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National Aeronautics and Space Administration www.nasa.gov Enabling Additive Manufacturing Technologies for Advanced Aero Propulsion Materials & Components Michael C. Halbig 1 and Mrityunjay Singh 2 1-NASA Glenn Research Center, Cleveland, OH 2-Ohio Aerospace Institute, Cleveland, OH Pacific Rim Conference of Ceramic Societies, PACRIM13 Okinawa, Japan, Oct. 27-31, 2019. https://ntrs.nasa.gov/search.jsp?R=20190034069 2020-06-08T02:51:51+00:00Z

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Page 1: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Enabling Additive Manufacturing Technologies for

Advanced Aero Propulsion Materials & Components

Michael C. Halbig1 and Mrityunjay Singh2

1-NASA Glenn Research Center, Cleveland, OH

2-Ohio Aerospace Institute, Cleveland, OH

Pacific Rim Conference of Ceramic Societies, PACRIM13

Okinawa, Japan, Oct. 27-31, 2019.

• https://ntrs.nasa.gov/search.jsp?R=20190034069 2020-06-08T02:51:51+00:00Z

Page 2: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Outline

• Background, Applications, and NASA Strategic Thrusts

• AM of CMCs and Polymer Materials for Turbine Engine Applications

– Laminated Object Manufacturing (OAI) for continuous fiber composites

– Binder Jet Printing for short fiber composites

– FDM of polymer-based materials

• AM of Materials and Components for Electric Motors

– CAMIEM intro: the objectives and approach

– New component designs for integration into the motor

– Direct writing of conductors

– Fabrication and evaluation of a baseline motor

• Summary and next steps

2

Page 3: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Fused Deposition ModelingPlastic is heated and supplied

through an extrusion nozzle

and deposited.

Binder JettingAn inkjet-like printing head moves

across a bed of powder and

deposits a liquid binding material.

Direct Write PrintingControlled dispensing of

inks, pastes, and slurries.

Additive Manufacturing Technologies

3

• Filament

Binder solution Head ---- .,._.-

Pressure

UJ

Dispensing

Tip

~ heigh~~•--- Substrate

Platform

Page 4: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Components for Turbine Engine Applications

Turbine Engines -Targeted Components (CMCs and PMCs)

4

Fan DuctShrouds & Vanes

Exhaust

Components

Combustor

Liners

NASA CMC Components from

Conventional Fabrication Methods

EBC Coated

SiC/SiC Vanes

Oxide/Oxide

Mixer Nozzle

SiC/SiC Combustion

Liners: Outer Liner and

EBC Coated Inner Liner

\ / INTAKE COMPRESSION EXHAUST

Combustion Chambers Turbine

Cold Section Hot Section / '

Page 5: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Components for Electric Motor Applications

Radial Flux

Machine

Axial Flux Machine

Housing

Rotor

Magnet(s)Stator

Electric Motors- Targeted Components

(structural, functional, and electrical)

NASA Aeronautics

Research Six

Strategic Thrusts

Achieve and exceed N+2

and N+3 goals for

increased efficiencies and

reduced emissions.

STARC-ABL

Vertical

Lift

5

Uber ElevateNASA 15-PAX

tiltwing aircraft

Electrified Aircraft

3.

4.

Ultra-Efficient Commercial Vehicles • Pioneer technologies for big leaps in efficiency and

environmental performance

Transition to Low-Carbon Propulsion • Characterize drop-in alternative fuels and pioneer

low-carbon propulsion technology

Page 6: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Laminated Object Manufacturing For Silicon

Carbide-Based Composites

Fabrics and Prepregs cut at

different laser powers/speeds

Universal Laser System (Two 60 watt

laser heads and a work area of 32”x18”)

LOM allows for continuous

fiber reinforced CMCs.

Prepregs for Composite Processing

• A number of SiC (Hi-Nicalon S, uncoated)

fabrics (~6”x6”) were prepregged.

• These prepregs were used for optimization

of laser cutting process.

