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A New Architecture for Parallelization of Complex Spacecraft Trajectory Optimization Scans

This paper describes CopScanner, a new component of the Copernicus ecosystem for spacecraft trajectory design and optimization. CopScanner is a Python library being developed at the NASA JSC which enables easy parallelization of Copernicus scans. CopScanner is currently being developed and implemented for production of Copernicus trajectory scans for upcoming Artemis Missions (Artemis II and beyond). On the backend, CopScanner utilizes Dask, an open-source Python library for parallel computing which enables parallelization over both multi-core local machines and large-scale distributed computing clusters. CopScanner abstracts the trajectory scanning process into a DAG which is constructed using a chain of individual subscans. Each node in the DAG executes a python module, called the callable, for which there are built-in defaults, or users may specify their own. Support for custom callables makes CopScanner a versatile trajectory optimization software. All output files and associated metadata from a CopScanner scan are compressed and stored in a two-file output, collectively called the FileStore, consisting of a SQLite database and a compressed JSON MessagePack file, for which CopScanner provides a Python class for interaction.

Quentin Moore↗
NASA NTRS2024

Current Status of Martian Moons eXploration (MMX) Contamination Control and Curation Activity

Martian Moons eXploration (MMX) is a sample return mission from the Martian moon Phobos. The MMX spacecraft is scheduled to launch in 2026 and return to Earth in 2031. The main science goals of MMX are “to reveal the origin of the Martian moons and make progress in the understanding of planetary system formation and material transport in the solar system, and to observe processes that impact the circumplanetary and surface environments of Mars”. MMX has two sampling systems: coring (C)-sampler and pneumatic (P)-sampler and plans to bring back >10 g of Phobos sample. The retuned sample in the sample capsule will be transferred to the curation facility in ISAS/JAXA for sample curation and subsequent sample analysis. Contamination control of the sample return mission requires special care to prevent terrestrial contamination to the spacecraft, which would ruin the scientific value of the returned sample. Retaining the pristineness of the retuned sample is an important task of the MMX Curation and Sampler Science teams. The basis of the contamination control is (1) to minimize and understand the nature and amount of contaminants, (2) to perform contamination assessment and evaluate the effect of contaminants in the spacecraft on the retuned sample, (3) to employ a contamination knowledge (CK) material coupon in the spacecraft to identify the contaminants in the returned samples. In the MMX contamination control plan, the allowable contamination level for each contaminant is carefully defined. They are mostly set to be 1/1000 of the expected amount of each material in the returned sample and are divided into two main categories: organic and inorganic. The allowable atmospheric leakage rate to the sample container is also defined. The allowable contamination level of the organic materials is based on the composition of carbonaceous chondrites. The target contaminants are amino acids, aliphatic and aromatic hydrocarbons, carboxylic acids, etc. In case of the inorganic materials, the target contaminants are important elements to permit distinguishing the origin of the Martian moon by nucleosynthetic isotope anomalies (Cr, Ti, and Mo) and to reveal the evolution of the Martian moon by chronology (Hf, W, U, Pb, Rb, Sr, Sm, and Nd). The key instrument of contamination control in the sample return mission is the sampler system. The C-sampler has been developed by JAXA and the P-sampler was provided by Honeybee/NASA. In MMX, materials used in the two samplers (C- and P- sampler) were carefully selected to avoid potential contamination from the design stage of the system. The individual parts of the C-sampler FM (Flight Model) were thoroughly cleaned at the curation facility in ISAS/JAXA by the full-course cleaning procedure, which is an ultrasonic cleaning with organic solvents and ultrapure water in several steps. The equivalent level of cleaning was also carried out on the P-Samper FM as well by Honeybee Robotics in the USA. Now, MMX is in the critical phase for contamination control called ATLO: Assembly, Test, and Launch Operations. During the ATLO phase, sampler FM is constantly purged with nitrogen gas and maintained at positive pressure to prevent environmental contamination. The surrounding environments of the sampler FM are also simultaneously monitored using the CK Monitoring Coupon Set, which consists of several witness materials such as a glass petri dish, sapphire glass disk, and carbon adhesive tape (Figure 1). The detailed environmental assessment of each clean room used for the assembly and test of the sampler FM has also been conducted. This assessment includes microbial analysis, which was performed for OSIRIS-REx. Regarding the sample recovery and sample curation, we have started the designing of Sample Container Disassembling Instrument for the sample recovery from the sample container and the MMX curation chamber for sample curation. The curation protocol for the Phobos returned sample has also been discussed by the MMX Sample Analysis Working Team (SAWT). The MMX curation protocol consists of three phases: (1) quick analysis, (2) pre-basic characterization, and (3) basic characterization. (1) is extraction of the sample gas from the sample container and analysis by mass spectrometry, (2) is observation in bulk level, and (3) is observation in grain level and allocation of the sample aliquots. In parallel with the curation protocol, the returned sample undergoes preliminary examination for scientific investigations to achieve science goals. In addition, the CK witness plates made of sapphire glass are on board the sampler system. The CK witness plates will be recovered from the sampler system and analyzed by SAWT for the assessment of in-flight contamination.

