which is desirable from a stiffness point of view but decreases the braidability; the highest conductivity fibers are simply too brittle to be braided. Considerable effort has been expended on determining the optimal braidability--conductivity region. While a number of preforms have been fabricated, one other complication intervenes; graphite and copper are immiscible, resulting in a poor mechanical bond and difficulties in infiltration by molten copper. The approach taken is to utilize a proprietary fiber coating process developed by TRA, of Salt Lake City, Utah, which forms an itermediary bond. A number of preforms have been fabricated from a variety of fiber types and two sets of these have been infiltrated with OFHC copper, one with the TRA coating and one without. Mechanical tests have been performed using a small-scale specimen method and show the coated specimens to have superior mechanical properties. Final batches of preforms, including a finned, near net shape tube, are being fabricated and will be infiltrated before summer.

Incorporation of Fiber Bragg Sensors for Shape Memory Polyurethanes Characterization.

PubMed

Alberto, Nélia; Fonseca, Maria A; Neto, Victor; Nogueira, Rogério; Oliveira, Mónica; Moreira, Rui

2017-11-11

Shape memory polyurethanes (SMPUs) are thermally activated shape memory materials, which can be used as actuators or sensors in applications including aerospace, aeronautics, automobiles or the biomedical industry. The accurate characterization of the memory effect of these materials is therefore mandatory for the technology's success. The shape memory characterization is normally accomplished using mechanical testing coupled with a heat source, where a detailed knowledge of the heat cycle and its influence on the material properties is paramount but difficult to monitor. In this work, fiber Bragg grating (FBG) sensors were embedded into SMPU samples aiming to study and characterize its shape memory effect. The samples were obtained by injection molding, and the entire processing cycle was successfully monitored, providing a process global quality signature. Moreover, the integrity and functionality of the FBG sensors were maintained during and after the embedding process, demonstrating the feasibility of the technology chosen for the purpose envisaged. The results of the shape memory effect characterization demonstrate a good correlation between the reflected FBG peak with the temperature and induced strain, proving that this technology is suitable for this particular application.

Incorporation of Fiber Bragg Sensors for Shape Memory Polyurethanes Characterization

PubMed Central

Nogueira, Rogério; Moreira, Rui

2017-01-01

Shape memory polyurethanes (SMPUs) are thermally activated shape memory materials, which can be used as actuators or sensors in applications including aerospace, aeronautics, automobiles or the biomedical industry. The accurate characterization of the memory effect of these materials is therefore mandatory for the technology’s success. The shape memory characterization is normally accomplished using mechanical testing coupled with a heat source, where a detailed knowledge of the heat cycle and its influence on the material properties is paramount but difficult to monitor. In this work, fiber Bragg grating (FBG) sensors were embedded into SMPU samples aiming to study and characterize its shape memory effect. The samples were obtained by injection molding, and the entire processing cycle was successfully monitored, providing a process global quality signature. Moreover, the integrity and functionality of the FBG sensors were maintained during and after the embedding process, demonstrating the feasibility of the technology chosen for the purpose envisaged. The results of the shape memory effect characterization demonstrate a good correlation between the reflected FBG peak with the temperature and induced strain, proving that this technology is suitable for this particular application. PMID:29137136

ICAN Computer Code Adapted for Building Materials

NASA Technical Reports Server (NTRS)

Murthy, Pappu L. N.

1997-01-01

The NASA Lewis Research Center has been involved in developing composite micromechanics and macromechanics theories over the last three decades. These activities have resulted in several composite mechanics theories and structural analysis codes whose applications range from material behavior design and analysis to structural component response. One of these computer codes, the Integrated Composite Analyzer (ICAN), is designed primarily to address issues related to designing polymer matrix composites and predicting their properties - including hygral, thermal, and mechanical load effects. Recently, under a cost-sharing cooperative agreement with a Fortune 500 corporation, Master Builders Inc., ICAN was adapted to analyze building materials. The high costs and technical difficulties involved with the fabrication of continuous-fiber-reinforced composites sometimes limit their use. Particulate-reinforced composites can be thought of as a viable alternative. They are as easily processed to near-net shape as monolithic materials, yet have the improved stiffness, strength, and fracture toughness that is characteristic of continuous-fiber-reinforced composites. For example, particlereinforced metal-matrix composites show great potential for a variety of automotive applications, such as disk brake rotors, connecting rods, cylinder liners, and other hightemperature applications. Building materials, such as concrete, can be thought of as one of the oldest materials in this category of multiphase, particle-reinforced materials. The adaptation of ICAN to analyze particle-reinforced composite materials involved the development of new micromechanics-based theories. A derivative of the ICAN code, ICAN/PART, was developed and delivered to Master Builders Inc. as a part of the cooperative activity.

Crystallinity as a tunable switch of poly(L-lactide) shape memory effects.

PubMed

Sobota, Michał; Jurczyk, Sebastian; Kwiecień, Michał; Smola-Dmochowska, Anna; Musioł, Marta; Domański, Marian; Janeczek, Henryk; Kawalec, Michał; Kurcok, Piotr

2017-02-01

Materials with shape memory effect (SME) have already been widely used in the medical field. The interesting part of this group is represented by double function materials. The bioresorption and SME ability are common in polyesters implants. The first information about vascular stent made of bioresorbable polyester with SME was published in 2000. However, there are not many investigations about SME control of elements in the aspect of material processing. In the present work, the ability to control the shape memory (SM) of bioresorbable and semicrystalline poly(L-lactide) (PLLA) is investigated. The studies are based on the unexpected effect of material orientation which was demonstrated even at low percentage deformation in crystallized mould injected material. The presented studies revealed that the different degrees of crystallinity obtained during processing might be a useful switch to create a tailored SME for a specific application. The prepared samples of variable morphology revealed a possibility to control the value of material stress during permanent shape recovery. The degree of shape recovery of the prepared samples was also controlable. The highest stress value observed during permanent shape recovery reached 10MPa for the sample annealed 60min at 115°C even when the sample was only deformed in 8%. The other significant aspect of this work is to present the problem of slow crystallization of the material during and after processing (cooling rate) as well as the possibility of negative SME change during the shelf life of the fabric. Copyright © 2016 Elsevier Ltd. All rights reserved.

Method and apparatus for making articles from particle based materials

DOEpatents

Moorhead, A.J.; Menchhofer, P.A.

1995-12-19

A method and apparatus are disclosed for the production of articles made of a particle-based material; e.g., ceramics and sintered metals. In accordance with the invention, a thermally settable slurry containing a relatively high concentration of the particles is conveyed through an elongate flow area having a desired cross-sectional configuration. The slurry is heated as it is advanced through the flow area causing the slurry to set or harden in a shape which conforms to the cross-sectional configuration of the flow area. The material discharges from the flow area as a self-supporting solid of near net final dimensions. The article may then be sintered to consolidate the particles and provide a high density product. 10 figs.

Proto-experiences and subjective experiences: classical and quantum concepts.

PubMed

Vimal, Ram Lakhan Pandey

2008-03-01

Deterministic reductive monism and non-reductive substance dualism are two opposite views for consciousness, and both have serious problems. An alternative view is needed. For this, we hypothesize that strings or elementary particles (fermions and bosons) have two aspects: (i) elemental proto-experiences (PEs) as phenomenal aspect, and (ii) mass, charge, and spin as material aspect. Elemental PEs are hypothesized to be the properties of elementary particles and their interactions, which are composed of irreducible fundamental subjective experiences (SEs)/PEs that are in superimposed form in elementary particles and in their interactions. Since SEs/PEs are superimposed, elementary particles are not specific to any SE/PE; they (and all inert matter) are carriers of SEs/PEs, and hence, appear as non-experiential material entities. Furthermore, our hypothesis is that matter and associated elemental PEs co-evolved and co-developed into neural-nets and associated neural-net PEs (neural Darminism), respectively. The signals related to neural PEs interact in a neural-net and neural-net PEs emerges from random process of self-organization. The neural-net PEs are a set of SEs embedded in the neural-net by a non-computational or non-algorithmic process. The non-specificity of elementary particles is transformed into the specificity of neural-nets by neural Darwinism. The specificity of SEs emerges when feedforward and feedback signal interacts in the neuropil and are dependent on wakefulness (i.e., activation) attention, re-entry between neural populations, working memory, stimulus at above threshold, and neural net PE signals. This PE-SE framework integrates reductive and non-reductive views, complements the existing models, bridges the explanatory gaps, and minimizes the problem of causation.

Hydrothermal carbonization of food waste and associated packaging materials for energy source generation.

PubMed

Li, Liang; Diederick, Ryan; Flora, Joseph R V; Berge, Nicole D

2013-11-01

Hydrothermal carbonization (HTC) is a thermal conversion technique that converts food wastes and associated packaging materials to a valuable, energy-rich resource. Food waste collected from local restaurants was carbonized over time at different temperatures (225, 250 and 275°C) and solids concentrations to determine how process conditions influence carbonization product properties and composition. Experiments were also conducted to determine the influence of packaging material on food waste carbonization. Results indicate the majority of initial carbon remains integrated within the solid-phase at the solids concentrations and reaction temperatures evaluated. Initial solids concentration influences carbon distribution because of increased compound solubilization, while changes in reaction temperature imparted little change on carbon distribution. The presence of packaging materials significantly influences the energy content of the recovered solids. As the proportion of packaging materials increase, the energy content of recovered solids decreases because of the low energetic retention associated with the packaging materials. HTC results in net positive energy balances at all conditions, except at a 5% (dry wt.) solids concentration. Carbonization of food waste and associated packaging materials also results in net positive balances, but energy needs for solids post-processing are significant. Advantages associated with carbonization are not fully realized when only evaluating process energetics. A more detailed life cycle assessment is needed for a more complete comparison of processes. Copyright © 2013 Elsevier Ltd. All rights reserved.

Spray forming system for producing molds, dies and related tooling

DOEpatents

McHugh, Kevin M.

2000-01-01

A system for the spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as powders, whiskers or fibers.

Nanostructure characterisation of flow-formed Cr-Mo-V steel using transmission Kikuchi diffraction technique.

PubMed

Birosca, S; Ding, R; Ooi, S; Buckingham, R; Coleman, C; Dicks, K

2015-06-01

Nowadays flow-forming has become a desired near net shape manufacturing method as it provides excellent mechanical properties with improved surface finish and significant manufacturing cost reduction. However, the material is subjected to excessive plastic deformation during flow-forming process, generating a very fine and complex microstructure. In addition, the intense dislocation density and residual stress that is generated in the component during processing makes the microstructure characterisation using conventional micro-analytical tools challenging. Thus, the microstructure/property relationship study in such a material is rather difficult. In the present study a flow-formed Cr-Mo-V steel nanostructure and crystallographic texture were characterised by means of Transmission Kikuchi Diffraction (TKD). Here, TKD is shown to be a powerful technique in revealing very fine martensite laths within an austenite matrix. Moreover, fine precipitates in the order of 20-70 nm on the martensite lath boundaries were clearly imaged and characterised. This greatly assisted in understanding the preferable site formation of the carbides in such a complex microstructure. The results showed that the actual TKD spatial resolution was in the range of 5-10 nm using 25 kV for flow-formed Cr-Mo-V steel. Copyright © 2015 Elsevier B.V. All rights reserved.

Understanding the High Temperature Behavior of Niobium Aluminides; First Year Summary Report

DTIC Science & Technology

1990-11-08

characterization to follow. Near-net shape processing may be used to form test specimens. A transmission elec- tron microscopy effort will be used ...to identify deformation mechanisms. ,, 20 DISTRIBUTION/AVAII ABILITY OF ABSTRACT SK’NCI ASSIFIFD’UNL MITED • SAME AS R"T • DTC USEDS J...ingots have been processed for us (gratis) by Nippon Mining Corporation by vacuum induction melted from a stock of niobium oxide and elemental aluminum

Thermal analysis and evolution of shape loss phenomena during polymer burnout in powder metal processing

NASA Astrophysics Data System (ADS)

Enneti, Ravi Kumar

2005-07-01

Powder metallurgy technology involves manufacturing of net shape or near net shape components starting from metal powders. Polymers are used to provide lubrication during shaping and handling strength to the shaped component. After shaping, the polymers are removed from the shaped components by providing thermal energy to burnout the polymers. Polymer burnout is one of the most critical step in powder metal processing. Improper design of the polymer burnout cycle will result in formation of defects, shape loss, or carbon contamination of the components. The effect of metal particles on polymer burnout and shape loss were addressed in the present research. The study addressing the effect of metal powders on polymer burnout was based on the hypothesis that metal powders act to catalyze polymer burnout. Thermogravimetric analysis (TGA) on pure polymer, ethylene vinyl acetate (EVA), and on admixed powders of 316L stainless steel and 1 wt. % EVA were carried out to verify the hypothesis. The effect of metal powders additions was studied by monitoring the onset temperature for polymer degradation and the temperature at which maximum rate of weight loss occurred from the TGA data. The catalytic behavior of the powders was verified by varying the particle size and shape of the 316L stainless powder. The addition of metal particles lowered the polymer burnout temperatures. The onset temperature for burnout was found to be sensitive to the surface area of the metal particle as well as the polymer distribution. Powders with low surface area and uniform distribution of polymer showed a lower burnout temperature. The evolution of shape loss during polymer burnout was based on the hypothesis that shape loss occurs during the softening of the polymer and depends on the sequence of chemical bonding in the polymer during burnout. In situ observation of shape loss was carried out on thin beams compacted from admixed powders of 316L stainless steel and 1 wt. % ethylene vinyl acetate (EVA). The results showed that shape loss primarily occurs by viscous creep during the softening of the polymer. At the onset of burnout of EVA, a recovery in shape loss was observed. The recovery occurred primarily during the first stage burnout of EVA and was attributed to the formation of polyethylene co-polyacetylene which forms with a carbon double bond. The in situ strength was also found to increase during the formation of polyethylene co-polyacetylene. No recovery of shape loss was observed during burnout of polymers (polyethylene and polypropylene) which convert to yield hydrocarbons without forming carbon double bonds. (Abstract shortened by UMI.)

Laser Engineered Net Shape (LENS) Technology for the Repair of Ni-Base Superalloy Turbine Components

NASA Astrophysics Data System (ADS)

Liu, Dejian; Lippold, John C.; Li, Jia; Rohklin, Stan R.; Vollbrecht, Justin; Grylls, Richard

2014-09-01

The capability of the laser engineered net shape (LENS) process was evaluated for the repair of casting defects and improperly machined holes in gas turbine engine components. Various repair geometries, including indentations, grooves, and through-holes, were used to simulate the actual repair of casting defects and holes in two materials: Alloy 718 and Waspaloy. The influence of LENS parameters, including laser energy density, laser scanning speed, and deposition pattern, on the repair of these defects and holes was studied. Laser surface remelting of the substrate prior to repair was used to remove machining defects and prevent heat-affected zone (HAZ) liquation cracking. Ultrasonic nondestructive evaluation techniques were used as a possible approach for detecting lack-of-fusion in repairs. Overall, Alloy 718 exhibited excellent repair weldability, with essentially no defects except for some minor porosity in repairs representative of deep through-holes and simulated large area casting defects. In contrast, cracking was initially observed during simulated repair of Waspaloy. Both solidification cracking and HAZ liquation cracking were observed in the repairs, especially under conditions of high heat input (high laser power and/or low scanning speed). For Waspaloy, the degree of cracking was significantly reduced and, in most cases, completely eliminated by the combination of low laser energy density and relatively high laser scanning speeds. It was found that through-hole repairs of Waspaloy made using a fine powder size exhibited excellent repair weldability and were crack-free relative to repairs using coarser powder. Simulated deep (7.4 mm) blind-hole repairs, representative of an actual Waspaloy combustor case, were successfully produced by the combination use of fine powder and relatively high laser scanning speeds.

Surface dynamics of amorphous polymers used for high-voltage insulators.

PubMed

Shemella, Philip T; Laino, Teodoro; Fritz, Oliver; Curioni, Alessandro

2011-11-24

Amorphous siloxane polymers are the backbone of high-voltage insulation materials. The natural hydrophobicity of their surface is a necessary property for avoiding leakage currents and dielectric breakdown. As these surfaces are exposed to the environment, electrical discharges or strong mechanical impact can temporarily destroy their water-repellent properties. After such events, however, a self-healing process sets in and restores the original hydrophobicity within some hours. In the present study, we investigate possible mechanisms of this restoration process. Using large-scale, all-atom molecular dynamics simulations, we show that molecules on the material surface have augmented motion that allows them to rearrange with a net polarization. The overall surface region has a net orientation that contributes to hydrophobicity, and charged groups that are placed at the surface migrate inward, away from the vacuum interface and into the bulk-like region. Our simulations provide insight into the mechanisms for hydrophobic self-recovery that repair material strength and functionality and suggest material compositions for future high-voltage insulators. © 2011 American Chemical Society

The prediction of the building precision in the Laser Engineered Net Shaping process using advanced networks

NASA Astrophysics Data System (ADS)

Lu, Z. L.; Li, D. C.; Lu, B. H.; Zhang, A. F.; Zhu, G. X.; Pi, G.

2010-05-01

Laser Engineered Net Shaping (LENS) is an advanced manufacturing technology, but it is difficult to control the depositing height (DH) of the prototype because there are many technology parameters influencing the forming process. The effect of main parameters (laser power, scanning speed and powder feeding rate) on the DH of single track is firstly analyzed, and then it shows that there is the complex nonlinear intrinsic relationship between them. In order to predict the DH, the back propagation (BP) based network improved with Adaptive learning rate and Momentum coefficient (AM) algorithm, and the least square support vector machine (LS-SVM) network are both adopted. The mapping relationship between above parameters and the DH is constructed according to training samples collected by LENS experiments, and then their generalization ability, function-approximating ability and real-time are contrastively investigated. The results show that although the predicted result by the BP-AM approximates the experimental result, above performance index of the LS-SVM are better than those of the BP-AM. Finally, high-definition thin-walled parts of AISI316L are successfully fabricated. Hence, the LS-SVM network is more suitable for the prediction of the DH.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nick Cannell; Dr. Mark Samonds; Adi Sholapurwalla

The investment casting process is an expendable mold process where wax patterns of the part and rigging are molded, assembled, shelled and melted to produce a ceramic mold matching the shape of the component to be cast. Investment casting is an important manufacturing method for critical parts because of the ability to maintain dimensional shape and tolerances. However, these tolerances can be easily exceeded if the molding components do not maintain their individual shapes well. In the investment casting process there are several opportunities for the final casting shape to not maintain the intended size and shape, such as shrinkagemore » of the wax in the injection tool, the modification of the shape during shell heating, and with the thermal shrink and distortion in the casting process. Studies have been completed to look at the casting and shell distortions through the process in earlier phases of this project. Dr. Adrian Sabau at Oak Ridge National Labs performed characterizations and validations of 17-4 PH stainless steel in primarily fused silica shell systems with good agreement between analysis results and experimental data. Further tasks provided material property measurements of wax and methodology for employing a viscoelastic definition of wax materials into software. The final set of tasks involved the implementation of the findings into the commercial casting analysis software ProCAST, owned and maintained by ESI Group. This included: o the transfer of the wax material property data from its raw form into separate temperature-dependent thermophysical and mechanical property datasets o adding this wax material property data into an easily viewable and modifiable user interface within the pre-processing application of the ProCAST suite, namely PreCAST o and validating the data and viscoelastic wax model with respect to experimental results« less

Advanced Materials and Processing for Drug Delivery: The Past and the Future

PubMed Central

Zhang, Ying; Chan, Hon Fai; Leong, Kam W.

2012-01-01

Design and synthesis of efficient drug delivery systems are of vital importance for medicine and healthcare. Materials innovation and nanotechnology have synergistically fueled the advancement of drug delivery. Innovation in material chemistry allows the generation of biodegradable, biocompatible, environment-responsive, and targeted delivery systems. Nanotechnology enables control over size, shape and multi-functionality of particulate drug delivery systems. In this review, we focus on the materials innovation and processing of drug delivery systems and how these advances have shaped the past and may influence the future of drug delivery. PMID:23088863

Improvements to the single screw extruder

NASA Technical Reports Server (NTRS)

Hiemenz, C.; Ziegmann, G.; Franzkoch, B.; Hoffmanns, W.; Michaeli, W.

1977-01-01

The extrusion on a single screw extruder is examined. The process is divided into several steps: the dosage of the materials to be conveyed; the modification of the shape of the feeding opening which influences the feeding process and consequently the throughput of the extruder; optimizing the shape of the feeding zone to meet the specific material requirements; and plasticizing and homogenizing.

Structural Integrity of an Electron Beam Melted Titanium Alloy

PubMed Central

Lancaster, Robert; Davies, Gareth; Illsley, Henry; Jeffs, Spencer; Baxter, Gavin

2016-01-01

Advanced manufacturing encompasses the wide range of processes that consist of “3D printing” of metallic materials. One such method is Electron Beam Melting (EBM), a modern build technology that offers significant potential for lean manufacture and a capability to produce fully dense near-net shaped components. However, the manufacture of intricate geometries will result in variable thermal cycles and thus a transient microstructure throughout, leading to a highly textured structure. As such, successful implementation of these technologies requires a comprehensive assessment of the relationships of the key process variables, geometries, resultant microstructures and mechanical properties. The nature of this process suggests that it is often difficult to produce representative test specimens necessary to achieve a full mechanical property characterisation. Therefore, the use of small scale test techniques may be exploited, specifically the small punch (SP) test. The SP test offers a capability for sampling miniaturised test specimens from various discrete locations in a thin-walled component, allowing a full characterisation across a complex geometry. This paper provides support in working towards development and validation strategies in order for advanced manufactured components to be safely implemented into future gas turbine applications. This has been achieved by applying the SP test to a series of Ti-6Al-4V variants that have been manufactured through a variety of processing routes including EBM and investigating the structural integrity of each material and how this controls the mechanical response. PMID:28773590

Material flow data for numerical simulation of powder injection molding

NASA Astrophysics Data System (ADS)

Duretek, I.; Holzer, C.

2017-01-01

The powder injection molding (PIM) process is a cost efficient and important net-shape manufacturing process that is not completely understood. For the application of simulation programs for the powder injection molding process, apart from suitable physical models, exact material data and in particular knowledge of the flow behavior are essential in order to get precise numerical results. The flow processes of highly filled polymers are complex. Occurring effects are very hard to separate, like shear flow with yield stress, wall slip, elastic effects, etc. Furthermore, the occurrence of phase separation due to the multi-phase composition of compounds is quite probable. In this work, the flow behavior of a 316L stainless steel feedstock for powder injection molding was investigated. Additionally, the influence of pre-shearing on the flow behavior of PIM-feedstocks under practical conditions was examined and evaluated by a special PIM injection molding machine rheometer. In order to have a better understanding of key factors of PIM during the injection step, 3D non-isothermal numerical simulations were conducted with a commercial injection molding simulation software using experimental feedstock properties. The simulation results were compared with the experimental results. The mold filling studies amply illustrate the effect of mold temperature on the filling behavior during the mold filling stage. Moreover, the rheological measurements showed that at low shear rates no zero shear viscosity was observed, but instead the viscosity further increased strongly. This flow behavior could be described with the Cross-WLF approach with Herschel-Bulkley extension very well.

Development of a super-pressure balloon with a diamond-shaped net

NASA Astrophysics Data System (ADS)

Saito, Y.; Iijima, I.; Matsuzaka, Y.; Matsushima, K.; Tanaka, S.; Kajiwara, K.; Shimadu, S.

2014-10-01

The essential reason of the lobed-pumpkin shaped super-pressure balloon to withstand against the high pressure is that the local curvature of the balloon film is kept small. Recently, it has been found that the small local curvature can also be obtained if the balloon is covered by a diamond-shaped net with a vertically elongated shape. The development of the super-pressure balloon using this method was started from a 3-m balloon with a polyethylene film covered by a net using Kevlar ropes. The ground inflation test showed the expected high burst pressure. Then, a 6-m and a 12-m balloon using a polyethylene film and a net using the Vectran were developed and stable deployment was checked through the ground inflation tests. The flight test of a 3000 m3 balloon was performed in 2013 and shown to resist a pressure of at least 400 Pa. In the future, after testing a new design to relax a possible stress concentration around the polar area, test flights of scaled balloons will be performed gradually enlarging their size. The goal is to launch a 300,000 m3 super-pressure balloon.

Determining casting defects in near-net shape casting aluminum parts by computed tomography

NASA Astrophysics Data System (ADS)

Li, Jiehua; Oberdorfer, Bernd; Habe, Daniel; Schumacher, Peter

2018-03-01

Three types of near-net shape casting aluminum parts were investigated by computed tomography to determine casting defects and evaluate quality. The first, second, and third parts were produced by low-pressure die casting (Al-12Si-0.8Cu-0.5Fe-0.9Mg-0.7Ni-0.2Zn alloy), die casting (A356, Al-7Si-0.3Mg), and semi-solid casting (A356, Al-7Si-0.3Mg), respectively. Unlike die casting (second part), low-pressure die casting (first part) significantly reduced the formation of casting defects (i.e., porosity) due to its smooth filling and solidification under pressure. No significant casting defect was observed in the third part, and this absence of defects indicates that semi-solid casting could produce high-quality near-net shape casting aluminum parts. Moreover, casting defects were mostly distributed along the eutectic grain boundaries. This finding reveals that refinement of eutectic grains is necessary to optimize the distribution of casting defects and reduce their size. This investigation demonstrated that computed tomography is an efficient method to determine casting defects in near-net shape casting aluminum parts.

Method for manufacturing lightning strike mitigation composites

NASA Technical Reports Server (NTRS)

Vaidyanathan, K. Ranji (Inventor); Campbell, Jeffrey (Inventor)

2012-01-01

A method for manufacturing a composite material utilizes a tooling material having a desired shape. The surface of the tooling material is coated with a composite film that includes a conductive filler material. A composite composition is introduced into contact with the surface of the tooling material to form a desired shape. The composite composition is processed to produce the composite material, and the composite material has a conductive composite surface layer that includes the conductive filler material.

Networks of myelin covariance.

PubMed

Melie-Garcia, Lester; Slater, David; Ruef, Anne; Sanabria-Diaz, Gretel; Preisig, Martin; Kherif, Ferath; Draganski, Bogdan; Lutti, Antoine

2018-04-01

Networks of anatomical covariance have been widely used to study connectivity patterns in both normal and pathological brains based on the concurrent changes of morphometric measures (i.e., cortical thickness) between brain structures across subjects (Evans, ). However, the existence of networks of microstructural changes within brain tissue has been largely unexplored so far. In this article, we studied in vivo the concurrent myelination processes among brain anatomical structures that gathered together emerge to form nonrandom networks. We name these "networks of myelin covariance" (Myelin-Nets). The Myelin-Nets were built from quantitative Magnetization Transfer data-an in-vivo magnetic resonance imaging (MRI) marker of myelin content. The synchronicity of the variations in myelin content between anatomical regions was measured by computing the Pearson's correlation coefficient. We were especially interested in elucidating the effect of age on the topological organization of the Myelin-Nets. We therefore selected two age groups: Young-Age (20-31 years old) and Old-Age (60-71 years old) and a pool of participants from 48 to 87 years old for a Myelin-Nets aging trajectory study. We found that the topological organization of the Myelin-Nets is strongly shaped by aging processes. The global myelin correlation strength, between homologous regions and locally in different brain lobes, showed a significant dependence on age. Interestingly, we also showed that the aging process modulates the resilience of the Myelin-Nets to damage of principal network structures. In summary, this work sheds light on the organizational principles driving myelination and myelin degeneration in brain gray matter and how such patterns are modulated by aging. © 2017 The Authors Human Brain Mapping Published by Wiley Periodicals, Inc.

Processing of Ni30Pt20Ti50 High-Temperature Shape-Memory Alloy Into Thin Rod Demonstrated

NASA Technical Reports Server (NTRS)

Noebe, Ronald D.; Draper, Susan L.; Biles, Tiffany A.; Leonhardt, Todd

2005-01-01

High-temperature shape-memory alloys (HTSMAs) based on nickel-titanium (NiTi) with significant ternary additions of palladium (Pd), platinum (Pt), gold (Au), or hafnium (Hf) have been identified as potential high-temperature actuator materials for use up to 500 C. These materials provide an enabling technology for the development of "smart structures" used to control the noise, emissions, or efficiency of gas turbine engines. The demand for these high-temperature versions of conventional shape-memory alloys also has been growing in the automotive, process control, and energy industries. However these materials, including the NiPtTi alloys being developed at the NASA Glenn Research Center, will never find widespread acceptance unless they can be readily processed into useable forms.

Validated simulator for space debris removal with nets and other flexible tethers applications

NASA Astrophysics Data System (ADS)

Gołębiowski, Wojciech; Michalczyk, Rafał; Dyrek, Michał; Battista, Umberto; Wormnes, Kjetil

2016-12-01

In the context of active debris removal technologies and preparation activities for the e.Deorbit mission, a simulator for net-shaped elastic bodies dynamics and their interactions with rigid bodies, has been developed. Its main application is to aid net design and test scenarios for space debris deorbitation. The simulator can model all the phases of the debris capturing process: net launch, flight and wrapping around the target. It handles coupled simulation of rigid and flexible bodies dynamics. Flexible bodies were implemented using Cosserat rods model. It allows to simulate flexible threads or wires with elasticity and damping for stretching, bending and torsion. Threads may be combined into structures of any topology, so the software is able to simulate nets, pure tethers, tether bundles, cages, trusses, etc. Full contact dynamics was implemented. Programmatic interaction with simulation is possible - i.e. for control implementation. The underlying model has been experimentally validated and due to significant gravity influence, experiment had to be performed in microgravity conditions. Validation experiment for parabolic flight was a downscaled process of Envisat capturing. The prepacked net was launched towards the satellite model, it expanded, hit the model and wrapped around it. The whole process was recorded with 2 fast stereographic camera sets for full 3D trajectory reconstruction. The trajectories were used to compare net dynamics to respective simulations and then to validate the simulation tool. The experiments were performed on board of a Falcon-20 aircraft, operated by National Research Council in Ottawa, Canada. Validation results show that model reflects phenomenon physics accurately enough, so it may be used for scenario evaluation and mission design purposes. The functionalities of the simulator are described in detail in the paper, as well as its underlying model, sample cases and methodology behind validation. Results are presented and typical use cases are discussed showing that the software may be used to design throw nets for space debris capturing, but also to simulate deorbitation process, chaser control system or general interactions between rigid and elastic bodies - all in convenient and efficient way. The presented work was led by SKA Polska under the ESA contract, within the CleanSpace initiative.

Development of Spray on Bag for manufacturing of large composites parts: Diffusivity analysis

NASA Astrophysics Data System (ADS)

Dempah, Maxime Joseph

Bagging materials are utilized in many composites manufacturing processes. The selection is mainly driven by cost, temperature requirements, chemical compatibility and tear properties of the bag. The air barrier properties of the bag are assumed to be adequate or in many cases are not considered at all. However, the gas barrier property of a bag is the most critical parameter, as it can negatively affect the quality of the final laminate. The barrier property is a function of the bag material, uniformity, thickness and temperature. Improved barrier properties are needed for large parts, high pressure consolidated components and structures where air stays entrapped on the part surface. The air resistance property of the film is defined as permeability and is investigated in this thesis. A model was developed to evaluate the gas transport through the film and an experimental cell was implemented to characterize various commercial films. Understanding and characterizing the transport phenomena through the film allows optimization of the bagging material for various manufacturing processes. Spray-on-Bag is a scalable alternative bagging method compared to standard films. The approach allows in-situ fabrication of the bag on large and complex geometry structures where optimization of the bag properties can be varied on a local level. An experimental setup was developed and implemented using a six axis robot and an automated spraying system. Experiments were performed on a flat surface and specimens were characterized and compared to conventional films. Air barrier properties were within range of standard film approaches showing the potential to fabricate net shape bagging structures in an automated process.

Net Gains

ERIC Educational Resources Information Center

Fielker, David

2008-01-01

The Easter conference 2008 had several activities which for the author raised the same questions on cube nets in some work with eight-year-olds some time ago. In this article, the author muses on some problems from the Easter conference regarding nets of shapes. (Contains 1 note.)

Solidification in direct metal deposition by LENS processing

NASA Astrophysics Data System (ADS)

Hofmeister, William; Griffith, Michelle

2001-09-01

Thermal imaging and metallographic analysis were used to study Laser Engineered Net Shaping (LENS™) processing of 316 stainless steel and H13 tool steel. The cooling rates at the solid-liquid interface were measured over a range of conduction conditions. The length scale of the molten zone controls cooling rates during solidification in direct metal deposition. In LENS processing, the molten zone ranges from 0.5 mm in length to 1.5 mm, resulting in cooling rates at the solid-liquid interface ranging from 200 6,000 Ks-1.

All-optical conversion scheme from binary to its MTN form with the help of nonlinear material based tree-net architecture

NASA Astrophysics Data System (ADS)

Maiti, Anup Kumar; Nath Roy, Jitendra; Mukhopadhyay, Sourangshu

2007-08-01

In the field of optical computing and parallel information processing, several number systems have been used for different arithmetic and algebraic operations. Therefore an efficient conversion scheme from one number system to another is very important. Modified trinary number (MTN) has already taken a significant role towards carry and borrow free arithmetic operations. In this communication, we propose a tree-net architecture based all optical conversion scheme from binary number to its MTN form. Optical switch using nonlinear material (NLM) plays an important role.

Identification and characterization of neutrophil extracellular trap shapes in flow cytometry

NASA Astrophysics Data System (ADS)

Ginley, Brandon; Emmons, Tiffany; Sasankan, Prabhu; Urban, Constantin; Segal, Brahm H.; Sarder, Pinaki

2017-03-01

Neutrophil extracellular trap (NET) formation is an alternate immunologic weapon used mainly by neutrophils. Chromatin backbones fused with proteins derived from granules are shot like projectiles onto foreign invaders. It is thought that this mechanism is highly anti-microbial, aids in preventing bacterial dissemination, is used to break down structures several sizes larger than neutrophils themselves, and may have several more uses yet unknown. NETs have been implied to be involved in a wide array of systemic host immune defenses, including sepsis, autoimmune diseases, and cancer. Existing methods used to visually quantify NETotic versus non-NETotic shapes are extremely time-consuming and subject to user bias. These limitations are obstacles to developing NETs as prognostic biomarkers and therapeutic targets. We propose an automated pipeline for quantitatively detecting neutrophil and NET shapes captured using a flow cytometry-imaging system. Our method uses contrast limited adaptive histogram equalization to improve signal intensity in dimly illuminated NETs. From the contrast improved image, fixed value thresholding is applied to convert the image to binary. Feature extraction is performed on the resulting binary image, by calculating region properties of the resulting foreground structures. Classification of the resulting features is performed using Support Vector Machine. Our method classifies NETs from neutrophils without traps at 0.97/0.96 sensitivity/specificity on n = 387 images, and is 1500X faster than manual classification, per sample. Our method can be extended to rapidly analyze whole-slide immunofluorescence tissue images for NET classification, and has potential to streamline the quantification of NETs for patients with diseases associated with cancer and autoimmunity.