• Baseline laser cutting data was also

generated for different types of SiC fabrics

(CG Nicalon, Hi-Nicalon, and Hi-Nicalon S)

Laser cut prepregs used

for composite processing

SEM specimens cut with

different laser power/speeds 6

Page 7: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Fibers Used for Prepregs: SiC (Hi-Nicalon S Fibers, 5 HS weave)

Fiber Interface Coating: None

Prepreg Composition: Prepreg 5A Nano 2 + Si

• Dense matrix after silicon infiltration. However,

uncoated fibers are damaged due to exothermic

Si+C reaction.

• Fiber coatings needed to prevent silicon reaction

and provide weak interface for debonding and

composite toughness.

Green Preforms:

8 layers of prepregs; warm

pressed @75-85°C

7

Microstructure of SiC/SiC Composites Fabricated Using Single Step Reaction Forming Process plus Si Infiltration

Heat Treatment:

1475°C, 30 minutes

in vacuum

Page 8: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Fibers Used for Prepregs: SiC (Hi-Nicalon S Fibers, 5 HS weave)

Fiber Coating: None

Prepreg Composition: Prepreg 5A Nano 2 + Si

Uncoated SiC fibers

show no visible damage

due to Si exothermic

reaction.

Green Preforms:

8 layers of prepregs; warm

pressed @75-85°C

Heat Treatment:

1475°C, 30 minutes

in vacuum

Micrographs show

good distribution of

SiC and Si phases.

8

Microstructure of SiC/SiC Composites Fabricated Using Single Step Reaction Forming Process plus Si Infiltration •

Page 9: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Infiltration Green part

De-powdering

Powder Blending

Final Part

Binder Jet Additive Manufacturing of SiC

ExOne Innovent

An inkjet printing head

moves across a bed of

powder and deposits a

liquid binding material.

Binder jet printing capability allows for powder bed processing with

tailored binders and chopped fiber reinforcements for advanced ceramics. 9

• • •

• Binder solution ~---~

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National Aeronautics and Space Administration

www.nasa.gov 10

Binder Jetting of SiC Fiber / SiC Matrix CompositesExOne Innovent

Fiber Reinforced Ceramic

Matrix Composite

High pressure turbine cooled doublet vane sections.

Si-TUFF iSiC fbers

(Advanced Composite Materials, LLC)

Constituents

SiC powder loaded SMP-10

SiC powder

SiC powder

~70 µm long and

~7 µm in diameter

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National Aeronautics and Space Administration

www.nasa.gov

Processing

- Constituents

• SiC powders: Carborex 220, 240, 360, and 600 powders (median grain

sizes of 53, 45, 23, and 9 microns respectively). Used solely and in powder

blends

• Infiltrants: SMP-10 (polycarbosilane), SiC powder loaded SMP-10, phenolic

(C, Si, SiC powder loaded), pure silicon

• Fiber reinforcement: Si-TUFF SiC fiber; 7 micron mean diameter x 65-70

micron mean length

Microstructure

- Optical microscopy

- Scanning electron microscopy

Properties

- Material density (as-manufactured and after infiltration steps)

- Mechanical properties: 4-point bend tests

Approach for Additive Manufacturing of CMCs

Si-TUFF SiC fibers

(Advanced Composite

Materials, LLC)

Constituents

SiC powder loaded SMP-10

SiC powder

SiC

powder

Phenolic infiltrant

SiC powder

SiC powder

Processing, microstructure, and property correlations

provide an iterative process for improving the CMC materials.

11

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National Aeronautics and Space Administration

www.nasa.gov

Binder Jetting: Density of SiC Panels

1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

2.20

Den

sity

(g

/cc)

Density at as-processed through 1, 2, and 3 infiltrations

I5

N5

O5

G5

P6

Q6

0 321

Densities increased by up to 33% from additional

PCS infiltration steps and were maintained even at

higher SiC fiber loadings of 45, 55, and 65 vol.%.