Haruna Sugahara↗
NASA NTRS1985

The problem of the Earth's CO2 content and the iron core

The near absence of metallic iron and the presence of magnetite and FeS in the C-1 chondrites imply that metallic iron was a minor phase present during the accretion process that formed the C-1 chondrites. If the C-1 chondrites provided the bulk of the initial planetary growth materials, the carbon reduction model is favored. The above estimates suggest that some 1240 to 227 times as much CO2 may have been produced during the formation of the core than can be accounted for in the crust and mantle. This discrepancy taken to the extreme suggests either that: (1) the Earth has lost more than 99 percent of its initial CO2 during early differentiation (this is highly unlikely) or: (2) the Earth has acquired some 90 percent of its present mass by the accretion of debris from previously reduced and differentiated but subsequently disrupted planetary bodies whereby the associated CO2 would not be captured, or: (3) the C-1 chondrites represent only a trivial fraction of the initial accretion materials present in the nebular cloud or: (4) condensed iron and anhydrous silicate phases were preferentially accreted during the initial formation of the planetary bodies.

Devore, G. W.↗
DOE OSTI2022

Block-structured, equal-workload, multi-grid-nesting interface for the Boussinesq wave model FUNWAVE-TVD (Total Variation Diminishing)

Abstract. We describe the development of a block-structured, equal-CPU-load (central processing unit), multi-grid-nesting interface for the Boussinesq wave model FUNWAVE-TVD (Fully Nonlinear Boussinesq Wave Model with Total Variation Diminishing Solver). The new model framework does not interfere with the core solver, and thus the core program, FUNWAVE-TVD, is still a standalone model used for a single grid. The nesting interface manages the time sequencing and two-way nesting processes between the parent grid and child grid with grid refinement in a hierarchical manner. Workload balance in the MPI-based (message passing interface) parallelization is handled by an equal-load scheme. A strategy of shared array allocation is applied for data management that allows for a large number of nested grids without creating additional memory allocations. Four model tests are conducted to verify the nesting algorithm with assessments of model accuracy and the robustness in the application in modeling transoceanic tsunamis and coastal effects.

Choi, Young-Kwang↗
DOE OSTI2021

Possible impacts of molten salt reactors on the International Monitoring System

Molten salt reactors (MSRs) are gaining support as many countries look for ways to increase power generation and replace aging nuclear energy production facilities. MSRs have inherently safe designs, are scalable in size, can burn transuranic wastes from traditional solid fuel nuclear reactors, can store excess heat in thermal reservoirs for water desalination, and can be used to produce medical isotopes as part of the real-time liquid-fuel recycling process. The ability to remove 135 Xe in real time from the fuel improves the power production in an MSR because 135 Xe is the most significant neutron-absorbing isotope generated by nuclear fission. Xenon-135, and other radioactive gases, are removed by sparging the fuel with an inert gas while the liquid fuel is recirculated from the reactor inner core through the heat exchangers. Without effective abatement technologies, large amounts of radioactive gas could be released during the sparging process. This work examines the potential impact of radioxenon releases on samplers used by the International Monitoring System (IMS) to detect nuclear explosions. Here, atmospheric transport simulations from seven hypothetical MSRs on different continents were used to evaluate the holdup time needed before release of radioxenon so IMS samplers would register few detections. Abatement technologies that retain radioxenon isotopes for at least 120 d before their release will be needed to mitigate the impacts from a molten salt breeder reactor used to replace a nuclear power plant. A holdup time of about 150 d is needed to reduce emissions to the average level of current nuclear power plants.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2023

Fabrication of engineered dopant profiles in Er/Lu:YAG transparent laser ceramics via additive manufacturing

Transparent ceramic Er:YAG laser rods were fabricated via the direct ink write (DIW) method with engineered doping profiles featuring an Er-doped core with endcaps and core-clad structures. Laser rods up to 11 cm in length were produced which required development of a scalable process. To achieve this, multiple improvements were implemented, including printing the rods horizontally on a substrate, rather than vertically, eliminating the need for an external support structure and using a sacrificial drying layer to mitigate warping and defects. Highly transparent rods were achieved with optical scatter levels as low as 0.5%/cm (at 543 nm). A small refractive index difference of 5.7 ppm was measured at the interface between the Er-doped core and the Lu-doped endcaps and cladding. These results demonstrate DIW as a straightforward method for making good optical quality laser rods with engineered doping profiles to improve laser performance.