Laser rapid forming technology of high-performance dense metal components with complex structure

NASA Astrophysics Data System (ADS)

Huang, Weidong; Chen, Jing; Li, Yanming; Lin, Xin

2005-01-01

Laser rapid forming (LRF) is a new and advanced manufacturing technology that has been developed on the basis of combining high power laser cladding technology with rapid prototyping (RP) to realize net shape forming of high performance dense metal components without dies. Recently we have developed a set of LRF equipment. LRF experiments were carried out on the equipment to investigate the influences of processing parameters on forming characterizations systematically with the cladding powder materials as titanium alloys, superalloys, stainless steel, and copper alloys. The microstructure of laser formed components is made up of columnar grains or columnar dendrites which grow epitaxially from the substrate since the solid components were prepared layer by layer additionally. The result of mechanical testing proved that the mechanical properties of laser formed samples are similar to or even over that of forging and much better than that of casting. It is shown in this paper that LRF technology is providing a new solution for some difficult processing problems in the high tech field of aviation, spaceflight and automobile industries.

Accelerating Industrial Adoption of Metal Additive Manufacturing Technology

NASA Astrophysics Data System (ADS)

Vartanian, Kenneth; McDonald, Tom

2016-03-01

While metal additive manufacturing (AM) technology has clear benefits, there are still factors preventing its adoption by industry. These factors include the high cost of metal AM systems, the difficulty for machinists to learn and operate metal AM machines, the long approval process for part qualification/certification, and the need for better process controls; however, the high AM system cost is the main barrier deterring adoption. In this paper, we will discuss an America Makes-funded program to reduce AM system cost by combining metal AM technology with conventional computerized numerical controlled (CNC) machine tools. Information will be provided on how an Optomec-led team retrofitted a legacy CNC vertical mill with laser engineered net shaping (LENS®—LENS is a registered trademark of Sandia National Labs) AM technology, dramatically lowering deployment cost. The upgraded system, dubbed LENS Hybrid Vertical Mill, enables metal additive and subtractive operations to be performed on the same machine tool and even on the same part. Information on the LENS Hybrid system architecture, learnings from initial system deployment and continuing development work will also be provided to help guide further development activities within the materials community.

Influences on particle shape in underwater pelletizing processes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kast, O., E-mail: oliver.kast@ikt.uni-stuttgart.de, E-mail: matthias.musialek@ikt.uni-stuttgart.de, E-mail: kalman.geiger@ikt.uni-stuttgart.de, E-mail: christian.bonten@ikt.uni-stuttgart.de; Musialek, M., E-mail: oliver.kast@ikt.uni-stuttgart.de, E-mail: matthias.musialek@ikt.uni-stuttgart.de, E-mail: kalman.geiger@ikt.uni-stuttgart.de, E-mail: christian.bonten@ikt.uni-stuttgart.de; Geiger, K., E-mail: oliver.kast@ikt.uni-stuttgart.de, E-mail: matthias.musialek@ikt.uni-stuttgart.de, E-mail: kalman.geiger@ikt.uni-stuttgart.de, E-mail: christian.bonten@ikt.uni-stuttgart.de

2014-05-15

Underwater pelletizing has gained high importance within the last years among the different pelletizing technologies, due to its advantages in terms of throughput, automation, pellet quality and applicability to a large variety of thermoplastics. The resulting shape and quality of pellets, however, differ widely, depending on material characteristics and effects not fully understood yet. In an experimental set-up, pellets of different volumes and shapes were produced and the medium pellet mass, the pellet surface and the bulk density were analyzed in order to identify the influence of material properties and process parameters. Additionally, the shaping kinetics at the die openingmore » were watched with a specially developed camera system. It was found that rheological material properties correlate with process parameters and resulting particle form in a complex way. Higher cutting speeds were shown to have a deforming influence on the pellets, leading to less spherical s and lower bulk densities. More viscous materials, however, showed a better resistance against this. Generally, the viscous properties of polypropylene proofed to be dominant over the elastic ones in regard to their influence on pellet shape. It was also shown that the shapes filmed at the die opening and the actual form of the pellets after a cooling track do not always correlate, indicating a significant influence of thermodynamic properties during the cooling.« less

Combustion Synthesis of Ca3(PO4)2 Net-Shape Surgical Implants

NASA Technical Reports Server (NTRS)

Ayers, Reed A.; Castillo, Martin; Gottoli, Guglielmo; Moore, John J.; Simske, Steven J.

2006-01-01

Self-propagating high-temperature combustion synthesis (SHS) is the basis of a method of making components of porous tricalcium phosphate [Ca3(PO4)2] and related compounds in net sizes and shapes for use as surgical implants that are compatible with bone. The SHS method offers advantages over prior methods of manufacturing Ca3(PO4)2-based surgical implants.

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

NASA Astrophysics Data System (ADS)

Yang, Nancy; Yee, J.; Zheng, B.; Gaiser, K.; Reynolds, T.; Clemon, L.; Lu, W. Y.; Schoenung, J. M.; Lavernia, E. J.

2017-04-01

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. The study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. The study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS process control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. The current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.

Improvement of mechanical strength of sintered Mo alloyed steel by optimization of sintering and cold-forging processes with densification

NASA Astrophysics Data System (ADS)

Kamakoshi, Y.; Shohji, I.; Inoue, Y.; Fukuda, S.

2017-10-01

Powder metallurgy (P/M) materials have been expected to be spread in automotive industry. Generally, since sintered materials using P/M ones contain many pores and voids, mechanical properties of them are inferior to those of conventional wrought materials. To improve mechanical properties of the sintered materials, densification is effective. The aim of this study is to improve mechanical strength of sintered Mo-alloyed steel by optimizing conditions in sintering and cold-forging processes. Mo-alloyed steel powder was compacted. Then, pre-sintering (PS) using a vacuum sintering furnace was conducted. Subsequently, coldforging (CF) by a backward extrusion method was conducted to the pre-sintered specimen. Moreover, the cold-forged specimen was heat treated by carburizing, tempering and quenching (CQT). Afterwards, mechanical properties were investigated. As a result, it was found that the density of the PS specimen is required to be more than 7.4 Mg/m3 to strengthen the specimen by heat treatment after CF. Furthermore, density and the microstructure of the PS specimen are most important factors to make the high density and strength material by CF. At the CF load of 1200 kN, the maximum density ratio reached approximately 99% by the use of the PS specimen with proper density and microstructure. At the CF load of 900 kN, although density ratio was high like more than 97.8%, transverse rupture strength decreased sharply. Since densification caused high shear stress and stress concentration in the surface layer, microcracks occurred by the damages of inter-particle sintered connection of the surface layer. On the contrary, in case of the CF load of 1200 kN, ultra-densification of the surface layer occurred by a sufficient plastic flow. Such sufficient compressed specimens regenerated the sintered connections by high temperature heat treatment and thus the high strength densified material was obtained. These processes can be applicable to near net shape manufacturing without surface machining.

The Microstructure Evolution of a Fe₃Al Alloy during the LENS Process.

PubMed

Karczewski, Krzysztof; Durejko, Tomasz; Czujko, Tomasz

2018-03-07

A Fe₃Al intermetallic alloy has been successfully prepared by the laser-engineered net shaping (LENS) process. The applied process parameters were selected to provide various cooling rates during the solidification of the laser-melted material. The macro- and microstructure and the micro- and macrotexture of Fe₃Al samples were investigated. The influence of the cooling rate on grain morphology and texture is discussed. For the applied cooling rate range of 0.64 × 10⁴ K/s-2.6 × 10⁴ K/s, the structure is characterized by the presence of columnar grains for which the growth is directed upwards from the substrate. The intensity of the microtexture varies with the height of the sample and the cooling rate. The intensity of the texture increases with the decrease in the cooling rate. The samples that were obtained with low and medium cooling rates are characterized by the well-developed <100> and <111> macrotextures. The Fe₃Al alloy that was produced with a high cooling rate did not show a specific texture, which is reflected in the fairly uniform distribution of the normalized density intensity. Only a very weak texture with a <100> type component was observed.

Five-Axis Ultrasonic Additive Manufacturing for Nuclear Component Manufacture

NASA Astrophysics Data System (ADS)

Hehr, Adam; Wenning, Justin; Terrani, Kurt; Babu, Sudarsanam Suresh; Norfolk, Mark

2017-03-01

Ultrasonic additive manufacturing (UAM) is a three-dimensional metal printing technology which uses high-frequency vibrations to scrub and weld together both similar and dissimilar metal foils. There is no melting in the process and no special atmosphere requirements are needed. Consequently, dissimilar metals can be joined with little to no intermetallic compound formation, and large components can be manufactured. These attributes have the potential to transform manufacturing of nuclear reactor core components such as control elements for the High Flux Isotope Reactor at Oak Ridge National Laboratory. These components are hybrid structures consisting of an outer cladding layer in contact with the coolant with neutron-absorbing materials inside, such as neutron poisons for reactor control purposes. UAM systems are built into a computer numerical control (CNC) framework to utilize intermittent subtractive processes. These subtractive processes are used to introduce internal features as the component is being built and for net shaping. The CNC framework is also used for controlling the motion of the welding operation. It is demonstrated here that curved components with embedded features can be produced using a five-axis code for the welder for the first time.

Five-axis ultrasonic additive manufacturing for nuclear component manufacture

DOE PAGES

Hehr, Adam; Wenning, Justin; Terrani, Kurt A.; ...

2016-01-01

Ultrasonic additive manufacturing (UAM) is a three-dimensional metal printing technology which uses high-frequency vibrations to scrub and weld together both similar and dissimilar metal foils. There is no melting in the process and no special atmosphere requirements are needed. Consequently, dissimilar metals can be joined with little to no intermetallic compound formation, and large components can be manufactured. These attributes have the potential to transform manufacturing of nuclear reactor core components such as control elements for the High Flux Isotope Reactor at Oak Ridge National Laboratory. These components are hybrid structures consisting of an outer cladding layer in contact withmore » the coolant with neutron-absorbing materials inside, such as neutron poisons for reactor control purposes. UAM systems are built into a computer numerical control (CNC) framework to utilize intermittent subtractive processes. These subtractive processes are used to introduce internal features as the component is being built and for net shaping. The CNC framework is also used for controlling the motion of the welding operation. Lastly, it is demonstrated here that curved components with embedded features can be produced using a five-axis code for the welder for the first time.« less

Rapid process for producing transparent, monolithic porous glass

DOEpatents

Coronado, Paul R [Livermore, CA

2006-02-14

A process for making transparent porous glass monoliths from gels. The glass is produced much faster and in much larger sizes than present technology for making porous glass. The process reduces the cost of making large porous glass monoliths because: 1) the process does not require solvent exchange nor additives to the gel to increase the drying rates, 2) only moderate temperatures and pressures are used so relatively inexpensive equipment is needed, an 3) net-shape glass monoliths are possible using this process. The process depends on the use of temperature to control the partial pressure of the gel solvent in a closed vessel, resulting in controlled shrinking during drying.

The alloy with a memory, 55-Nitinol: Its physical metallurgy, properties, and applications

NASA Technical Reports Server (NTRS)

Jackson, C. M.; Wagner, H. J.; Wasilewski, R. J.

1972-01-01

A series of nickel titanium alloys (55-Nitinol), which are unique in that they possess a shape memory, are described. Components made of these materials that are altered in their shapes by deformation under proper conditions return to predetermined shapes when they are heated to the proper temperature range. The shape memory, together with the force exerted and the ability of the material to do mechanical work as it returns to its predetermined shape, suggest a wide variety of industrial applications for the alloy. Also included are discussions of the physical metallurgy and the mechanical, physical, and chemical properties of 55-Nitinol; procedures for melting and processing the material into useful shapes; and a summary of applications.

Residual stresses in injection molded shape memory polymer parts

NASA Astrophysics Data System (ADS)

Katmer, Sukran; Esen, Huseyin; Karatas, Cetin

2016-03-01

Shape memory polymers (SMPs) are materials which have shape memory effect (SME). SME is a property which has the ability to change shape when induced by a stimulator such as temperature, moisture, pH, electric current, magnetic field, light, etc. A process, known as programming, is applied to SMP parts in order to alter them from their permanent shape to their temporary shape. In this study we investigated effects of injection molding and programming processes on residual stresses in molded thermoplastic polyurethane shape memory polymer, experimentally. The residual stresses were measured by layer removal method. The study shows that injection molding and programming process conditions have significantly influence on residual stresses in molded shape memory polyurethane parts.

Constructivism, Optimality Theory and Language Acquisition. The Shapes We Make in Each Other's Heads.

ERIC Educational Resources Information Center

Whincop, Chris

1996-01-01

This paper identifies a feature of human brain neural nets that may be described as the principle of ease of processing (PEP), and that, it is argued, is the primary force guiding a learner towards a target grammar. It is suggested that the same principle lies at the heart of Optimality Theory, which characterizes the course of language…

Material migration studies with an ITER first wall panel proxy on EAST

NASA Astrophysics Data System (ADS)

Ding, R.; Pitts, R. A.; Borodin, D.; Carpentier, S.; Ding, F.; Gong, X. Z.; Guo, H. Y.; Kirschner, A.; Kocan, M.; Li, J. G.; Luo, G.-N.; Mao, H. M.; Qian, J. P.; Stangeby, P. C.; Wampler, W. R.; Wang, H. Q.; Wang, W. Z.

2015-02-01

The ITER beryllium (Be) first wall (FW) panels are shaped to protect leading edges between neighbouring panels arising from assembly tolerances. This departure from a perfectly cylindrical surface automatically leads to magnetically shadowed regions where eroded Be can be re-deposited, together with co-deposition of tritium fuel. To provide a benchmark for a series of erosion/re-deposition simulation studies performed for the ITER FW panels, dedicated experiments have been performed on the EAST tokamak using a specially designed, instrumented test limiter acting as a proxy for the FW panel geometry. Carbon coated molybdenum plates forming the limiter front surface were exposed to the outer midplane boundary plasma of helium discharges using the new Material and Plasma Evaluation System (MAPES). Net erosion and deposition patterns are estimated using ion beam analysis to measure the carbon layer thickness variation across the surface after exposure. The highest erosion of about 0.8 µm is found near the midplane, where the surface is closest to the plasma separatrix. No net deposition above the measurement detection limit was found on the proxy wall element, even in shadowed regions. The measured 2D surface erosion distribution has been modelled with the 3D Monte Carlo code ERO, using the local plasma parameter measurements together with a diffusive transport assumption. Excellent agreement between the experimentally observed net erosion and the modelled erosion profile has been obtained.

Determining the Mechanical Properties of Lattice Block Structures

NASA Technical Reports Server (NTRS)

Wilmoth, Nathan

2013-01-01

Lattice block structures and shape memory alloys possess several traits ideal for solving intriguing new engineering problems in industries such as aerospace, military, and transportation. Recent testing at the NASA Glenn Research Center has investigated the material properties of lattice block structures cast from a conventional aerospace titanium alloy as well as lattice block structures cast from nickel-titanium shape memory alloy. The lattice block structures for both materials were sectioned into smaller subelements for tension and compression testing. The results from the cast conventional titanium material showed that the expected mechanical properties were maintained. The shape memory alloy material was found to be extremely brittle from the casting process and only compression testing was completed. Future shape memory alloy lattice block structures will utilize an adjusted material composition that will provide a better quality casting. The testing effort resulted in baseline mechanical property data from the conventional titanium material for comparison to shape memory alloy materials once suitable castings are available.

Evaluating CMA equalization of SOQPSK-TG data for aeronautical telemetry

NASA Astrophysics Data System (ADS)

Cole-Rhodes, Arlene; KoneDossongui, Serge; Umuolo, Henry; Rice, Michael

2015-05-01

This paper presents the results of using a constant modulus algorithm (CMA) to recover shaped offset quadrature-phase shift keying (SOQPSK)-TG modulated data, which has been transmitted using the iNET data packet structure. This standard is defined and used for aeronautical telemetry. Based on the iNET-packet structure, the adaptive block processing CMA equalizer can be initialized using the minimum mean square error (MMSE) equalizer [3]. This CMA equalizer is being evaluated for use on iNET structured data, with initial tests being conducted on measured data which has been received in a controlled laboratory environment. Thus the CMA equalizer is applied at the receiver to data packets which have been experimentally generated in order to determine the feasibility of our equalization approach, and its performance is compared to that of the MMSE equalizer. Performance evaluation is based on computed bit error rate (BER) counts for these equalizers.

Cost-Benefit Analysis for the Advanced Near Net Shape Technology (ANNST) Method for Fabricating Stiffened Cylinders

NASA Technical Reports Server (NTRS)

Stoner, Mary Cecilia; Hehir, Austin R.; Ivanco, Marie L.; Domack, Marcia S.

2016-01-01

This cost-benefit analysis assesses the benefits of the Advanced Near Net Shape Technology (ANNST) manufacturing process for fabricating integrally stiffened cylinders. These preliminary, rough order-of-magnitude results report a 46 to 58 percent reduction in production costs and a 7-percent reduction in weight over the conventional metallic manufacturing technique used in this study for comparison. Production cost savings of 35 to 58 percent were reported over the composite manufacturing technique used in this study for comparison; however, the ANNST concept was heavier. In this study, the predicted return on investment of equipment required for the ANNST method was ten cryogenic tank barrels when compared with conventional metallic manufacturing. The ANNST method was compared with the conventional multi-piece metallic construction and composite processes for fabricating integrally stiffened cylinders. A case study compared these three alternatives for manufacturing a cylinder of specified geometry, with particular focus placed on production costs and process complexity, with cost analyses performed by the analogy and parametric methods. Furthermore, a scalability study was conducted for three tank diameters to assess the highest potential payoff of the ANNST process for manufacture of large-diameter cryogenic tanks. The analytical hierarchy process (AHP) was subsequently used with a group of selected subject matter experts to assess the value of the various benefits achieved by the ANNST method for potential stakeholders. The AHP study results revealed that decreased final cylinder mass and quality assurance were the most valued benefits of cylinder manufacturing methods, therefore emphasizing the relevance of the benefits achieved with the ANNST process for future projects.

Polymer infiltration studies

NASA Technical Reports Server (NTRS)

Marchello, Joseph M.

1995-01-01

Polymer infiltration investigations were directed toward development of methods by which to produce advanced composite material for automated part fabrication utilizing textile and robotic technology in the manufacture of subsonic and supersonic aircraft. Significant progress was made during the project on the preparation of carbon fiber composites using advanced polymer resins. The findings and results of the project are summarized in the attached paper entitled 'Powder-Coated Towpreg: Avenues to Near Net Shape Fabrication of High Performance Composite.' Also attached to this report is the second of two patent applications submitted as a result of these studies.

Shape Modification and Size Classification of Microcrystalline Graphite Powder as Anode Material for Lithium-Ion Batteries

NASA Astrophysics Data System (ADS)

Wang, Cong; Gai, Guosheng; Yang, Yufen

2018-03-01

Natural microcrystalline graphite (MCG) composed of many crystallites is a promising new anode material for lithium-ion batteries (LiBs) and has received considerable attention from researchers. MCG with narrow particle size distribution and high sphericity exhibits excellent electrochemical performance. A nonaddition process to prepare natural MCG as a high-performance LiB anode material is described. First, raw MCG was broken into smaller particles using a pulverization system. Then, the particles were modified into near-spherical shape using a particle shape modification system. Finally, the particle size distribution was narrowed using a centrifugal rotor classification system. The products with uniform hemispherical shape and narrow size distribution had mean particle size of approximately 9 μm, 10 μm, 15 μm, and 20 μm. Additionally, the innovative pilot experimental process increased the product yield of the raw material. Finally, the electrochemical performance of the prepared MCG was tested, revealing high reversible capacity and good cyclability.

Role of Erosion in Shaping Point Bars

NASA Astrophysics Data System (ADS)

Moody, J.; Meade, R.

2012-04-01

A powerful metaphor in fluvial geomorphology has been that depositional features such as point bars (and other floodplain features) constitute the river's historical memory in the form of uniformly thick sedimentary deposits waiting for the geomorphologist to dissect and interpret the past. For the past three decades, along the channel of Powder River (Montana USA) we have documented (with annual cross-sectional surveys and pit trenches) the evolution of the shape of three point bars that were created when an extreme flood in 1978 cut new channels across the necks of two former meander bends and radically shifted the location of a third bend. Subsequent erosion has substantially reshaped, at different time scales, the relic sediment deposits of varying age. At the weekly to monthly time scale (i.e., floods from snowmelt or floods from convective or cyclonic storms), the maximum scour depth was computed (by using a numerical model) at locations spaced 1 m apart across the entire point bar for a couple of the largest floods. The maximum predicted scour is about 0.22 m. At the annual time scale, repeated cross-section topographic surveys (25 during 32 years) indicate that net annual erosion at a single location can be as great as 0.5 m, and that the net erosion is greater than net deposition during 8, 16, and 32% of the years for the three point bars. On average, the median annual net erosion was 21, 36, and 51% of the net deposition. At the decadal time scale, an index of point bar preservation often referred to as completeness was defined for each cross section as the percentage of the initial deposit (older than 10 years) that was still remaining in 2011; computations indicate that 19, 41, and 36% of the initial deposits of sediment were eroded. Initial deposits were not uniform in thickness and often represented thicker pods of sediment connected by thin layers of sediment or even isolated pods at different elevations across the point bar in response to multiple floods during a water year. Erosion often was preferential and removed part or all of pods at lower elevations, and in time left what appears to be a random arrangement of sediment pods forming the point bar. Thus, we conclude that the erosional process is as important as the deposition process in shaping the final form of the point bar, and that point bars are not uniformly aggradational or transgressive deposits of sediment in which the age of the deposit increases monotonically downward at all locations across the point bar.

A novel one-pot process for near-net-shape fabrication of open-porous resorbable hydroxyapatite/protein composites and in vivo assessment.

PubMed

Mueller, Berit; Koch, Dietmar; Lutz, Rainer; Schlegel, Karl A; Treccani, Laura; Rezwan, Kurosch

2014-09-01

We present a mild one-pot freeze gelation process for fabricating near-net, complex-shaped hydroxyapatite scaffolds and to directly incorporate active proteins during scaffold processing. In particular, the direct protein incorporation enables a simultaneous adjustment and control of scaffold microstructure, porosity, resorbability and enhancement of initial mechanical and handling stability. Two proteins, serum albumin and lysozyme, are selected and their effect on scaffold stability and microstructure investigated by biaxial strength tests, electron microscopy, and mercury intrusion porosimetry. The resulting hydroxyapatite/protein composites feature adjustable porosities from 50% to 70% and a mechanical strength ranging from 2 to 6 MPa comparable to that of human spongiosa without any sintering step. Scaffold degradation behaviour and protein release are assessed by in vitro studies. A preliminary in vivo assessment of scaffold biocompatibility and resorption behaviour in adult domestic pigs is discussed. After implantation, composites were resorbed up to 50% after only 4 weeks and up to 65% after 8 weeks. In addition, 14% new bone formation after 4 weeks and 37% after 8 weeks were detected. All these investigations demonstrate the outstanding suitability of the one-pot-process to create, in a customisable and reliable way, biocompatible scaffolds with sufficient mechanical strength for handling and surgical insertion, and for potential use as biodegradable bone substitutes and versatile platform for local drug delivery. Copyright © 2014 Elsevier B.V. All rights reserved.

Recent developments in multi-layer flat knitting technology for waste free production of complex shaped 3D-reinforcing structures for composites

NASA Astrophysics Data System (ADS)

Trümper, W.; Lin, H.; Callin, T.; Bollengier, Q.; Cherif, C.; Krzywinski, S.

2016-07-01

Constantly increasing prices for raw materials and energy as well as the current discourse on the reduction of CO2-emissions places a special emphasis on the advantages of lightweight constructions and its resource conserving production methods. Fibre-reinforced composites are already seeing a number of applications in automobile, energy and mechanical engineering. Future applications within the named areas require greater material and energy efficiency and therefore manufacturing methods for textile preforms and lightweight constructions enabling an optimal arrangement of the reinforcing fibres while in the same time limiting waste to a minimum. One manufacturing method for textile reinforced preforms fulfilling quite many of the named requirements is the multilayer weft knitting technology. Multilayer weft knitted fabrics containing straight reinforcing yarns at least in two directions. The arrangement of these yarns is fixed by the loop yarn. Used yarn material in each knitting row is adaptable e. g. according to the load requirements or for the local integration of sensors. Draping properties of these fabrics can be varied within a great range and through this enabling draping of very complex shaped 3D-preforms without wrinkles from just one uncut fabric. The latest developments at ITM are concentrating on the development of a full production chain considering the 3D-CAD geometry, the load analysis, the generation of machine control programs as well as the development of technology and machines to enable the manufacturing of innovative net shape 3D-multilayer weft knitted fabrics such as complex shaped spacer fabrics and tubular fabrics with biaxial reinforcement.

Texture measurement of shaped material by impulse acoustic microscopy

PubMed

Eyraud; Nadal; Gondard

2000-03-01

All the microstructural parameters involved in metallurgical processes are difficult to determine directly on a shaped material. The aim of this paper is to use an impulse line-focus acoustic microscope (LFAM) as a non-destructive alternative to X-ray diffraction for measuring texture of slightly anisotropic materials. We apply it to characterize the rolling and annealing texture for tantalum sheets.

Superplastic forming of ceramic insulation

NASA Technical Reports Server (NTRS)

Nieh, T. G.; Wittenauer, J. P.; Wadsworth, J.

1992-01-01

Superplasticity has been demonstrated in many fine-grained structural ceramics and ceramic composites, including yttria-stabilized tetragonal zirconia polycrystal (YTZP), alumina, and Al2O3-reinforced zirconia (Al2O3/YTZ) duplex composites and SiC-reinforced Si3N4. These superplastic ceramics obviously offer the potential benefit of forming net shape or near net shape parts. This could be particularly useful for forming complicated shapes that are difficult to achieve using conventional forming techniques, or require elaborate, subsequent machining. In the present study, we successfully demonstrated the following: (1) superplastic 3Y-TXP and 20 percent Al2O3/YTZ composite have for the first time been successfully deformed into hemispherical caps via a biaxial gas-pressure forming technique; (2) no experimental difficulty was encountered in applying the required gas pressures and temperatures to achieve the results, thus, it is certain that higher rates of deformation than those presented in this study will be possible by using the current test apparatus at higher temperatures and pressures; and (3) an analytical model incorporating material parameters, such as variations during forming in the strain rate sensitivity exponent and grain growth-induced strain hardening, is needed to model accurately and therefore precisely control the biaxial gas-pressure forming of superplastic ceramics. Based on the results of this study, we propose to fabricate zirconia insulation tubes by superplastic extrusion of zirconia polycrystal. This would not only reduce the cost, but also improve the reliability of the tube products.

Shape-morphing composites with designed micro-architectures

NASA Astrophysics Data System (ADS)

Rodriguez, Jennifer N.; Zhu, Cheng; Duoss, Eric B.; Wilson, Thomas S.; Spadaccini, Christopher M.; Lewicki, James P.

2016-06-01

Shape memory polymers (SMPs) are attractive materials due to their unique mechanical properties, including high deformation capacity and shape recovery. SMPs are easier to process, lightweight, and inexpensive compared to their metallic counterparts, shape memory alloys. However, SMPs are limited to relatively small form factors due to their low recovery stresses. Lightweight, micro-architected composite SMPs may overcome these size limitations and offer the ability to combine functional properties (e.g., electrical conductivity) with shape memory behavior. Fabrication of 3D SMP thermoset structures via traditional manufacturing methods is challenging, especially for designs that are composed of multiple materials within porous microarchitectures designed for specific shape change strategies, e.g. sequential shape recovery. We report thermoset SMP composite inks containing some materials from renewable resources that can be 3D printed into complex, multi-material architectures that exhibit programmable shape changes with temperature and time. Through addition of fiber-based fillers, we demonstrate printing of electrically conductive SMPs where multiple shape states may induce functional changes in a device and that shape changes can be actuated via heating of printed composites. The ability of SMPs to recover their original shapes will be advantageous for a broad range of applications, including medical, aerospace, and robotic devices.

Hybrid Ultra-Microporous Materials for Selective Xenon Adsorption and Separation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mohamed, Mona H.; Elsaidi, Sameh K.; Pham, Tony

2016-05-30

The demand for Xe/Kr separation continues to grow due to the industrial significance of high-purity Xe gas. Current separation processes rely on energy intensive cryogenic distillation. Therefore, there is a need to develop less energy intensive alternatives such as physisorptive separation using porous materials. Here we show that an underexplored class of porous materials called hybrid ultramicroporous materials (HUMs) based upon inorganic and organic building blocks affords new benchmark selectivity for Xe separation from Xe/Kr mixtures. The isostructural materials, CROFOUR-1-Ni and CROFOUR-2-Ni, are coordination networks that exhibit coordinatively saturated metal centres and two distinct types of micropores, one of whichmore » is lined by CrO42- (CROFOUR) anions and the other is decorated by the functionalized organic linker. These nets offer unprecedented selectivity towards Xe, and also address processing and stability limitations of existing porous materials. Modelling experiments indicate that the extraordinary selectivity of these nets is tailored by synergy between the pore size, which is just above the kinetic diameter of Xe, and the strong electrostatics afforded by the CrO42- anions. Column breakthrough experiments demonstrate the potential of the practical use of these materials in Xe/Kr separation at low concentrations at the levels relevant to Xe capture from air and in nuclear fuel reprocessing.« less

Additive Manufacturing of Shape Memory Alloys

NASA Astrophysics Data System (ADS)

Van Humbeeck, Jan

2018-04-01

Selective Laser Melting (SLM) is an additive manufacturing production process, also called 3D printing, in which functional, complex parts are produced by selectively melting patterns in consecutive layers of powder with a laser beam. The pattern the laser beam is following is controlled by software that calculates the pattern by slicing a 3D CAD model of the part to be constructed. Apart from SLM, also other additive manufacturing techniques such as EBM (Electron Beam Melting), FDM (Fused Deposition Modelling), WAAM (Wire Arc Additive Manufacturing), LENS (Laser Engineered Net Shaping such as Laser Cladding) and binder jetting allow to construct complete parts layer upon layer. But since more experience of AM of shape memory alloys is collected by SLM, this paper will overview the potentials, limits and problems of producing NiTi parts by SLM.

Design of a 4D Printing System Using Thermal Sensitive Smart Materials and Photoactivated Shape Changing Polymers

NASA Astrophysics Data System (ADS)

Leist, Steven Kyle

4D printing is an emerging additive manufacturing technology that combines 3D printing with smart materials. Current 3D printing technology can print objects with a multitude of materials; however, these objects are usually static, geometrically permanent, and not suitable for multi-functional use. The 4D printed objects can change their shape over time when exposed to different external stimuli such as heat, pressure, magnetic fields, or moisture. In this research, heat and light reactive smart materials are explored as a 4D printing materials. Synthetization of a material that actuates when exposed to stimulus can be a very difficult process, and merging that same material with the ability to be 3D printed can be further difficult. A common 3D printing thermoplastic, poly(lactic) acid (PLA), is used as a shape memory material that is 3D printed using a fused deposition machine (FDM) and combined with nylon fabric for the exploration of smart textiles. The research shows that post printed PLA possesses shape memory properties depending on the thickness of the 3D printed material and the activation temperature. PLA can be thermomechanically trained into temporary shapes and return to its original shape when exposed to high temperatures. PLA can be 3D printed onto nylon fabrics for the creation of the smart textiles. Additionally, a photoisomerable shape changing material is explored because light activation is wireless, controllable, focusable, abundant, causes rapid shape change of the smart material, and induces reversible shape change in the material. This study supports the fundamental research to generate knowledge needed for synthesis of a novel azobenzene shape changing polymer (SCP) and integrating this smart material into objects printed with a 4D printing process using syringe printing. Multiple versions of azobenzene SCP are synthesized that actuate when exposed to 365 nm and 455 nm light. Two SCPs, MeOABHx and DR1Hx, are selected for the 4D printing research because of their ability to photoisomerize at room temperature and 3D printability. The physical properties of these polymers are characterized, photomechanical bending tests are performed, and the photo-generated stress is measured using a dynamic mechanical analyzer (DMA). The SCPs are deposited onto a passive layer to create bilayer films in order to actuate. The photomechanical efficiency of bilayer films is evaluated depending on the thickness of the passive layer film, type of azobenzene SCP, wavelength of the light source, intensity of the light source, and distance between the light and films. 4D printing can be used to streamline the design and manufacturing process of actuating parts. Complex heavy parts can be removed from actuation systems such as onboard power storage, motors, sensors, and processors by embedding these capabilities into the material themselves. This reduces the amount of required parts, the amount of materials, and reduces the cost of producing these parts. 4D printed products possess the properties of programmability, reaction and adaption to their environment, and automation. Therefore, they can find wider applications including foldable unmanned aerial vehicles, artificial muscles, grippers, biomedical drug delivery systems, stents, and minimally invasive surgeries.

A Framework for Modeling and Simulation of the Artificial

DTIC Science & Technology

2012-01-01

y or n) >> y Name: petra Simple Aspects: face_shape/thin, nose/small, skintone/light, hair_color/black, hair_type/curly Integrated Aspects...Multiconference. Orlando, FL (2012) 23. Mittal, S., Risco- Martin , J.: Netcentric System of Systems Engineering with DEVS Unified Process. CRC Press (2012) 24...Mittal, S., Risco- Martin , J., Zeigler, B.: DEVS-based simulation web services for net-centric T&E. In: Proceedings of the 2007 summer computer

Effects of Temperature and Steam Environment on Fatigue Behavior of Three SIC/SIC Ceramic Matrix Composites

DTIC Science & Technology

2008-09-01

Infiltration (CVI), Chemical Vapor Deposition (CVD) and polymer impregnation/ pyrolysis (PIP) [5:20, 32]. The SiC fibers currently... composite was infiltrated with a mixture of polymer , filler particles and solvent. During pyrolysis under nitrogen at temperatures > 1000 °C, the...using polymer infiltration and pyrolysis (PIP) method. Polymer infiltration and pyrolysis processing method allows near-net-shape molding and

Inspection of Space Station Cold Plate Using Visual and Automated Holographic Techniques

NASA Technical Reports Server (NTRS)

Decker, Arthur J.; Melis, Matthew E.; Weiland, Kenneth E.

1999-01-01

Real-time holography has been used to confirm the presence of non-uniformity in the construction of an International Space Station cold plate. Ultrasonic C-scans have previously shown suspected areas of cooling fin disbonds. But both neural-net processed and visual holography did not evidence any progressive permanent changes resulting from 3000 pressurization and relaxation cycles of a Dash 8 cold plate. Neural-net and visual inspections were performed of characteristic patterns generated from electronic time-average holograms of the vibrating cold plate. Normal modes of vibration were excited at very low amplitudes for this purpose, The neural nets were trained to flag very small changes in the mode shapes as encoded in the characteristic patterns. Both the whole cold plate and a zoomed region were inspected. The inspections were conducted before, after, and during pressurization and relaxation cycles of the cold plate. A water-filled cold plate was pressurized to 120 psig (827 kPa) and relaxed for each cycle. Each cycle required 5 seconds. Both the artificial neural networks and the inspectors were unable to detect changes in the mode shapes of the relaxed cold plate. The cold plate was also inspected visually using real-time holography and double-exposure holography. Regions of non-uniformity correlating with the C-scans were apparent, but the interference patterns did not change after 3000 pressurization and relaxation cycles. These tests constituted the first practical application of a neural-net inspection technique developed originally with support from the Director's Discretionary Fund at the Glenn Research Center at Lewis Field.