2”x2” CMC

coupons

Polymer approach has a limitation

on achievable densities.

Melt infiltration methods

such, e.g. silicon melt, can

achieve near full density.

Multiple PCS infiltration steps.

45 vol. % Si Tuff fiber

65 vol. % Si Tuff fiber

55 vol. % Si Tuff fiber

75 vol. % Si Tuff fiber

12

Demonstration of full densification

through silicon melt-infiltration.

SiC

SiC

Silicon

infiltrationSiC

.......

.......

.......

.......

.......

.......

• ---1 I ~1-~·~~,,.,~J

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National Aeronautics and Space Administration

www.nasa.gov 13

Carborex Powder mix with 65 vol.% Si-Tough SiC fiber, SMP-10 w/800 nano SiC particles vacuum infiltration.

Binder Jetting: Cross-Section and Fracture Surface from

SiC/SiC Sample with 65 vol.% SiC Fiber

Good densities achieved

with high fiber loading.

Page 14: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Binder Jetting: 4 Point Flexure Tests of the

Monolithic SiC and CMC materials - at R.T.

0

10

20

30

40

50

60

70

80

0.00 0.02 0.04 0.06 0.08 0.10

Str

es

s (

MP

a)

Strain (%)

Non-Reinforced SiC - Set G

0

10

20

30

40

50

60

70

80

0.00 0.02 0.04 0.06 0.08 0.10

Str

es

s (

MP

a)

Strain (%)

65 vol. % SiC Fiber Reinforced SiC - Set N

The fiber loaded SiC materials had significantly higher

stresses and higher strains to failure.

Bend bars for

strength testing

14

Page 15: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

• Four point bend tests were conducted on samples after 4 SMP-10 infiltrations

• 50 mm long samples were loaded with a 20 mm loading span and 40 mm support span

• The maximum strength was 111 MPa

• For comparison: Dense CVD SiC and sintered alpha SiC bend strength ranges from 200-450 MPa

• Samples that were tested after 6 infiltrations showed no difference in strength

Recent SiC Binder Jetting Results

- Processing and Mechanical Strength Improvements

POC:

Craig Smith

NASA GRC

Optical Microscopy of AM

SiC after 4 PIP Cycles

15

Four Point Bend Strength

~ Average Strength - Average Density

120

100

20

120 2.5

2.4

ro 100 a..

2.3

~ .. ..c +-' ~

u C u ~ ~ 2.2 _, ~ vi ..,I .... I'll

2.1 i::::

2

1.9

ClJ Q

""C C (lJ

cc

80

60

40

20

0

0 1.8 Powder Powder Powder Powder 65% D, 70% D, 70% C,

A B C D 35% F 30% E 30% F

2

• •

2.1

0 0

• •• 0

0

0 <9

2.2

• • •

2.3

Density, g/cc

• 0

• 0

• •

2.4 2.S

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National Aeronautics and Space Administration

www.nasa.gov

Demonstration of Polymer

Components from FDM

Engine Panel Access Door

Inlet Guide Vanes from

ABS and Ultem 1000

Acoustic Liner

Test Articles

High temp. polymers

with chopped carbon

fiber reinforcement.

Fortus

400

Lightweight

Structures

FDM Process

Standard Liner Complex Geometry Advanced Liner

Design

The focus is on unique structures,

high temperature capability, and

fiber reinforcement.

16

FDM head

temperature control

1 filament

rollers( OO J

• liquefier

supporting bars

_] <=:)x-yaxes

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National Aeronautics and Space Administration

www.nasa.gov 17

0.1 mm

0.4 mm

Highest strength and modulus in CNT reinforced coupons

versus standard ABS Coupons. Less porosity for lower print heights.