36 MATERIALS SCIENCE↗
NASA NTRS2003

Radiated Sound Power from a Curved Honeycomb Panel

The validation of finite element and boundary element model for the vibro-acoustic response of a curved honeycomb core composite aircraft panel is completed. The finite element and boundary element models were previously validated separately. This validation process was hampered significantly by the method in which the panel was installed in the test facility. The fixture used was made primarily of fiberboard and the panel was held in a groove in the fiberboard by a compression fitting made of plastic tubing. The validated model is intended to be used to evaluate noise reduction concepts from both an experimental and analytic basis simultaneously. An initial parametric study of the influence of core thickness on the radiated sound power from this panel, using this numerical model was subsequently conducted. This study was significantly influenced by the presence of strong boundary condition effects but indicated that the radiated sound power from this panel was insensitive to core thickness primarily due to the offsetting effects of added mass and added stiffness in the frequency range investigated.

Robinson, Jay H.↗
DOE OSTI2019

Fabrication and Characterization of Core–Shell Density-Graded 316L Stainless Steel Porous Structure

In the present work, cylindrical shape 316 L cellular structure with different densities in its core and outer layer (shell) is fabricated by using carbamide as a space holder, via powder metallurgy route and layer-by-layer technique. The arrangement of the created pore is the same as face-centered cubic atomic structure, and different densities are created in two regions by using carbamide particles having two different sizes in the range of 1.7-2 and 2-2.4 mm. The effect of creating a structure with higher porosity (64.5%) in the core and lower porosity (53.8%) in the shell and vice versa and also change in the ratio of the core to the cylinder cross-sectional areas, on the mechanical properties and compaction load bearing of the fabricated foam samples were investigated. In leaching process of the carbamide particles, as an important step of porous structure’s fabrication, it is shown that discontinuous leaching process is more favorable than continuous, by which it would be possible to remove more carbamide particles (around 20%) at the same time. Furthermore, the deformation of the density-graded foam shows the parallel mechanism in the core and shell sections, and the contribution of each part depends on its density and thickness. The energy absorption behavior of the fabricated specimens is evaluated optimally in terms of the energy absorption value associated with the ideal adsorption behavior. The maximum ideal energy absorption efficiency for the samples with more porosity in the shell was approximately equal to 0.91, while for the sample includes the lower amount of porosity in the shell, this value was in the range of 0.85 and 0.89.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Bioregenerative technologies for waste processing and resource recovery in advanced space life support system

The Controlled Ecological Life Support System (CELSS) for producing oxygen, water, and food in space will require an interactive facility to process and return wastes as resources to the system. This paper examines the bioregenerative techologies for waste processing and resource recovery considered for a CELSS Resource Recovery system. The components of this system consist of a series of biological reactors to treat the liquid and solid material fractions, in which the aerobic and anaerobic reactors are combined in a block called the Combined Reactor Equipment (CORE) block. The CORE block accepts the human wastes, kitchen wastes, inedible refractory plant materials, grey waters from the CELLS system, and aquaculture solids and processes these materials in either aerobic or anaerobic reactors depending on the desired product and the rates required by the integrated system.

Chamberland, Dennis↗
DOE OSTI2025

A Versatile Simulated Data Transport Layer for in Situ Workflows Performance Evaluation