METHOD OF MAKING REFRACTORY BODIES

DOEpatents

Andersen, J.C.

1960-05-31

A method is given for the manufacture of silicon carbide bodies that are characterized by high density, high purity, and superior resistance to oxidative deterioration. Dense silicon bodies are obtained by a process in which granular silicon carbide, a carbonizable material, and a carbonaceous material are mixed together, the mixture is shaped as desired, and then the shape is fired in the presence of more than the stoichiometric amount of silicon. The carbonizable material preferably includes a temporary binder that is set before the firing step to hold the mix in shape for firing.

High-Temperature Oxidation of Fe3Al Intermetallic Alloy Prepared by Additive Manufacturing LENS

PubMed Central

Łyszkowski, Radosław

2015-01-01

The isothermal oxidation of Fe-28Al-5Cr (at%) intermetallic alloy microalloyed with Zr and B (<0.08 at%) in air atmosphere, in the temperature range of 1000 to 1200 °C, was studied. The investigation was carried out on the thin-walled (<1 mm) elements prepared by Laser Engineered Net Shaping (LENS) from alloy powder of a given composition. Characterization of the specimens, after the oxidation, was conducted using X-ray diffraction (XRD) and scanning electron microscopy (SEM, with back-scatter detector (BSE) and energy-dispersive X-ray spectroscopy (EDS) attachments). The investigation has shown, that the oxidized samples were covered with a thin, homogeneous α-Al2O3 oxide layers. The intensity of their growth indicates that the material lost its resistance to oxidation at 1200 °C. Structural analysis of the thin-walled components’ has not shown intensification of the oxidation process at the joints of additive layers. PMID:28788014

Review of the Methods for Production of Spherical Ti and Ti Alloy Powder

NASA Astrophysics Data System (ADS)

Sun, Pei; Fang, Zhigang Zak; Zhang, Ying; Xia, Yang

2017-10-01

Spherical titanium alloy powder is an important raw material for near-net-shape fabrication via a powder metallurgy (PM) manufacturing route, as well as feedstock for powder injection molding, and additive manufacturing (AM). Nevertheless, the cost of Ti powder including spherical Ti alloy has been a major hurdle that prevented PM Ti from being adopted for a wide range of applications. Especially with the increasing importance of powder-bed based AM technologies, the demand for spherical Ti powder has brought renewed attention on properties and cost, as well as on powder-producing processes. The performance of Ti components manufactured from powder has a strong dependence on the quality of powder, and it is therefore crucial to understand the properties and production methods of powder. This article aims to provide a cursory review of the basic techniques of commercial and emerging methods for making spherical Ti powder. The advantages as well as limitations of different methods are discussed.

History, Structure and Agency in Global Health Governance

PubMed Central

Gill, Stephen; Benatar, Solomon R.

2017-01-01

Ilona Kickbusch’s thought provoking editorial is criticized in this commentary, partly because she fails to refer to previous critical work on the global conditions and policies that sustain inequality, poverty, poor health and damage to the biosphere and, as a result, she misreads global power and elides consideration of the fundamental historical structures of political and material power that shape agency in global health governance. We also doubt that global health can be improved through structures and processes of multilateralism that are premised on the continued reproduction of the ecologically myopic and socially unsustainable market civilization model of capitalist development that currently prevails in the world economy. This model drives net financial flows from poor to rich countries and from the poor to the affluent and super wealthy individuals. By contrast, we suggest that significant progress in global health requires a profound and socially just restructuring of global power, greater global solidarity and the "development of sustainability." PMID:28812808

SEM and AFM Studies of Two-Phase Magnetic Alkali Borosilicate Glasses

PubMed Central

Tomkovich, M.; Nacke, B.; Filimonov, A.; Alekseeva, O.; Vanina, P.; Nizhankovskii, V.

2017-01-01

The morphology and composition of four types of two-phase alkali borosilicate glasses with magnetic atoms prepared by inductive melting have been studied. The results of scanning electron microscopy point to uniform distribution of Na, Si, and O atoms in these samples while magnetic iron atoms form ball-shaped agglomerates. The magnetic properties of these agglomerates have been confirmed by magnetic force microscopy. Atomic force microscopy had shown that in these samples two different morphological structures, drop-like and dendrite net, are formed. The formation of dendrite-like structure is a necessary condition for production of porous magnetic glasses. The obtained results allow us to optimize the melting and heat treatment processes leading to production of porous alkali borosilicate glasses with magnetic properties. The first results for nanocomposite materials on the basis of magnetic glasses containing the embedded ferroelectrics KH2PO4 demonstrate the effect of applied magnetic field on the ferroelectric phase transition. PMID:28428976

Tailored laser beam shaping for efficient and accurate microstructuring

NASA Astrophysics Data System (ADS)

Häfner, T.; Strauß, J.; Roider, C.; Heberle, J.; Schmidt, M.

2018-02-01

Large-area processing with high material removal rates by ultrashort pulsed (USP) lasers is coming into focus by the development of high-power USP laser systems. However, currently the bottleneck for high-rate production is given by slow and inefficient beam manipulation. On the one hand, slow beam deflection with regard to high pulse repetition rates leads to heat accumulation and shielding effects, on the other hand, a conventional focus cannot provide the optimum fluence due to the Gaussian intensity profile. In this paper, we emphasize on two approaches of dynamic laser beam shaping with liquid crystal on silicon spatial light modulation and acousto-optic beam shaping. Advantages and limitations of dynamic laser beam shaping with regard to USP laser material processing and methods for reducing the influence of speckle are discussed. Additionally, the influence of optics induced aberrations on speckle characteristics is evaluated. Laser material processing results are presented correlating the achieved structure quality with the simulated and measured beam quality. Experimental and analytical investigations show a certain fluence dependence of the necessary number of alternative holograms to realize homogeneous microstructures.

Parametric analysis and temperature effect of deployable hinged shells using shape memory polymers

NASA Astrophysics Data System (ADS)

Tao, Ran; Yang, Qing-Sheng; He, Xiao-Qiao; Liew, Kim-Meow

2016-11-01

Shape memory polymers (SMPs) are a class of intelligent materials, which are defined by their capacity to store a temporary shape and recover an original shape. In this work, the shape memory effect of SMP deployable hinged shell is simulated by using compiled user defined material subroutine (UMAT) subroutine of ABAQUS. Variations of bending moment and strain energy of the hinged shells with different temperatures and structural parameters in the loading process are given. The effects of the parameters and temperature on the nonlinear deformation process are emphasized. The entire thermodynamic cycle of SMP deployable hinged shell includes loading at high temperature, load carrying with cooling, unloading at low temperature and recovering the original shape with heating. The results show that the complicated thermo-mechanical deformation and shape memory effect of SMP deployable hinge are influenced by the structural parameters and temperature. The design ability of SMP smart hinged structures in practical application is prospected.

Laser Hot Wire Process: A Novel Process for Near-Net Shape Fabrication for High-Throughput Applications

NASA Astrophysics Data System (ADS)

Kottman, Michael; Zhang, Shenjia; McGuffin-Cawley, James; Denney, Paul; Narayanan, Badri K.

2015-03-01

The laser hot wire process has gained considerable interest for additive manufacturing applications, leveraging its high deposition rate, low dilution, thermal stability, and general metallurgical control including the ability to introduce and preserve desired meta-stable phases. Recent advancements in closed-loop process control and laser technology have increased productivity, process stability, and control of deposit metallurgy. The laser hot wire process has shown success in several applications: repairing and rejuvenating casting dies, depositing a variety of alloys including abrasion wear-resistant overlays with solid and tubular wires, and producing low-dilution (<5%) nickel alloy overlays for corrosion applications. The feasibility of fabricating titanium buildups is being assessed for aerospace applications.

Precision cast vs. wrought superalloys

NASA Technical Reports Server (NTRS)

Tien, J. K.; Borofka, J. C.; Casey, M. E.

1986-01-01

While cast polycrystalline superalloys recommend themselves in virtue of better 'buy-to-fly' ratios and higher strengthening gamma-prime volume fractions than those of wrought superalloys, the expansion of their use into such critical superalloy applications as gas turbine hot section components has been slowed by insufficient casting process opportunities for microstructural control. Attention is presently drawn, however, to casting process developments facilitating the production of defect-tolerant superalloy castings having improved fracture reliability. Integrally bladed turbine wheel and thin-walled turbine exhaust case near-net-shape castings have been produced by these means.

Effect of Bottoming on Material Property during Sheet Forming Process through Finite Element Method

NASA Astrophysics Data System (ADS)

Akinlabi, Stephen A.; Fatoba, Olawale S.; Mashinini, Peter M.; Akinlabi, Esther T.

2018-03-01

Metal forming is one of the conventional manufacturing processes of immense relevance till date even though modern manufacturing processes have evolved over the years. It is a known fact that material tends to return or spring back to its original form during forming or bending. The phenomena have been well managed through its application in various manufacturing processes by compensating for the spring back through overbending and bottoming. Overbending is bending the material beyond the desired shape to allow the material to spring back to the expected shape. Bottoming, on the other hand, is a process of undergoing plastic deformation at the point of bending. This study reports on the finite element analysis of the effect of bottoming on the material property during the sheet forming process with the aim of optimising the process. The result of the analysis revealed that the generated plastic strains are in the order between 1.750e00-1 at the peak of the bending and 3.604e00-2, which was at the early stage of the bending.

The Formation of Life-sustaining Planets in Extrasolar Systems

NASA Technical Reports Server (NTRS)

Chambers, J. E.

2003-01-01

The spatial exploration is providing us a large quantity of information about the composition of the planets and satellites crusts. However, most of the experiences that are proposed in the guides of activities in Planetary Geology are based exclusively on the images utilization: photographs, maps, models or artistic reconstructions [1,2]. That things help us to recognize shapes and to deduce geological processes, but they says us little about the materials that they are implicated. In order to avoid this dicotomy between shapes and materials, we have designed an experience in the one which, employing of rocks and landscapes of our geological environment more next, the pupils be able to do an exercise of compared planetology analyzing shapes, processes and material of several planetary bodies of the Solar System.

Process of making porous ceramic materials with controlled porosity

DOEpatents

Anderson, Marc A.; Ku, Qunyin

1993-01-01

A method of making metal oxide ceramic material is disclosed by which the porosity of the resulting material can be selectively controlled by manipulating the sol used to make the material. The method can be used to make a variety of metal oxide ceramic bodies, including membranes, but also pellets, plugs or other bodies. It has also been found that viscous sol materials can readily be shaped by extrusion into shapes typical of catalytic or adsorbent bodies used in industry, to facilitate the application of such materials for catalytic and adsorbent applications.

Characterization of Al-Cu-Li Alloy 2090 Near Net Shape Extrusion

NASA Technical Reports Server (NTRS)

Birt, M. J.; Domack, M. S.; Hafley, R. A.; Pollock, W. D.

1998-01-01

Aluminum-lithium (Al-Li) alloys near net shape extrusions are being evaluated for potential application in launch vehicle structures. The objective of this study was to determine tensile and fracture properties, corrosion resistance, and weldability of integrally stiffened panels of Al-Cu-Li alloy 2090 in the T8 temper. The microstructure was pre-dominantly unrecrystallized. Texture analyses revealed the presence of fiber components in the stiffeners and a combination of fiber and rolling components in the skin. Variations in grain morphology and texture through the extruded cross section were correlated with the tensile, fracture, and corrosion behavior. Tensile strengths at room and cryogenic temperatures of the 2090 extrusions were similar to other 2090 product forms and were higher than 2219-T87, the primary structural material in the Space Shuttle external tank; however, ductilities were lower. The fracture resistance of the 2090 extrusion was lower than 2219-T87 plate at room temperature. At cryogenic temperatures, tensile ductility and fracture behavior of the 2090 extrusion were similar to other 2090 product forms but were lower than 2219-T87 plate. The exfoliation and stress corrosion resistance of the 2090 extrusion compared favorably with the characteristics of other 2090 product forms. The weldability and weldment properties of the extrusions were similar to 2090 and 2219 plates.

Deformation and annealing study of Nicraly

NASA Technical Reports Server (NTRS)

Trela, D. M.; Ebert, L. J.

1975-01-01

Extensive experiments were carried out on the ODS alloy Nicraly, (an alloy prepared by mechanical alloying and consolidating a powder blend consisting of 16% chromium, 4% aluminum, 2-3% yttria, balance nickel), in efforts to develop methods of controlling the grain size and grain shape of the material. The experiments fell into two general categories: variations in the annealing parameters using the as-extruded material as it was received, and various thermomechanical processing schedules (various combinations of cold work and annealing). Success was achieved in gaining grain size and grain shape control by annealing of the as-extruded material. By proper selection of annealing temperature and cooling rates, the grain size of the as-received material was increased almost two orders of magnitude (from an average grain dimension of 0.023 mm to 1.668 mm) while the aspect ratio was increased by some 50% (from 20:1 to 30:1). No success was achieved in gaining significant control of the grain size and shape of the material by thermo-mechanical processing.

High Velocity Burner Rig Oxidation and Thermal Fatigue Behavior of Si3N4- and SiC Base Ceramics to 1370 Deg C

NASA Technical Reports Server (NTRS)

Sanders, W. A.; Johnston, J. R.

1978-01-01

One SiC material and three Si3N4 materials including hot-pressed Si3N4 as a baseline were exposed in a Mach-1-gas-velocity burner rig simulating a turbine engine environment. Criteria for the materials selection were: potential for gas-turbine usage, near-net-shape fabricability and commercial/domestic availability. Cyclic exposures of test vanes up to 250 cycles (50 hr at temperature) were at leading-edge temperatures to 1370 C. Materials and batches were compared as to weight change, surface change, fluorescent penetrant inspection, and thermal fatigue behavior. Hot-pressed Si3N4 survived the test to 1370 C with slight weight losses. Two types of reaction-sintered Si3N4 displayed high weight gains and considerable weight-change variability, with one material exhibiting superior thermal fatigue behavior. A siliconized SiC showed slight weight gains, but considerable batch variability in thermal fatigue.

Time-resolved study of femtosecond laser induced micro-modifications inside transparent brittle materials

NASA Astrophysics Data System (ADS)

Hendricks, F.; Matylitsky, V. V.; Domke, M.; Huber, Heinz P.

2016-03-01

Laser processing of optically transparent or semi-transparent, brittle materials is finding wide use in various manufacturing sectors. For example, in consumer electronic devices such as smartphones or tablets, cover glass needs to be cut precisely in various shapes. The unique advantage of material processing with femtosecond lasers is efficient, fast and localized energy deposition in nearly all types of solid materials. When an ultra-short laser pulse is focused inside glass, only the localized region in the neighborhood of the focal volume absorbs laser energy by nonlinear optical absorption. Therefore, the processing volume is strongly defined, while the rest of the target stays unaffected. Thus ultra-short pulse lasers allow cutting of the chemically strengthened glasses such as Corning Gorilla glass without cracking. Non-ablative cutting of transparent, brittle materials, using the newly developed femtosecond process ClearShapeTM from Spectra-Physics, is based on producing a micron-sized material modification track with well-defined geometry inside. The key point for development of the process is to understand the induced modification by a single femtosecond laser shot. In this paper, pump-probe microscopy techniques have been applied to study the defect formation inside of transparent materials, namely soda-lime glass samples, on a time scale between one nanosecond to several tens of microseconds. The observed effects include acoustic wave propagation as well as mechanical stress formation in the bulk of the glass. Besides better understanding of underlying physical mechanisms, our experimental observations have enabled us to find optimal process parameters for the glass cutting application and lead to better quality and speed for the ClearShapeTM process.

Cu-Al-Ni Shape Memory Single Crystal Wires with High Transformation Temperature

NASA Technical Reports Server (NTRS)

Hautcoeur, Alain; Fouché, Florian; Sicre, Jacques

2016-01-01

CN-250X is a new material with higher performance than Nickel-Titanium Shape Memory Alloy (SMA). For space mechanisms, the main disadvantage of Nickel-Titanium Shape Memory Alloy is the limited transformation temperature. The new CN-250X Nimesis alloy is a Cu-Al-Ni single crystal wire available in large quantity because of a new industrial process. The triggering of actuators made with this Cu-Al-Ni single crystal wire can range from ambient temperature to 200 C in cycling and even to 250 C in one-shot mode. Another advantage of CN-250X is a better shape recovery (8 to 10%) than Ni-Ti (6 to 7%). Nimesis is the first company able to produce this type of material with its new special industrial process. A characterization study is presented in this work, including the two main solicitation modes for this material: tensile and torsion. Different tests measure the shape recovery of Cu-Al-Ni single crystals wires during heating from room temperature to a temperature higher than temperature of end of martensitic transformation.

The pH dependency of N-converting enzymatic processes, pathways and microbes: effect on net N2 O production.

PubMed

Blum, Jan-Michael; Su, Qingxian; Ma, Yunjie; Valverde-Pérez, Borja; Domingo-Félez, Carlos; Jensen, Marlene Mark; Smets, Barth F

2018-05-01

Nitrous oxide (N 2 O) is emitted during microbiological nitrogen (N) conversion processes, when N 2 O production exceeds N 2 O consumption. The magnitude of N 2 O production vs. consumption varies with pH and controlling net N 2 O production might be feasible by choice of system pH. This article reviews how pH affects enzymes, pathways and microorganisms that are involved in N-conversions in water engineering applications. At a molecular level, pH affects activity of cofactors and structural elements of relevant enzymes by protonation or deprotonation of amino acid residues or solvent ligands, thus causing steric changes in catalytic sites or proton/electron transfer routes that alter the enzymes' overall activity. Augmenting molecular information with, e.g., nitritation or denitrification rates yields explanations of changes in net N 2 O production with pH. Ammonia oxidizing bacteria are of highest relevance for N 2 O production, while heterotrophic denitrifiers are relevant for N 2 O consumption at pH > 7.5. Net N 2 O production in N-cycling water engineering systems is predicted to display a 'bell-shaped' curve in the range of pH 6.0-9.0 with a maximum at pH 7.0-7.5. Net N 2 O production at acidic pH is dominated by N 2 O production, whereas N 2 O consumption can outweigh production at alkaline pH. Thus, pH 8.0 may be a favourable pH set-point for water treatment applications regarding net N 2 O production. © 2018 Society for Applied Microbiology and John Wiley & Sons Ltd.

Decision-making deficits in patients with chronic schizophrenia: Iowa Gambling Task and Prospect Valence Learning model.

PubMed

Kim, Myung-Sun; Kang, Bit-Na; Lim, Jae Young

2016-01-01

Decision-making is the process of forming preferences for possible options, selecting and executing actions, and evaluating the outcome. This study used the Iowa Gambling Task (IGT) and the Prospect Valence Learning (PVL) model to investigate deficits in risk-reward related decision-making in patients with chronic schizophrenia, and to identify decision-making processes that contribute to poor IGT performance in these patients. Thirty-nine patients with schizophrenia and 31 healthy controls participated. Decision-making was measured by total net score, block net scores, and the total number of cards selected from each deck of the IGT. PVL parameters were estimated with the Markov chain Monte Carlo sampling scheme in OpenBugs and BRugs, its interface to R, and the estimated parameters were analyzed with the Mann-Whitney U-test. The schizophrenia group received significantly lower total net scores compared to the control group. In terms of block net scores, an interaction effect of group × block was observed. The block net scores of the schizophrenia group did not differ across the five blocks, whereas those of the control group increased as the blocks progressed. The schizophrenia group obtained significantly lower block net scores in the fourth and fifth blocks of the IGT and selected cards from deck D (advantageous) less frequently than the control group. Additionally, the schizophrenia group had significantly lower values on the utility-shape, loss-aversion, recency, and consistency parameters of the PVL model. These results indicate that patients with schizophrenia experience deficits in decision-making, possibly due to failure in learning the expected value of each deck, and incorporating outcome experiences of previous trials into expectancies about options in the present trial.

Shape-morphing composites with designed micro-architectures

DOE PAGES

Rodriguez, Jennifer N.; Zhu, Cheng; Duoss, Eric B.; ...

2016-06-15

Shape memory polymers (SMPs) are attractive materials due to their unique mechanical properties, including high deformation capacity and shape recovery. SMPs are easier to process, lightweight, and inexpensive compared to their metallic counterparts, shape memory alloys. However, SMPs are limited to relatively small form factors due to their low recovery stresses. Lightweight, micro-architected composite SMPs may overcome these size limitations and offer the ability to combine functional properties (e.g., electrical conductivity) with shape memory behavior. Fabrication of 3D SMP thermoset structures via traditional manufacturing methods is challenging, especially for designs that are composed of multiple materials within porous microarchitectures designedmore » for specific shape change strategies, e.g. sequential shape recovery. We report thermoset SMP composite inks containing some materials from renewable resources that can be 3D printed into complex, multi-material architectures that exhibit programmable shape changes with temperature and time. Through addition of fiber-based fillers, we demonstrate printing of electrically conductive SMPs where multiple shape states may induce functional changes in a device and that shape changes can be actuated via heating of printed composites. As a result, the ability of SMPs to recover their original shapes will be advantageous for a broad range of applications, including medical, aerospace, and robotic devices.« less

Migration and sensory properties of plastics-based nets used as food-contacting materials under ambient and high temperature heating conditions.

PubMed

Kontominas, M G; Goulas, A E; Badeka, A V; Nerantzaki, A

2006-06-01

Overall migration from a wide range of commercial plastics-based netting materials destined to be used as either meat or vegetable packaging materials into the fatty food simulant isooctane or the aqueous simulant distilled water, respectively, was studied. In addition, sensory tests of representative netting materials were carried out in bottled water in order to investigate possible development of off-odour/taste and discoloration in this food simulant as a result of migration from the netting material. Sensory tests were supplemented by determination of the volatile compounds' profile in table water exposed to the netting materials using SPME-GC/MS. Test conditions for packaging material/food simulant contact and method of overall migration analysis were according to European Union Directives 90/128 (EEC, 1990) and 2002/72 (EEC, 2002). The results showed that for both PET and polyethylene-based netting materials, overall migration values into distilled water ranged between 11.5 and 48.5 mg l(-1), well below the upper limit (60 mg l(-1)) for overall migration values from plastics-packaging materials set by the European Union. The overall migration values from netting materials into isooctane ranged between 38.0 and 624.0 mg l(-1), both below and above the European Union upper limit for migration. Sensory tests involving contact of representative samples with table water under refluxing (100 degrees C/4 h) conditions showed a number of the netting materials produced both off-odour and/or taste as well as discoloration of the food simulant rendering such materials unfit for the packaging of foodstuffs in applications involving heating at elevated temperatures. GC/MS analysis showed the presence of numerous volatile compounds being produced after netting materials/water contact under refluxing conditions. Although it is extremely difficult to establish a clear correlation between sensory off-odour development and GC/MS volatile compounds' profile, it may be postulated that plastics oxidation products such as hexanal, heptanal, octanal and 2,6 di-tert-butylquinone may contribute to off-odour development using commercially bottled table water as a food simulant. Likewise, compounds such as carbon disulfide, [1,1'-biphenyl]-2-ol and propanoic acid, 2 methyl 1-(1,1-dimethyl)-2-methyl-1,3-propanediyl ester probably originating from cotton and rubber components of netting materials may also contribute to off-odour/taste development.

Characterization of origami shape memory metamaterials (SMMM) made of bio-polymer blends

NASA Astrophysics Data System (ADS)

Kshad, Mohamed Ali E.; Naguib, Hani E.

2016-04-01

Shape memory materials (SMMs) are materials that can return to their virgin state and release mechanically induced strains by external stimuli. Shape memory polymers (SMPs) are a class of SMMs that show a high shape recoverability and which have attractive potential for structural applications. In this paper, we experimentally study the shape memory effect of origami based metamaterials. The main focus is on the Muira origami metamaterials. The fabrication technique used to produce origami structure is direct molding where all the geometrical features are molded from thermally virgin polymers without post folding of flat sheets. The study shows experimental investigations of shape memory metamaterials (SMMMs) made of SMPs that can be used in different applications such as medicine, robotics, and lightweight structures. The origami structure made from SMP blends, activated with uniform heating. The effect of blend composition on the shape memory behavior was studied. Also the influence of the thermomechanical and the viscoelastic properties of origami unit cell on the activation process have been discussed, and stress relaxation and shape recovery were investigated. Activation process of the unit cell has been demonstrated.

Shape adjustment optimization and experiment of cable-membrane reflectors

NASA Astrophysics Data System (ADS)

Du, Jingli; Gu, Yongzhen; Bao, Hong; Wang, Congsi; Chen, Xiaofeng

2018-05-01

Cable-membrane structures are widely employed for large space reflectors due to their lightweight, compact and easy package. In these structures, membranes are attached to cable net, serving as reflectors themselves or as supporting structures for other reflective surface. The cable length and membrane shape have to be carefully designed and fabricated to guarantee the desired reflector surface shape. However, due to inevitable error in cable length and membrane shape during the manufacture and assembly of cable-membrane reflectors, some cables have to be designed to be capable of length adjustment. By carefully adjusting the length of these cables, the degeneration in reflector shape precision due to this inevitable error can be effectively reduced. In the paper a shape adjustment algorithm for cable-membrane reflectors is proposed. Meanwhile, model updating is employed during shape adjustment to decrease the discrepancy of the numerical model with respect to the actual reflector. This discrepancy has to be considered because during attaching membranes to cable net, the accuracy of the membrane shape is hard to guarantee. Numerical examples and experimental results demonstrate the proposed method.

Electrochemical and mechanical polishing and shaping method and system

NASA Technical Reports Server (NTRS)

Engelhaupt, Darell E. (Inventor); Gubarev, Mikhail V. (Inventor); Jones, William David (Inventor); Ramsey, Brian D. (Inventor); Benson, Carl M. (Inventor)

2011-01-01

A method and system are provided for the shaping and polishing of the surface of a material selected from the group consisting of electrically semi-conductive materials and conductive materials. An electrically non-conductive polishing lap incorporates a conductive electrode such that, when the polishing lap is placed on the material's surface, the electrode is placed in spaced-apart juxtaposition with respect to the material's surface. A liquid electrolyte is disposed between the material's surface and the electrode. The electrolyte has an electrochemical stability constant such that cathodic material deposition on the electrode is not supported when a current flows through the electrode, the electrolyte and the material. As the polishing lap and the material surface experience relative movement, current flows through the electrode based on (i) adherence to Faraday's Law, and (ii) a pre-processing profile of the surface and a desired post-processing profile of the surface.

Demonstration of Minimally Machined Honeycomb Silicon Carbide Mirrors

NASA Technical Reports Server (NTRS)

Goodman, William

2012-01-01

Honeycomb silicon carbide composite mirrors are made from a carbon fiber preform that is molded into a honeycomb shape using a rigid mold. The carbon fiber honeycomb is densified by using polymer infiltration pyrolysis, or through a reaction with liquid silicon. A chemical vapor deposit, or chemical vapor composite (CVC), process is used to deposit a polishable silicon or silicon carbide cladding on the honeycomb structure. Alternatively, the cladding may be replaced by a freestanding, replicated CVC SiC facesheet that is bonded to the honeycomb. The resulting carbon fiber-reinforced silicon carbide honeycomb structure is a ceramic matrix composite material with high stiffness and mechanical strength, high thermal conductivity, and low CTE (coefficient of thermal expansion). This innovation enables rapid, inexpensive manufacturing. The web thickness of the new material is less than 1 millimeter, and core geometries tailored. These parameters are based on precursor carbon-carbon honeycomb material made and patented by Ultracor. It is estimated at the time of this reporting that the HoneySiC(Trademark) will have a net production cost on the order of $38,000 per square meter. This includes an Ultracor raw material cost of about $97,000 per square meter, and a Trex silicon carbide deposition cost of $27,000 per square meter. Even at double this price, HoneySiC would beat NASA's goal of $100,000 per square meter. Cost savings are estimated to be 40 to 100 times that of current mirror technologies. The organic, rich prepreg material has a density of 56 kilograms per cubic meter. A charred carbon-carbon panel (volatile organics burnt off) has a density of 270 kilograms per cubic meter. Therefore, it is estimated that a HoneySiC panel would have a density of no more than 900 kilograms per cubic meter, which is about half that of beryllium and about onethird the density of bulk silicon carbide. It is also estimated that larger mirrors could be produced in a matter of weeks. Each cell is completely uniform, maintaining the shape of the inserted mandrel. Furthermore, the layup creates pressure that insures node bond strength. Each node is a composite laminate using only the inherent resin system to form the bond. This contrasts starkly with the other known method of producing composite honeycomb, in which individual corrugations are formed, cured, and then bonded together in a secondary process. By varying the size of the mandrels within the layup, varying degrees of density can be achieved. Typical sizes are 3/8 and 3/16 in. (approximately 10 and 5 millimeters). Cell sizes up to 1 in. (approximately 25 millimeters) have been manufactured. Similarly, the shape of the core can be altered for a flexible honeycomb structure.

Direct-write fabrication of 4D active shape-changing behavior based on a shape memory polymer and its nanocomposite (Conference Presentation)

NASA Astrophysics Data System (ADS)

Wei, Hongqiu; Zhang, Qiwei; Yao, Yongtao; Liu, Liwu; Liu, Yanju; Leng, Jinsong

2017-04-01

Shape memory polymers (SMPs), a typical class of smart materials, have been witnessed significant advances in the past decades. Based on the unique performance to recover the initial shape after going through a shape deformation, the applications of SMPs have aroused growing interests. However, most of the researches are hindered by traditional processing technologies which limit the design space of SMPs-based structures. Three-dimension (3D) printing as an emerging technology endows design freedom to manufacture materials with complex structures. In present article, we show that by employing direct-write printing method; one can realize the printing of SMPs to achieve 4D active shape-changing structures. We first fabricated a kind of 3D printable polylactide (PLA)-based SMPs and characterized the overall properties of such materials. Results demonstrated the prepared PLA-based SMPs presenting excellent shape memory effect. In what follows, the rheological properties of such PLA-based SMP ink during printing process were discussed in detail. Finally, we designed and printed several 3D configurations for investigation. By combining 3D printing with shape memory behavior, these printed structures achieve 4D active shape-changing performance under heat stimuli. This research presents a high flexible method to realize the fabrication of SMP-based 4D active shape-changing structures, which opens the way for further developments and improvements of high-tech fields like 4D printing, soft robotics, micro-systems and biomedical devices.

Reversible TAD Chemistry as a Convenient Tool for the Design of (Re)processable PCL-Based Shape-Memory Materials.

PubMed

Defize, Thomas; Riva, Raphaël; Thomassin, Jean-Michel; Alexandre, Michaël; Herck, Niels Van; Prez, Filip Du; Jérôme, Christine

2017-01-01

A chemically cross-linked but remarkably (re)processable shape-memory polymer (SMP) is designed by cross-linking poly(ε-caprolactone) (PCL) stars via the efficient triazolinedione click chemistry, based on the very fast and reversible Alder-ene reaction of 1,2,4-triazoline-3,5-dione (TAD) with indole compounds. Typically, a six-arm star-shaped PCL functionalized by indole moieties at the chain ends is melt-blended with a bisfunctional TAD, directly resulting in a cross-linked PCL-based SMP without the need of post-curing treatment. As demonstrated by the stress relaxation measurement, the labile character of the TAD-indole adducts under stress allows for the solid-state plasticity reprocessing of the permanent shape at will by compression molding of the raw cross-linked material, while keeping excellent shape-memory properties. © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Molecules, muscles, and machines: Universal performance characteristics of motors

PubMed Central

Marden, James H.; Allen, Lee R.

2002-01-01

Animal- and human-made motors vary widely in size and shape, are constructed of vastly different materials, use different mechanisms, and produce an enormous range of mass-specific power. Despite these differences, there is remarkable consistency in the maximum net force produced by broad classes of animal- and human-made motors. Motors that use force production to accomplish steady translational motion of a load (myosin, kinesin, dynein, and RNA polymerase molecules, muscle cells, whole muscles, winches, linear actuators, and rockets) have maximal force outputs that scale as the two-thirds power of mass, i.e., with cross-sectional area. Motors that use cyclical motion to generate force and are more subject to multiaxial stress and vibration have maximal force outputs that scale as a single isometric function of motor mass with mass-specific net force output averaging 57 N⋅kg−1 (SD = 14). Examples of this class of motors includes flying birds, bats, and insects, swimming fish, various taxa of running animals, piston engines, electric motors, and all types of jets. Dependence of force production and stress resistance on cross-sectional area is well known, but the isometric scaling and common upper limit of mass-specific force production by cyclical motion motors has not been recognized previously and is not explained by an existing body of theory. Remarkably, this finding indicates that most of the motors used by humans and animals for transportation have a common upper limit of mass-specific net force output that is independent of materials and mechanisms. PMID:11917097

Molecules, muscles, and machines: universal performance characteristics of motors.

PubMed

Marden, James H; Allen, Lee R

2002-04-02

Animal- and human-made motors vary widely in size and shape, are constructed of vastly different materials, use different mechanisms, and produce an enormous range of mass-specific power. Despite these differences, there is remarkable consistency in the maximum net force produced by broad classes of animal- and human-made motors. Motors that use force production to accomplish steady translational motion of a load (myosin, kinesin, dynein, and RNA polymerase molecules, muscle cells, whole muscles, winches, linear actuators, and rockets) have maximal force outputs that scale as the two-thirds power of mass, i.e., with cross-sectional area. Motors that use cyclical motion to generate force and are more subject to multiaxial stress and vibration have maximal force outputs that scale as a single isometric function of motor mass with mass-specific net force output averaging 57 N x kg(-1) (SD = 14). Examples of this class of motors includes flying birds, bats, and insects, swimming fish, various taxa of running animals, piston engines, electric motors, and all types of jets. Dependence of force production and stress resistance on cross-sectional area is well known, but the isometric scaling and common upper limit of mass-specific force production by cyclical motion motors has not been recognized previously and is not explained by an existing body of theory. Remarkably, this finding indicates that most of the motors used by humans and animals for transportation have a common upper limit of mass-specific net force output that is independent of materials and mechanisms.

Material migration studies with an ITER first wall panel proxy on EAST

DOE PAGES

Ding, R.; Pitts, R. A.; Borodin, D.; ...

2015-01-23

The ITER beryllium (Be) first wall (FW) panels are shaped to protect leading edges between neighbouring panels arising from assembly tolerances. This departure from a perfectly cylindrical surface automatically leads to magnetically shadowed regions where eroded Be can be re-deposited, together with co-deposition of tritium fuel. To provide a benchmark for a series of erosion/re-deposition simulation studies performed for the ITER FW panels, dedicated experiments have been performed on the EAST tokamak using a specially designed, instrumented test limiter acting as a proxy for the FW panel geometry. Carbon coated molybdenum plates forming the limiter front surface were exposed tomore » the outer midplane boundary plasma of helium discharges using the new Material and Plasma Evaluation System (MAPES). Net erosion and deposition patterns are estimated using ion beam analysis to measure the carbon layer thickness variation across the surface after exposure. The highest erosion of about 0.8 µm is found near the midplane, where the surface is closest to the plasma separatrix. No net deposition above the measurement detection limit was found on the proxy wall element, even in shadowed regions. The measured 2D surface erosion distribution has been modelled with the 3D Monte Carlo code ERO, using the local plasma parameter measurements together with a diffusive transport assumption. In conclusion, excellent agreement between the experimentally observed net erosion and the modelled erosion profile has been obtained.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Geng, J.; Nlebedim, I. C.; Besser, M. F.