Effect of print layer height

FDM of Composite Filaments for Multi-Functional ApplicationsPotential Missions/Benefits:

• On demand fabrication of as needed functional components in space

• Tailored, high strength, lightweight support structures reinforced with CNT

• Tailored facesheets for functional properties, i.e. wear resistance, vibration

dampening, radiation shielding, acoustic attenuation, thermal management

Color Fab,

copper fill

metal, PLA

Proto Pasta,

Magnetic iron, PLAGMASS,

Tungsten, ABS

GMASS,

Bismuth, ABS

C-Fiber Reinforced

ABS Filaments

Filaments used: ABS-standard abs, P-premium abs, CNT-w/carbon

nanotubes, C-w/chopped carbon, Home-lab extruded filament

n:, 0. \.!:I

2.5 ~------------,

] 2.0 +---¥~~ ~ -----­::,

-g ~ II)

CNT

-a-5% C

---+-- Prem

-~ 1.5 +-----~ ---............ ::-----i-.-ABS ::J

40 ~ ----------------, nl a. ~~ -I---~~ --,-,----------, .. -= t~ -·~- ~::::::::~s;::;;~~~-7 .. ~ ~ -+---------~:,---------;

CII .. nl

0 >

E 20 +------------~ ---, E Home ::,

(b) 15 4-----,-----,-----,---r------i

1.0 -1--------,-----.--- 0.0 0.1 0.2 0.3 0.4 0.5

0.0 0.2 0.4 Layer Height, mm

layer Height, mm

-&- CNT

--e- p

~ ABS

---e- 5%(

Home

. •• •1 • • • • •• ::. • ; · • ••• • •• f . 7 • • :. ~·· .. . . . . ,, .. , . ~. . . •.. . ... .... .. , ......... ~

i • :,• • ~ . • • ·• ••• : . _,. •• . -f : . . : . . . .. . . ..; . · ... • !. •·~! .-.• , .:. ... • ..,. .• • • • lt . ' .. • .... •: • . ~~ .· .• . ... . . .. ·• .. ' .. .. . • • . • . . ,l • ••••.. . , : . ' ' . ·~· '. . . :. ... . . . . ' ... . . . _,. .

•:.:. /Ii~ ., l' .: •• ~ . . · •• V-• l ~ t • :,. : ...

- . ... . -·--...:

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National Aeronautics and Space Administration

www.nasa.gov

Aircraft Utilizing Electric Motors

X-57: Distributed Propulsion

Greased Lightning GL-10

Urban Air

MobilitySTARC-ABL Hybrid Electric

Uber Elevate

NASA 15-PAX

tiltwing aircraft

Large Single Isle Transports

18

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National Aeronautics and Space Administration

www.nasa.gov

Objective: Utilize additive manufacturing (AM) methods to achieve new motor

designs that have significantly higher power densities and/or efficiency.

Methods:

• New topologies with compact designs, lightweight structures, innovative

cooling, high copper fill, and multi-material systems/components.

• New component designs for the rotors, housing, finned stator cooling ring,

direct printed stator, and a wire embed stator.

• Compare new components/new motor against a baseline motor.

CAMIEM: Compact Additively Manufactured Innovative

Electric Motors

Mission: efficient, low emission

aircraft for Urban Air Mobility.

Compact Additively Manufactured Innovative Electric Motor (CAMIEM) team members:

NASA (GRC, LaRC, ARC), LaunchPoint Technologies and the University of Texas - El Paso

• Motor Width: ~ 7.5”• Total weight ~ 4lbs (1.8 kg)

CAMIEM Baseline Motor CAMIEM AM Motor Design

GRC Dynamometer

Already SOA due to compact design, high power density, and halbach array of magnets.

Projecting a 2x increase in Power Density to 10 kW/kg.

For development of advanced materials, structures, and components.

19

Page 20: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Feasibility Assessment

Baseline Motor

Baseline Motor Testingfor baseline performance

Innovative Motor

DesignAircraft Level System Studies

Additive Manufacturing

Processes and Advanced

Components

Testing of “New” Motor

Configurations to Determine

Improved Performance

Feasibility

Assessed and

Benefits

Determined

20

• ~ -----~ ~..-, ·· I

IL_ _J

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National Aeronautics and Space Administration

www.nasa.gov 21

AM and Hybrid Approaches for Electric Motor Components

Components of a Commercial

Axial Flux Motor

NASA Electric Motor with

AM Components

Additively Manufactured

Rotor Plate

Rotor Constituents:

• Permanent magnets.