In situ processing does not only allow scientific applications to face the explosion in data volume and velocity but also to address the time constraints of many simulation-analysis workflows by providing scientists with early insights about their applications at runtime. Multiple frameworks implement the concept of a data transport layer (DTL) to enable such in situ workflows. These tools are very versatile, directly or indirectly access the data generated on the same node, another node of the same compute cluster, or a completely distinct node, and allow data publishers and subscribers to run on the same computing resources or not. This versatility puts on researchers the onus of taking key decisions related to resource allocation and how to transport data to ensure the most efficient execution of their in situ workflows. However, domain scientists and workflow practitioners lack the appropriate tools to assess the respective performance of particular design and deployment options. In this paper we introduce a versatile simulated DTL designed to provide researchers with insights on the respective performance of different execution scenarios of in situ workflows. This open-source, standalone library builds on the SimGrid toolkit and can be linked to any SimGrid-based simulator. It facilitates the evaluation of the performance behavior, at scale, of different data transport configurations and the study of the effects of resource allocation strategies. We demonstrate the scalability, versatility, and accuracy of this simulated DTL by reproducing the execution of two synthetic benchmarks and of a real-world in situ workflow composed of an MPI application and a parallel data analysis. Results of simulations run on a single core show that the proposed library can simulate the interactions of tens of thousands of simulated processes deployed on two interconnected commodity clusters in a few seconds, and the execution by a thousand simulated processes of an in situ workflow in less than three minutes.

Suter, Fred [ORNL] (ORCID:0000000319021955)↗
DOE OSTI2019

A novel chlorophyll protein complex in the repair cycle of photosystem II

In oxygenic photosynthetic organisms, photosystem II (PSII) is a unique membrane protein complex that catalyzes light-driven oxidation of water. PSII undergoes frequent damage due to its demanding photochemistry. It must undergo a repair and reassembly process following photodamage, many facets of which remain unknown. We have discovered a PSII subcomplex that lacks 5 key PSII core reaction center polypeptides: D1, D2, PsbE, PsbF, and PsbI. This pigment–protein complex does contain the PSII core antenna proteins CP47 and CP43, as well as most of their associated low molecular mass subunits, and the assembly factor Psb27. Immunoblotting, mass spectrometry, and ultrafast spectroscopic results support the absence of a functional reaction center in this complex, which we call the “no reaction center” complex (NRC). Analytical ultracentrifugation and clear native PAGE analysis show that NRC is a stable pigment–protein complex and not a mixture of free CP47 and CP43 proteins. NRC appears in higher abundance in cells exposed to high light and impaired protein synthesis, and genetic deletion of PsbO on the PSII luminal side results in an increased NRC population, indicative that NRC forms in response to photodamage as part of the PSII repair process. Our finding challenges the current model of the PSII repair cycle and implies an alternative PSII repair strategy. Formation of this complex may maximize PSII repair economy by preserving intact PSII core antennas in a single complex available for PSII reassembly, minimizing the risk of randomly diluting multiple recycling components in the thylakoid membrane following a photodamage event.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Important Human Actions for Advanced Reactors: Implications for Human Factors

As advanced reactor platforms continue to develop and gain traction in the energy sector there is a need for risk-informed, scalable regulations that match that progress. This is a core component of the U.S. Nuclear Regulatory Commission’s proposed Part 53 Rule Making; the Accelerating Deployment of Versatile, Advanced Nuclear for Clean Energy (ADVANCE) Act; and other efforts that seek to update nuclear power regulations. This paper covers one key aspect of that regulatory evolution: Important Human Actions (IHA). In this paper, we discuss how the understanding and definitions of IHAs have changed and what that means for human factors engagement through the process of developing these technologies. Instead of a narrow focus on control actions that led to an increase in core damage risk, the new focus is on IHAs is “wherever they occur.” What this means is that having a highly automated or passive safety system does not eliminate IHAs. Rather, it shifts the focus point to all the actions that enable these systems. Everything from maintenance, to design, to training can be considered an IHA and that dramatically shifts the efforts and level of engagement necessary for human factors to enable these technologies. We discuss the notions of risk-informed human factors that underpin these efforts, give several examples, and briefly describe the risk assessment methodologies that will be needed. In the past, IHAs were identified and then became a focus point of human factors engineering (HFE) activities to ensure a robust evaluation of the task was completed. The future is less clear. HFE for nuclear energy will need to evolve and become more integrated in technology development than ever before.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