A bulk combinatorial approach for synthesizing alloy libraries using laser engineered net shaping (LENS; i.e., 3D printing) was utilized to rapidly assess material systems for magnetic applications. The LENS system feeds powders in different ratios into a melt pool created by a laser to synthesize samples with bulk (millimeters) dimensions. By analyzing these libraries with autosampler differential scanning calorimeter/thermal gravimetric analysis and vibrating sample magnetometry, we are able to rapidly characterize the thermodynamic and magnetic properties of the libraries. Furthermore, the Fe-Co binary alloy was used as a model system and the results were compared with data in the literature.

Investigation of atypical molten pool dynamics in tungsten carbide-cobalt during laser deposition using in-situ thermal imaging

NASA Astrophysics Data System (ADS)

Xiong, Yuhong; Hofmeister, William H.; Smugeresky, John E.; Delplanque, Jean-Pierre; Schoenung, Julie M.

2012-01-01

An atypical "swirling" phenomenon observed during the laser deposition of tungsten carbide-cobalt cermets by laser engineered net shaping (LENS®) was studied using in-situ high-speed thermal imaging. To provide fundamental insight into this phenomenon, the thermal behavior of pure cobalt during LENS was also investigated for comparison. Several factors were considered as the possible source of the observed differences. Of those, phase difference, material emissivity, momentum transfer, and free surface disruption from the powder jets, and, to a lesser extent, Marangoni convection were identified as the relevant mechanisms.

Magnetic Resonance Imaging of Gel-cast Ceramic Composites

DOE R&D Accomplishments Database

Dieckman, S. L.; Balss, K. M.; Waterfield, L. G.; Jendrzejczyk, J. A.; Raptis, A. C.

1997-01-16

Magnetic resonance imaging (MRI) techniques are being employed to aid in the development of advanced near-net-shape gel-cast ceramic composites. MRI is a unique nondestructive evaluation tool that provides information on both the chemical and physical properties of materials. In this effort, MRI imaging was performed to monitor the drying of porous green-state alumina - methacrylamide-N.N`-methylene bisacrylamide (MAM-MBAM) polymerized composite specimens. Studies were performed on several specimens as a function of humidity and time. The mass and shrinkage of the specimens were also monitored and correlated with the water content.

Visualization of Neutrophil Extracellular Traps and Fibrin Meshwork in Human Fibrinopurulent Inflammatory Lesions: II. Ultrastructural Study

PubMed Central

Onouchi, Takanori; Shiogama, Kazuya; Matsui, Takahiro; Mizutani, Yasuyoshi; Sakurai, Kouhei; Inada, Ken-ichi; Tsutsumi, Yutaka

2016-01-01

Neutrophil extracellular traps (NETs) represent an extracellular, spider’s web-like structure resulting from cell death of neutrophils. NETs play an important role in innate immunity against microbial infection, but their roles in human pathological processes remain largely unknown. NETs and fibrin meshwork both showing fibrillar structures are observed at the site of fibrinopurulent inflammation, as described in our sister paper [Acta Histochem. Cytochem. 49; 109–116, 2016]. In the present study, immunoelectron microscopic study was performed for visualizing NETs and fibrin fibrils (thick fibrils in our tongue) in formalin-fixed, paraffin-embedded sections of autopsied lung tissue of legionnaire’s pneumonia. Lactoferrin and fibrinogen gamma chain were utilized as markers of NETs and fibrin, respectively. Analysis of immuno-scanning electron microscopy indicated that NETs constructed thin fibrils and granular materials were attached onto the NETs fibrils. The smooth-surfaced fibrin fibrils were much thicker than the NETs fibrils. Pre-embedding immunoelectron microscopy demonstrated that lactoferrin immunoreactivities were visible as dots on the fibrils, whereas fibrinogen gamma chain immunoreactivities were homogeneously observed throughout the fibrils. Usefulness of immunoelectron microscopic analysis of NETs and fibrin fibrils should be emphasized. PMID:27682015

Solid Freeform Fabrication of Composite-Material Objects

NASA Technical Reports Server (NTRS)

Wang, C. Jeff; Yang, Jason; Jang, Bor Z.

2005-01-01

Composite solid freeform fabrication (C-SFF) or composite layer manufacturing (CLM) is an automated process in which an advanced composite material (a matrix reinforced with continuous fibers) is formed into a freestanding, possibly complex, three-dimensional object. In CLM, there is no need for molds, dies, or other expensive tooling, and there is usually no need for machining to ensure that the object is formed to the desired net size and shape. CLM is a variant of extrusion-type rapid prototyping, in which a model or prototype of a solid object is built up by controlled extrusion of a polymeric or other material through an orifice that is translated to form patterned layers. The second layer is deposited on top of the first layer, the third layer is deposited on top of the second layer, and so forth, until the stack of layers reaches the desired final thickness and shape. The elements of CLM include (1) preparing a matrix resin in a form in which it will solidify subsequently, (2) mixing the fibers and matrix material to form a continuous pre-impregnated tow (also called "towpreg"), and (3) dispensing the pre-impregnated tow from a nozzle onto a base while moving the nozzle to form the dispensed material into a patterned layer of controlled thickness. When the material deposited into a given layer has solidified, the material for the next layer is deposited and patterned similarly, and so forth, until the desired overall object has been built up as a stack of patterned layers. Preferably, the deposition apparatus is controlled by a computer-aided design (CAD) system. The basic CLM concept can be adapted to the fabrication of parts from a variety of matrix materials. It is conceivable that a CLM apparatus could be placed at a remote location on Earth or in outer space where (1) spare parts are expected to be needed but (2) it would be uneconomical or impractical to store a full inventory of spare parts. A wide variety of towpregs could be prepared and stored on spools until needed. Long-shelf-life towpreg materials suitable for such use could include thermoplastic-coated carbon fibers and metal-coated SiC fibers. When a spare part was needed, the part could be fabricated by CLM under control by a CAD data file; thus, the part could be built automatically, at the scene, within hours or minutes.

The technology and commercial status of powder-injection molding

NASA Astrophysics Data System (ADS)

Bose, Animesh

1995-08-01

The process of powder-injection molding (PIM) is a viable and competitive commercial technique that is being used to process complex-shaped parts of various materials in moderate to high volumes. The hey advantage of the process is its unique ability to combine materials selection flexibility with the complex shape-forming ability of plastics. Although the PIM process has been discussed in the open literature for more than quarter of a century, it has become a commercial reality only during the last decade or so. Currently, there is a tremendous interest in this unique technology throughout the world. As a result, the PIM industry is poised for significant growth.

Performance of Integrated Fiber Optic, Piezoelectric, and Shape Memory Alloy Actuators/Sensors in Thermoset Composites

NASA Technical Reports Server (NTRS)

Trottier, C. Michael

1996-01-01

Recently, scientists and engineers have investigated the advantages of smart materials and structures by including actuators in material systems for controlling and altering the response of structural environments. Applications of these materials systems include vibration suppression/isolation, precision positioning, damage detection and tunable devices. Some of the embedded materials being investigated for accomplishing these tasks include piezoelectric ceramics, shape memory alloys, and fiber optics. These materials have some benefits and some shortcomings; each is being studied for use in active material design in the SPICES (Synthesis and Processing of Intelligent Cost Effective Structures) Consortium. The focus of this paper concerns the manufacturing aspects of smart structures by incorporating piezoelectric ceramics, shape memory alloys and fiber optics in a reinforced thermoset matrix via resin transfer molding (RTM).

Quantitative CT analysis for the preoperative prediction of pathologic grade in pancreatic neuroendocrine tumors

NASA Astrophysics Data System (ADS)

Chakraborty, Jayasree; Pulvirenti, Alessandra; Yamashita, Rikiya; Midya, Abhishek; Gönen, Mithat; Klimstra, David S.; Reidy, Diane L.; Allen, Peter J.; Do, Richard K. G.; Simpson, Amber L.

2018-02-01

Pancreatic neuroendocrine tumors (PanNETs) account for approximately 5% of all pancreatic tumors, affecting one individual per million each year.1 PanNETs are difficult to treat due to biological variability from benign to highly malignant, indolent to very aggressive. The World Health Organization classifies PanNETs into three categories based on cell proliferative rate, usually detected using the Ki67 index and cell morphology: low-grade (G1), intermediate-grade (G2) and high-grade (G3) tumors. Knowledge of grade prior to treatment would select patients for optimal therapy: G1/G2 tumors respond well to somatostatin analogs and targeted or cytotoxic drugs whereas G3 tumors would be targeted with platinum or alkylating agents.2, 3 Grade assessment is based on the pathologic examination of the surgical specimen, biopsy or ne-needle aspiration; however, heterogeneity in the proliferative index can lead to sampling errors.4 Based on studies relating qualitatively assessed shape and enhancement characteristics on CT imaging to tumor grade in PanNET,5 we propose objective classification of PanNET grade with quantitative analysis of CT images. Fifty-five patients were included in our retrospective analysis. A pathologist graded the tumors. Texture and shape-based features were extracted from CT. Random forest and naive Bayes classifiers were compared for the classification of G1/G2 and G3 PanNETs. The best area under the receiver operating characteristic curve (AUC) of 0:74 and accuracy of 71:64% was achieved with texture features. The shape-based features achieved an AUC of 0:70 and accuracy of 78:73%.

Process Makes Thermoplastic Prepreg Ribbon

NASA Technical Reports Server (NTRS)

Wilson, Maywood L.; Johnson, Gary S.

1995-01-01

Manufacturing process produces ribbon of composite material (prepreg) consisting of continuous lengthwise fibers impregnated with thermoplastic resin. Ribbon can later be cut into sheets of required sizes and shapes, stacked, then heated under pressure to form composite-material structural components. Process accommodates variety of thermoplastic resins and variety of fibers.

Regional difference of the vertical structure of seasonal thermocline and its impact on sea surface temperature in the North Pacific

NASA Astrophysics Data System (ADS)

Yamaguchi, R.; Suga, T.

2016-12-01

Recent observational studies show that, during the warming season, a large amount of heat flux is penetrated through the base of thin mixed layer by vertical eddy diffusion, in addition to penetration of solar radiation [1]. In order to understand this heat penetration process due to vertical eddy diffusivity and its contribution to seasonal variation of sea surface temperature, we investigated the evolution of thermal stratification below the summertime thin mixed layer (i.e. evolution of seasonal thermocline) and its vertical structure in the North Pacific using high vertical resolution temperature profile observed by Argo floats. We quantified the vertical structure of seasonal thermocline as deviations from the linear structure where the vertical gradient of temperature is constant, that is, "shape anomaly". The shape anomaly is variable representing the extent of the bend of temperature profiles. We found that there are larger values of shape anomaly in the region where the seasonal sea surface temperature warming is relatively faster. To understand the regional difference of shape anomalies, we investigated the relationship between time changes in shape anomalies and net surface heat flux and surface kinetic energy flux. From May to July, the analysis indicated that, in a large part of North Pacific, there's a tendency for shape anomalies to develop strongly (weakly) under the conditions of large (small) downward net surface heat flux and small (large) downward surface kinetic energy flux. Since weak (strong) development of shape anomalies means efficient (inefficient) downward heat transport from the surface, these results suggest that the regional difference of the downward heat penetration below mixed layer is explained reasonably well by differences in surface heat forcing and surface wind forcing in a vertical one dimensional framework. [1] Hosoda et al. (2015), J. Oceanogr., 71, 541-556.

Building on knowledge base of sodium cooled fast spectrum reactors to develop materials technology for fusion reactors

NASA Astrophysics Data System (ADS)

Raj, Baldev; Rao, K. Bhanu Sankara

2009-04-01

The alloys 316L(N) and Mod. 9Cr-1Mo steel are the major structural materials for fabrication of structural components in sodium cooled fast reactors (SFRs). Various factors influencing the mechanical behaviour of these alloys and different modes of deformation and failure in SFR systems, their analysis and the simulated tests performed on components for assessment of structural integrity and the applicability of RCC-MR code for the design and validation of components are highlighted. The procedures followed for optimal design of die and punch for the near net shape forming of petals of main vessel of 500 MWe prototype fast breeder reactor (PFBR); the safe temperature and strain rate domains established using dynamic materials model for forming of 316L(N) and 9Cr-1Mo steels components by various industrial processes are illustrated. Weldability problems associated with 316L(N) and Mo. 9Cr-1Mo are briefly discussed. The utilization of artificial neural network models for prediction of creep rupture life and delta-ferrite in austenitic stainless steel welds is described. The usage of non-destructive examination techniques in characterization of deformation, fracture and various microstructural features in SFR materials is briefly discussed. Most of the experience gained on SFR systems could be utilized in developing science and technology for fusion reactors. Summary of the current status of knowledge on various aspects of fission and fusion systems with emphasis on cross fertilization of research is presented.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Galarraga, Haize; Lados, Diana A.; Dehoff, Ryan R.

Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology that makes possible the fabrication of three dimensional near-net-shaped parts directly from computer models. EBM technology has been in continuously updating, obtaining optimized properties of the processed alloys. Ti-6Al-4V titanium alloy is the most widely used and studied alloy for this technology and is the focus of this work. Several research works have been completed to study the mechanisms of microstructure formation as well as its influence on mechanical properties. However, the relationship is not completely understood, and more systematic research work is necessary in order tomore » attain a better understanding of these features. In this work, samples fabricated at different locations, orientations, and distances from the build platform have been characterized, studying the relationship of these variables with the resulting material intrinsic characteristics and properties (surface topography, microstructure, porosity, micro-hardness and static mechanical properties). This study has revealed that porosity is the main factor controlling mechanical properties relative to the other studied variables. Therefore, in future process developments, decreasing of the porosity should be considered as the primary goal in order to improve mechanical properties.« less

Method of Fabricating Chopped-Fiber Composite Piston

NASA Technical Reports Server (NTRS)

Rivers, H. Kevin (Inventor); Ransone, Philip O. (Inventor); Northam, G. Burton (Inventor)

1999-01-01

A three-dimensional piston molding is fabricated from a mixture of chopped, carbon tow filaments of variable length, which are prepregged with carbonaceous organic resins and/or pitches and molded by conventional molding processes into a near net shape, to form a carbon-fiber reinforced organic-matrix composite part. Continuous reinforcement in the form of carbon-carbon composite tapes or pieces of fabric can be also laid in the mold before or during the charging of the mold with the chopped-fiber mixture, to enhance the strength in the crown and wrist-pin areas. The molded chopped-fiber reinforced organic-matrix composite parts are then pyrolized in an inert atmosphere, to convert the organic matrix materials to carbon. These pyrolized parts are then densified by reimpregnation with resins or pitches, which are subsequently carbonized. Densification is also accomplished by direct infiltration with carbon by vapor deposition processes. Once the desired density has been achieved, the piston molds are machined to final piston dimensions, and piston ring grooves are added. To prevent oxidation and/or to seal the piston surface or near surface, the chopped-fiber piston is coated with ceramic and/or metallic sealants: and/or coated with a catalyst.

Microstructures and Grain Refinement of Additive-Manufactured Ti- xW Alloys

NASA Astrophysics Data System (ADS)

Mendoza, Michael Y.; Samimi, Peyman; Brice, David A.; Martin, Brian W.; Rolchigo, Matt R.; LeSar, Richard; Collins, Peter C.

2017-07-01

It is necessary to better understand the composition-processing-microstructure relationships that exist for materials produced by additive manufacturing. To this end, Laser Engineered Net Shaping (LENS™), a type of additive manufacturing, was used to produce a compositionally graded titanium binary model alloy system (Ti- xW specimen (0 ≤ x ≤ 30 wt pct), so that relationships could be made between composition, processing, and the prior beta grain size. Importantly, the thermophysical properties of the Ti- xW, specifically its supercooling parameter ( P) and growth restriction factor ( Q), are such that grain refinement is expected and was observed. The systematic, combinatorial study of this binary system provides an opportunity to assess the mechanisms by which grain refinement occurs in Ti-based alloys in general, and for additive manufacturing in particular. The operating mechanisms that govern the relationship between composition and grain size are interpreted using a model originally developed for aluminum and magnesium alloys and subsequently applied for titanium alloys. The prior beta grain factor observed and the interpretations of their correlations indicate that tungsten is a good grain refiner and such models are valid to explain the grain-refinement process. By extension, other binary elements or higher order alloy systems with similar thermophysical properties should exhibit similar grain refinement.

Selective Laser Melting of Hot Gas Turbine Components: Materials, Design and Manufacturing Aspects

NASA Astrophysics Data System (ADS)

Goutianos, Stergios

2017-07-01

Selective Laser Melting (SLM) allows the design and manufacturing of novel parts and structures with improved performance e.g. by incorporating complex and more efficient cooling schemes in hot gas turbine parts. In contrast to conventional manufacturing of removing material, with SLM parts are built additively to nearly net shape. This allows the fabrication of arbitrary complex geometries that cannot be made by conventional manufacturing techniques. However, despite the powerful capabilities of SLM, a number of issues (e.g. part orientation, support structures, internal stresses), have to be considered in order to manufacture cost-effective and high quality parts at an industrial scale. These issues are discussed in the present work from an engineering point of view with the aim to provide simple quidelines to produce high quality SLM parts.

Experimental study of thermo-mechanical behavior of a thermosetting shape-memory polymer

NASA Astrophysics Data System (ADS)

Liu, Ruoxuan; Li, Yunxin; Liu, Zishun

2018-01-01

The thermo-mechanical behavior of shape-memory polymers (SMPs) serves for the engineering applications of SMPs. Therefore the understanding of thermo-mechanical behavior of SMPs is of great importance. This paper investigates the influence of loading rate and loading level on the thermo-mechanical behavior of a thermosetting shape-memory polymer through experimental study. A series of cyclic tension tests and shape recovery tests at different loading conditions are performed to study the strain level and strain rate effect. The results of tension tests show that the thermosetting shape-memory polymer will behave as rubber material at temperature lower than the glass transition temperature (Tg) and it can obtain a large shape fix ratio at cyclic loading condition. The shape recovery tests exhibit that loading rate and loading level have little effect on the beginning and ending of shape recovery process of the thermosetting shape-memory polymer. Compared with the material which is deformed at temperature higher than Tg, the material deformed at temperature lower than Tg behaves a bigger recovery speed.

Composite materials molding simulation for purpose of automotive industry

NASA Astrophysics Data System (ADS)

Grabowski, Ł.; Baier, A.; Majzner, M.; Sobek, M.

2016-08-01

Composite materials loom large increasingly important role in the overall industry. Composite material have a special role in the ever-evolving automotive industry. Every year the composite materials are used in a growing number of elements included in the cars construction. Development requires the search for ever new applications of composite materials in areas where previously were used only metal materials. Requirements for modern solutions, such as reducing the weight of vehicles, the required strength and vibration damping characteristics go hand in hand with the properties of modern composite materials. The designers faced the challenge of the use of modern composite materials in the construction of bodies of power steering systems in vehicles. The initial choice of method for producing composite bodies was the method of molding injection of composite material. Molding injection of polymeric materials is a widely known and used for many years, but the molding injection of composite materials is a relatively new issue, innovative, it is not very common and is characterized by different conditions, parameters and properties in relation to the classical method. Therefore, for the purpose of selecting the appropriate composite material for injection for the body of power steering system computer analysis using Siemens NX 10.0 environment, including Moldex 3d and EasyFill Advanced tool to simulate the injection of materials from the group of possible solutions were carried out. Analyses were carried out on a model of a modernized wheel case of power steering system. During analysis, input parameters, such as temperature, pressure injectors, temperature charts have been analysed. An important part of the analysis was to analyse the propagation of material inside the mold during injection, so that allowed to determine the shape formability and the existence of possible imperfections of shapes and locations air traps. A very important parameter received from computer analysis was to determine the occurrence of the shrinkage of the material, which significantly affects the behaviour of the assumed geometry of the tested component. It also allowed the prediction of existence of shrincage of material during the process of modelling the shape of body. The next step was to analyse the numerical analysis results received from Siemens NX 10 and Moldex 3D EasyFlow Advanced environment. The process of injection were subjected to shape of prototype body of power steering. The material used in process of injection was similar to one of excepted material to be used in process of molding. Nextly, the results were analysed in purpose of geometry, where samples has aberrations in comparison to a given shape of mold. The samples were also analysed in terms of shrinkage. Research and results were described in detail in this paper.

Thermal-mechanical modeling of laser ablation hybrid machining

NASA Astrophysics Data System (ADS)

Matin, Mohammad Kaiser

2001-08-01

Hard, brittle and wear-resistant materials like ceramics pose a problem when being machined using conventional machining processes. Machining ceramics even with a diamond cutting tool is very difficult and costly. Near net-shape processes, like laser evaporation, produce micro-cracks that require extra finishing. Thus it is anticipated that ceramic machining will have to continue to be explored with new-sprung techniques before ceramic materials become commonplace. This numerical investigation results from the numerical simulations of the thermal and mechanical modeling of simultaneous material removal from hard-to-machine materials using both laser ablation and conventional tool cutting utilizing the finite element method. The model is formulated using a two dimensional, planar, computational domain. The process simulation acronymed, LAHM (Laser Ablation Hybrid Machining), uses laser energy for two purposes. The first purpose is to remove the material by ablation. The second purpose is to heat the unremoved material that lies below the ablated material in order to ``soften'' it. The softened material is then simultaneously removed by conventional machining processes. The complete solution determines the temperature distribution and stress contours within the material and tracks the moving boundary that occurs due to material ablation. The temperature distribution is used to determine the distance below the phase change surface where sufficient ``softening'' has occurred, so that a cutting tool may be used to remove additional material. The model incorporated for tracking the ablative surface does not assume an isothermal melt phase (e.g. Stefan problem) for laser ablation. Both surface absorption and volume absorption of laser energy as function of depth have been considered in the models. LAHM, from the thermal and mechanical point of view is a complex machining process involving large deformations at high strain rates, thermal effects of the laser, removal of materials and contact between workpiece and tool. The theoretical formulation associated with LAHM for solving the thermal-mechanical problem using the finite element method is presented. The thermal formulation is incorporated in the user defined subroutines called by ABAQUS/Standard. The mechanical portion is modeled using ABAQUS/Explicit's general capabilities of modeling interactions involving contact and separation. The results obtained from the FEA simulations showed that the cutting force decrease considerably in both LAEM Surface Absorption (LARM-SA) and LAHM volume absorption (LAHM-VA) models relative to LAM model. It was observed that the HAZ can be expanded or narrowed depending on the laser speed and power. The cutting force is minimal at the last extent of the HAZ. In both the models the laser ablates material thus reducing material stiffness as well as relaxing the thermal stress. The stress values obtained showed compressive yield stress just below the ablated surface and chip. The failure occurs by conventional cutting where tensile stress exceeds the tensile strength of the material at that temperature. In this hybrid machining process the advantages of both the individual machining processes were realized.

Effects of process variables on the properties of YBa2Cu3O(7-x) ceramics formed by investment casting

NASA Technical Reports Server (NTRS)

Hooker, M. W.; Taylor, T. D.; Leigh, H. D.; Wise, S. A.; Buckley, J. D.; Vasquez, P.; Buck, G. M.; Hicks, L. P.

1993-01-01

An investment casting process has been developed to produce net-shape, superconducting ceramics. In this work, a factorial experiment was performed to determine the critical process parameters for producing cast YBa2Cu3O7 ceramics with optimum properties. An analysis of variance procedure indicated that the key variables in casting superconductive ceramics are the particle size distribution and sintering temperature. Additionally, the interactions between the sintering temperature and the other process parameters (e.g., particle size distribution and the use of silver dopants) were also found to influence the density, porosity, and critical current density of the fired ceramics.

Direct Numerical Simulations of Microstructure Effects During High-Rate Loading of Additively Manufactured Metals

NASA Astrophysics Data System (ADS)

Battaile, Corbett; Owen, Steven; Moore, Nathan

2017-06-01

The properties of most engineering materials depend on the characteristics of internal microstructures and defects. In additively manufactured (AM) metals, these can include polycrystalline grains, impurities, phases, and significant porosity that qualitatively differ from conventional engineering materials. The microscopic details of the interactions between these internal defects, and the propagation of applied loads through the body, act in concert to dictate macro-observable properties like strength and compressibility. In this work, we used Sandia's ALEGRA finite element software to simulate the high-strain-rate loading of AM metals from laser engineered net shaping (LENS) and thermal spraying. The microstructural details of the material were represented explicitly, such that internal features like second phases and pores are captured and meshed as individual entities in the computational domain. We will discuss the dependence of the high-strain-rate mechanical properties on microstructural characteristics such as the shapes, sizes, and volume fractions of second phases and pores. In addition, we will examine how the details of the microstructural representation affect the microscopic material response to dynamic loads, and the effects of using ``stair-step'' versus conformal interfaces smoothed via the SCULPT tool in Sandia's CUBIT software. Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the US DOE NNSA under contract DE-AC04-94AL85000.

Computer-Aided Process Model For Carbon/Phenolic Materials

NASA Technical Reports Server (NTRS)

Letson, Mischell A.; Bunker, Robert C.

1996-01-01

Computer program implements thermochemical model of processing of carbon-fiber/phenolic-matrix composite materials into molded parts of various sizes and shapes. Directed toward improving fabrication of rocket-engine-nozzle parts, also used to optimize fabrication of other structural components, and material-property parameters changed to apply to other materials. Reduces costs by reducing amount of laboratory trial and error needed to optimize curing processes and to predict properties of cured parts.

Fracture Strength of Single-Crystal Silicon Carbide Microspecimens at Room and Elevated Temperature

NASA Technical Reports Server (NTRS)

Nemeth, Noel N.; Sharpe, William N., Jr.; Beheim, Glenn M.; Evans, Laura J.; Jadaan, Osama M.

2007-01-01

Three shapes of tensile specimens were tested--curved with a very low stress concentration factor and straight with either a circular hole or an elliptical hole. The nominal thickness was 125 micron with a net section 100 micron wide; the overall length of these microspecimens was 3.1 mm. They were fabricated by an improved version of deep reactive ion etching, which produced specimens with smooth sidewalls and cross-sections having a slightly trapezoidal shape that was exaggerated inside the holes. The novel test setup used a vertical load train extending into a resistance furnace. The specimens had wedge-shaped ends which fit into ceramic grips. The fixed grip was mounted on a ceramic post, and the movable grip was connected to a load cell and actuator outside the furnace with a ceramic-encased nichrome wire. The same arrangement was used for tests at 24 and at 1000 C. The strengths of the curved specimens for two batches of material (made with slightly different processes) were 0.66+/-0.12 GPa and 0.45+/-0.20 GPa respectively at 24 C with identical values at 1000 C. The fracture strengths of the circular-hole and elliptical-hole specimens (computed from the stress concentration factors and measured loads at failure) were approximately 1.2 GPa with slight decreases at the higher temperature. Fractographic examinations showed failures initiating on the surface--primarily at corners. Weibull predictions of fracture strengths for the hole specimens based on the properties of the curved specimens were reasonably effective for the circular holes, but not for the elliptical holes.

Finite element simulation of the T-shaped ECAP processing of round samples

NASA Astrophysics Data System (ADS)

Shaban Ghazani, Mehdi; Fardi-Ilkhchy, Ali; Binesh, Behzad

2018-05-01

Grain refinement is the only mechanism that increases the yield strength and toughness of the materials simultaneously. Severe plastic deformation is one of the promising methods to refine the microstructure of materials. Among different severe plastic deformation processes, the T-shaped equal channel angular pressing (T-ECAP) is a relatively new technique. In the present study, finite element analysis was conducted to evaluate the deformation behavior of metals during T-ECAP process. The study was focused mainly on flow characteristics, plastic strain distribution and its homogeneity, damage development, and pressing force which are among the most important factors governing the sound and successful processing of nanostructured materials by severe plastic deformation techniques. The results showed that plastic strain is localized in the bottom side of sample and uniform deformation cannot be possible using T-ECAP processing. Friction coefficient between sample and die channel wall has a little effect on strain distributions in mirror plane and transverse plane of deformed sample. Also, damage analysis showed that superficial cracks may be initiated from bottom side of sample and their propagation will be limited due to the compressive state of stress. It was demonstrated that the V shaped deformation zone are existed in T-ECAP process and the pressing load needed for execution of deformation process is increased with friction.

Near net shape processing of continuous lengths of superconducting wire

DOEpatents

Danyluk, Steven; McNallan, Michael; Troendly, Robert; Poeppel, Roger; Goretta, Kenneth; Lanagan, Michael

1997-01-01

A system and method for mechanically forming a ceramic superconductor product. A system for making the ceramic superconductor includes a metallic channel portion having a cross section for receiving a ceramic superconductor powder, a roll to mechanically reduce the channel cross section and included superconductor powder and a cap portion welded to the channel portion using a localized high energy source. The assembled bar is then mechanically reduced to form a tape or wire end product.

Metal Matrix Composite LOX Turbopump Housing via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.

2003-01-01

Metal matrix composites for propulsion components offer high performance and affordability, resulting in low weight and cost. The following sections in this viewgraph presentation describe the pressure infiltration casting of a metal matrix composite LOX turbopump housing: 1) Baseline Pump Design and Stress Analysis; 2) Tool-less Advanced Pressure Infiltration Casting Process; 3) Preform Splicing and Joining for Large Components such as Pump Housing; 4) Fullscale Pump Housing Redesign.

Automated Fabrication Technologies for High Performance Polymer Composites

NASA Technical Reports Server (NTRS)

Shuart , M. J.; Johnston, N. J.; Dexter, H. B.; Marchello, J. M.; Grenoble, R. W.

1998-01-01

New fabrication technologies are being exploited for building high graphite-fiber-reinforced composite structure. Stitched fiber preforms and resin film infusion have been successfully demonstrated for large, composite wing structures. Other automatic processes being developed include automated placement of tacky, drapable epoxy towpreg, automated heated head placement of consolidated ribbon/tape, and vacuum-assisted resin transfer molding. These methods have the potential to yield low cost high performance structures by fabricating composite structures to net shape out-of-autoclave.

Plant-Based, Shape-Memory Material Could Replace Today’s Conductors

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

A novel approach that creates a renewable, leathery material—programmed to remember its shape—may offer a low-cost alternative to conventional conductors for applications in sensors and robotics. To make the bio-based, shape-memory material, Oak Ridge National Laboratory scientists streamlined a solvent-free process that mixes rubber with lignin—the by-product of woody plants used to make biofuels. They fashioned the leathery material into small strips and brushed on a thin layer of silver nanoparticles to activate electrical conductivity. The strips were stretched or curled and then frozen as part of the process to program the material to return to its intended shape, whichmore » occurs after the application of low heat. “The performance of this polymer can be tuned further,” said ORNL’s Amit Naskar. “Variant lignins can be used at different ratios, which determines the material’s pliability.” This research was sponsored by the Department of Energy’s Bioenergy Technologies Office.« less

Mechanical properties of Ti-6Al-4V specimens produced by shaped metal deposition

PubMed Central

Baufeld, Bernd; van der Biest, Omer

2009-01-01

Shaped metal deposition is a novel technique to build near net-shape components layer by layer by tungsten inert gas welding. Especially for complex shapes and small quantities, this technique can significantly lower the production cost of components by reducing the buy-to-fly ratio and lead time for production, diminishing final machining and preventing scrap. Tensile testing of Ti-6Al-4V components fabricated by shaped metal deposition shows that the mechanical properties are competitive to material fabricated by conventional techniques. The ultimate tensile strength is between 936 and 1014 MPa, depending on the orientation and location. Tensile testing vertical to the deposition layers reveals ductility between 14 and 21%, whereas testing parallel to the layers gives a ductility between 6 and 11%. Ultimate tensile strength and ductility are inversely related. Heat treatment within the α+β phase field does not change the mechanical properties, but heat treatment within the β phase field increases the ultimate tensile strength and decreases the ductility. The differences in ultimate tensile strength and ductility can be related to the α lath size and orientation of the elongated, prior β grains. The micro-hardness and Young’s modulus are similar to conventional Ti-6Al-4V with low oxygen content. PMID:27877271

Optical Computing Based on Neuronal Models

DTIC Science & Technology

1988-05-01

walking, and cognition are far too complex for existing sequential digital computers. Therefore new architectures, hardware, and algorithms modeled...collective behavior, and iterative processing into optical processing and artificial neurodynamical systems. Another intriguing promise of neural nets is...with architectures, implementations, and programming; and material research s -7- called for. Our future research in neurodynamics will continue to

Neural-Net Processing of Characteristic Patterns From Electronic Holograms of Vibrating Blades

NASA Technical Reports Server (NTRS)

Decker, Arthur J.

1999-01-01

Finite-element-model-trained artificial neural networks can be used to process efficiently the characteristic patterns or mode shapes from electronic holograms of vibrating blades. The models used for routine design may not yet be sufficiently accurate for this application. This document discusses the creation of characteristic patterns; compares model generated and experimental characteristic patterns; and discusses the neural networks that transform the characteristic patterns into strain or damage information. The current potential to adapt electronic holography to spin rigs, wind tunnels and engines provides an incentive to have accurate finite element models lor training neural networks.

Producing Zirconium Diboride Components with Complex, Near-Net Shape Geometries by Aqueous Room-Temperature Injection Molding

NASA Technical Reports Server (NTRS)

Wiesner, Valerie L.; Youngblood, Jeffrey; Trice, Rodney

2014-01-01

Room-temperature injection molding is proposed as a novel, low-cost and more energy efficient manufacturing process capable of forming complex-shaped zirconium diboride (ZrB2) parts. This innovative processing method utilized aqueous suspensions with high powder loading and a minimal amount (5 vol.) of water-soluble polyvinylpyrrolidone (PVP), which was used as a viscosity modifier. Rheological characterization was performed to evaluate the room-temperature flow properties of ZrB2-PVP suspensions. ZrB2 specimens were fabricated with high green body strength and were machinable prior to binder removal despite their low polymer content. After binder burnout and pressureless sintering, the bulk density and microstructure of specimens were characterized using Archimedes technique and scanning electron microscopy. X-Ray Diffraction was used to determine the phase compositions present in sintered specimens. Ultimate strength of sintered specimens will be determined using ASTM C1323-10 compressive C-ring test.

Processing and properties of Ti-6Al-4V hollow sphere foams from hydride powder

NASA Astrophysics Data System (ADS)

Hardwicke, Canan Uslu

Honeycomb structures currently used in aerospace systems are expensive to manufacture, limited to sheet form, and present joining problems and mechanical anisotropy that promotes shear failure at low stresses. Metallic foams produced by point contact bonding of monosized hollow spheres offer an alternative if they can be processed into strong, light-weight, and reasonably priced structural materials. In this work, technology has been established for fabricating good quality, Ti-6Al-4V hollow sphere foams using the coaxial nozzle powder slurry technique. It was shown that hydride form of Ti-ELI can be used as the starting precursor powder and processed into fine particles of 1-10 mum size range without increasing the impurity levels. Hydride dispersion in acetone was provided by the addition of polyester/polyamine copolymers through electrosteric stabilization. Addition of PMMA to the pseudoplastically dispersed organic slurries helped bind hydride powder spherical shells. Furthermore, monosized Ti-6Al-4V hollow spheres were sintered to 98% dense cell walls in Ar and point-contact bonded into closed-cell foams through solid-state diffusion. These findings suggest that near-net shape Ti-6Al-4V structures may be produced with isotropic properties, strength, toughness, and densities as low as 10% of the bulk. Findings concerning the optimum processing parameters and implications for future research are discussed.