• High strength structure

(typically metallic).

PCB Coreless StatorLitz Wire

Coreless Stator

Stator Constituents:

• Conductor: copper,

silver.

• Insulators: coatings,

dielectrics, epoxy, high

temp. polymer.

• Soft magnets (for cores):

iron alloys. Iron Core Stator with

Direct Printed Coils

Electric Motors Stators Rotors•

Page 22: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Direct Printed StatorsBenefits – Higher magnetic flux, torque, and motor constant (Km). – Higher temp. capability of >220C instead of 160C for baseline stator.– Direct printed silver coils with high fill.

Stator Plate from Cobalt-Iron Alloy

Cirlex Middle Layer

Outer Rings22

Concept A

Details of machined features

Substrate

Silver paste

nScrypt 3Dn-300

4-point probe method

Direct Printed Silver Coils -High Current Test

l )

Page 23: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

www.nasa.gov

Additively Manufactured Stator Plates

FDM from Extem (Tg of 311C) (left) and Ultem

1010 (TG of 217C) (right) FDM filament.

Low cost and rapidly manufactured sub-components may be

possible with further advancements or alternate AM processes.23

FDM

Process

Stator Plate from Cobalt-Iron Alloy

1200°C – 51.3% TD

500 μm

High Temp.

Polymer

Soft Magnet

Binder Jetting

Process: lay down of a me lt s t ran d

'..--- nozz le prototype ....,..,.,..- linewise

1'==~~=""1!;..... ........................ ~/" ap plicat ion

supporting s t ructure ~ base plate

e~e,soutlon ----- Electric magnetic laminated sheets

Laminated sheets which are coated by insulating layer

High Joule heat in plane which is perpendicular to the magnetic field

Insulating layer

X ::,

• Soft magnetic composite materials

Compacting powders which are covered with insulating film

Low Joule heat x along any direction u

Insulating film

Eddy current

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National Aeronautics and Space Administration

www.nasa.gov 24

Fabrication Method Machine/EDM Machine/MillFabrication Time 4+ months 3 months

Fabrication Costs $21,400 $19, 870Material Costs $600 $330Total Costs $22,000 $20,200

Comparison of Methods to Obtain Outside

Fabrication for Channeled Plates for Stators

Concept B - Stator Plates from Ultem1010

Concept B - Stator Plates from Cirlex

Concept A - Stator Plates from Cobalt-Iron Alloy

3D Print/FDM1 week (92.3% reduction)

$1,000$0 (included in fab.)$1,000 (95.0% reduction)

Currently relying on machined stator plates.

Page 25: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

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Samples were printed on

the nScrypt 3Dn-300.

Crucial Parameters:

–Print Speed

–Dispensing Pressure

–Nozzle Diameter

–Print Offset

–Valve Opening

Substrate

Trace

Thin Surface and Imbedded

Thick 4-Pt Probe Windings

4-point probe

method

Direct Printing for Innovative Stator Designs for Electric Motors

25

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National Aeronautics and Space Administration

www.nasa.gov

Evaluation of Silver Pastes

Conductivity of bulk metals [Ωm]^-1:

-Silver: 6.3 x 107

-Copper: 6.0 x 107

Litz Wire ~60%

fill and less in

stator windings

Printed conductors will have a higher

effective conductivity than the Litz

wire conductors.