THE DYNAMICAL EVOLUTION OF STELLAR BLACK HOLES IN GLOBULAR CLUSTERS

Our current understanding of the stellar initial mass function and massive star evolution suggests that young globular clusters (GCs) may have formed hundreds to thousands of stellar-mass black holes (BHs), the remnants of stars with initial masses from ∼20-100 M {sub ☉}. Birth kicks from supernova explosions may eject some BHs from their birth clusters, but most should be retained. Using a Monte Carlo method we investigate the long-term dynamical evolution of GCs containing large numbers of stellar BHs. We describe numerical results for 42 models, covering a broad range of realistic initial conditions, including up to 1.6 × 10{sup 6} stars. In almost all models we find that significant numbers of BHs (up to ∼10{sup 3}) are retained all the way to the present. This is in contrast to previous theoretical expectations that most BHs should be ejected dynamically within a few gigayears The main reason for this difference is that core collapse driven by BHs (through the Spitzer {sup m}ass segregation instability{sup )} is easily reverted through three-body processes, and involves only a small number of the most massive BHs, while lower-mass BHs remain well-mixed with ordinary stars far from the central cusp. Thus the rapid segregation of stellar BHs does not lead to a long-term physical separation of most BHs into a dynamically decoupled inner core, as often assumed previously. Combined with the recent detections of several BH X-ray binary candidates in Galactic GCs, our results suggest that stellar BHs could still be present in large numbers in many GCs today, and that they may play a significant role in shaping the long-term dynamical evolution and the present-day dynamical structure of many clusters.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2017

HEP Analysis Ecosystem Workshop Report

Over the past 20 years the HEP community has developed and gravitated around an analysis ecosystem centered on ROOT. ROOT and its ecosystem both dominate HEP analysis and impact the full event processing chain, providing foundation libraries, I/O services etc. that have prevalence in the field. The analysis tools landscape is however evolving in ways that can have a durable impact on the analysis ecosystem and a strong influence on the analysis and core software landscape a decade from now, a timescale currently in an intensive planning round with the HEP Software Foundation(HSF) Community White Paper process. Data intensive analysis is growing in importance in other sciences and in the wider world. Powerful tools and new development initiatives, both within our field and in the wider open source community, have emerged. Creative developers have an ever more powerful open source toolkit available and are applying it towards innovations that leverage both open source and the ROOT ecosystem. ROOT itself is approaching a major re-engineering with ROOT 7, leveraging the powerful evolution of C++, with a major overhaul in its interfaces as seen both by its users and by satellite tools in the ROOT ecosystem.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2015

TESTING THE ROLE OF SNe Ia FOR GALACTIC CHEMICAL EVOLUTION OF p-NUCLEI WITH TWO-DIMENSIONAL MODELS AND WITH s-PROCESS SEEDS AT DIFFERENT METALLICITIES

The bulk of p isotopes is created in the ''gamma processes'' mainly by sequences of photodisintegrations and beta decays in explosive conditions in Type Ia supernovae (SNIa) or in core collapse supernovae (ccSN). The contribution of different stellar sources to the observed distribution of p-nuclei in the solar system is still under debate. We explore single degenerate Type Ia supernovae in the framework of two-dimensional SNIa delayed-detonation explosion models. Travaglio et al. discussed the sensitivity of p-nuclei production to different SNIa models, i.e., delayed detonations of different strength, deflagrations, and the dependence on selected s-process seed distributions. Here we present a detailed study of p-process nucleosynthesis occurring in SNIa with s-process seeds at different metallicities. Based on the delayed-detonation model DDT-a of TRV11, we analyze the dependence of p-nucleosynthesis on the s-seed distribution obtained from different strengths of the {sup 13}C pocket. We also demonstrate that {sup 208}Pb seed alone changes the p-nuclei production considerably. The heavy-s seeds (140 ≤A < 208) contribute with about 30%-40% to the total light-p nuclei production up to {sup 132}Ba (with the exception of {sup 94}Mo and {sup 130}Ba, to which the heavy-s seeds contribute with about 15% only). Using a Galactic chemical evolution code from Travaglio et al., we study the contribution of SNIa to the solar stable p-nuclei. We find that explosions of Chandrasekhar-mass single degenerate systems produce a large amount of p-nuclei in our Galaxy, both in the range of light (A ≤ 120) and heavy p-nuclei, at almost flat average production factors (within a factor of about three). We discussed in details p-isotopes such as {sup 94}Mo with a behavior diverging from the average, which we attribute to uncertainties in the nuclear data or in SNIa modeling. Li et al. find that about 70% of all SNeIa are normal events. If these are explained in the framework of explosions of Chandrasekhar-mass white dwarfs resulting from the single-degenerate progenitor channel, we find that they are responsible for at least 50% of the p-nuclei abundances in the solar system.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Raptor

Raptor is an efficient Python-based tool for predicting the formation and morphology of stochastic lack of fusion defects in metal AM processes. A major obstacle for the qualification and certification of additively manufactured parts in critical applications continues to be performance variability caused in part by porosity-related defects. High-fidelity process models that could predict these defect features are currently too computationally expensive for component-level analysis. To address this, Raptor employs a high-performance geometric method to model the dynamic melt pool rather than relying on computationally intensive thermal fluid dynamics. This allows Raptor to rapidly identify regions of unmelted material that correspond to lack of fusion pores. The efficiency of this approach significantly reduces the time and resources needed for generating 3D defect predictions, which enables users to conduct large-scale parameter studies and evaluate how process variations affect part quality. The framework offers operational flexibility; users can execute simulations through a simple command line interface or integrate core functions as a library within larger computational workflows. Simulation outputs include 3D porosity maps for visualization and tools for quantitative morphological analysis. These results are suitable for direct comparison with experimental characterization data from methods such as X-ray computed tomography and can be used for statistical process optimization.