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yang, Nancy; Yee, J.; Zheng, B.

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS processmore » control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.« less

Tailorable Burning Behavior of Ti14 Alloy by Controlling Semi-Solid Forging Temperature.

PubMed

Chen, Yongnan; Yang, Wenqing; Zhan, Haifei; Zhang, Fengying; Huo, Yazhou; Zhao, Yongqing; Song, Xuding; Gu, Yuantong

2016-08-16

Semi-solid processing (SSP) is a popular near-net-shape forming technology for metals, while its application is still limited in titanium alloy mainly due to its low formability. Recent works showed that SSP could effectively enhance the formability and mechanical properties of titanium alloys. The processing parameters such as temperature and forging rate/ratio, are directly correlated with the microstructure, which endow the alloy with different chemical and physical properties. Specifically, as a key structural material for the advanced aero-engine, the burn resistant performance is a crucial requirement for the burn resistant titanium alloy. Thus, this work aims to assess the burning behavior of Ti14, a kind of burn resistant alloy, as forged at different semi-solid forging temperatures. The burning characteristics of the alloy are analyzed by a series of burning tests with different burning durations, velocities, and microstructures of burned sample. The results showed that the burning process is highly dependent on the forging temperature, due to the fact that higher temperatures would result in more Ti₂Cu precipitate within grain and along grain boundaries. Such a microstructure hinders the transport of oxygen in the stable burning stage through the formation of a kind of oxygen isolation Cu-enriched layer under the burn product zone. This work suggests that the burning resistance of the alloy can be effectively tuned by controlling the temperature during the semi-solid forging process.

Finite Element Analysis of Laser Engineered Net Shape (LENS™) Tungsten Clad Squeeze Pins

NASA Astrophysics Data System (ADS)

Sakhuja, Amit; Brevick, Jerald R.

2004-06-01

In the aluminum high-pressure die-casting and indirect squeeze casting processes, local "squeeze" pins are often used to minimize internal solidification shrinkage in heavy casting sections. Squeeze pins frequently fail in service due to molten aluminum adhering to the H13 tool steel pins ("soldering"). A wide variety of coating materials and methods have been developed to minimize soldering on H13. However, these coatings are typically very thin, and experience has shown their performance on squeeze pins is highly variable. The LENS™ process was employed in this research to deposit a relatively thick tungsten cladding on squeeze pins. An advantage of this process was that the process parameters could be precisely controlled in order to produce a satisfactory cladding. Two fixtures were designed and constructed to enable the end and outer diameter (OD) of the squeeze pins to be clad. Analyses were performed on the clad pins to evaluate the microstructure and chemical composition of the tungsten cladding and the cladding-H13 substrate interface. A thermo-mechanical finite element analysis (FEA) was performed to assess the stress distribution as a function of cladding thickness on the pins during a typical casting thermal cycle. FEA results were validated via a physical test, where the clad squeeze pins were immersed into molten aluminum. Pins subjected to the test were evaluated for thermally induced cracking and resistance to soldering of the tungsten cladding.

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

DOE PAGES

Yang, Nancy; Yee, J.; Zheng, B.; ...

2016-12-08

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS processmore » control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.« less

NetCTLpan: pan-specific MHC class I pathway epitope predictions

PubMed Central

Larsen, Mette Voldby; Lundegaard, Claus; Nielsen, Morten

2010-01-01

Reliable predictions of immunogenic peptides are essential in rational vaccine design and can minimize the experimental effort needed to identify epitopes. In this work, we describe a pan-specific major histocompatibility complex (MHC) class I epitope predictor, NetCTLpan. The method integrates predictions of proteasomal cleavage, transporter associated with antigen processing (TAP) transport efficiency, and MHC class I binding affinity into a MHC class I pathway likelihood score and is an improved and extended version of NetCTL. The NetCTLpan method performs predictions for all MHC class I molecules with known protein sequence and allows predictions for 8-, 9-, 10-, and 11-mer peptides. In order to meet the need for a low false positive rate, the method is optimized to achieve high specificity. The method was trained and validated on large datasets of experimentally identified MHC class I ligands and cytotoxic T lymphocyte (CTL) epitopes. It has been reported that MHC molecules are differentially dependent on TAP transport and proteasomal cleavage. Here, we did not find any consistent signs of such MHC dependencies, and the NetCTLpan method is implemented with fixed weights for proteasomal cleavage and TAP transport for all MHC molecules. The predictive performance of the NetCTLpan method was shown to outperform other state-of-the-art CTL epitope prediction methods. Our results further confirm the importance of using full-type human leukocyte antigen restriction information when identifying MHC class I epitopes. Using the NetCTLpan method, the experimental effort to identify 90% of new epitopes can be reduced by 15% and 40%, respectively, when compared to the NetMHCpan and NetCTL methods. The method and benchmark datasets are available at http://www.cbs.dtu.dk/services/NetCTLpan/. Electronic supplementary material The online version of this article (doi:10.1007/s00251-010-0441-4) contains supplementary material, which is available to authorized users. PMID:20379710

Field mappers for laser material processing

NASA Astrophysics Data System (ADS)

Blair, Paul; Currie, Matthew; Trela, Natalia; Baker, Howard J.; Murphy, Eoin; Walker, Duncan; McBride, Roy

2016-03-01

The native shape of the single-mode laser beam used for high power material processing applications is circular with a Gaussian intensity profile. Manufacturers are now demanding the ability to transform the intensity profile and shape to be compatible with a new generation of advanced processing applications that require much higher precision and control. We describe the design, fabrication and application of a dual-optic, beam-shaping system for single-mode laser sources, that transforms a Gaussian laser beam by remapping - hence field mapping - the intensity profile to create a wide variety of spot shapes including discs, donuts, XY separable and rotationally symmetric. The pair of optics transform the intensity distribution and subsequently flatten the phase of the beam, with spot sizes and depth of focus close to that of a diffraction limited beam. The field mapping approach to beam-shaping is a refractive solution that does not add speckle to the beam, making it ideal for use with single mode laser sources, moving beyond the limits of conventional field mapping in terms of spot size and achievable shapes. We describe a manufacturing process for refractive optics in fused silica that uses a freeform direct-write process that is especially suited for the fabrication of this type of freeform optic. The beam-shaper described above was manufactured in conventional UV-fused silica using this process. The fabrication process generates a smooth surface (<1nm RMS), leading to laser damage thresholds of greater than 100J/cm2, which is well matched to high power laser sources. Experimental verification of the dual-optic filed mapper is presented.

What Shapes the Phylogenetic Structure of Anuran Communities in a Seasonal Environment? The Influence of Determinism at Regional Scale to Stochasticity or Antagonistic Forces at Local Scale

PubMed Central

Ferreira, Vanda Lúcia; Strüssmann, Christine; Tomas, Walfrido Moraes

2015-01-01

Ecological communities are structured by both deterministic and stochastic processes. We investigated phylogenetic patterns at regional and local scales to understand the influences of seasonal processes in shaping the structure of anuran communities in the southern Pantanal wetland, Brazil. We assessed the phylogenetic structure at different scales, using the Net Relatedness Index (NRI), the Nearest Taxon Index (NTI), and phylobetadiversity indexes, as well as a permutation test, to evaluate the effect of seasonality. The anuran community was represented by a non-random set of species with a high degree of phylogenetic relatedness at the regional scale. However, at the local scale the phylogenetic structure of the community was weakly related with the seasonality of the system, indicating that oriented stochastic processes (e.g. colonization, extinction and ecological drift) and/or antagonist forces drive the structure of such communities in the southern Pantanal. PMID:26102202

What Shapes the Phylogenetic Structure of Anuran Communities in a Seasonal Environment? The Influence of Determinism at Regional Scale to Stochasticity or Antagonistic Forces at Local Scale.

PubMed

Martins, Clarissa de Araújo; Roque, Fabio de Oliveira; Santos, Bráulio A; Ferreira, Vanda Lúcia; Strüssmann, Christine; Tomas, Walfrido Moraes

2015-01-01

Ecological communities are structured by both deterministic and stochastic processes. We investigated phylogenetic patterns at regional and local scales to understand the influences of seasonal processes in shaping the structure of anuran communities in the southern Pantanal wetland, Brazil. We assessed the phylogenetic structure at different scales, using the Net Relatedness Index (NRI), the Nearest Taxon Index (NTI), and phylobetadiversity indexes, as well as a permutation test, to evaluate the effect of seasonality. The anuran community was represented by a non-random set of species with a high degree of phylogenetic relatedness at the regional scale. However, at the local scale the phylogenetic structure of the community was weakly related with the seasonality of the system, indicating that oriented stochastic processes (e.g. colonization, extinction and ecological drift) and/or antagonist forces drive the structure of such communities in the southern Pantanal.

Effect of storage conditions on the calorific value of municipal solid waste.

PubMed

Nzioka, Antony Mutua; Hwang, Hyeon-Uk; Kim, Myung-Gyun; Yan, Cao Zheng; Lee, Chang-Soo; Kim, Young-Ju

2017-08-01

Storage conditions are considered to be an important factor as far as waste material characteristics are concerned. This experimental investigation was conducted using municipal solid waste (MSW) with a high moisture content and varying composition of organic waste. The objective of this study was to understand the effect of storage conditions and temperature on the moisture content and calorific value of the waste. Samples were subjected to two different storage conditions and investigated at specified temperatures. The composition of sample materials investigated was varied for each storage condition and temperature respectively. Gross calorific value was determined experimentally while net calorific value was calculated using empirical formulas proposed by other researchers. Results showed minimal changes in moisture content as well as in gross and net calorific values when the samples were subjected to sealed storage conditions. Moisture content reduced due to the ventilation process and the rate of moisture removal increased with a rise in storage temperature. As expected, rate of moisture removal had a positive effect on gross and net calorific values. Net calorific values also increased at varying rates with a simultaneous decrease in moisture content. Experimental investigation showed the effectiveness of ventilation in improving the combustion characteristics of the waste.

Neural net applied to anthropological material: a methodical study on the human nasal skeleton.

PubMed

Prescher, Andreas; Meyers, Anne; Gerf von Keyserlingk, Diedrich

2005-07-01

A new information processing method, an artificial neural net, was applied to characterise the variability of anthropological features of the human nasal skeleton. The aim was to find different types of nasal skeletons. A neural net with 15*15 nodes was trained by 17 standard anthropological parameters taken from 184 skulls of the Aachen collection. The trained neural net delivers its classification in a two-dimensional map. Different types of noses were locally separated within the map. Rare and frequent types may be distinguished after one passage of the complete collection through the net. Statistical descriptive analysis, hierarchical cluster analysis, and discriminant analysis were applied to the same data set. These parallel applications allowed comparison of the new approach to the more traditional ones. In general the classification by the neural net is in correspondence with cluster analysis and discriminant analysis. However, it goes beyond these classifications because of the possibility of differentiating the types in multi-dimensional dependencies. Furthermore, places in the map are kept blank for intermediate forms, which may be theoretically expected, but were not included in the training set. In conclusion, the application of a neural network is a suitable method for investigating large collections of biological material. The gained classification may be helpful in anatomy and anthropology as well as in forensic medicine. It may be used to characterise the peculiarity of a whole set as well as to find particular cases within the set.

Potential High-Temperature Shape-Memory Alloys Identified in the Ti(Ni,Pt) System

NASA Technical Reports Server (NTRS)

Noebe, Ronald D.; Biles, Tiffany A.; Garg, Anita; Nathal, Michael V.

2004-01-01

"Shape memory" is a unique property of certain alloys that, when deformed (within certain strain limits) at low temperatures, will remember and recover to their original predeformed shape upon heating. It occurs when an alloy is deformed in the low-temperature martensitic phase and is then heated above its transformation temperature back to an austenitic state. As the material passes through this solid-state phase transformation on heating, it also recovers its original shape. This behavior is widely exploited, near room temperature, in commercially available NiTi alloys for connectors, couplings, valves, actuators, stents, and other medical and dental devices. In addition, there are limitless applications in the aerospace, automotive, chemical processing, and many other industries for materials that exhibit this type of shape-memory behavior at higher temperatures. But for high temperatures, there are currently no commercial shape-memory alloys. Although there are significant challenges to the development of high-temperature shape-memory alloys, at the NASA Glenn Research Center we have identified a series of alloy compositions in the Ti-Ni-Pt system that show great promise as potential high-temperature shape-memory materials.

Resin transfer molding of textile preforms for aircraft structural applications

NASA Technical Reports Server (NTRS)

Hasko, Gregory H.; Dexter, H. Benson; Weideman, Mark H.

1992-01-01

The NASA LaRC is conducting and supporting research to develop cost-effective fabrication methods that are applicable to primary composite aircraft structures. One of the most promising fabrication methods that has evolved is resin transfer molding (RTM) of dry textile material forms. RTM has been used for many years for secondary structures, but has received increased emphasis because it is an excellent method for applying resin to damage-tolerant textile preforms at low cost. Textile preforms based on processes such as weaving, braiding, knitting, stitching, and combinations of these have been shown to offer significant improvements in damage tolerance compared to laminated tape composites. The use of low-cost resins combined with textile preforms could provide a major breakthrough in achieving cost-effective composite aircraft structures. RTM uses resin in its lowest cost form, and storage and spoilage costs are minimal. Near net shape textile preforms are expected to be cost-effective because automated machines can be used to produce the preforms, post-cure operations such as machining and fastening are minimized, and material scrap rate may be reduced in comparison with traditional prepreg molding. The purpose of this paper is to discuss experimental and analytical techniques that are under development at NASA Langley to aid the engineer in developing RTM processes for airframe structural elements. Included are experimental techniques to characterize preform and resin behavior and analytical methods that were developed to predict resin flow and cure kinetics.

Experimental study on deep hole drilling of 17-4PH material

NASA Astrophysics Data System (ADS)

Uzhanfeng, LI; Uquantai, LI

2018-02-01

This paper uses 17-4PH material as the research object, according to the material characteristics of 17-4PH, designed and carried out deep hole drilling test. The purpose of the experiment is to study and discuss the three major problems of tool wear, chip shape and axial deviation of the hole in the process of deep hole drilling of 17-4PH materials. Through the deep hole drilling test of 17-4PH material, the variation of the chip shape and the deflection of the hole axis was obtained under different wear conditions.

Cycle time and cost reduction in large-size optics production

NASA Astrophysics Data System (ADS)

Hallock, Bob; Shorey, Aric; Courtney, Tom

2005-09-01

Optical fabrication process steps have remained largely unchanged for decades. Raw glass blanks have been rough-machined, generated to near net shape, loose abrasive or fine bound diamond ground and then polished. This set of processes is sequential and each subsequent operation removes the damage and micro cracking induced by the prior operational step. One of the long-lead aspects of this process has been the glass polishing. Primarily, this has been driven by the need to remove relatively large volumes of glass material compared to the polishing removal rate to ensure complete damage removal. The secondary time driver has been poor convergence to final figure and the corresponding polish-metrology cycles. The overall cycle time and resultant cost due to labor, equipment utilization and shop efficiency is increased, often significantly, when the optical prescription is aspheric. In addition to the long polishing cycle times, the duration of the polishing time is often very difficult to predict given that current polishing processes are not deterministic processes. This paper will describe a novel approach to large optics finishing, relying on several innovative technologies to be presented and illustrated through a variety of examples. The cycle time reductions enabled by this approach promises to result in significant cost and lead-time reductions for large size optics. In addition, corresponding increases in throughput will provide for less capital expenditure per square meter of optic produced. This process, comparative cycles time estimates and preliminary results will be discussed.

Phosphorus Segregation in Meta-Rapidly Solidified Carbon Steels

NASA Astrophysics Data System (ADS)

Li, Na; Qiao, Jun; Zhang, Junwei; Sha, Minghong; Li, Shengli

2017-09-01

Twin-roll strip casters for near-net-shape manufacture of steels have received increased attention in the steel industry. Although negative segregation of phosphorus occurred in twin-roll strip casting (TRSC) steels in our prior work, its mechanism is still unclear. In this work, V-shaped molds were designed and used to simulate a meta-rapid solidification process without roll separating force during twin roll casting of carbon steels. Experimental results show that no obvious phosphorus segregation exist in the V-shaped mold casting (VMC) steels. By comparing TRSC and the VMC, it is proposed that the negative phosphorus segregation during TRSC results from phosphorus redistribution driven by recirculating and vortex flow in the molten pool. Meanwhile, solute atoms near the advancing interface are overtaken and incorporated into the solid because of the high solidification speed. The high rolling force could promote the negative segregation of alloying elements in TRSC.

Modelling of current loads on aquaculture net cages

NASA Astrophysics Data System (ADS)

Kristiansen, Trygve; Faltinsen, Odd M.

2012-10-01

In this paper we propose and discuss a screen type of force model for the viscous hydrodynamic load on nets. The screen model assumes that the net is divided into a number of flat net panels, or screens. It may thus be applied to any kind of net geometry. In this paper we focus on circular net cages for fish farms. The net structure itself is modelled by an existing truss model. The net shape is solved for in a time-stepping procedure that involves solving a linear system of equations for the unknown tensions at each time step. We present comparisons to experiments with circular net cages in steady current, and discuss the sensitivity of the numerical results to a set of chosen parameters. Satisfactory agreement between experimental and numerical prediction of drag and lift as function of the solidity ratio of the net and the current velocity is documented.

Active materials by four-dimension printing

NASA Astrophysics Data System (ADS)

Ge, Qi; Qi, H. Jerry; Dunn, Martin L.

2013-09-01

We advance a paradigm of printed active composite materials realized by directly printing glassy shape memory polymer fibers in an elastomeric matrix. We imbue the active composites with intelligence via a programmed lamina and laminate architecture and a subsequent thermomechanical training process. The initial configuration is created by three-dimension (3D) printing, and then the programmed action of the shape memory fibers creates time dependence of the configuration—the four-dimension (4D) aspect. We design and print laminates in thin plate form that can be thermomechanically programmed to assume complex three-dimensional configurations including bent, coiled, and twisted strips, folded shapes, and complex contoured shapes with nonuniform, spatially varying curvature. The original flat plate shape can be recovered by heating the material again. We also show how the printed active composites can be directly integrated with other printed functionalities to create devices; here we demonstrate this by creating a structure that can assemble itself.

The Effect of Defects on the Fatigue Initiation Process in Two P/M Superalloys.

DTIC Science & Technology

1980-09-01

determine the effect of Sdfect size, shape, and population on the fatigue initiation process in two high strength P/M superalloys, AF-l5 and AF2-lDA. The...to systematically determine the effects of defect size, shape, and population on fatigue. It is true that certain trends have been established...to determine the relative effects of defect size, shape, and population on the crack initiation life of a representative engineering material

The ultrasonic machining of silicon carbide / alumina composites

NASA Astrophysics Data System (ADS)

Nicholson, Garth Martyn John

Silicon carbide fibre reinforced alumina is a ceramic composite which was developed in conjunction with the Rolls-Royce Aerospace Group. The material is intended for use in the latest generation of jet engines, specifically for high temperature applications such as flame holders, combustor barrel segments and turbine blade tip seals. The material in question has properties which have been engineered by optimizing fibre volume fractions, weaves and fibre interface materials to meet the following main requirements : high thermal resistance, high thermal shock resistance and low density.Components intended for manufacture using this material will use the "direct metal oxidation" (DIMOX) method. This process involves manufacturing a near net shape component from the woven fibre matting, and infiltrating the matting with the alumina matrix material. Some of the components outlined require high tolerance features to be included in their design. The combustor barrel segments for example require slots to be formed within them for sealing purposes, the dimensions of these features preclude their formation using DIMOX, and therefore require a secondary process to be performed. Conventional machining techniques such as drilling, turning and milling cannot be used because of the brittle nature of the material. Electrodischarge machining (E.D.M.) cannot be used since the material is an insulator. Electrochemical machining (E.C.M.) cannot be used since the material is chemically inert. One machining method which could be used is ultrasonic machining (U.S.M.).The research programme investigated the feasibility of using ultrasonic machining as a manufacturing method for this new fibre reinforced composite. Two variations of ultrasonic machining were used : ultrasonic drilling and ultrasonic milling. Factors such as dimensional accuracy, surface roughness and delamination effects were examined. Previously performed ultrasonic machining experimental programmes were reviewed, as well as process models which have been developed. The process models were found to contain empirical constants which usually require specific material data for their calculation.Since a limited amount of the composite was available, and ultrasonic machining has many process variables, a Taguchi factorial experiment was conducted in order to ascertain the most relevant factors in machining. A full factorial experiment was then performed using the relevant factors. Techniques used in the research included both optical and scanning electron microscopy, surface roughness analysis, x-ray analysis and finite element stress analysis. A full set of machining data was obtained including relationships between the factors examined and both material removal rates, and surface roughness values. An attempt was made to explain these findings by examining established brittle fracture mechanisms. These established mechanisms did not seem to apply entirely to this material, an alternative method of material removal is therefore proposed. It is hoped that the data obtained from this research programme may contribute to the development of a more realistic mathematical model.

Children's schemes for anticipating the validity of nets for solids

NASA Astrophysics Data System (ADS)

Wright, Vince; Smith, Ken

2017-09-01

There is growing acknowledgement of the importance of spatial abilities to student achievement across a broad range of domains and disciplines. Nets are one way to connect three-dimensional shapes and their two-dimensional representations and are a common focus of geometry curricula. Thirty-four students at year 6 (upper primary school) were interviewed on two occasions about their anticipation of whether or not given nets for the cube- and square-based pyramid would fold to form the target solid. Vergnaud's ( Journal of Mathematical Behavior, 17(2), 167-181, 1998, Human Development, 52, 83-94, 2009) four characteristics of schemes were used as a theoretical lens to analyse the data. Successful schemes depended on the interaction of operational invariants, such as strategic choice of the base, rules for action, particularly rotation of shapes, and anticipations of composites of polygons in the net forming arrangements of faces in the solid. Inferences were rare. These data suggest that students need teacher support to make inferences, in order to create transferable schemes.

Production of superconductor/carbon bicomponent fibers

NASA Technical Reports Server (NTRS)

Wise, S. A.; Fain, C. C.; Leigh, H. D.

1991-01-01

Certain materials are unable to be drawn or spun into fiber form due to their improper melting characteristics or brittleness. However, fibrous samples of such materials are often necessary for the fabrication of intricate shapes and composites. In response to this problem, a unique process, referred to as the piggyback process, was developed to prepare fibrous samples of a variety of nonspinnable ceramics. In this technique, specially produced C shaped carbon fibers serve as micromolds to hold the desired materials prior to sintering. Depending on the sintering atmosphere used, bicomponent or single component fibers result. While much has been shown worldwide concerning the YBa2Cu3O(7-x) superconductor, fabrication into unique forms has proven quite difficult. However, a variety of intricate shapes are necessary for rapid commercialization of the superconducting materials. The potential for producing fibrous samples of the YBa2Cu3O(7-x) compound by the piggyback process is being studied. Various organic and acrylic materials were studied to determine suspending ability, reactivity with the YBa2Cu3O(7-x) compound during long term storage, and burn out characteristics. While many questions were answered with respect to the interfacial reactions between YBa2Cu3O(7-x) and carbon, much work is still necessary to improve the quality of the sintered material if the fibers produced are to be incorporated into useful composite or cables.

Microstructure, Fatigue Behavior, and Failure Mechanisms of Direct Laser-Deposited Inconel 718

NASA Astrophysics Data System (ADS)

Johnson, Alex S.; Shao, Shuai; Shamsaei, Nima; Thompson, Scott M.; Bian, Linkan

2017-03-01

Inconel 718 is considered to be a superalloy with a series of superior properties such as high strength, creep resistance, and corrosion resistance at room and elevated temperatures. Additive manufacturing (AM) is particularly appealing to Inconel 718 because of its near-net-shape production capability for circumventing the poor machinability of this superalloy. Nevertheless, AM parts are prone to porosity, which is detrimental to their fatigue resistance. Thus, further understanding of their fatigue behavior is required before their widespread use in load-bearing applications. In this work, the microstructure and fatigue properties of AM Inconel 718, produced in a Laser Engineered Net Shaping (LENS™) system and heat treated with a standard heat treatment schedule, are evaluated at room temperature. Fully reversed strain controlled fatigue tests were performed on cylindrical specimens with straight gage sections at strain amplitudes ranging from 0.001 mm/mm to 0.01 mm/mm. The fracture surfaces of fatigue specimens were inspected with a scanning electron microscope. The results indicate that the employed heat treatment allowed the large, elongated grains and dendritic structure of the as-built material to break down into smaller, equiaxed grains, with some dendritic structures remaining between layers. The AM specimens were found to possess lower fatigue resistance than wrought Inconel 718, and this is primarily attributed to the presence of brittle metal-carbide/oxide inclusions or pores near their surface.

Fatigue Behavior of Porous Ti-6Al-4V Made by Laser-Engineered Net Shaping.

PubMed

Razavi, Seyed Mohammad Javad; Bordonaro, Giancarlo G; Ferro, Paolo; Torgersen, Jan; Berto, Filippo

2018-02-12

The fatigue behavior and fracture mechanisms of additively manufactured Ti-6Al-4V specimens are investigated in this study. Three sets of testing samples were fabricated for the assessment of fatigue life. The first batch of samples was built by using Laser-Engineered Net Shaping (LENS) technology, a Direct Energy Deposition (DED) method. Internal voids and defects were induced in a second batch of samples by changing LENS machine processing parameters. Fatigue performance of these samples is compared to the wrought Ti-6Al-4V samples. The effects of machine-induced porosity are assessed on mechanical properties and results are presented in the form of SN curves for the three sets of samples. Fracture mechanisms are examined by using Scanning Electron Microscopy (SEM) to characterize the morphological characteristics of the failure surface. Different fracture surface morphologies are observed for porous and non-porous specimens due to the combination of head write speed and laser power. Formation of defects such as pores, unmelted regions, and gas entrapments affect the failure mechanisms in porous specimens. Non-porous specimens exhibit fatigue properties comparable with that of the wrought specimens, but porous specimens are found to show a tremendous reduced fatigue strength.

Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

NASA Technical Reports Server (NTRS)

O'Neal, Derek

2016-01-01

A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. The near-net shape DMLS parts have been delivered and final machining is underway. Fabrication of the traditionally manufactured hardware is also proceeding. Testing in liquid oxygen is planned for Q2 of FY2017. This topic explores the design of the turbopump along with fabrication and material testing of the DMLS hardware.

AGT101 automotive gas turbine system development

NASA Technical Reports Server (NTRS)

Rackley, R. A.; Kidwell, J. R.

1982-01-01

The AGT101 automotive gas turbine system consisting of a 74.6 kw regenerated single-shaft gas turbine engine, is presented. The development and testing of the system is reviewed, and results for aerothermodynamic components indicate that compressor and turbine performance levels are within one percent of projected levels. Ceramic turbine rotor development is encouraging with successful cold spin testing of simulated rotors to speeds over 12,043 rad/sec. Spin test results demonstrate that ceramic materials having the required strength levels can be fabricated by net shape techniques to the thick hub cross section, which verifies the feasibility of the single-stage radial rotor in single-shaft engines.

Near net shape processing of continuous lengths of superconducting wire

DOEpatents

Danyluk, S.; McNallan, M.; Troendly, R.; Poeppel, R.; Goretta, K.; Lanagan, M.

1997-08-26

A system and method for mechanically forming a ceramic superconductor product are disclosed. A system for making the ceramic superconductor includes a metallic channel portion having a cross section for receiving a ceramic superconductor powder, a roll to mechanically reduce the channel cross section and included superconductor powder and a cap portion welded to the channel portion using a localized high energy source. The assembled bar is then mechanically reduced to form a tape or wire end product. 9 figs.

Process for preparing silicon carbide foam

DOEpatents

Whinnery, LeRoy Louis; Nichols, Monte Carl; Wheeler, David Roger; Loy, Douglas Anson

1997-01-01

A method of preparing near net shape, monolithic, porous SiC foams is disclosed. Organosilicon precursors are used to produce polymeric gels by thermally induced phase separation, wherein, a sufficiently concentrated solution of an organosilicon polymer is cooled below its solidification temperature to form a gel. Following solvent removal from the gel, the polymer foam is pretreated in an oxygen plasma in order to raise its glass transition temperature. The pretreated foam is then pyrolized in an inert atmosphere to form a SiC foam.

Process for preparing silicon carbide foam

DOEpatents

Whinnery, L.L.; Nichols, M.C.; Wheeler, D.R.; Loy, D.A.

1997-09-16

A method of preparing near net shape, monolithic, porous SiC foams is disclosed. Organosilicon precursors are used to produce polymeric gels by thermally induced phase separation, wherein, a sufficiently concentrated solution of an organosilicon polymer is cooled below its solidification temperature to form a gel. Following solvent removal from the gel, the polymer foam is pretreated in an oxygen plasma in order to raise its glass transition temperature. The pretreated foam is then pyrolyzed in an inert atmosphere to form a SiC foam. 9 figs.

Numerical Simulation of Molten Flow in Directed Energy Deposition Using an Iterative Geometry Technique

NASA Astrophysics Data System (ADS)

Vincent, Timothy J.; Rumpfkeil, Markus P.; Chaudhary, Anil

2018-03-01

The complex, multi-faceted physics of laser-based additive metals processing tends to demand high-fidelity models and costly simulation tools to provide predictions accurate enough to aid in selecting process parameters. Of particular difficulty is the accurate determination of melt pool shape and size, which are useful for predicting lack-of-fusion, as this typically requires an adequate treatment of thermal and fluid flow. In this article we describe a novel numerical simulation tool which aims to achieve a balance between accuracy and cost. This is accomplished by making simplifying assumptions regarding the behavior of the gas-liquid interface for processes with a moderate energy density, such as Laser Engineered Net Shaping (LENS). The details of the implementation, which is based on the solver simpleFoam of the well-known software suite OpenFOAM, are given here and the tool is verified and validated for a LENS process involving Ti-6Al-4V. The results indicate that the new tool predicts width and height of a deposited track to engineering accuracy levels.

Numerical Simulation of Molten Flow in Directed Energy Deposition Using an Iterative Geometry Technique

NASA Astrophysics Data System (ADS)

Vincent, Timothy J.; Rumpfkeil, Markus P.; Chaudhary, Anil

2018-06-01

The complex, multi-faceted physics of laser-based additive metals processing tends to demand high-fidelity models and costly simulation tools to provide predictions accurate enough to aid in selecting process parameters. Of particular difficulty is the accurate determination of melt pool shape and size, which are useful for predicting lack-of-fusion, as this typically requires an adequate treatment of thermal and fluid flow. In this article we describe a novel numerical simulation tool which aims to achieve a balance between accuracy and cost. This is accomplished by making simplifying assumptions regarding the behavior of the gas-liquid interface for processes with a moderate energy density, such as Laser Engineered Net Shaping (LENS). The details of the implementation, which is based on the solver simpleFoam of the well-known software suite OpenFOAM, are given here and the tool is verified and validated for a LENS process involving Ti-6Al-4V. The results indicate that the new tool predicts width and height of a deposited track to engineering accuracy levels.

PROCESS OF PRODUCING SHAPED PLUTONIUM

DOEpatents

Anicetti, R.J.

1959-08-11

A process is presented for producing and casting high purity plutonium metal in one step from plutonium tetrafluoride. The process comprises heating a mixture of the plutonium tetrafluoride with calcium while the mixture is in contact with and defined as to shape by a material obtained by firing a mixture consisting of calcium oxide and from 2 to 10% by its weight of calcium fluoride at from 1260 to 1370 deg C.

Direct Reduction of Waste through Refining of DOE Metal Assets - 13632

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hargett, Michael C.; Terekhov, Dimitri; Khozan, Kamran M.

2013-07-01

CVMR{sup R} presents a technology for refining nickel from the enrichment barrier materials of the DOE that is proven through 100 years of use by the metals industry. CVMR{sup R} applies modern controls, instrumentation for process and monitoring of the system, and innovative production methods to produce a wide spectrum of products that generate new technology applications and improvements to our society and economy. CVMR{sup R} will receive barrier materials as a secure operation and size reduce the metal to a shred that is fed to a carbonylation reactor where nickel is reacted with carbon monoxide and generate nickel carbonyl.more » The carbonyl will be filtered and decomposed with heat to form a variety of products that include high value nano powders, coated substrates, net shapes and pure nickel. The residue from the reactor will retain radionuclides from enrichment activities. The carbon monoxide will only react and extract nickel under the operating conditions to leave volumetric contamination in the unreacted residue. A demonstration plant was designed and built by CVMR{sup R} and operated by BWXT, to demonstrate the systems capabilities to DOE in 2006. A pilot plant operation precedes the detailed design of the nickel refinery and provides essential data for design, safe work practices, waste characterizations and system kinetics and confirms the project feasibility. CVMR{sup R} produces nickel products that are cleaner than the nickel in U.S. commerce and used by industry today. The CVMR{sup R} process and systems for nickel refining is well suited for DOE materials and will provide value through environmental stewardship, recovery of high value assets, and support of the DOE environmental remediation programs as the refined nickel generates additional long term benefits to local communities. (authors)« less

Cryogenic Fracture Toughness Evaluation of an Investment Cast Al-Be Alloy for Structural Applications

NASA Technical Reports Server (NTRS)

Gamwell, W. R.; McGill, P. B.

2006-01-01

Aluminum-Beryllium metal matrix composite materials are useful due to their desirable performance characteristics for aerospace applications. Desirable characteristics of this material includes light-weight, dimensional stability, stiffness, good vibration damping characteristics, low coefficient of thermal expansion, and workability, This material is 3.5 times stiffer and 22% lighter than conventional aluminum alloys. electro-optical systems, advanced sensor and guidance components for flight and satellite systems, components for light-weight high-performance aircraft engines, and structural components for helicopters. Aluminum-beryllium materials are now available in the form of near net shape investment castings. In this materials properties characterization study, the cryogenic tensile and fracture properties of an investment casting alloy, Beralcast 363, were determined. Tensile testing was performed at 21 C (70 F), -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F), and fracture (K(sub lc) and da/dN) testing was performed at -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F). Their use is attractive for weight critical structural applications such as advanced

Additive manufacturing for steels: a review

NASA Astrophysics Data System (ADS)

Zadi-Maad, A.; Rohib, R.; Irawan, A.

2018-01-01

Additive manufacturing (AM) of steels involves the layer by layer consolidation of powder or wire feedstock using a heating beam to form near net shape products. For the past decades, the AM technique reaches the maturation of both research grade and commercial production due to significant research work from academic, government and industrial research organization worldwide. AM process has been implemented to replace the conventional process of steel fabrication due to its potentially lower cost and flexibility manufacturing. This paper provides a review of previous research related to the AM methods followed by current challenges issues. The relationship between microstructure, mechanical properties, and process parameters will be discussed. Future trends and recommendation for further works are also provided.