Sample 71017G: Heraeus

CL20-11127

Silver paste

PLAIN PASTE

Paste Composition Lowest Resistivity Obtained [Ωm] Conductivity [Ωm]^-1 Max Temp (*C) Vendor Resistivity

CL-11190 (Heraeus) 2.06 x 10-8 4.86 x 107 300 N/A

CB028 (DuPont) 2.82 x 10-8 3.54 x 107 175 7 – 10 (mΩ/sq/mil)

CL20-11127 (Heraeus) 3.6 x 10-8 2.78 x 107 300 N/A

CB100 (DuPont) 5.23 x 10-8 1.91 x 107 175 >7.5 x 10-8 Ωm

Ag-PM100 (Applied Nanotech) 9.13 x 10-8 1.10 x 107 300 >5 x 10-8 Ωm

Kapton (DuPont) 2.11 x 10-7 4.74 x 106 225 <5 (mΩ/sq/mil)

Substrate

26

••• •••• :.•-•-•-~ ·····•~ ~ .. _. _) . uuu

~

Page 27: Enabling Additive Manufacturing Technologies for Advanced … · 2019-12-27 · Binder Jetting An inkjet-like printing head moves across a bed of powder and deposits a liquid binding

National Aeronautics and Space Administration

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Pastes Additions for Higher Electrical Conductivity

27

Additions of Graphene and

Carbon Nanostructures

Most Conductive Composites

Paste Composition Resistivity

[Ωm]

Conductivity

[Ωm]^-1

CB028 + 0.2 wt%

QUATTRO Graphene

8.148E-08 1.23E+07

Heraeus + 0.04 wt% CNS 8.297E-08 1.21E+07

CB028 + 0.1 wt%

QUATTRO Graphene

1.036E-07 9.65E+06

CB028 + 0.085 wt% CNS 1.114E-07 8.97E+06

Heraeus + 0.14 wt% CNS 1.191E-07 8.40E+06

CB028 + 0.2 wt% MONO

Graphene

1.261E-07 7.93E+06

CB028 + 0.5 wt% MONO

Graphene

1.419E-07 7.05E+06

Plain Pastes

Paste Composition Resistivity

[Ωm]

Conductivity

[Ωm]^-1

Plain CB028 2.82 E-08 3.54 E+07

Plain Heraeus 4.124E-08 2.42E+07

Peng-Cheng Ma, “Enhanced Electrical Conductivity

of Nanocomposites Containing Hybrid Fillers of

Carbon Nanotubes and Carbon Black.”

Y. Kim, et al. U.S. Patent 8,481,86, 2013 –

Conductive Paste Containing Silver

Decorated CNT

0 1.0 -0

-2 1.0 -04

E - 4 TARGET CONTENT OF CARBON ~ 1.0 -06

(..) -- tl3 en - 6 NANOTUBES REQUIRED -b8 FOR ELECTRICAL NETWORK ;~ 1.0 -0 · > Cl - 8 0 . 1 ~ 1 WE I GHT% ...

0 ·~ _J

1 l.O lO -10

- 12 1.0 -12

- 14 I .0E-l4 0 1 2 3 4 () L5 2 CONTENT OF CARBON NANOTUBES (WEIGHT%)

liellt (w ¼)

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National Aeronautics and Space Administration

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Heraeus CL20-11127 Thermally Cured on Fiberglass (195C/1hr due to substrate limitations)

Sample Name Resistance [Ωm] Conductivity [Ωm]^-1

71017G 4.37 x 10-8 2.29 x 107

71017H 5.75 x 10-8 1.74 x 107

Heraeus CL20-11127 Thermally Cured on Vespel (300C/1hr)

72117A 4.12 x 10-8 2.42 x 107

Heraeus CL20-11127 Photonically Cured

71017A 4.89 x 10-8 2.05 x 107

71017B 4.55 x 10-8 2.20 x 107

71017C 6.04 x 10-8 1.65 x 107

DuPont CB028 Thermally Cured on Fiberglass (150C/1hr)

032917-6 2.82 x 10-8 3.54 x 107

Thermal/Oven

Curing

Photonic SinteringInvestigating the use for photonic sintering for printed silver inks.

