Manufacturing & Prototyping

Melt Infiltration of SiC/SiC Preforms Using Cr-Si Alloys

These composites can be used in aircraft engine turbine blades, vanes, combustor lines, and shrouds.

The goal of this work was to develop engineered matrix SiC/SiC ceramic composites with crack blunting and self-healing capabilities for 1588 to 1755 K applications. The work optimized the temperature and time conditions for melt-infiltrating SiC/SiC preforms with chromium silicide alloys, and established that these alloys do not react with the coatings on the SiC fibers. Traditional ways of fabricating SiC fiber-based ceramic matrix composites (CMCs) use silicon to melt-infiltrate the CMC preforms, where the Si is often converted to SiC by reaction with carbon. The traditional SiC matrices have poor high-temperature creep properties due to the presence of residual silicon. They also have low fracture toughness and a low matrix cracking stress.

Posted in: Briefs, Manufacturing & Prototyping, Product development, Ceramics, Coatings, colorants, and finishes, Composite materials, Silicon alloys, Smart materials
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Method of Making a Composite Panel Having Subsonic Transverse Wave Speed Characteristics

Applications include internal aircraft structures, buildings, and enclosures for machines.

NASA's Langley Research Center has developed an enhanced design for a composite panel with a recessed core. NASA designed it to decrease the radiation efficiency and increase the transmission loss while maintaining load-bearing capability so it could be used in applications such as aircraft floors. Similar to traditional composite panels, the innovation possesses low weight characteristics, but in addition, it can be used in load-bearing applications. The invention was developed for NASA's Quiet Aircraft Technology Program. The superior design of the composite panel can be used in a wide variety of commercial applications wherever honeycomb is needed and improved acoustics are desired. NASA has patented and tested the novel design, and is interested in attracting development partners and potential licensees for the recessed core composite panel design.

Posted in: Briefs, Manufacturing & Prototyping, Aircraft structures, Design processes, Flooring, Composite materials
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Additively Manufactured Modular Thrust Chamber

Thrust chambers have historically been difficult to manufacture. They require extensive tooling and labor, and are expensive with long lead times. Thrust chambers were designed for manufacture using conventional machining. As a result, designs required multiple pieces to ensure machine tool access to each surface. The individual pieces would then be joined and assembled into a single thrust chamber. These joining operations typically required process development due to the complexity of the parts and the need for joining to provide a seal between parts. A faster, more reliable and affordable manufacturing method was desired.

Posted in: Briefs, Manufacturing & Prototyping, Additive manufacturing, Productivity, Engine components, Rocket engines, Reliability
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Challenges of 3D Printing Large Metal Aerospace Parts

Learn why Addaero has selected Arcam EBM for large, bulky parts for aerospace applications The applications for metal additive manufacturing are many, but the aerospace sector is one area that is leveraging metal AM for actual production parts. While both laser and EBM have advantages and disadvantages for a given application, Arcam EBM excels in printing larger parts for fatigue applications. Addaero works with leading aerospace companies to supply metal AM parts using both laser and EBM and has first-hand experience of how to best produce parts for a given application utilizing the best suitable technology.

Posted in: On-Demand Webinars, Manufacturing & Prototyping
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Flexible Coupling Solutions for OEM Applications

Gain insights into specifying a flexible coupling for your application that offers the best combination of value and performance. Attendees will see examples of solutions provided for real world applications that leveraged the engineering support and technical skill of Helical Products. Designing and manufacturing a custom coupling for OEM applications provides savings by optimizing the size and targeting environmental conditions that would not be met by off-the-shelf products. The incorporation of special attachment features will reduce the time and expense of design, purchase and inventory of multiple parts.

Posted in: On-Demand Webinars, Manufacturing & Prototyping
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Integrating 3D Printing into the Product Development Process at Volvo Construction Equipment

In conjunction with SAE

3D printing in the product development process is becoming increasingly important with the increase in the pace of the construction industry. Volvo Construction Equipment (CE) has embraced this into its work process. Equipped with a Stratasys Eden 260V, Volvo CE has the ability to create engine component prototypes that are mounted directly on the engine and then tested. Volvo CE also quickly builds 3D models of its new product concepts for stakeholders to get timely feedback, reducing risk and lead time in all development stages. This advantage gives Volvo CE the ability to make better project decisions throughout the development and production cycles.

Posted in: On-Demand Webinars, Manufacturing & Prototyping
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Survival of the Fittest - the Process Control Imperative

In tough times, manufacturers focus on reducing their operating costs, but may not be able to afford to spend their way out by buying more productive machinery. With that pathway closed, what are the opportunities for radically reducing costs without replacing existing machines? This paper explores Productive Process Pyramid™ and the four areas where substantial savings can be found if firms are prepared to change the way they control their machining processes.

Posted in: White Papers, Defense, Energy, Manufacturing & Prototyping
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Thermoplastics: The Strongest Choice for 3D Printing

Fused deposition modeling (FDM) gives you the option of making functional plastic parts with the most commonly used industrial-grade thermoplastics – the same types of raw materials found in injection molding facilities. That’s important because the best way to predict a product’s end performance is to prototype it with a material as similar as possible to the finished part.

Posted in: Dynamic White Papers, Manufacturing & Prototyping
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Hot Isostatic Pressing of 60-Nitinol

The material 60-Nitinol (60wt%Ni-40wt%Ti) has a unique combination of physical properties, including high hardness, low apparent elastic modulus, and resistance to saltwater corrosion. These properties give the material tremendous potential for use in aerospace and defense-related components such as bearings, gears, and other apparatuses. Various methods of primary processing are being explored for fabrication of high-performance components that are free of metallurgical defects that might lead to premature failure. Hot isostatic pressing (HIP) is one process under consideration. The steps in the HIP process include (a) filling a sealed canister of the appropriate dimensions with powder, (b) heating the canister under vacuum to remove volatile and gaseous contents, (c) applying heat and pressure to the evacuated and sealed canister to consolidate the contents, and (d) removing the canister.

Posted in: Briefs, Manufacturing & Prototyping, Fabrication, Materials properties, Reliability
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Logistics for Building Radiation Storm Shelters and their Operational Evaluation

Various habitat structures were tested for use in exploration activities.

Over the past three years, NASA has been studying the operational effectiveness and astronaut protection efficacy of numerous radiation protection shelters for use in space exploration activities outside of Earth's magnetosphere. The work was part of NASA's Advanced Exploration Systems (AES) RadWorks Storm Shelter project. Fabricated items were integrated into mockup deep space habitat vehicle sections for operational evaluations. Two full-scale human-in-loop simulations were designed, fabricated, and implemented. The goal was to provide design and performance assessment information for consideration by mission designers who must quantify the radiation protection characteristics of their exploration trade space.

Posted in: Briefs, Manufacturing & Prototyping, Protective structures, Radiation protection, Spacecraft
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