Programming 2D/3D shape-shifting with hobbyist 3D printers† †Electronic supplementary information (ESI) available. See DOI: 10.1039/c7mh00269f

PubMed Central

van Manen, Teunis; Janbaz, Shahram

2017-01-01

Materials and devices with advanced functionalities often need to combine complex 3D shapes with functionality-inducing surface features. Precisely controlled bio-nanopatterns, printed electronic components, and sensors/actuators are all examples of such surface features. However, the vast majority of the refined technologies that are currently available for creating functional surface features work only on flat surfaces. Here we present initially flat constructs that upon triggering by high temperatures change their shape to a pre-programmed 3D shape, thereby enabling the combination of surface-related functionalities with complex 3D shapes. A number of shape-shifting materials have been proposed during the last few years based on various types of advanced technologies. The proposed techniques often require multiple fabrication steps and special materials, while being limited in terms of the 3D shapes they could achieve. The approach presented here is a single-step printing process that requires only a hobbyist 3D printer and inexpensive off-the-shelf materials. It also lends itself to a host of design strategies based on self-folding origami, instability-driven pop-up, and ‘sequential’ shape-shifting to unprecedentedly expand the space of achievable 3D shapes. This combination of simplicity and versatility is a key to widespread applications. PMID:29308207

Mineral Carbonation Potential of CO2 from Natural and Industrial-based Alkalinity Sources

NASA Astrophysics Data System (ADS)

Wilcox, J.; Kirchofer, A.

2014-12-01

Mineral carbonation is a Carbon Capture and Storage (CSS) technology where gaseous CO2 is reacted with alkaline materials (such as silicate minerals and alkaline industrial wastes) and converted into stable and environmentally benign carbonate minerals (Metz et al., 2005). Here, we present a holistic, transparent life cycle assessment model of aqueous mineral carbonation built using a hybrid process model and economic input-output life cycle assessment approach. We compared the energy efficiency and the net CO2 storage potential of various mineral carbonation processes based on different feedstock material and process schemes on a consistent basis by determining the energy and material balance of each implementation (Kirchofer et al., 2011). In particular, we evaluated the net CO2 storage potential of aqueous mineral carbonation for serpentine, olivine, cement kiln dust, fly ash, and steel slag across a range of reaction conditions and process parameters. A preliminary systematic investigation of the tradeoffs inherent in mineral carbonation processes was conducted and guidelines for the optimization of the life-cycle energy efficiency are provided. The life-cycle assessment of aqueous mineral carbonation suggests that a variety of alkalinity sources and process configurations are capable of net CO2 reductions. The maximum carbonation efficiency, defined as mass percent of CO2 mitigated per CO2 input, was 83% for CKD at ambient temperature and pressure conditions. In order of decreasing efficiency, the maximum carbonation efficiencies for the other alkalinity sources investigated were: olivine, 66%; SS, 64%; FA, 36%; and serpentine, 13%. For natural alkalinity sources, availability is estimated based on U.S. production rates of a) lime (18 Mt/yr) or b) sand and gravel (760 Mt/yr) (USGS, 2011). The low estimate assumes the maximum sequestration efficiency of the alkalinity source obtained in the current work and the high estimate assumes a sequestration efficiency of 85%. The total CO2 storage potential for the alkalinity sources considered in the U.S. ranges from 1.3% to 23.7% of U.S. CO2 emissions, depending on the assumed availability of natural alkalinity sources and efficiency of the mineral carbonation processes.

Exhaust-stack nozzle area and shape for individual cylinder exhaust-gas jet-propulsion system

NASA Technical Reports Server (NTRS)

Pinkel, Benjamin; Turner, Richard; Voss, Fred; Humble, Leroy V

1943-01-01

This report presents the results of an investigation conducted on the effect of exhaust-stack nozzle area, shape, and length on engine power, jet thrust, and gain in net thrust (engine propeller plus jet). Single-cylinder engine data were obtained using three straight stacks 25, 44, and 108 inches in length; an S-shaped stack, a 90 degree bend, a 180 degree bend, and a short straight stack having a closed branch faired into it. Each stack was fitted with nozzles varying in exit area from 0.91 square inch to the unrestricted area of the stack of 4.20 square inches. The engine was generally operated over a range of engine speeds from 1300 to 2100 r.p.m, inlet-manifold pressures from 22 to 30 inches of mercury absolute, and a fuel-air ratio of 0.08. The loss in engine power, the jet thrust, and the gain in net thrust are correlated in terms of several simple parameters. An example is given for determining the optimum nozzle area and the overall net thrust.

Development of geometry materials based on scientific approach for junior high school students

NASA Astrophysics Data System (ADS)

Nurafni; Siswanto, R. D.; Azhar, E.

2018-01-01

A scientific approach is a learning process designed so that learners can actively construct concepts, encourage learners to find out from various sources through observation, and not just be told. Therefore, learning by scientific approach offers a solution, because the goals, principles, and stages of the scientific approach allow for a good understanding of the students. Because of the absence of teaching materials “polyhedron geometry based on scientific approach” which is widely published in Indonesia, then we need to develop the teaching materials. The results obtained in this study are the tasks presented on teaching materials with a scientific approach both in defining the cube and the beam, identify and solve problems related to the properties and elements of cubes and beams, making cube and beam nets, solving problems related to cube and beam nets, solving problems related to cube and beam surface area. Beginning with the difficulties students face. Then, based on the results of interviews with teachers and analysis of student difficulties on each indicator, researchers revise the teaching materials as needed. Teaching materials that have not found any more student difficulties then the teaching materials are considered valid and ready for use by teachers and students.

A geomorphic process law for detachment-limited hillslopes

NASA Astrophysics Data System (ADS)

Turowski, Jens

2015-04-01

Geomorphic process laws are used to assess the shape evolution of structures at the Earth's surface over geological time scales, and are routinely used in landscape evolution models. There are two currently available concepts on which process laws for hillslope evolution rely. In the transport-limited concept, the evolution of a hillslope is described by a linear or a non-linear diffusion equation. In contrast, in the threshold slope concept, the hillslope is assumed to collapse to a slope equal to the internal friction angle of the material when the load due to the relief exists the material strength. Many mountains feature bedrock slopes, especially in the high mountains, and material transport along the slope is limited by the erosion of the material from the bedrock. Here, I suggest a process law for detachment-limited or threshold-dominated hillslopes, in which the erosion rate is a function of the applied stress minus the surface stress due to structural loading. The process law leads to the prediction of an equilibrium form that compares well to the shape of many mountain domes.

Producing High-Quality Titanium Alloy by a Cost-Effective Route Combining Fast Heating and Hot Processing

NASA Astrophysics Data System (ADS)

Yang, Fei; Raynova, Stella; Singh, Ajit; Zhao, Qinyang; Romero, Carlos; Bolzoni, Leandro

2018-02-01

Powder metallurgy is a very attractive method for producing titanium alloys, which can be near-net-shape formed and have freedom in composition selection. However, applications are still limited due to product affordability. In this paper, we will discuss a possible cost-effective route, combining fast heating and hot processing, to produce titanium alloys with similar or even better mechanical properties than that of ingot metallurgy titanium alloys. Two titanium alloys, Ti-5Al-5V-5Mo-3Cr (Ti-5553) and Ti-5Fe, were successfully produced from HDH titanium powder and other master alloy powders using the proposed processing route. The effect of the processing route on microstructural variation and mechanical properties have been discussed.

Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carpenter, John S.; Beese, Allison M.; Bourell, David L.

Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

DOE PAGES

Carpenter, John S.; Beese, Allison M.; Bourell, David L.; ...

2015-06-26

Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

Space Technology Mission Directorate Game Changing Development Program FY2015 Annual Program Review: Advanced Manufacturing Technology

NASA Technical Reports Server (NTRS)

Vickers, John; Fikes, John

2015-01-01

The Advance Manufacturing Technology (AMT) Project supports multiple activities within the Administration's National Manufacturing Initiative. A key component of the Initiative is the Advanced Manufacturing National Program Office (AMNPO), which includes participation from all federal agencies involved in U.S. manufacturing. In support of the AMNPO the AMT Project supports building and Growing the National Network for Manufacturing Innovation through a public-private partnership designed to help the industrial community accelerate manufacturing innovation. Integration with other projects/programs and partnerships: STMD (Space Technology Mission Directorate), HEOMD, other Centers; Industry, Academia; OGA's (e.g., DOD, DOE, DOC, USDA, NASA, NSF); Office of Science and Technology Policy, NIST Advanced Manufacturing Program Office; Generate insight within NASA and cross-agency for technology development priorities and investments. Technology Infusion Plan: PC; Potential customer infusion (TDM, HEOMD, SMD, OGA, Industry); Leverage; Collaborate with other Agencies, Industry and Academia; NASA roadmap. Initiatives include: Advanced Near Net Shape Technology Integrally Stiffened Cylinder Process Development (launch vehicles, sounding rockets); Materials Genome; Low Cost Upper Stage-Class Propulsion; Additive Construction with Mobile Emplacement (ACME); National Center for Advanced Manufacturing.

Colloidal quantum dot solar cells exploiting hierarchical structuring.

PubMed

Labelle, André J; Thon, Susanna M; Masala, Silvia; Adachi, Michael M; Dong, Haopeng; Farahani, Maryam; Ip, Alexander H; Fratalocchi, Andrea; Sargent, Edward H

2015-02-11

Extremely thin-absorber solar cells offer low materials utilization and simplified manufacture but require improved means to enhance photon absorption in the active layer. Here, we report enhanced-absorption colloidal quantum dot (CQD) solar cells that feature transfer-stamped solution-processed pyramid-shaped electrodes employed in a hierarchically structured device. The pyramids increase, by up to a factor of 2, the external quantum efficiency of the device at absorption-limited wavelengths near the absorber band edge. We show that absorption enhancement can be optimized with increased pyramid angle with an appreciable net improvement in power conversion efficiency, that is, with the gain in current associated with improved absorption and extraction overcoming the smaller fractional decrease in open-circuit voltage associated with increased junction area. We show that the hierarchical combination of micron-scale structured electrodes with nanoscale films provides for an optimized enhancement at absorption-limited wavelengths. We fabricate 54.7° pyramid-patterned electrodes, conformally apply the quantum dot films, and report pyramid CQD solar cells that exhibit a 24% improvement in overall short-circuit current density with champion devices providing a power conversion efficiency of 9.2%.

Data related to cyclic deformation and fatigue behavior of direct laser deposited Ti-6Al-4V with and without heat treatment.

PubMed

Sterling, Amanda J; Torries, Brian; Shamsaei, Nima; Thompson, Scott M

2016-03-01

Data is presented describing the strain-controlled, fully-reversed uniaxial cyclic deformation and fatigue behavior of Ti-6Al-4V specimens additively manufactured via Laser Engineered Net Shaping (LENS) - a Direct Laser Deposition (DLD) process. The data was collected by performing multiple fatigue tests on specimens with various microstructural states/conditions, i.e. in their 'as-built', annealed (below the beta transus temperature), or heat treated (above the beta transus temperature) condition. Such data aids in characterizing the mechanical integrity and fatigue resistance of DLD parts. Data presented herein also allows for elucidating the strong microstructure coupling of the fatigue behavior of DLD Ti-6Al-4V, as the data trends were found to vary with material condition (i.e. as-built, annealed or heat treated) [1]. This data is of interest to the additive manufacturing and fatigue scientific communities, as well as the aerospace and biomedical industries, since additively-manufactured parts cannot be reliably deployed for public use, until their mechanical properties are understood with high certainty.

Data related to cyclic deformation and fatigue behavior of direct laser deposited Ti–6Al–4V with and without heat treatment

PubMed Central

Sterling, Amanda J.; Torries, Brian; Shamsaei, Nima; Thompson, Scott M.

2016-01-01

Data is presented describing the strain-controlled, fully-reversed uniaxial cyclic deformation and fatigue behavior of Ti–6Al–4V specimens additively manufactured via Laser Engineered Net Shaping (LENS) – a Direct Laser Deposition (DLD) process. The data was collected by performing multiple fatigue tests on specimens with various microstructural states/conditions, i.e. in their ‘as-built’, annealed (below the beta transus temperature), or heat treated (above the beta transus temperature) condition. Such data aids in characterizing the mechanical integrity and fatigue resistance of DLD parts. Data presented herein also allows for elucidating the strong microstructure coupling of the fatigue behavior of DLD Ti–6Al–4V, as the data trends were found to vary with material condition (i.e. as-built, annealed or heat treated) [1]. This data is of interest to the additive manufacturing and fatigue scientific communities, as well as the aerospace and biomedical industries, since additively-manufactured parts cannot be reliably deployed for public use, until their mechanical properties are understood with high certainty. PMID:26949728

Dry Sintered Metal Coating of Halloysite Nanotubes

DOE PAGES

Nicholson, James C.; Weisman, Jeffery A.; Boyer, Christen J.; ...

2016-09-19

Halloysite nanotubes (HNTs) are a naturally-occurring aluminosilicate whose dimensions measure microns in length and tens of nanometers in diameter. Bonding defects between the alumina and silica lead to net negative and positive charges on the exterior and interior lumen, respectively. HNTs have been shown to enhance the material properties of polymer matrices and enable the sustained release of loaded chemicals, drugs, and growth factors. Due to the net charges, these nanotubes can also be readily coated in layered-depositions using the HNT exterior lumen’s net negative charge as the basis for assembly. These coatings are primarily done through wet chemical processes,more » the majority of which are limited in their use of desired chemicals, due to the polarity of the halloysite. Furthermore, this restriction in the type of chemicals used often requires the use of more toxic chemicals in place of greener options, and typically necessitates the use of a significantly longer chemical process to achieve the desired coating. In this study, we show that HNTs can be coated with metal acetylacetonates—compounds primarily employed in the synthesis of nanoparticles, as metal catalysts, and as NMR shift reagents—through a dry sintering process. This method was capable of thermally decaying the metal acetylacetonate, resulting in a free positively-charged metal ion that readily bonded to the negatively-charged HNT exterior, resulting in metallic coatings forming on the HNT surface. Our coating method may enable greater deposition of coated material onto these nanotubes as required for a desired application. Moreover, the use of chemical processes using toxic chemicals is not required, thus eliminating exposure« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nicholson, James C.; Weisman, Jeffery A.; Boyer, Christen J.

Halloysite nanotubes (HNTs) are a naturally-occurring aluminosilicate whose dimensions measure microns in length and tens of nanometers in diameter. Bonding defects between the alumina and silica lead to net negative and positive charges on the exterior and interior lumen, respectively. HNTs have been shown to enhance the material properties of polymer matrices and enable the sustained release of loaded chemicals, drugs, and growth factors. Due to the net charges, these nanotubes can also be readily coated in layered-depositions using the HNT exterior lumen’s net negative charge as the basis for assembly. These coatings are primarily done through wet chemical processes,more » the majority of which are limited in their use of desired chemicals, due to the polarity of the halloysite. Furthermore, this restriction in the type of chemicals used often requires the use of more toxic chemicals in place of greener options, and typically necessitates the use of a significantly longer chemical process to achieve the desired coating. In this study, we show that HNTs can be coated with metal acetylacetonates—compounds primarily employed in the synthesis of nanoparticles, as metal catalysts, and as NMR shift reagents—through a dry sintering process. This method was capable of thermally decaying the metal acetylacetonate, resulting in a free positively-charged metal ion that readily bonded to the negatively-charged HNT exterior, resulting in metallic coatings forming on the HNT surface. Our coating method may enable greater deposition of coated material onto these nanotubes as required for a desired application. Moreover, the use of chemical processes using toxic chemicals is not required, thus eliminating exposure« less

Making Plant-Support Structures From Waste Plant Fiber

NASA Technical Reports Server (NTRS)

Morrow, Robert C.; < oscjmocl. < attjew K/; {ertzbprm. A,amda; Ej (e. Cjad); Hunt, John

2006-01-01

Environmentally benign, biodegradable structures for supporting growing plants can be made in a process based on recycling of such waste plant fiber materials as wheat straw or of such derivative materials as paper and cardboard. Examples of structures that can be made in this way include plant plugs, pots, planter-lining mats, plant fences, and root and shoot barriers. No chemical binders are used in the process. First, the plant material is chopped into smaller particles. The particles are leached with water or steam to remove material that can inhibit plant growth, yielding a fibrous slurry. If the desired structures are plugs or sheets, then the slurry is formed into the desired shapes in a pulp molding subprocess. If the desired structures are root and shoot barriers, pots, or fences, then the slurry is compression-molded to the desired shapes in a heated press. The processed materials in these structures have properties similar to those of commercial pressboard, but unlike pressboard, these materials contain no additives. These structures have been found to withstand one growth cycle, even when wet

Materials ``alchemy'': Shape-preserving chemical transformation of micro-to-macroscopic 3-D structures

NASA Astrophysics Data System (ADS)

Sandhage, Kenneth H.

2010-06-01

The scalable fabrication of nano-structured materials with complex morphologies and tailorable chemistries remains a significant challenge. One strategy for such synthesis consists of the generation of a solid structure with a desired morphology (a “preform”), followed by reactive conversion of the preform into a new chemistry. Several gas/solid and liquid/solid reaction processes that are capable of such chemical conversion into new micro-to-nano-structured materials, while preserving the macroscopic-to-microscopic preform morphologies, are described in this overview. Such shape-preserving chemical transformation of one material into another could be considered a modern type of materials “alchemy.”

Ring-Opening Polymerization of Cyclic Hemiacetal Esters for the Preparation of Hydrolytically and Thermally Degradable Polymers

NASA Astrophysics Data System (ADS)

Neitzel, Angelika Susanne Elisabeth

During the course of tokamak operation, material is routinely eroded from plasma facing components and transported to other regions of the machine. This net-reshaping process will lead to many challenges in a high duty cycle magnetic fusion reactor, and is also highly relevant to the wall conditioning process in current experiments. Proper modeling of this mechanism requires a global treatment of the entire tokamak, and integration of tightly coupled plasma and surface processes. This thesis focuses on extending and applying the WallDYN mixed-material migration code [1] [2], which couples local erosion and deposition processes with plasma impurity transport in a non-iterative, self-consistent manner that maintains overall material balance. NSTX-U operated in 2016 with carbon PFCs, periodically conditioned with boron-containing films to suppress oxygen impurities. However, oxygen levels tended to return to a pre-conditioned state following repeated plasma exposure, and this occurred on a faster time scale when conditioning with less boron. This C/B/O migration is interpretively modeled with WallDYN, which successfully reproduces observed trends in oxygen evolution. A new model for spatially inhomogenous mixed material films has been developed for WallDYN, which allows for the differentiation between conditioning films of varying thicknesses. A boron coverage model for the NSTX-U glow discharge boronization process is also developed. These new capabilities improve WallDYN agreement with observed NSTX-U spectroscopic data by at least a factor of 2. As part of the integrated model, plasma backgrounds representing NSTX-U H-modes and L-modes are calculated using OSM-EIRENE, constrained by a combination of NSTX-U data and NSTX SOLPS calculations. The effect of modifying the assumed parallel SOL profile is examined, with the result that inner divertor-directed flows turn the outer divertor from a region of net boron deposition to one of net boron erosion. Plasma impurity transport calculations are carried out with DIVIMP, and mixed-material sputtering calculations are carried out for a range of possible surfaces with SDTRIMSP. WallDYN modeling of C/Li/O migration in NSTX is presented, utilizing OSM-EIRENE calculations of lithiated NSTX plasmas. An adatom model of temperature-enhanced sputtering has been added to WallDYN, and the effect of various surface temperature scenarios is examined. A sensitivity study of surface binding energies used in WallDYN sputtering calculations is carried out, finding that mixed material effects become dominant when the system contains both tightly- and weakly- bound elements (such as C and Li).

Microstructure and calorimetric behavior of laser welded open cell foams in CuZnAl shape memory alloy

NASA Astrophysics Data System (ADS)

Biffi, Carlo Alberto; Previtali, Barbara; Tuissi, Ausonio

Cellular shape memory alloys (SMAs) are very promising smart materials able to combine functional properties of the material with lightness, stiffness, and damping capacity of the cellular structure. Their processing with low modification of the material properties remains an open question. In this work, the laser weldability of CuZnAl SMA in the form of open cell foams was studied. The cellular structure was proved to be successfully welded in lap joint configuration by using a thin plate of the same alloy. Softening was seen in the welded bead in all the investigated ranges of process speed as well as a double stage heat affected zone was identified due to different microstructures; the martensitic transformation was shifted to higher temperatures and the corresponding peaks were sharper with respect to the base material due to the rapid solidification of the material. Anyways, no compositional variations were detected in the joints.

Material properties and their influence on the behaviour of tungsten as plasma facing material

NASA Astrophysics Data System (ADS)

Wirtz, M.; Uytdenhouwen, I.; Barabash, V.; Escourbiac, F.; Hirai, T.; Linke, J.; Loewenhoff, Th.; Panayotis, S.; Pintsuk, G.

2017-06-01

With the aim of a possible improvement of the material specification for tungsten, five different tungsten products by different companies and by different production technologies (forging and rolling) are subject to a materials characterization program. Tungsten produced by forging results in an uniaxial elongated grain shape while rolled products have a plate like grain shape which has an influence on the mechanical properties of the material. The materials were investigated with respect to the following parameters: hardness measurements, microstructural investigations, tensile tests and recrystallisation sensitivity tests at 3 different temperatures. The obtained results show that different production processes have an influence on the resulting anisotropic microstructure and the related material properties of tungsten in the as-received state. Additionally, the recrystallization sensitivity varies between the different products, what could be a result of the different production processes. Additionally, two tungsten products were exposed to thermal shocks. The obtained results show that the improved recrystallisation behaviour has no major impact on the thermal shock performance.

3-D Characterization of Detrital Zircon Grains and its Implications for Fluvial Transport, Mixing, and Preservation Bias

NASA Astrophysics Data System (ADS)

Markwitz, V.; Kirkland, C. L.; Mehnert, A.; Gessner, K.; Shaw, J.

2017-12-01

Detrital zircon studies can suffer from selective loss of provenance information due to U-Pb age discordance, metamictization, metamorphic overprinting and fluviatile transport processes. The relationship between isotopic composition and zircon grain shape, and how grain shape is modified during transport, is largely unknown. We combine X-ray tomography with U-Pb geochronology to quantify how fluvial transport affects 3-D zircon shape, detrital age signature, and grain density along the Murchison River, whose catchment comprises Eoarchean to Early Paleozoic source rocks in Western Australia. We acquired tomographic volumes and isotopic data from 373 detrital zircons to document changes in size, shape and density in transport direction, and explore how grain shape, age spectra and the proportion of discordant material vary along the channel. Results show that shape characteristics are sensitive to transport distance, stream gradient, proximity to source material, and whether the source consists of primary or recycled zircons. With increasing transport distance, grain lengths decrease more than their widths. Furthermore, the loss of metamict grains occurs at a near constant rate, resulting in a linear increase of mean calculated zircon density by ca. 0.03 g/cm3 per 100 km transport distance. 3-D grain shape is therefore strongly linked to detrital age signature, and mean grain density is a function of the absolute transport distance. 3-D shape characteristics provide valuable information on detrital zircon populations, including the interaction between source materials with fluvial transport processes, which significantly affects preservation bias and, by inference, the representativeness of the sampled data.

Method for atmospheric pressure reactive atom plasma processing for surface modification

DOEpatents

Carr, Jeffrey W [Livermore, CA

2009-09-22

Reactive atom plasma processing can be used to shape, polish, planarize and clean the surfaces of difficult materials with minimal subsurface damage. The apparatus and methods use a plasma torch, such as a conventional ICP torch. The workpiece and plasma torch are moved with respect to each other, whether by translating and/or rotating the workpiece, the plasma, or both. The plasma discharge from the torch can be used to shape, planarize, polish, and/or clean the surface of the workpiece, as well as to thin the workpiece. The processing may cause minimal or no damage to the workpiece underneath the surface, and may involve removing material from the surface of the workpiece.

Robot based deposition of WC-Co HVOF coatings on HSS cutting tools as a substitution for solid cemented carbide cutting tools

NASA Astrophysics Data System (ADS)

Tillmann, W.; Schaak, C.; Biermann, D.; Aßmuth, R.; Goeke, S.

2017-03-01

Cemented carbide (hard metal) cutting tools are the first choice to machine hard materials or to conduct high performance cutting processes. Main advantages of cemented carbide cutting tools are their high wear resistance (hardness) and good high temperature strength. In contrast, cemented carbide cutting tools are characterized by a low toughness and generate higher production costs, especially due to limited resources. Usually, cemented carbide cutting tools are produced by means of powder metallurgical processes. Compared to conventional manufacturing routes, these processes are more expensive and only a limited number of geometries can be realized. Furthermore, post-processing and preparing the cutting edges in order to achieve high performance tools is often required. In the present paper, an alternative method to substitute solid cemented carbide cutting tools is presented. Cutting tools made of conventional high speed steels (HSS) were coated with thick WC-Co (88/12) layers by means of thermal spraying (HVOF). The challenge is to obtain a dense, homogenous, and near-net-shape coating on the flanks and the cutting edge. For this purpose, different coating strategies were realized using an industrial robot. The coating properties were subsequently investigated. After this initial step, the surfaces of the cutting tools were ground and selected cutting edges were prepared by means of wet abrasive jet machining to achieve a smooth and round micro shape. Machining tests were conducted with these coated, ground and prepared cutting tools. The occurring wear phenomena were analyzed and compared to conventional HSS cutting tools. Overall, the results of the experiments proved that the coating withstands mechanical stresses during machining. In the conducted experiments, the coated cutting tools showed less wear than conventional HSS cutting tools. With respect to the initial wear resistance, additional benefits can be obtained by preparing the cutting edge by means of wet abrasive jet machining.

Digital Microdroplet Ejection Technology-Based Heterogeneous Objects Prototyping

PubMed Central

Yang, Jiquan; Feng, Chunmei; Yang, Jianfei; Zhu, Liya; Guo, Aiqing

2016-01-01

An integrate fabrication framework is presented to build heterogeneous objects (HEO) using digital microdroplets injecting technology and rapid prototyping. The heterogeneous materials part design and manufacturing method in structure and material was used to change the traditional process. The net node method was used for digital modeling that can configure multimaterials in time. The relationship of material, color, and jetting nozzle was built. The main important contributions are to combine the structure, material, and visualization in one process and give the digital model for manufacture. From the given model, it is concluded that the method is effective for HEO. Using microdroplet rapid prototyping and the model given in the paper HEO could be gotten basically. The model could be used in 3D biomanufacturing. PMID:26981110

Digital Microdroplet Ejection Technology-Based Heterogeneous Objects Prototyping.

PubMed

Li, Na; Yang, Jiquan; Feng, Chunmei; Yang, Jianfei; Zhu, Liya; Guo, Aiqing

2016-01-01

An integrate fabrication framework is presented to build heterogeneous objects (HEO) using digital microdroplets injecting technology and rapid prototyping. The heterogeneous materials part design and manufacturing method in structure and material was used to change the traditional process. The net node method was used for digital modeling that can configure multimaterials in time. The relationship of material, color, and jetting nozzle was built. The main important contributions are to combine the structure, material, and visualization in one process and give the digital model for manufacture. From the given model, it is concluded that the method is effective for HEO. Using microdroplet rapid prototyping and the model given in the paper HEO could be gotten basically. The model could be used in 3D biomanufacturing.

77 FR 23319 - Public Hearing

Federal Register 2010, 2011, 2012, 2013, 2014

2012-04-18

... Plan for the Water Resources of the Susquehanna River Basin. The public should take note that this... available at the SRBC Water Resource Portal at www.srbc.net/wrp . Materials and supporting documents are... Processing Fee Schedule; and (3) amendment to the Comprehensive Plan for the Water Resources of the...

Morphogenesis and mechanostabilization of complex natural and 3D printed shapes

PubMed Central

Tiwary, Chandra Sekhar; Kishore, Sharan; Sarkar, Suman; Mahapatra, Debiprosad Roy; Ajayan, Pulickel M.; Chattopadhyay, Kamanio

2015-01-01

The natural selection and the evolutionary optimization of complex shapes in nature are closely related to their functions. Mechanostabilization of shape of biological structure via morphogenesis has several beautiful examples. With the help of simple mechanics-based modeling and experiments, we show an important causality between natural shape selection as evolutionary outcome and the mechanostabilization of seashells. The effect of biological growth on the mechanostabilization process is identified with examples of two natural shapes of seashells, one having a diametrically converging localization of stresses and the other having a helicoidally concentric localization of stresses. We demonstrate how the evolved shape enables predictable protection of soft body parts of the species. The effect of bioavailability of natural material is found to be a secondary factor compared to shape selectivity, where material microstructure only acts as a constraint to evolutionary optimization. This is confirmed by comparing the mechanostabilization behavior of three-dimensionally printed synthetic polymer structural shapes with that of natural seashells consisting of ceramic and protein. This study also highlights interesting possibilities in achieving a new design of structures made of ordinary materials which have bio-inspired optimization objectives. PMID:26601170

"When I sleep under the net, nothing bothers me; I sleep well and I'm happy": Senegal's culture of net use and how inconveniences to net use do not translate to net abandonment.

PubMed

Berthe, Sara; Loll, Dana; Faye, Sylvain L; Wone, Issa; Koenker, Hannah; Arnold, Bethany; Weber, Rachel

2014-09-12

Despite recent advances in the fight against the disease, malaria remains a serious threat to the health and well-being of populations in endemic countries. The use of long-lasting insecticidal nets (LLIN) reduces contact between the vector and humans, thereby reducing transmission of the disease. LLINs have become an essential component of malaria control programmes worldwide. The Culture of Net Use study used qualitative and quantitative methods in a longitudinal and iterative design over two phases, in order to capture changes in net use over a year and a half period and covering both dry and rainy seasons. Data were collected from a total of 56 households in eight regions to understand variations due to geographical, cultural, and universal coverage differences. At the time of the data collection, the universal coverage campaign had been completed in six of the eight regions (Dakar and Thies excluded). Perceived barriers to use were primarily related to the characteristics of the net itself, include shape, insecticide, and a variety of minority responses, such as perceived lack of mosquito density and being unaccustomed to using nets. Insecticide-related complaints found that insecticide did not present a significant barrier to use, but was cited as a nuisance. Feelings of suffocation continued to be the most commonly cited nuisance. Respondents who favoured the use of insecticide on nets appeared to be more aware of the health and malaria prevention benefits of the insecticide than those who perceived it negatively. Despite prior evidence that barriers such as heat, shape, insecticide and perceived mosquito density contribute to non-use of LLINs in other countries, this study has shown that these factors are considered more as nuisances and that they do not consistently prevent the use of nets among respondents in Senegal. Of those who cited inconveniences with their nets, few were moved to stop using a net. Respondents from this study overcame these barriers and continue to value the importance of nets.

Materials for x-ray refractive lenses minimizing wavefront distortions

DOE Office of Scientific and Technical Information (OSTI.GOV)

Roth, Thomas; Alianelli, Lucia; Lengeler, Daniel

2017-06-09

Refraction through curved surfaces, reflection from curved mirrors in grazing incidence, and diffraction from Fresnel zone plates are key hard x-ray focusing mechanisms. In this article, we present materials used for refractive x-ray lenses. Important properties of such x-ray lenses include focusing strength, shape, and the material’s homogeneity and absorption coefficient. Both the properties of the initial material and the fabrication process result in a lens with imperfections, which can lead to unwanted wavefront distortions. Different fabrication methods for one-dimensional and two-dimensional focusing lenses are presented, together with the respective benefits and inconveniences that are mostly due to shape fidelity.more » Different materials and material grades have been investigated in terms of their homogeneity and the absence of inclusions. Single-crystalline materials show high homogeneity, but suffer from unwanted diffracted radiation, which can be avoided using amorphous materials. Lastly, we show that shape imperfections can be corrected using a correction lens.« less

A PetriNet-Based Approach for Supporting Traceability in Cyber-Physical Manufacturing Systems

PubMed Central

Huang, Jiwei; Zhu, Yeping; Cheng, Bo; Lin, Chuang; Chen, Junliang

2016-01-01

With the growing popularity of complex dynamic activities in manufacturing processes, traceability of the entire life of every product has drawn significant attention especially for food, clinical materials, and similar items. This paper studies the traceability issue in cyber-physical manufacturing systems from a theoretical viewpoint. Petri net models are generalized for formulating dynamic manufacturing processes, based on which a detailed approach for enabling traceability analysis is presented. Models as well as algorithms are carefully designed, which can trace back the lifecycle of a possibly contaminated item. A practical prototype system for supporting traceability is designed, and a real-life case study of a quality control system for bee products is presented to validate the effectiveness of the approach. PMID:26999141

A PetriNet-Based Approach for Supporting Traceability in Cyber-Physical Manufacturing Systems.

PubMed

Huang, Jiwei; Zhu, Yeping; Cheng, Bo; Lin, Chuang; Chen, Junliang

2016-03-17

With the growing popularity of complex dynamic activities in manufacturing processes, traceability of the entire life of every product has drawn significant attention especially for food, clinical materials, and similar items. This paper studies the traceability issue in cyber-physical manufacturing systems from a theoretical viewpoint. Petri net models are generalized for formulating dynamic manufacturing processes, based on which a detailed approach for enabling traceability analysis is presented. Models as well as algorithms are carefully designed, which can trace back the lifecycle of a possibly contaminated item. A practical prototype system for supporting traceability is designed, and a real-life case study of a quality control system for bee products is presented to validate the effectiveness of the approach.

Deformation behavior of carbon-fiber reinforced shape-memory-polymer composites used for deployable structures (Conference Presentation)

NASA Astrophysics Data System (ADS)

Lan, Xin; Liu, Liwu; Li, Fengfeng; Pan, Chengtong; Liu, Yanju; Leng, Jinsong

2017-04-01

Shape memory polymers (SMPs) are a new type of smart material, they perform large reversible deformation with a certain external stimulus (e.g., heat and electricity). The properties (e.g., stiffness, strength and other mechanically static or quasi-static load-bearing capacity) are primarily considered for conventional resin-based composite materials which are mainly used for structural materials. By contrast, the mechanical actuating performance with finite deformation is considered for the shape memory polymers and their composites which can be used for both structural materials and functional materials. For shape memory polymers and their composites, the performance of active deformation is expected to further promote the development in smart active deformation structures, such as deployable space structures and morphing wing aircraft. The shape memory polymer composites (SMPCs) are also one type of High Strain Composite (HSC). The space deployable structures based on carbon fiber reinforced shape memory polymer composites (SMPCs) show great prospects. Considering the problems that SMPCs are difficult to meet the practical applications in space deployable structures in the recent ten years, this paper aims to research the mechanics of deformation, actuation and failure of SMPCs. In the overall view of the shape memory polymer material's nonlinearity (nonlinearity and stress softening in the process of pre-deformation and recovery, relaxation in storage process, irreversible deformation), by the multiple verifications among theory, finite element and experiments, one obtains the deformation and actuation mechanism for the process of "pre-deformation, energy storage and actuation" and its non-fracture constraint domain. Then, the parameters of SMPCs will be optimized. Theoretical analysis is realized by the strain energy function, additionally considering the interaction strain energy between the fiber and the matrix. For the common resin-based or soft-material-based composites under pure bending deformation, we expect to uniformly explain the whole process of buckling occurrence, evolution and finally failure, especially for the early evolution characteristics of fiber microbuckling inside the microstructures. The research results are meaningful for the practical applications for SMPC deployable structures in space. Considering the deformation mechanisms of SMPCs, the local post-microbuckling is required for the unidirectional fiber reinforced composite materials, at the conditions of its large geometrical deflection. The cross section of SMPC is divided into three areas: non-buckling stretching area, non-buckling compressive area, and buckling compressive area. Three variables are considered: critical buckling position, and neutral plane, the fiber buckling half-wavelength. Considering the condition of the small strain and large displacement, the strain energy expression of the SMP/fiber system was derived, which contains two types, e.g., strain energy of SMP and fiber. According to the minimum energy principle, the expression for all key parameters were derived, including the critical buckling curvature, neutral plane position, the buckling half-wavelength, fiber buckling amplitude, and strain.