• Rapid post processing of conductive patterns

• Few second to minute processing times without

damaging/heating the substrate

Photonic Sintering for

high through-put

Advanced Sintering Processes for

Higher Electrical Conductivity

Resistivity greatly improved from 8 ohm in

green state to 1.8 ohm after photonic sintering.

Potential, further optimization by investigating

offset distance, kV setting, pulses, duration

and nano-sized silver particles.

28

Xenon lamp

camera

Fiber optic light guide

llll Xenon lamp light

~ Deposited nanoparticles

••••• !Subsbalel

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Direct Printed Silver Coils - High Current Test

Temperature capability far exceeds that

of the baseline motor which is 180C.

Temperature decreases with extended heat

potentially due to self sintering and decreasing

resistance within the paste traces.

29

350

325

300

275

250

225

u -;- 200 ... ::l ~ 175 ... QI e 1so t2!

125

100

75

so

2S

0 2

• Temperature Observation Over Time with Varying Current

FlrstlO min

25A

10A

SA

4 s 6 8 9 lO 20 30 so 60

Time (Min)

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AFRC prop motor testing:

- Baseline motor

- Motor Version 1: Structural LaRC parts -

rotors and housing

GRC motor testing in a dynamometer:

- Baseline motor

- Motor Version 2: Structural LaRC parts -

rotors, housing, finned cooling ring

Baseline

Motor

V1. Motor

V2.

Motor

Dynamometer

Prop Test Stand

Testing of Motor Configurations

30

Mass =

1968 g

Mass = 1870 g

(5% less mass)

Total heat sink

mass = 92 g

Mass = 1833 g

(7% less mass)

NASA G RC Dyna Avg Motor Efficiency vs Avg Torque

105

95 ' 85 - 3000 RPM '?ft. > u 75 - 4000 RPM C: a,

65 ·.; :f - 5000 RPM w

55

45 - 6000 RPM

35 - 7500 RPM

0 2 4 6 8 10

Torque (N-M)

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Summary and Conclusions

Summary

• Good progress is being made in applying additive manufacturing methods to the

fabrication of components for turbine engine and electric motors.

• LOM offers continuous fiber reinforced CMCs while the binder jet method offers short

fiber reinforced SiC-based ceramics.

• AM offers the potential for electric motors with much higher efficiencies and power

densities.

• Additive manufacturing technologies were demonstrated to be capable of enabling

new innovative direct printed stator designs for electric motors.

• New electric motor component designs will offer performance gains through such

improvements as lighter weights, higher coil packing, higher coil electrically

conductive, higher temperature operation, and higher magnetic flux.

31

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The CAMIEM Team and AcknowledgementsSupport provided by the Convergent Aeronautics Solutions Project

within the ARMD Transformative Aeronautics Concepts Program.

Also Summer Interns at GRC (Anton Salem and Hunter Leonard) and LaRC.

Organization Name Role Organization Name Role

Glenn Research

Center

Michael Halbig (POC) PI and GRC POC

Armstrong Flight Research

Center

Ethan Niemen (POC) AFRC POC and ground testing

Mrityunjay "Jay" Singh Additive manufacturing

Otto Schnarr IIIElectric propulsion ground

testingValerie Wiesner Kirsten Fogg

Greg Piper / Daniel Gorican AM /Direct printing Patricia Martinez

Derek Quade Dynamometer

Langley Research Center

Samuel Hocker (POC) Additive manufacturing

Steven Geng Motors and magnets Christopher Stelter

Chip Redding Design Russell “Buzz” Wincheski NDE

Chun-Hua “Kathy" Chuang Insulator materials Stephen Hales Materials evaluation

Peter Kascak Electric Motors John Newman Computational materials

Jeff Chin System benefitsUniversity of Texas El Paso

Jose Coronel (POC)Stator winding and cooling

efficiencyLaunchPointTechnologies

Michael Ricci (POC)Baseline & innovative

motor designs

David Espalin

Brian Clark Ryan Wicker

Dave Paden

32

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