Subraveti, Vamsi [Vanderbilt Univ., Nashville, TN ↗
NASA NTRS1999

Monte Carlo Simulation of Nanoparticle Encapsulation in Flames

Two critical challenges facing the application of flames for synthesis of nanopowder materials are: (1) overcoming formation of agglomerates and (2) ensuring that the highly reactive nanopowders that are synthesized in flames can be produced in such a manner that their purity is maintained during subsequent processing. Agglomerates are produced in flames because particle formation occurs in a high temperature and high number density environment. They are undesirable in most advanced applications of powders. For example, agglomerates have a deleterious effect on compaction density, leading to voids when nanopowders are consolidated. Efforts to avoid agglomeration in flames without substantially reducing particle number density and, consequently, production rate, have had limited success. Powder purity must also be maintained during subsequent handling of nanopowders and this poses a significant challenge for any synthesis route because nanopowders, particularly metals and non-oxide ceramic powders, are inherently reactive. Impurities acquired during handling of nanopowders have slowed the advancement of the nanostructured materials industry. One promising approach that has been proposed to address these problems is nano-encapsulation. In this approach, the core particles are encapsulated in a removable material while they are within the flame but before excessive agglomeration has occurred. Condensation can be very rapid so that core particles are trapped within the condensed material and agglomeration is limited. Nano-encapsulation also addresses the handling concerns for post-synthesis processing. Results have shown that when nano-encapsulated powders are exposed to atmosphere the core particles are protected from oxidation and/or hydrolysis. Thus, handling of the powders does not require extreme care. If, for example, at the time of consolidation the encapsulation material is removed by vacuum annealing, the resulting powder remains unagglomerated and free of impurities. In this work, we described a novel aerosol model that has been developed to simulate particle encapsulation in flames. The model will ultimately be coupled to a one-dimensional spherical flame code and compared to results from microgravity flame experiments.

Sun, Z.↗
DOE OSTI2023

Bending and shear improvements in 3D-printed core sandwich composites through modification of resin uptake in the skin/core interphase region

Fused deposition modeling (FDM) printed polymers are rarely used as a structural material due to anisotropic and low mechanical properties compared with conventional composites. In recent years, greater need has been expressed for recycling of materials, such as recyclable FDM, at the end of service life to reduce environmental pollution and manufacture cost. However, how the amount of resin uptake in the skin and skin/core interphase affects the bending and shear performance of the sandwich composites when replacing the low strength and ductile core (conventional core) with a high strength and brittle core (FDM printed PLA (polylactic acid) core) still remains unclear. A new manufacturing routine is needed to improve the incorporation of FDM printed polymers in composite structures. In this work, FDM printed PLA was used as core material and sandwiched between two unidirectional glass fiber reinforced polymer (GFRP) skins to form a sandwich composite by compression-molding (CM) process, which provides a good manufacturing strategy for skin/core interphase modification. The significance of the CM process is proved by investigating the effect of resin uptake on bending and in-plane/out-of-plane shear performances. Current first order shear deformation (FSDT) theory lacks a direct connection between the in-plane shear stress and out-of-shear stress in the core region of sandwich composites. With the help of DIC, a connection between the in-plane shear and the out-of-plane shear strain was built and in-plane shear properties can acquire through out-of-plane shear properties, hence reducing the redundancy of sample preparation or the need for simulation. A significant improvement was found compared with the optimized resin uptake (Optimized resin uptake range: 20.43%–22.86 wt%) 3D-printed PLA core sandwich composite and lowest performance sandwich composite (Improvement: in-plane shear strength (~34%)/modulus (~29%), out-of-plane shear strength (~25%)/modulus (~31%), specific peak bending load (~19%)). Finally, compared with balsa core sandwich composites, the 3D-printed cores are suitable for use in composite sandwich structures in many applications with a satisfactory strength-to-weight ratio.

3D-printed core sandwich composite↗

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