Holocene hillslope processes and deposits in two U-shaped mountain valleys in western Norway

NASA Astrophysics Data System (ADS)

Laute, K.; Beylich, A. A.

2012-04-01

This doctoral research project is integrated in the Norwegian Research Council (NFR) funded SedyMONT-Norway Project within the ESF EUROCORES TOPO-EUROPE SedyMONT (Timescales of sediment dynamics, climate and topographic change in mountain landscapes) Programme. Research is carried out within two steep, U-shaped and glacier-connected tributary valleys (Erdalen and Bødalen) on the western side of the Jostedalsbreen ice cap in western Norway. Contemporary denudative processes in both valley systems include rock and boulder falls, avalanches, slush flows, debris flows, creep processes, wash- and chemical denudation and fluvial transport of solutes, suspended sediments and bedload. The main aims of this research project which are approached within a Holocene to contemporary timescale are: (i) to investigate the spatio-temporal variability of Holocene hillslope development, (ii) to analyse more specificly the morphometric influences and geomorphic consequences of the Little Ice Age (LIA) glacier advance on selected hillslope systems within defined headwater areas in both valleys, (iii) to study morphometric and meteorological controls of contemporary denudative slope processes as well as (iv) to quantify the rates of sediment delivery from headwater areas and its changes over time. A process-based approach is applied using a variety of different methods and techniques. Focus is on different temporal (Holocene to contemporary) and spatial (selected hillslope systems, headwater areas and entire valley system) scales. The applied methods include orthophoto- and topographical map interpretation, GIS and DEM computing, geomorphological fieldmapping and hillslope profile surveying complemented by relative dating techniques (lichenometry and dendrochronology), geophysical investigations and terrestrial laser scanning (LIDAR). For monitoring contemporary rates of slope processes a designed monitoring programme (running since 2009) with a wide spectrum of instrumentation; e.g. installed nets for collecting freshly accumulated rockfall debris, continuous photo-monitoring of rapid mass movement events (avalanches, slush- and debris flows) as well as installed temperature loggers both in rock walls and talus slopes for analysing rock temperatures and mechanical weathering is applied at selected hillslope test sites within the two valley systems. The overall tendency of landscape development is a Postglacial modification of the defined U-shaped valley morphometry (valley widening) throughout rockwall retreat and connected accumulation of debris material beneath these rockwalls. Active fluvial material removal at the base of slopes is almost negligible due to a very limited hillslope-channel coupling in both valleys. Results regarding the spatio-temporal variability of Holocene hillslope development show Holocene rockwall retreat rates for the two valleys which are in a comparable range with other estimates of rockwall retreat rates in other cold mountain environments worldwide. Further on the findings indicate probably higher accumulation rates of slope deposits mainly throughout an enhanced rockfall activity shortly after the glacier retreat as compared to subrecent and contemporary rates. Within the LIA period a recognizable modification of hillslopes in proximity to the outlet glaciers of the Jostedalsbreen is noticeable. A more complex hillslope morphometry (steepening of lower hillslope segments) as well as a more complex composition (inherited by a combination of debris from gravitational processes and lateral moraine ridges) of loose material generating a higher intensity of currently acting slope processes within the hillslope systems located inside of the LIA glacial advance limit as compared to hillslopes situated outside of this limit is found.

Ion-induced nucleation in solution: promotion of solute nucleation in charged levitated droplets.

PubMed

Draper, Neil D; Bakhoum, Samuel F; Haddrell, Allen E; Agnes, George R

2007-09-19

We have investigated the nucleation and growth of sodium chloride in both single quiescent charged droplets and charged droplet populations that were levitated in an electrodynamic levitation trap (EDLT). In both cases, the magnitude of a droplet's net excess charge (ions(DNEC)) influenced NaCl nucleation and growth, albeit in different capacities. We have termed the phenomenon ion-induced nucleation in solution. For single quiescent levitated droplets, an increase in ions(DNEC) resulted in a significant promotion of NaCl nucleation, as determined by the number of crystals observed. For levitated droplet populations, a change in NaCl crystal habit, from regular cubic shapes to dome-shaped dendrites, was observed once a surface charge density threshold of -9 x 10(-4) e.nm(-2) was surpassed. Although promotion of NaCl nucleation was observed for droplet population experiments, this can be attributed in part to the increased rate of solvent evaporation observed for levitated droplet populations having a high net charge. Promotion of nucleation was also observed for two organic acids, 2,4,6-trihydroxyacetophenone monohydrate (THAP) and alpha-cyano-4-hydroxycinnamic acid (CHCA). These results are of direct relevance to processes that occur in both soft-ionization techniques for mass spectrometry and to a variety of industrial processes. To this end, we have demonstrated the use of ion-induced nucleation in solution to form ammonium nitrate particles from levitated droplets to be used in in vitro toxicology studies of ambient particle types.

Thermochemical water decomposition processes

NASA Technical Reports Server (NTRS)

Chao, R. E.

1974-01-01

Thermochemical processes which lead to the production of hydrogen and oxygen from water without the consumption of any other material have a number of advantages when compared to other processes such as water electrolysis. It is possible to operate a sequence of chemical steps with net work requirements equal to zero at temperatures well below the temperature required for water dissociation in a single step. Various types of procedures are discussed, giving attention to halide processes, reverse Deacon processes, iron oxide and carbon oxide processes, and metal and alkali metal processes. Economical questions are also considered.

Process for forming exoergic structures with the use of a plasma

DOEpatents

Kelly, M.D.

1987-05-29

A method of forming exoergic structures, as well as exoergic structures produced by the method, is provided. The method comprises the steps of passing a plasma-forming gas through a plasma spray gun, forming a plasma spray, introducing exoergic material into the plasma spray and directing the plasma spray toward a substrate, and allowing the exoergic material to become molten in the plasma spray and to thereafter impinge on the substrate to form a solid mass of exoergic material, the shape of which corresponds to the shape of the substrate.

Vacuum/Zero Net-Gravity Application for On-Orbit TPS Tile Repair

NASA Technical Reports Server (NTRS)

Harvey, Gale A.; Humes, Donald H.; Siochi, Emilie J.

2004-01-01

The Orbiter Columbia catastrophically failed during reentry February 1, 2003. All Space Shuttle flights were suspended, including logistics support for the International Space Station. NASA Langley Research Center s (LaRC) Structures and Materials Competency is performing characterizations of candidate materials for on-orbit repair of orbiter Thermal Protection System (TPS) tiles to support Return-to-Flight activities led by Johnson Space Center (JSC). At least ten materials properties or attributes (adhesion to damage site, thermal protection, char/ash strength, thermal expansion, blistering, flaming, mixing ease, application in vacuum and zero gravity, cure time, shelf or storage life, and short-term outgassing and foaming) of candidate materials are of interest for on-orbit repair. This paper reports application in vacuum and zero net-gravity (for viscous flow repair materials). A description of the test apparatus and preliminary results of several candidate materials are presented. The filling of damage cavities is different for some candidate repair materials in combined vacuum and zero net-gravity than in either vacuum or zero net-gravity alone.

Vacuum/Zero Net-Gravity Application for On-Orbit TPS Tile Repair

NASA Technical Reports Server (NTRS)

Harvey, Gale A.; Humes, Donald H.; Siochi, Emilie J.

2004-01-01

The Orbiter Columbia catastrophically failed during reentry February 1, 2003. All space Shuttle flights were suspended, including logistics support for the International Space Station. NASA LaRC s Structures and Materials Competency is performing characterizations of candidate materials for on-orbit repair of orbiter Thermal Protection System (TPS) tiles to support Return-to-Flight activities led by JSC. At least ten materials properties or attributes (adhesion to damage site, thermal protection, char/ash strength, thermal expansion, blistering, flaming, mixing ease, application in vacuum and zero gravity, cure time, shelf or storage life, and short-term outgassing and foaming) of candidate materials are of interest for on-orbit repair. This paper reports application in vacuum and zero net-gravity (for viscous flow repair materials). A description of the test apparatus and preliminary results of several candidate materials are presented. The filling of damage cavities is different for some candidate repair materials in combined vacuum and zero net-gravity than in either vacuum or zero net- gravity alone.

Effects of the microstructure and porosity on properties of Ti-6Al-4V ELI alloy fabricated by electron beam melting (EBM)

DOE PAGES

Galarraga, Haize; Lados, Diana A.; Dehoff, Ryan R.; ...

2016-01-01

Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology that makes possible the fabrication of three dimensional near-net-shaped parts directly from computer models. EBM technology has been in continuously updating, obtaining optimized properties of the processed alloys. Ti-6Al-4V titanium alloy is the most widely used and studied alloy for this technology and is the focus of this work. Several research works have been completed to study the mechanisms of microstructure formation as well as its influence on mechanical properties. However, the relationship is not completely understood, and more systematic research work is necessary in order tomore » attain a better understanding of these features. In this work, samples fabricated at different locations, orientations, and distances from the build platform have been characterized, studying the relationship of these variables with the resulting material intrinsic characteristics and properties (surface topography, microstructure, porosity, micro-hardness and static mechanical properties). This study has revealed that porosity is the main factor controlling mechanical properties relative to the other studied variables. Therefore, in future process developments, decreasing of the porosity should be considered as the primary goal in order to improve mechanical properties.« less

Neutrophil extracellular traps in immunity and disease.

PubMed

Papayannopoulos, Venizelos

2018-02-01

Neutrophils are innate immune phagocytes that have a central role in immune defence. Our understanding of the role of neutrophils in pathogen clearance, immune regulation and disease pathology has advanced dramatically in recent years. Web-like chromatin structures known as neutrophil extracellular traps (NETs) have been at the forefront of this renewed interest in neutrophil biology. The identification of molecules that modulate the release of NETs has helped to refine our view of the role of NETs in immune protection, inflammatory and autoimmune diseases and cancer. Here, I discuss the key findings and concepts that have thus far shaped the field of NET biology.

Control of anisotropic shape deviation in single point incremental forming of paperboard

NASA Astrophysics Data System (ADS)

Stein, Philipp; Franke, Wilken; Hoppe, Florian; Hesse, Daniel; Mill, Katharina; Groche, Peter

2017-10-01

The increasing social demand for sustainable material use leads to new process strategies as well as to the use of new materials in nearly all industries. In light of this demand, paperboard shows potential to substitute polymer-based components while also exhibiting improved ecological properties. However, in contrast to polymer-based products, the forming limits of paperboard are relatively low. Therefore, three dimensional forming of paperboard is subject of current research. One area of research focuses on the control of the fiber orientation dependent anisotropic material behavior of industrial paperboard in forming processes. For an examined industrial paperboard, an average elongation at break of 1.2% in the so called machine direction (fiber preferential direction, MD) has been determined at standard climate conditions. In contrast, in cross-direction (orthogonal to the machine direction, CD) a value of 2.6% was observed. With increased moisture content of the specimens the difference between the mechanical properties in MD and CD even increases. As a result of the various fiber-orientation dependent mechanical properties, forming with symmetric tools leads to asymmetrically shaped final parts. Within this article, an approach to reduce the asymmetric shape of three-dimensional formed paperboard by using single point incremental forming technology is presented. For a free spatial processing strategy the 3D Servo Press Technology, which enables circular as well as free processing strategies, is used. Based on reference tests with a circular processing strategy, it is shown that by using an adapted, elliptical tool path, an almost symmetric shaped part can be formed.

New laser machining processes for shape memory alloys

NASA Astrophysics Data System (ADS)

Haferkamp, Heinz; Paschko, Stefan; Goede, Martin

2001-04-01

Due to special material properties, shape memory alloys (SMA) are finding increasing attention in micro system technology. However, only a few processes are available for the machining of miniaturized SMA-components. In this connection, laser material processing offers completely new possibilities. This paper describes the actual status of two projects that are being carried out to qualify new methods to machine SMA components by means of laser radiation. Within one project, the laser material ablation process of miniaturized SMA- components using ultra-short laser pulses (pulse duration: approx. 200 fs) in comparison to conventional laser material ablation is being investigated. Especially for SMA micro- sensors and actuators, it is important to minimize the heat affected zone (HAZ) to maintain the special mechanical properties. Light-microscopic investigations of the grain texture of SMA devices processed with ultra-short laser pulses show that the HAZ can be neglected. Presently, the main goal of the project is to qualify this new processing technique for the micro-structuring of complex SMA micro devices with high precision. Within a second project, investigations are being carried out to realize the induction of the two-way memory effect (TWME) into SMA components using laser radiation. By precisely heating SMA components with laser radiation, local tensions remain near the component surface. In connection with the shape memory effect, these tensions can be used to make the components execute complicated movements. Compared to conventional training methods to induce the TWME, this procedure is faster and easier. Furthermore, higher numbers of thermal cycling are expected because of the low dislocation density in the main part of the component.

Shape-memory alloy micro-actuator

NASA Technical Reports Server (NTRS)

Busch, John D. (Inventor); Johnson, Alfred D. (Inventor)

1991-01-01

A method of producing an integral piece of thermo-sensitive material, which is responsive to a shift in temperature from below to above a phase transformation temperature range to alter the material's condition to a shape-memory condition and move from one position to another. The method is characterized by depositing a thin film of shape-memory material, such as Nickel titanium (Ni-Ti) onto a substrate by vacuum deposition process such that the alloy exhibits an amorphous non-crystalline structure. The coated substrate is then annealed in a vacuum or in the presence of an inert atmosphere at a selected temperature, time and cool down rate to produce an ordered, partially disordered or fully disordered BCC structure such that the alloy undergoes thermoelastic, martinsetic phase transformation in response to alteration in temperature to pass from a martinsetic phase when at a temperature below a phase transformation range and capable of a high level of recoverable strain to a parent austenitic phase in a memory shape when at a temperature above the phase transformation range. Also disclosed are actuator devices employing shape-memory material actuators that deform from a set shape toward an original shape when subjected to a critical temperature level after having been initially deformed from the original shape into the set shape while at a lower temperature. The actuators are mechanically coupled to one or more movable elements such that the temperature-induce deformation of the actuators exerts a force or generates a motion of the mechanical element(s).

Methods of electrophoretic deposition for functionally graded porous nanostructures and systems thereof

DOEpatents

Worsley, Marcus A; Baumann, Theodore F; Satcher, Joe H; Olson, Tammy Y; Kuntz, Joshua D; Rose, Klint A

2015-03-03

In one embodiment, an aerogel includes a layer of shaped particles having a particle packing density gradient in a thickness direction of the layer, wherein the shaped particles are characterized by being formed in an electrophoretic deposition (EPD) process using an impurity. In another embodiment, a method for forming a functionally graded porous nanostructure includes adding particles of an impurity and a solution to an EPD chamber, applying a voltage difference across the two electrodes of the EPD chamber to create an electric field in the EPD chamber, and depositing the material onto surfaces of the particles of the impurity to form shaped particles of the material. Other functionally graded materials and methods are described according to more embodiments.

Productivity is a poor predictor of plant species richness

USGS Publications Warehouse

Adler, Peter B.; Seabloom, Eric W.; Borer, Elizabeth T.; Hillebrand, Helmut; Hautier, Yann; Hector, Andy; Harpole, W. Stanley; O'Halloran, Lydia R.; Grace, James B.; Anderson, T. Michael; Bakker, Jonathan D.; Biederman, Lori A.; Brown, Cynthia S.; Buckley, Yvonne M.; Calabrese, Laura B.; Chu, Cheng-Jin; Cleland, Elsa E.; Collins, Scott L.; Cottingham, Kathryn L.; Crawley, Michael J.; Damschen, Ellen Ingman; Davies, Kendi F.; DeCrappeo, Nicole M.; Fay, Philip A.; Firn, Jennifer; Frater, Paul; Gasarch, Eve I.; Gruner, Daneil S.; Hagenah, Nicole; Lambers, Janneke Hille Ris; Humphries, Hope; Jin, Virginia L.; Kay, Adam D.; Kirkman, Kevin P.; Klein, Julia A.; Knops, Johannes M.H.; La Pierre, Kimberly J.; Lambrinos, John G.; Li, Wei; MacDougall, Andrew S.; McCulley, Rebecca L.; Melbourne, Brett A.; Mitchell, Charles E.; Moore, Joslin L.; Morgan, John W.; Mortensen, Brent; Orrock, John L.; Prober, Suzanne M.; Pyke, David A.; Risch, Anita C.; Schuetz, Martin; Smith, Melinda D.; Stevens, Carly J.; Sullivan, Lauren L.; Wang, Gang; Wragg, Peter D.; Wright, Justin P.; Yang, Louie H.

2011-01-01

For more than 30 years, the relationship between net primary productivity and species richness has generated intense debate in ecology about the processes regulating local diversity. The original view, which is still widely accepted, holds that the relationship is hump-shaped, with richness first rising and then declining with increasing productivity. Although recent meta-analyses questioned the generality of hump-shaped patterns, these syntheses have been criticized for failing to account for methodological differences among studies. We addressed such concerns by conducting standardized sampling in 48 herbaceous-dominated plant communities on five continents. We found no clear relationship between productivity and fine-scale (meters-2) richness within sites, within regions, or across the globe. Ecologists should focus on fresh, mechanistic approaches to understanding the multivariate links between productivity an

The NIDDK Information Network: A Community Portal for Finding Data, Materials, and Tools for Researchers Studying Diabetes, Digestive, and Kidney Diseases

PubMed Central

Whetzel, Patricia L.; Grethe, Jeffrey S.; Banks, Davis E.; Martone, Maryann E.

2015-01-01

The NIDDK Information Network (dkNET; http://dknet.org) was launched to serve the needs of basic and clinical investigators in metabolic, digestive and kidney disease by facilitating access to research resources that advance the mission of the National Institute of Diabetes and Digestive and Kidney Diseases (NIDDK). By research resources, we mean the multitude of data, software tools, materials, services, projects and organizations available to researchers in the public domain. Most of these are accessed via web-accessible databases or web portals, each developed, designed and maintained by numerous different projects, organizations and individuals. While many of the large government funded databases, maintained by agencies such as European Bioinformatics Institute and the National Center for Biotechnology Information, are well known to researchers, many more that have been developed by and for the biomedical research community are unknown or underutilized. At least part of the problem is the nature of dynamic databases, which are considered part of the “hidden” web, that is, content that is not easily accessed by search engines. dkNET was created specifically to address the challenge of connecting researchers to research resources via these types of community databases and web portals. dkNET functions as a “search engine for data”, searching across millions of database records contained in hundreds of biomedical databases developed and maintained by independent projects around the world. A primary focus of dkNET are centers and projects specifically created to provide high quality data and resources to NIDDK researchers. Through the novel data ingest process used in dkNET, additional data sources can easily be incorporated, allowing it to scale with the growth of digital data and the needs of the dkNET community. Here, we provide an overview of the dkNET portal and its functions. We show how dkNET can be used to address a variety of use cases that involve searching for research resources. PMID:26393351

Acoustical levitation for space processing. [weightless molten material manipulation

NASA Technical Reports Server (NTRS)

Wang, T. G.; Saffren, M. M.; Elleman, D. D.

1974-01-01

It is pointed out that many space-manufacturing processes will require the manipulation of weightless molten material within a container in such a way that the material does not touch the container wall. A description is given of an acoustical method which can be used for the positioning and shaping of any molten material including nonconductors such as glasses. The new approach makes use of an acoustical standing wave which is excited within an enclosure or resonator.

Multiphysics modeling of selective laser sintering/melting

NASA Astrophysics Data System (ADS)

Ganeriwala, Rishi Kumar

A significant percentage of total global employment is due to the manufacturing industry. However, manufacturing also accounts for nearly 20% of total energy usage in the United States according to the EIA. In fact, manufacturing accounted for 90% of industrial energy consumption and 84% of industry carbon dioxide emissions in 2002. Clearly, advances in manufacturing technology and efficiency are necessary to curb emissions and help society as a whole. Additive manufacturing (AM) refers to a relatively recent group of manufacturing technologies whereby one can 3D print parts, which has the potential to significantly reduce waste, reconfigure the supply chain, and generally disrupt the whole manufacturing industry. Selective laser sintering/melting (SLS/SLM) is one type of AM technology with the distinct advantage of being able to 3D print metals and rapidly produce net shape parts with complicated geometries. In SLS/SLM parts are built up layer-by-layer out of powder particles, which are selectively sintered/melted via a laser. However, in order to produce defect-free parts of sufficient strength, the process parameters (laser power, scan speed, layer thickness, powder size, etc.) must be carefully optimized. Obviously, these process parameters will vary depending on material, part geometry, and desired final part characteristics. Running experiments to optimize these parameters is costly, energy intensive, and extremely material specific. Thus a computational model of this process would be highly valuable. In this work a three dimensional, reduced order, coupled discrete element - finite difference model is presented for simulating the deposition and subsequent laser heating of a layer of powder particles sitting on top of a substrate. Validation is provided and parameter studies are conducted showing the ability of this model to help determine appropriate process parameters and an optimal powder size distribution for a given material. Next, thermal stresses upon cooling are calculated using the finite difference method. Different case studies are performed and general trends can be seen. This work concludes by discussing future extensions of this model and the need for a multi-scale approach to achieve comprehensive part-level models of the SLS/SLM process.

Tailorable Burning Behavior of Ti14 Alloy by Controlling Semi-Solid Forging Temperature

PubMed Central

Chen, Yongnan; Yang, Wenqing; Zhan, Haifei; Zhang, Fengying; Huo, Yazhou; Zhao, Yongqing; Song, Xuding; Gu, Yuantong

2016-01-01

Semi-solid processing (SSP) is a popular near-net-shape forming technology for metals, while its application is still limited in titanium alloy mainly due to its low formability. Recent works showed that SSP could effectively enhance the formability and mechanical properties of titanium alloys. The processing parameters such as temperature and forging rate/ratio, are directly correlated with the microstructure, which endow the alloy with different chemical and physical properties. Specifically, as a key structural material for the advanced aero-engine, the burn resistant performance is a crucial requirement for the burn resistant titanium alloy. Thus, this work aims to assess the burning behavior of Ti14, a kind of burn resistant alloy, as forged at different semi-solid forging temperatures. The burning characteristics of the alloy are analyzed by a series of burning tests with different burning durations, velocities, and microstructures of burned sample. The results showed that the burning process is highly dependent on the forging temperature, due to the fact that higher temperatures would result in more Ti2Cu precipitate within grain and along grain boundaries. Such a microstructure hinders the transport of oxygen in the stable burning stage through the formation of a kind of oxygen isolation Cu-enriched layer under the burn product zone. This work suggests that the burning resistance of the alloy can be effectively tuned by controlling the temperature during the semi-solid forging process. PMID:28773820

Metal injection molding as enabling technology for the production of metal prosthesis components: electrochemical and in vitro characterization.

PubMed

Melli, Virginia; Rondelli, Gianni; Sandrini, Enrico; Altomare, Lina; Bolelli, Giovanni; Bonferroni, Benedetta; Lusvarghi, Luca; Cigada, Alberto; De Nardo, Luigi

2013-10-01

Industrial manufacturing of prosthesis components could take significant advantage by the introduction of new, cost-effective manufacturing technologies with near net-shape capabilities, which have been developed during the last years to fulfill the needs of different technological sectors. Among them, metal injection molding (MIM) appears particularly promising for the production of orthopedic arthroplasty components with significant cost saving. These new manufacturing technologies, which have been developed, however, strongly affect the chemicophysical structure of processed materials and their resulting properties. In order to investigate this relationship, here we evaluated the effects on electrochemical properties, ion release, and in vitro response of medical grade CoCrMo alloy processed via MIM compared to conventional processes. MIM of the CoCrMo alloy resulted in coarser polygonal grains, with largely varying sizes; however, these microstructural differences between MIM and forged/cast CoCrMo alloys showed a negligible effect on electrochemical properties. Passive current densities values observed were 0.49 µA cm(-2) for MIM specimens and 0.51 µA cm(-2) for forged CoCrMo specimens, with slightly lower transpassive potential in the MIM case; open circuit potential and Rp stationary values showed no significant differences. Moreover, in vitro biocompatibility tests resulted in cell viability levels not significantly different for MIM and conventionally processed alloys. Although preliminary, these results support the potential of MIM technology for the production of CoCrMo components of implantable devices. Copyright © 2013 Wiley Periodicals, Inc.

Advanced Rotorcraft Transmission (ART) program status

NASA Technical Reports Server (NTRS)

Bossler, Robert; Heath, Gregory

1991-01-01

Reported herein is work done on the Advanced Rotorcraft Transmission by McDonnell Douglas Helicopter Company under Army/NASA contract. The novel concept pursued includes the use of face gears for power transmission and a torque splitting arrangement. The design reduces the size and weight of the corner-turning hardware and the next reduction stage. New methods of analyzing face gears have increased confidence in their usefulness. Test gears have been designed and manufactured for power transmission testing on the NASA-Lewis spiral bevel test rig. Transmission design effort has included finite element modeling of the split torque paths to assure equal deflection under load. A finite element model of the Apache main transmission has been completed to substantiate noise prediction methods. A positive engagement overrunning clutch design is described. Test spur gears have been made by near-net-shape forging from five different materials. Three housing materials have been procured for evaluation testing.

Leveraging metal matrix composites to reduce costs in space mechanisms

NASA Technical Reports Server (NTRS)

Nye, Ted; Claridge, Rex; Walker, Jim

1994-01-01

Advanced metal matrix composites may be one of the most promising technologies for reducing cost in structural components without compromise to strength or stiffness. A microlight 12.50 N (2.81 lb), two-axis, solar array drive assembly (SADA) was made for the Advanced Materials Applications to Space Structures (AMASS) Program flight experiment. The SADA had both its inner and outer axis housings fabricated from silicon carbide particulate reinforced alumimun. Two versions of the housings were made. The first was machined from a solid billet of material. The second was plaster cast to a near net shape that required minimal finish machining. Both manufacturing methods were compared upon completion. Results showed a cost savings with the cast housing was possible for quantities greater than one and probable for quantities greater than two. For quantities approaching ten, casting resulted in a reduction factor of almost three in the cost per part.

Evaluating the Effect of Processing Parameters on Porosity in Electron Beam Melted Ti-6Al-4V via Synchrotron X-ray Microtomography

NASA Astrophysics Data System (ADS)

Cunningham, Ross; Narra, Sneha P.; Ozturk, Tugce; Beuth, Jack; Rollett, A. D.

2016-03-01

Electron beam melting (EBM) is one of the subsets of direct metal additive manufacturing (AM), an emerging manufacturing method that fabricates metallic parts directly from a three-dimensional (3D) computer model by the successive melting of powder layers. This family of technologies has seen significant growth in recent years due to its potential to manufacture complex components with shorter lead times, reduced material waste and minimal post-processing as a "near-net-shape" process, making it of particular interest to the biomedical and aerospace industries. The popular titanium alloy Ti-6Al-4V has been the focus of multiple studies due to its importance to these two industries, which can be attributed to its high strength to weight ratio and corrosion resistance. While previous research has found that most tensile properties of EBM Ti-6Al-4V meet or exceed conventional manufacturing standards, fatigue properties have been consistently inferior due to a significant presence of porosity. Studies have shown that adjusting processing parameters can reduce overall porosity; however, they frequently utilize methods that give insufficient information to properly characterize the porosity (e.g., Archimedes' method). A more detailed examination of the result of process parameter adjustments on the size and spatial distribution of gas porosity was performed utilizing synchrotron-based x-ray microtomography with a minimum feature resolution of 1.5 µm. Cross-sectional melt pool area was varied systematically via process mapping. Increasing melt pool area through the speed function variable was observed to significantly reduce porosity in the part.

Electron gun controlled smart structure

DOEpatents

Martin, Jeffrey W.; Main, John Alan; Redmond, James M.; Henson, Tammy D.; Watson, Robert D.

2001-01-01

Disclosed is a method and system for actively controlling the shape of a sheet of electroactive material; the system comprising: one or more electrodes attached to the frontside of the electroactive sheet; a charged particle generator, disposed so as to direct a beam of charged particles (e.g. electrons) onto the electrode; a conductive substrate attached to the backside of the sheet; and a power supply electrically connected to the conductive substrate; whereby the sheet changes its shape in response to an electric field created across the sheet by an accumulation of electric charge within the electrode(s), relative to a potential applied to the conductive substrate. Use of multiple electrodes distributed across on the frontside ensures a uniform distribution of the charge with a single point of e-beam incidence, thereby greatly simplifying the beam scanning algorithm and raster control electronics, and reducing the problems associated with "blooming". By placing a distribution of electrodes over the front surface of a piezoelectric film (or other electroactive material), this arrangement enables improved control over the distribution of surface electric charges (e.g. electrons) by creating uniform (and possibly different) charge distributions within each individual electrode. Removal or deposition of net electric charge can be affected by controlling the secondary electron yield through manipulation of the backside electric potential with the power supply. The system can be used for actively controlling the shape of space-based deployable optics, such as adaptive mirrors and inflatable antennae.

Microengineering as a tool to study substratum modulation and cell behaviour.

PubMed

Keatch, R P; Armoogum, K; Schor, S L; Pridham, M S; Banks, K; Khor, T Y; Matthew, C

2002-01-01

This research is an investigation of the means by which geometrical parameters (e.g. area and shape) and various surface attributes (materials and surface finish) of microengineered structures can modulate cellular response. This is based on biological observations indicating that: (i) the response of tissue cells to injury is determined by the net signal transduction response elicited by soluble regulatory molecules (e.g. cytokines), (ii) common matrix constituents (e.g. collagen) directly affect cell behaviour by the same signal transduction mechanisms mediating cytokine bioactivity, (iii) cellular response to cytokines is modulated by the precise nature of the extracellular matrix to which the target cells are adherent, including its biochemical composition and physical structure.

Graphene nanoFlakes with large spin.

PubMed

Wang, Wei L; Meng, Sheng; Kaxiras, Efthimios

2008-01-01

We investigate, using benzenoid graph theory and first-principles calculations, the magnetic properties of arbitrarily shaped finite graphene fragments to which we refer as graphene nanoflakes (GNFs). We demonstrate that the spin of a GNF depends on its shape due to topological frustration of the pi-bonds. For example, a zigzag-edged triangular GNF has a nonzero net spin, resembling an artificial ferrimagnetic atom, with the spin value scaling with its linear size. In general, the principle of topological frustration can be used to introduce large net spin and interesting spin distributions in graphene. These results suggest an avenue to nanoscale spintronics through the sculpting of graphene fragments.

UltraForm Finishing (UFF) a 5-axis computer controlled precision optical component grinding and polishing system

NASA Astrophysics Data System (ADS)

Bechtold, Michael; Mohring, David; Fess, Edward

2007-05-01

OptiPro Systems has developed a new finishing process for the manufacturing of precision optical components. UltraForm Finishing (UFF) has evolved from a tire shaped tool with polishing material on its periphery, to its newest design, which incorporates a precision rubber wheel wrapped with a band of polishing material passing over it. Through our research we have developed a user friendly graphical interface giving the optician a deterministic path for finishing precision optical components. Complex UFF Algorithms combine the removal function and desired depth of removal into a motion controlled tool path which minimizes surface roughness and form errors. The UFF process includes 5 axes of computer controlled motion, (3 linear and 2 rotary) which provide the flexibility for finishing a variety of shapes including spheres, aspheres, and freeform optics. The long arm extension, along with a range of diameters for the "UltraWheel" provides a unique solution for the finishing of steep concave shapes such as ogives and domes. The UltraForm process utilizes, fixed and loose abrasives, in combination with our proprietary "UltraBelts" made of a range of materials such as polyurethane, felt, resin, diamond and others.

Particle Morphology Analysis of Biomass Material Based on Improved Image Processing Method

PubMed Central

Lu, Zhaolin

2017-01-01

Particle morphology, including size and shape, is an important factor that significantly influences the physical and chemical properties of biomass material. Based on image processing technology, a method was developed to process sample images, measure particle dimensions, and analyse the particle size and shape distributions of knife-milled wheat straw, which had been preclassified into five nominal size groups using mechanical sieving approach. Considering the great variation of particle size from micrometer to millimeter, the powders greater than 250 μm were photographed by a flatbed scanner without zoom function, and the others were photographed using a scanning electron microscopy (SEM) with high-image resolution. Actual imaging tests confirmed the excellent effect of backscattered electron (BSE) imaging mode of SEM. Particle aggregation is an important factor that affects the recognition accuracy of the image processing method. In sample preparation, the singulated arrangement and ultrasonic dispersion methods were used to separate powders into particles that were larger and smaller than the nominal size of 250 μm. In addition, an image segmentation algorithm based on particle geometrical information was proposed to recognise the finer clustered powders. Experimental results demonstrated that the improved image processing method was suitable to analyse the particle size and shape distributions of ground biomass materials and solve the size inconsistencies in sieving analysis. PMID:28298925

The Physics of Pollen and Spore Rebound from Plant Surfaces.

NASA Astrophysics Data System (ADS)

Paw U, Kyaw Tha

1980-12-01

The problem of particle rebound from plant surfaces has been examined. Particle rebound is a component of net deposition; the other components are reentrainment and impingement. I carried out several sets of wind tunnel experiments to examine the nature of rebound, reentrainment and impingement. Quantitative and qualitative analyses were carried out on the data. A simple computer model was created to predict particle deposition in wind tunnel conditions. My work confirms that rebound is an important process in the wind tunnel, and implies the existence of a process I call 'rebound/reentrainment'. I tested several major hypotheses. The first was that biological materials exhibit the same physical rebound characteristics as artificial materials. The second was that particles rebound in a manner predicted by Dahneke's (1971, 1975) theory. The third was that rebound is a dominant component of net deposition. The fourth was that surface characteristics may seriously influence rebound. I carried out my experiments in a low-speed wind tunnel. For surfaces I used glass and the leaves of tulip poplar (Liriodendron tulipifera), Coleus (Coleus blumeii) and American elm (Ulmus americana). For particles I used glass microbeads, lycopodium spores (Lycopodium spp.), and ragweed pollen (Ambrosia trifida). Four main sets of experiments were carried out. I examined rebound, as a function of particle speed, of particles impinging upon leaf surfaces, reentrainment of spores and pollen as a function of wind speed and time, net deposition, as a function of wind speed, and adhesion of pollen and spores to the leaf surfaces. From these experiments I concluded that in general, pollen and spore rebound can be described well by Dahneke's (1971, 1975) theory. Particle differences are far more significant than surface differences in the rebound process. I postulate the existence of rebound/reentrainment when particles impinge on surfaces with tangential fluid flow present. Particles will bounce initially, be drawn back to the surface, but if the fluid flow is sufficiently strong, the particles will be reentrained. Rebound processes, if they are defined to include rebound and rebound/reentrainment, are generally more important than reentrainment in limiting net deposition. I used experimental and theoretical work to form a simple net deposition model for large particles in wind tunnel flow. Further development of similar models is necessary for more accurate results, and for linkage to macroscale deposition and transport models.

Beryllium fabrication/cost assessment for ITER (International Thermonuclear Experimental Reactor)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Beeston, J.M.; Longhurst, G.R.; Parsonage, T.

1990-06-01

A fabrication and cost estimate of three possible beryllium shapes for the International Thermonuclear Experimental Reactor (ITER) blanket is presented. The fabrication method by hot pressing (HP), cold isostatic pressing plus sintering (CIP+S), cold isostatic pressing plus sintering plus hot isostatic pressing (CIP+S+HIP), and sphere production by atomization or rotary electrode will be discussed. Conventional hot pressing blocks of beryllium with subsequent machining to finished shapes can be more expensive than production of a net shape by cold isostatic pressing and sintering. The three beryllium shapes to be considered here and proposed for ITER are: (1) cubic blocks (3 tomore » 17 cm on an edge), (2) tubular cylinders (33 to 50 mm i.d. by 62 mm o.d. by 8 m long), and (3) spheres (1--5 mm dia.). A rough cost estimate of the basic shape is presented which would need to be refined if the surface finish and tolerances required are better than the sintering process produces. The final cost of the beryllium in the blanket will depend largely on the machining and recycling of beryllium required to produce the finished product. The powder preparation will be discussed before shape fabrication. 10 refs., 6 figs.« less

Simulation of gross and net erosion of high-Z materials in the DIII-D divertor

DOE PAGES

Wampler, William R.; Ding, R.; Stangeby, P. C.; ...

2015-12-17

The three-dimensional Monte Carlo code ERO has been used to simulate dedicated DIII-D experiments in which Mo and W samples with different sizes were exposed to controlled and well-diagnosed divertor plasma conditions to measure the gross and net erosion rates. Experimentally, the net erosion rate is significantly reduced due to the high local redeposition probability of eroded high-Z materials, which according to the modelling is mainly controlled by the electric field and plasma density within the Chodura sheath. Similar redeposition ratios were obtained from ERO modelling with three different sheath models for small angles between the magnetic field and themore » material surface, mainly because of their similar mean ionization lengths. The modelled redeposition ratios are close to the measured value. Decreasing the potential drop across the sheath can suppress both gross and net erosion because sputtering yield is decreased due to lower incident energy while the redeposition ratio is not reduced owing to the higher electron density in the Chodura sheath. Taking into account material mixing in the ERO surface model, the net erosion rate of high-Z materials is shown to be strongly dependent on the carbon impurity concentration in the background plasma; higher carbon concentration can suppress net erosion. As a result, the principal experimental results such as net erosion rate and profile and redeposition ratio are well reproduced by the ERO simulations.« less

Nickel (II) nitrate hexahydrate triggered canine neutrophil extracellular traps release in vitro.

PubMed

Wei, Zhengkai; Zhang, Xu; Wang, Yanan; Wang, Jingjing; Fu, Yunhe; Yang, Zhengtao

2018-05-30

Nickel (II) nitrate hexahydrate (Ni) is a common heavy metal material in battery manufacturing, electroplating alloy parts and ceramic staining, therefore we frequently contact with Ni-related products in daily life. In this study, we aimed to investigate the effects of Ni on neutrophils extracellular traps (NETs) release by canine polymorphonuclear neutrophils (PMNs). The structure of Ni-induced NETs was observed by fluorescence confocal microscopy. Ni-triggered NETs release was quantified by Pico Green ® and fluorescence microplate reader. In addition, the inhibitors of NADPH oxidase, ERK1/2-, p38 - signaling pathways were used for preliminary inquiry into the potential mechanism of this process. The results showed that Ni markedly triggered the formation of NETs-like structures, and these structures were mainly consisted of DNA decorated with NE and MPO. Furthermore, quantification experiments showed that Ni significantly increased NETs formation compared to control groups. These results forcefully confirmed that nickel nitrate possesses the ability to induce NETs formation. However, inhibiting the NADPH oxidase, ERK1/2- and p38 MAPK-signaling pathways did not significantly change the quantitation of Ni-induced NETs release. To our knowledge, this study is the first report of Ni-triggered NETs release in vitro, which might provide an entirely new mechanism of several diseases and health issues induced by nickel overexposure. Copyright © 2018. Published by Elsevier Ltd.

Near Net-Shape, Ultra High Melting, Erosion Resistant Carbide/Metal Composites with Tailored Fibrillar Microstructures via the Displacive Compensation of Porosity Process

DTIC Science & Technology

2006-11-26

vapor species, formed over tungsten trioxide powder, is 1.25xl0Ŗ atm at 1400°C and 1 atm total pressure (assuming an oxygen partial pressure greater...with CO(g). ■19- These hollow tungsten fibers were then carburized via reaction with CO(g) to generate the polycrystalline WC-based fibers shown in...of tungsten carbide via reaction with a hafnium-copper melt," Ada Mater., 57(13), 3924-3931 (2009).) The kinetic mechanism of incongruent reduction

The structure-property relationships of powder processed Fe-Al-Si alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Prichard, Paul D.

1998-02-23

Iron-aluminum alloys have been extensively evaluated as semi-continuous product such as sheet and bar, but have not been evaluated by net shape P/M processing techniques such as metal injection molding. The alloy compositions of iron-aluminum alloys have been optimized for room temperature ductility, but have limited high temperature strength. Hot extruded powder alloys in the Fe-Al-Si system have developed impressive mechanical properties, but the effects of sintering on mechanical properties have not been explored. This investigation evaluated three powder processed Fe-Al-Si alloys: Fe-15Al, Fe-15Al-2.8Si, Fe-15Al-5Si (atomic %). The powder alloys were produced with a high pressure gas atomization (HPGA) processmore » to obtain a high fraction of metal injection molding (MIM) quality powder (D 84 < 32 μm). The powders were consolidated either by P/M hot extrusion or by vacuum sintering. The extruded materials were near full density with grain sizes ranging from 30 to 50 μm. The vacuum sintering conditions produced samples with density ranging from 87% to 99% of theoretical density, with an average grain size ranging from 26 μm to 104 μm. Mechanical property testing was conducted on both extruded and sintered material using a small punch test. Tensile tests were conducted on extruded bar for comparison with the punch test data. Punch tests were conducted from 25 to 550 C to determine the yield strength, and fracture energy for each alloy as a function of processing condition. The ductile to brittle transition temperature (DBTT) was observed to increase with an increasing silicon content. The Fe-15Al-2.8Si alloy was selected for more extensive testing due to the combination of high temperature strength and low temperature toughness due to the two phase α + DO 3 structure. This investigation provided a framework for understanding the effects of silicon in powder processing and mechanical property behavior of Fe-Al-Si alloys.« less

Development of a super-pressure balloon with a diamond-shaped net --- result of a ground inflation test of a 2,000 cubic-meter balloon ---

NASA Astrophysics Data System (ADS)

Saito, Yoshitaka; Nakashino, Kyoichi; Akita, Daisuke; Matsushima, Kiyoho; Shimadu, Shigeyuki; Goto, Ken; Hashimoto, Hiroyuki; Matsuo, Takuma

2016-07-01

A light super-pressure balloon has been developed using a method to cover a balloon with a diamond-shaped net of high-tensile fibers. The goal is to fly a payload of 900 kg to the altitude of 37 km with a 300,000 m^{3} balloon. Beginning from a demonstration test of the net-balloon with a 10 m^{3} balloon in 2010, we have been polished the net-balloon through ground inflation tests and flight tests, including a flight test of a 3,000 m ^{3} balloon in the tandem balloon configuration with a 15,000 m^{3} zero-pressure balloon in 2012, and a flight test of a 10 m^{3} balloon in the tandem balloon configuration with a 2 kg rubber balloon in 2013, as reported in the last COSPAR. In 2014, we developed a 5,000 m^{3} balloon and performed a ground inflation test to find that the balloon burst from a lip panel for termination with a differential pressure of 425 Pa. It was due to a stress concentration at the edge of a thick tape attached along the termination mechanism. In 2015, we modified the balloon by adding tapes on the lip panel to avoid the stress concentration, and also shorten the net length to leave some margin of the film and performed a ground inflation test again to find the balloon showed asymmetrical deployment and burst from the edge of the net with a differential pressure of 348 Pa. We consider it is due to the margin of the film along the circumferential direction, and proposed a gore shape which circumference length is kept as determined by the pumpkin shape of the balloon but setting meridian length longer than that. We developed a 10 m^{3} balloon with the gore design to find that the balloon deployed symmetrically and showed the burst pressure of 10,000 Pa. In 2016, we are going to develop a 2,000 m^{3} balloon with the gore design and perform its ground inflation test. In this paper, we are going to report its result with the sequence of the development.

Three-dimensional biocompatible matrix for reconstructive surgery

NASA Astrophysics Data System (ADS)

Reshetov, I. V.; Starceva, O. I.; Istranov, A. L.; Vorona, B. N.; Lyundup, A. V.; Gulyaev, I. V.; Melnikov, D. V.; Shtansky, D. V.; Sheveyko, A. N.; Andreev, V. A.

2016-08-01

A study into the development of an original bioengineered structure for reconstruction of hollow organs is presented. The basis for the structure was the creation of a mesh matrix made from titanium nickelide (NiTi), which has sufficient elasticity and shape memory for the reconstruction of hollow tubular orgrans. In order to increase the cell adhesion on the surface of the matrix, the grid needed to be cleaned of impurities, for which we used an ionic cleaning method. Additional advantages also may enable the application of the bioactive component to grid surface. These features of the matrix may improve the biocompatibility properties of the composite material. In the first stage, a mesh structure was made from NiTi fibers. The properties of the resulting mesh matrix were studied. In the second stage, the degrees of adhesion and cell growth rates in the untreated matrix, the matrix after ionic cleaning and the matrix after ionic cleaning and the application of the bioactive component were compared. The results showed more significant biocompatibility of the titanium nickelide matrix after its ionic cleaning. The ionic cleaning ensures the removal of toxic contaminants, which are a consequence of the technological production process of the material and provide optimal adhesion properties for the fiber surface. The NiTi net matrix with TiCaPCON coating may be the optimal basis for making the hollow elastic organs.

Fatigue Behavior of Porous Ti-6Al-4V Made by Laser-Engineered Net Shaping

PubMed Central

Bordonaro, Giancarlo G.; Berto, Filippo

2018-01-01

The fatigue behavior and fracture mechanisms of additively manufactured Ti-6Al-4V specimens are investigated in this study. Three sets of testing samples were fabricated for the assessment of fatigue life. The first batch of samples was built by using Laser-Engineered Net Shaping (LENS) technology, a Direct Energy Deposition (DED) method. Internal voids and defects were induced in a second batch of samples by changing LENS machine processing parameters. Fatigue performance of these samples is compared to the wrought Ti-6Al-4V samples. The effects of machine-induced porosity are assessed on mechanical properties and results are presented in the form of SN curves for the three sets of samples. Fracture mechanisms are examined by using Scanning Electron Microscopy (SEM) to characterize the morphological characteristics of the failure surface. Different fracture surface morphologies are observed for porous and non-porous specimens due to the combination of head write speed and laser power. Formation of defects such as pores, unmelted regions, and gas entrapments affect the failure mechanisms in porous specimens. Non-porous specimens exhibit fatigue properties comparable with that of the wrought specimens, but porous specimens are found to show a tremendous reduced fatigue strength. PMID:29439510

Laser engineered net shaping of quasi-continuous network microstructural TiB reinforced titanium matrix bulk composites: Microstructure and wear performance

NASA Astrophysics Data System (ADS)

Hu, Yingbin; Ning, Fuda; Wang, Hui; Cong, Weilong; Zhao, Bo

2018-02-01

Titanium (Ti) and its alloys have been successfully applied to the aeronautical and biomedical industries. However, their poor tribological properties restrict their fields of applications under severe wear conditions. Facing to these challenges, this study investigated TiB reinforced Ti matrix composites (TiB-TMCs), fabricated by in-situ laser engineered net shaping (LENS) process, through analyzing parts quality, microstructure formation mechanisms, microstructure characterizations, and workpiece wear performance. At high B content areas (original B particle locations), reaction between Ti and B particles took place, generating flower-like microstructure. At low B content areas, eutectic TiB nanofibers contacted with each other with the formation of crosslinking microstructure. The crosslinking microstructural TiB aggregated and connected at the boundaries of Ti grains, forming a three-dimensional quasi-continuous network microstructure. The results show that compared with commercially pure Ti bulk parts, the TiB-TMCs exhibited superior wear performance (i.e. indentation wear resistance and friction wear resistance) due to the present of TiB reinforcement and the innovative microstructures formed inside TiB-TMCs. In addition, the qualities of the fabricated parts were improved with fewer interior defects by optimizing laser power, thus rendering better wear performance.

The Impact Of Surface Shape Of Chip-Breaker On Machined Surface

NASA Astrophysics Data System (ADS)

Šajgalík, Michal; Czán, Andrej; Martinček, Juraj; Varga, Daniel; Hemžský, Pavel; Pitela, David

2015-12-01

Machined surface is one of the most used indicators of workpiece quality. But machined surface is influenced by several factors such as cutting parameters, cutting material, shape of cutting tool or cutting insert, micro-structure of machined material and other known as technological parameters. By improving of these parameters, we can improve machined surface. In the machining, there is important to identify the characteristics of main product of these processes - workpiece, but also the byproduct - the chip. Size and shape of chip has impact on lifetime of cutting tools and its inappropriate form can influence the machine functionality and lifetime, too. This article deals with elimination of long chip created when machining of shaft in automotive industry and with impact of shape of chip-breaker on shape of chip in various cutting conditions based on production requirements.

Continuous Severe Plastic Deformation Processing of Aluminum Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Raghavan Srinivasan; Prabir K. Chaudhury; Balakrishna Cherukuri

2006-06-30

Metals with grain sizes smaller than 1-micrometer have received much attention in the past decade. These materials have been classified as ultra fine grain (UFG) materials (grain sizes in the range of 100 to 1000-nm) and nano-materials (grain size <100-nm) depending on the grain size. This report addresses the production of bulk UFG metals through the use of severe plastic deformation processing, and their subsequent use as stock material for further thermomechanical processing, such as forging. A number of severe plastic deformation (SPD) methods for producing bulk UFG metals have been developed since the early 1990s. The most promising ofmore » these processes for producing large size stock that is suitable for forging is the equal channel angular extrusion or pressing (ECAE/P) process. This process involves introducing large shear strain in the work-piece by pushing it through a die that consists of two channels with the same cross-sectional shape that meet at an angle to each other. Since the cross-sections of the two channels are the same, the extruded product can be re-inserted into the entrance channel and pushed again through the die. Repeated extrusion through the ECAE/P die accumulates sufficient strain to breakdown the microstructure and produce ultra fine grain size. It is well known that metals with very fine grain sizes (< 10-micrometer) have higher strain rate sensitivity and greater elongation to failure at elevated temperature, exhibiting superplastic behavior. However, this superplastic behavior is usually manifest at high temperature (> half the melting temperature on the absolute scale) and very low strain rates (< 0.0001/s). UFG metals have been shown to exhibit superplastic characteristics at lower temperature and higher strain rates, making this phenomenon more practical for manufacturing. This enables part unitization and forging more complex and net shape parts. Laboratory studies have shown that this is particularly true for UFG metals produced by SPD techniques. This combination of properties makes UFG metals produced by SPD very attractive as machining, forging or extrusion stock, both from the point of view of formability as well as energy and cost saving. However, prior to this work there had been no attempt to transfer these potential benefits observed in the laboratory scale to industrial shop floor. The primary reason for this was that the laboratory scale studies had been conducted to develop a scientific understanding of the processes that result in grain refinement during SPD. Samples that had been prepared in the laboratory scale were typically only about 10-mm diameter and 50-mm long (about 0.5-inch diameter and 2-inches long). The thrust of this project was three-fold: (i) to show that the ECAE/P process can be scaled up to produce long samples, i.e., a continuous severe plastic deformation (CSPD) process, (ii) show the process can be scaled up to produce large cross section samples that could be used as forging stock, and (iii) use the large cross-section samples to produce industrial size forgings and demonstrate the potential energy and cost savings that can be realized if SPD processed stock is adopted by the forging industry. Aluminum alloy AA-6061 was chosen to demonstrate the feasibility of the approach used. The CSPD process developed using the principles of chamber-less extrusion and drawing, and was demonstrated using rolling and wire drawing equipment that was available at Oak Ridge National Laboratory. In a parallel effort, ECAE/P dies were developed for producing 100-mm square cross section SPD billets for subsequent forging. This work was carried out at Intercontinental Manufacturing Co. (IMCO), Garland TX. Forging studies conducted with the ECAE/P billets showed that many of the potential benefits of using UFG material can be realized. In particular, the material yield can be increased, and the amount of material that is lost as scrap can be reduced by as much as 50%. Forging temperatures can also be reduced by over 150ºC, resulting in energy savings in the operation of billet heating furnaces. Looking at only the energy required to make forgings from stock materials, estimated energy savings associated with reduced scrap and lower furnace operating temperatures were greater than 40% if ECAE/P stock material was used instead of conventionally extruded stock. Subsequent heat treatment of the forged materials to the T6 condition showed that the mechanical properties of parts made from the ECAE/P stock material were the same as of those made from conventional extruded stock material. Therefore, the energy and cost savings benefits can be realized by the use SPD processed material as forging stock without sacrificing properties in the final part.« less

Children's Schemes for Anticipating the Validity of Nets for Solids

ERIC Educational Resources Information Center

Wright, Vince; Smith, Ken

2017-01-01

There is growing acknowledgement of the importance of spatial abilities to student achievement across a broad range of domains and disciplines. Nets are one way to connect three-dimensional shapes and their two-dimensional representations and are a common focus of geometry curricula. Thirty-four students at year 6 (upper primary school) were…

The equivalency between logic Petri workflow nets and workflow nets.

PubMed

Wang, Jing; Yu, ShuXia; Du, YuYue

2015-01-01

Logic Petri nets (LPNs) can describe and analyze batch processing functions and passing value indeterminacy in cooperative systems. Logic Petri workflow nets (LPWNs) are proposed based on LPNs in this paper. Process mining is regarded as an important bridge between modeling and analysis of data mining and business process. Workflow nets (WF-nets) are the extension to Petri nets (PNs), and have successfully been used to process mining. Some shortcomings cannot be avoided in process mining, such as duplicate tasks, invisible tasks, and the noise of logs. The online shop in electronic commerce in this paper is modeled to prove the equivalence between LPWNs and WF-nets, and advantages of LPWNs are presented.

The Equivalency between Logic Petri Workflow Nets and Workflow Nets

PubMed Central

Wang, Jing; Yu, ShuXia; Du, YuYue

2015-01-01

Logic Petri nets (LPNs) can describe and analyze batch processing functions and passing value indeterminacy in cooperative systems. Logic Petri workflow nets (LPWNs) are proposed based on LPNs in this paper. Process mining is regarded as an important bridge between modeling and analysis of data mining and business process. Workflow nets (WF-nets) are the extension to Petri nets (PNs), and have successfully been used to process mining. Some shortcomings cannot be avoided in process mining, such as duplicate tasks, invisible tasks, and the noise of logs. The online shop in electronic commerce in this paper is modeled to prove the equivalence between LPWNs and WF-nets, and advantages of LPWNs are presented. PMID:25821845

A cost-benefit analysis of landfill mining and material recycling in China

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhou, Chuanbin, E-mail: cbzhou@rcees.ac.cn; Gong, Zhe; Hu, Junsong

Highlights: • Assessing the economic feasibility of landfill mining. • We applied a cost-benefit analysis model for landfill mining. • Four material cycling and energy recovery scenarios were designed. • We used net present value to evaluate the cost-benefit efficiency. - Abstract: Landfill mining is an environmentally-friendly technology that combines the concepts of material recycling and sustainable waste management, and it has received a great deal of worldwide attention because of its significant environmental and economic potential in material recycling, energy recovery, land reclamation and pollution prevention. This work applied a cost-benefit analysis model for assessing the economic feasibility, whichmore » is important for promoting landfill mining. The model includes eight indicators of costs and nine indicators of benefits. Four landfill mining scenarios were designed and analyzed based on field data. The economic feasibility of landfill mining was then evaluated by the indicator of net present value (NPV). According to our case study of a typical old landfill mining project in China (Yingchun landfill), rental of excavation and hauling equipment, waste processing and material transportation were the top three costs of landfill mining, accounting for 88.2% of the total cost, and the average cost per unit of stored waste was 12.7 USD ton{sup −1}. The top three benefits of landfill mining were electricity generation by incineration, land reclamation and recycling soil-like materials. The NPV analysis of the four different scenarios indicated that the Yingchun landfill mining project could obtain a net positive benefit varying from 1.92 million USD to 16.63 million USD. However, the NPV was sensitive to the mode of land reuse, the availability of energy recovery facilities and the possibility of obtaining financial support by avoiding post-closure care.« less

Process for forming exoergic structures with the use of a plasma

DOEpatents

Kelly, Michael D.

1989-02-21

A method of forming exoergic structures, as well as exoergic structures produced by the method, is provided. The method comprises the steps of passing a plasma-forming gas through a plasma spray gun, forming a plasma spray, introducing exoergic material into the plasma spray and directing the plasma spray toward a substrate, and allowing the exoergic material to become molten, without chemically reacting in the plasma spray and to thereafter impinge on the substrate to form a solid mass of exoergic material, the shape of which corresponds to the shape of the substrate.

Method for shaping sheet thermoplastic and the like

NASA Technical Reports Server (NTRS)

Akilian, Mireille K. (Inventor); Schattenburg, Mark L. (Inventor)

2011-01-01

Processes and apparati for shaping sheet glass or thermoplastic materials use force from a layer of a flowing fluid, such as air, between the sheet and a mandrel at close to the softening temperature of the thermoplastic. The shape is preserved by cooling. The shape of the air bearing mandrel and the pressure distribution of the fluid contribute to the final shape. A process can be conducted on one or two surfaces such that the force from the air layer is on one or two surfaces of the sheet. The gap size between the sheet and mandrel determines the pressure profile in the gap, which also determines the final sheet shape. In general, smaller gaps lead to larger viscous forces. The pressure profile depends on the shape of the mandrel, the size of the fluid gap and the sheet and the fluid supply pressure.

Analysis of intelligent hinged shell structures: deployable deformation and shape memory effect

NASA Astrophysics Data System (ADS)

Shi, Guang-Hui; Yang, Qing-Sheng; He, X. Q.

2013-12-01

Shape memory polymers (SMPs) are a class of intelligent materials with the ability to recover their initial shape from a temporarily fixable state when subjected to external stimuli. In this work, the thermo-mechanical behavior of a deployable SMP-based hinged structure is modeled by the finite element method using a 3D constitutive model with shape memory effect. The influences of hinge structure parameters on the nonlinear loading process are investigated. The total shape memory of the processes the hinged structure goes through, including loading at high temperature, decreasing temperature with load carrying, unloading at low temperature and recovering the initial shape with increasing temperature, are illustrated. Numerical results show that the present constitutive theory and the finite element method can effectively predict the complicated thermo-mechanical deformation behavior and shape memory effect of SMP-based hinged shell structures.

27 CFR 555.223 - Table of distances between fireworks process buildings and other specified areas.

Code of Federal Regulations, 2011 CFR

2011-04-01

... Consumer Fireworks and Articles Pyrotechnic, Magazines and Fireworks Shipping Buildings, and Inhabited... permitted. 1 Net weight is the weight of all pyrotechnic compositions, and exposive materials and fuse only. 2 While consumer fireworks or articles pyrotechnic in a finished state are not subject to regulation...

27 CFR 555.223 - Table of distances between fireworks process buildings and other specified areas.

Code of Federal Regulations, 2010 CFR

2010-04-01

... Consumer Fireworks and Articles Pyrotechnic, Magazines and Fireworks Shipping Buildings, and Inhabited... permitted. 1 Net weight is the weight of all pyrotechnic compositions, and exposive materials and fuse only. 2 While consumer fireworks or articles pyrotechnic in a finished state are not subject to regulation...

Enhancing biomass utilization for bioenergy-crop rotation systems and alternative conversion processes

USDA-ARS?s Scientific Manuscript database

Biomass for bioenergy has a great deal of potential for decreasing our dependence upon fossil fuels and decreasing the net CO2 accumulation in the atmosphere. Crop residues are often promoted as a means of meeting the total biomass goals to provide sufficient amounts of materials for liquid fuel pro...

Ferrocene adsorbed into the porous octakis(hydridodimethylsiloxy)silsesquioxane after thermolysis in tetrahydrofuran media: An applied surface for ascorbic acid determination

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ribeiro do Carmo, Devaney, E-mail: docarmo@dfq.feis.unesp.br; Lataro Paim, Leonardo; Ramos Stradiotto, Nelson

Highlights: Black-Right-Pointing-Pointer Octakis(hydridodimethylsiloxi)silsesquioxane was synthesized and Ferrocene was adsorbed. Black-Right-Pointing-Pointer Polymeric net through electrostatic interactions was observed. Black-Right-Pointing-Pointer The novel materials presents electroacatalytic activity for Ascorbic acid. -- Abstract: Octakis(hydridodimethylsiloxi)silsesquioxane (Q{sub 8}M{sub 8}{sup H}) was synthesized and Ferrocene was adsorbed in a polymeric net through electrostatic interactions, with anion forming after the cleavage of any siloxy groups (ESFc). The nanostructured materials (Q{sub 8}M{sub 8}{sup H} and EsFc) were characterized by Fourier transform infrared spectra (FT-IR), nuclear magnetic resonance (NMR), X-ray diffraction (XRD), Thermogravimetric analyses and Voltammetric technique The cyclic voltammograms of the graphite paste electrode modified with ESFc showed onemore » redox couple with E{sup 0} Prime = 0.320 V (1.0 mol L{sup -1} NaCl, v = 50 mV s{sup -1}), with a diffusion-controlled process and the redox process shows electrocatalytic activity for the oxidation of ascorbic acid.« less

Neutrophil Extracellular Traps Identification in Tegumentary Lesions of Patients with Paracoccidioidomycosis and Different Patterns of NETs Generation In Vitro

PubMed Central

Della Coletta, Amanda Manoel; Bachiega, Tatiana Fernanda; de Quaglia e Silva, Juliana Carvalho; Soares, Ângela Maria Victoriano de Campos; De Faveri, Julio; Marques, Silvio Alencar; Marques, Mariângela Esther Alencar; Ximenes, Valdecir Farias; Dias-Melicio, Luciane Alarcão

2015-01-01

Paracoccidioidomycosis (PCM) is a systemic mycosis, endemic in most Latin American countries, especially in Brazil. It is caused by the thermo-dimorphic fungus of the genus Paracoccidioides (Paracoccidioides brasiliensis and Paracoccidioides lutzii). Innate immune response plays a crucial role in host defense against fungal infections, and neutrophils (PMNs) are able to combat microorganisms with three different mechanisms: phagocytosis, secretion of granular proteins, which have antimicrobial properties, and the most recent described mechanism called NETosis. This new process is characterized by the release of net-like structures called Neutrophil Extracellular Traps (NETs), which is composed of nuclear (decondensed DNA and histones) and granular material such as elastase. Several microorganisms have the ability of inducing NETs formation, including gram-positive and gram-negative bacteria, viruses and some fungi. We proposed to identify NETs in tegumentary lesions of patients with PCM and to analyze the interaction between two strains of P. brasiliensis and human PMNs by NETs formation in vitro. In this context, the presence of NETs in vivo was evidenced in tegumentary lesions of patients with PCM by confocal spectrum analyzer. Furthermore, we showed that the high virulent P. brasiliensis strain 18 (Pb18) and the lower virulent strain Pb265 are able to induce different patterns of NETs formation in vitro. The quantification of extracellular DNA corroborates the idea of the ability of P. brasiliensis in inducing NETs release. In conclusion, our data show for the first time the identification of NETs in lesions of patients with PCM and demonstrate distinct patterns of NETs in cultures challenged with fungi in vitro. The presence of NETs components both in vivo and in vitro open new possibilities for the detailed investigation of immunity in PCM. PMID:26327485

Virtual Parts Engineering Research Center

DTIC Science & Technology

2010-05-20

engineering 10 materials. High strength alloys , composites (polymer composites and metallic composites), and the like cannot merely be replaced by...ceramics, smart materials, shape memory alloys , super plastic materials and nano- structured materials may be more appropriate substitutes in a reverse...molding process using thermosetting Bakelite. For remanufacturing the part in small quantities, machining has been identified as the most economical

Thermo-mechanical behavior and structure of melt blown shape-memory polyurethane nonwovens.

PubMed

Safranski, David L; Boothby, Jennifer M; Kelly, Cambre N; Beatty, Kyle; Lakhera, Nishant; Frick, Carl P; Lin, Angela; Guldberg, Robert E; Griffis, Jack C

2016-09-01

New processing methods for shape-memory polymers allow for tailoring material properties for numerous applications. Shape-memory nonwovens have been previously electrospun, but melt blow processing has yet to be evaluated. In order to determine the process parameters affecting shape-memory behavior, this study examined the effect of air pressure and collector speed on the mechanical behavior and shape-recovery of shape-memory polyurethane nonwovens. Mechanical behavior was measured by dynamic mechanical analysis and tensile testing, and shape-recovery was measured by unconstrained and constrained recovery. Microstructure changes throughout the shape-memory cycle were also investigated by micro-computed tomography. It was found that increasing collector speed increases elastic modulus, ultimate strength and recovery stress of the nonwoven, but collector speed does not affect the failure strain or unconstrained recovery. Increasing air pressure decreases the failure strain and increases rubbery modulus and unconstrained recovery, but air pressure does not influence recovery stress. It was also found that during the shape-memory cycle, the connectivity density of the fibers upon recovery does not fully return to the initial values, accounting for the incomplete shape-recovery seen in shape-memory nonwovens. With these parameter to property relationships identified, shape-memory nonwovens can be more easily manufactured and tailored for specific applications. Copyright © 2016 Elsevier Ltd. All rights reserved.

Shape memory system with integrated actuation using embedded particles

DOEpatents

Buckley, Patrick R [New York, NY; Maitland, Duncan J [Pleasant Hill, CA

2009-09-22

A shape memory material with integrated actuation using embedded particles. One embodiment provides a shape memory material apparatus comprising a shape memory material body and magnetic pieces in the shape memory material body. Another embodiment provides a method of actuating a device to perform an activity on a subject comprising the steps of positioning a shape memory material body in a desired position with regard to the subject, the shape memory material body capable of being formed in a specific primary shape, reformed into a secondary stable shape, and controllably actuated to recover the specific primary shape; including pieces in the shape memory material body; and actuating the shape memory material body using the pieces causing the shape memory material body to be controllably actuated to recover the specific primary shape and perform the activity on the subject.

Shape memory system with integrated actuation using embedded particles

DOEpatents

Buckley, Patrick R [New York, NY; Maitland, Duncan J [Pleasant Hill, CA

2012-05-29

A shape memory material with integrated actuation using embedded particles. One embodiment provides a shape memory material apparatus comprising a shape memory material body and magnetic pieces in the shape memory material body. Another embodiment provides a method of actuating a device to perform an activity on a subject comprising the steps of positioning a shape memory material body in a desired position with regard to the subject, the shape memory material body capable of being formed in a specific primary shape, reformed into a secondary stable shape, and controllably actuated to recover the specific primary shape; including pieces in the shape memory material body; and actuating the shape memory material body using the pieces causing the shape memory material body to be controllably actuated to recover the specific primary shape and perform the activity on the subject.

Shape memory system with integrated actuation using embedded particles

DOEpatents

Buckley, Patrick R.; Maitland, Duncan J.

2014-04-01

A shape memory material with integrated actuation using embedded particles. One embodiment provides a shape memory material apparatus comprising a shape memory material body and magnetic pieces in the shape memory material body. Another embodiment provides a method of actuating a device to perform an activity on a subject comprising the steps of positioning a shape memory material body in a desired position with regard to the subject, the shape memory material body capable of being formed in a specific primary shape, reformed into a secondary stable shape, and controllably actuated to recover the specific primary shape; including pieces in the shape memory material body; and actuating the shape memory material body using the pieces causing the shape memory material body to be controllably actuated to recover the specific primary shape and perform the activity on the subject.

The influence of grating shape formation fluctuation on DFB laser diode threshold condition

NASA Astrophysics Data System (ADS)

Bao, Shiwei; Song, Qinghai; Xie, Chunmei

2018-03-01

Not only the grating material refractive index itself but also the Bragg grating physical shape formation affects the coupling strength greatly. The Bragg grating shape includes three factors, namely grating depth, duty ratio and grating angle. During the lithography and wet etching process, there always will be some fluctuation between the target and real grating shape formation after fabrication process. This grating shape fluctuation will affect the DFB coupling coefficient κ , and then consequently threshold current and corresponding wavelength. This paper studied the grating shape formation fluctuation influence to improve the DFB fabrication yield. A truncated normal random distribution fluctuation is considered in this paper. The simulation results conclude that it is better to choose relative thicker grating depth with lower refractive index to obtain a better fabrication tolerance, while not quite necessary to spend too much effort on improving lithography and wet etching process to get a precisely grating duty ratio and grating angle.

The influence of grating shape formation fluctuation on DFB laser diode threshold condition

NASA Astrophysics Data System (ADS)

Bao, Shiwei; Song, Qinghai; Xie, Chunmei

2018-06-01

Not only the grating material refractive index itself but also the Bragg grating physical shape formation affects the coupling strength greatly. The Bragg grating shape includes three factors, namely grating depth, duty ratio and grating angle. During the lithography and wet etching process, there always will be some fluctuation between the target and real grating shape formation after fabrication process. This grating shape fluctuation will affect the DFB coupling coefficient κ, and then consequently threshold current and corresponding wavelength. This paper studied the grating shape formation fluctuation influence to improve the DFB fabrication yield. A truncated normal random distribution fluctuation is considered in this paper. The simulation results conclude that it is better to choose relative thicker grating depth with lower refractive index to obtain a better fabrication tolerance, while not quite necessary to spend too much effort on improving lithography and wet etching process to get a precisely grating duty ratio and grating angle.

Manufacturing and Machining Challenges of Hybrid Aluminium Metal Matix Composites

NASA Astrophysics Data System (ADS)

Baburaja, Kammuluri; Sainadh Teja, S.; Karthik Sri, D.; Kuldeep, J.; Gowtham, V.

2017-08-01

Manufacturing which involves material removal processes or material addition processes or material transformation processes. One or all the processes to obtain the final desired properties for a material with desired shape which meets the required precision and accuracy values for the expected service life of a material in working conditions. Researchers found the utility of aluminium to be the second largest after steel. Aluminium and its metal matrix composite possess wide applications in various applications in aerospace industry, automobile industry, Constructions and even in kitchen utensils. Hybrid Al-MMCconsist of two different materials, and one will be from organic origin along with the base material. In this paper an attempt is made to bring out the importance of utilization of aluminium and the challenges concerned in manufacturing and machining of hybrid aluminium MMC.

Parametric Study of Reactive Melt Infiltration

NASA Technical Reports Server (NTRS)

Nelson, Emily S.; Colella, Phillip

2000-01-01

Reactive melt infiltration is viewed as a promising means of achieving near-net shape manufacturing with quick processing time and at low cost. Since the reactants and products are, in general, of varying density, overall conservation of mass dictates that there is a force related to chemical conversion which can directly influence infiltration behavior. In effect, the driving pressure forces may compete with the forces from chemical conversion, affecting the advancement of the front. We have developed a two-dimensional numerical code to examine these effects, using reaction-formed silicon carbide as a model system for this process. We have examined a range of initial porosities, pore radii, and reaction rates in order to investigate their effects on infiltration dynamics.