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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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197 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Minimizing Ground Risk in Cellular-Connected Drone Corridors With mmWave Links

Unmanned Aircraft Systems (UASs) have been receiving significant interest and support from academia, industry, and regulatory bodies over the past decade due to their various use cases. To safely integrate UAS operations into the national airspace, particularly overpopulated regions, the risk posed to ground users, buildings, and vehicles due to unmanned aerial vehicle (UAV) flight should be minimized. This risk can be represented by a numerical metric, which we refer to in this article as the “ground risk.” Many UAS applications also depend on the presence of a reliable wireless communication link between the UAV and a control station for the transmission of UAV position, surveillance video, UAV payload commands, and other mission-related data. Such wireless communication requirements also need to be considered in the design of UAS operations. In this article, we consider both these aspects and study the design of nonintersecting trajectories for UAS operations to minimize ground risk, subject to constraints on the wireless signal strength and geometry of the trajectory, specified in terms of: 1) an enclosing cylinder within which the trajectory must lie and 2) an integrated angular change along the UAV's trajectory. The performance of a computationally expensive optimal algorithm is compared with that of a computationally faster heuristic approach within the dense urban environment of Manhattan, NY, USA. Performance evaluation using ray-tracing simulations shows that the heuristic approach performs close to the optimal algorithm at a reduced computation cost. In conclusion, this research can be utilized to make UAS operations safe and reliable and accelerate their adoption.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Perception Testing in Fog for Autonomous Flight

As the path towards Urban Air Mobility (UAM) continues to take shape, there are outstanding technical challenges to achieving safe and effective air transportation operations under this new paradigm. To inform and guide technology development for UAM, NASA is investigating the current state-of-the-art in key technology areas including traffic management, detect-and-avoid, and autonomy. In support of this effort, a new perception testbed was developed at NASA Ames Research Center to collect data from an array of sensing systems representative of those that could be found on a future UAM vehicle. This testbed, featuring a Light-Detection-and-Ranging (LIDAR) instrument, a long-wave infrared sensor, and a visible spectrum camera was deployed for a multiday test campaign in the Fog Chamber at Sandia National Laboratories (SNL), in Albuquerque, New Mexico. During the test campaign, fog conditions were created for tests with targets including a human, a resolution chart, and a small unmanned aerial vehicle (sUAV). Here, this paper describes in detail, the developed perception testbed, the experimental setup in the fog chamber, the resulting data, and presents an initial result from analysis of the data with the evaluation of methods to increase contrast through filtering techniques.

aeronautics↗
DOE OSTI2025

Aircraft in-situ measurements from SOCRATES constrain the anthropogenic perturbations of cloud droplet number

Aerosol-cloud interactions (ACI) in warm clouds alter reflected shortwave radiation by influencing cloud microphysical and macrophysical properties. The variable of state controlling ACI is the cloud droplet number concentration (N d ). Here, we examine the perturbations in N d due to anthropogenic aerosols (ΔN d, PD-PI ) using a perturbed parameter ensemble (PPE) hosted in the sixth Community Atmosphere Model (CAM6). Surrogate models are created for the CAM6 PPE outputs and are used to generate 1 million model variants of CAM6 by sampling 45 sources of parameter uncertainty. The range of uncertain physical parameters related to ACI are constrained with observations of aerosol and cloud properties from SOCRATES. The likely range of uncertain parameters and the associated range of ΔN d, PD-PI are more strongly constrained with observations of N d relative to observations of cloud condensation nuclei. We conduct sensitivity tests of how constraints on ΔN d, PD-PI are affected by systematic uncertainties in observations and our limitations in our surrogate models created for CAM6 PPE outputs. Based on this, we provide guidance on the impact of reducing systematic uncertainty in airborne microphysical observations and in surrogate models.

Song, Ci [Univ. of Wyoming, Laramie, WY (United St↗
DOE OSTI2023

Arctic tropospheric ozone: assessment of current knowledge and model performance

As the third most important greenhouse gas (GHG) after carbon dioxide (CO 2 ) and methane (CH 4 ), tropospheric ozone (O 3 ) is also an air pollutant causing damage to human health and ecosystems. This study brings together recent research on observations and modeling of tropospheric O 3 in the Arctic, a rapidly warming and sensitive environment. At different locations in the Arctic, the observed surface O 3 seasonal cycles are quite different. Coastal Arctic locations, for example, have a minimum in the springtime due to O 3 depletion events resulting from surface bromine chemistry. In contrast, other Arctic locations have a maximum in the spring. The 12 state-of-the-art models used in this study lack the surface halogen chemistry needed to simulate coastal Arctic surface O 3 depletion in the springtime; however, the multi-model median (MMM) has accurate seasonal cycles at non-coastal Arctic locations. There is a large amount of variability among models, which has been previously reported, and we show that there continues to be no convergence among models or improved accuracy in simulating tropospheric O 3 and its precursor species. The MMM underestimates Arctic surface O 3 by 5% to 15% depending on the location. The vertical distribution of tropospheric O 3 is studied from recent ozonesonde measurements and the models. The models are highly variable, simulating free-tropospheric O 3 within a range of ±50% depending on the model and the altitude. The MMM performs best, within ±8% for most locations and seasons. However, nearly all models overestimate O 3 near the tropopause (~300 hPa or ~8 km), likely due to ongoing issues with underestimating the altitude of the tropopause and excessive downward transport of stratospheric O 3 at high latitudes. For example, the MMM is biased high by about 20% at Eureka. Observed and simulated O 3 precursors (CO, NO x , and reservoir PAN) are evaluated throughout the troposphere. Models underestimate wintertime CO everywhere, likely due to a combination of underestimating CO emissions and possibly overestimating OH. Throughout the vertical profile (compared to aircraft measurements), the MMM underestimates both CO and NO x but overestimates PAN. Perhaps as a result of competing deficiencies, the MMM O 3 matches the observed O 3 reasonably well. Our findings suggest that despite model updates over the last decade, model results are as highly variable as ever and have not increased in accuracy for representing Arctic tropospheric O 3 .

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Emerging mobile lidar technology to study boundary layer winds influenced by operating turbines

The development of a microjoule-class pulsed Doppler lidar and deployment of this compact system on mobile platforms such as aircraft, ships, or trucks have opened a new opportunity to characterize the dynamics of complex mesoscale wind flows. The PickUp-based Mobile Atmospheric Sounder (PUMAS) truck-based lidar system was recently used during the American Wake Experiment (AWAKEN) to assess the general structure of boundary layer (BL) wind and turbulence around wind turbines in central Oklahoma. Wind speed profiles averaged over PUMAS transects influenced by the operating turbines (waked flow) show a 1–2 m s −1 reduction compared to mean undisturbed (free flow) wind speed profiles. Spatial variability in wind speed was observed in time–height cross-sections at different distances from turbines. The wind speeds were about 9–12 m s −1 at 6 km distance compared to 5–7 m s −1 at the transects near the turbines. The PUMAS dataset from AWAKEN demonstrated the capability of the mobile Doppler lidar system to document spatial variability in wind flows at different distances from wind turbines and obtain quantitative estimates of wind speed reduction in the waked flow. The high-frequency, simultaneous measurements of the horizontal and vertical winds provide a new approach for characterizing dynamic processes critical for wind farm wake analyses.

17 WIND ENERGY↗
DOE OSTI2026

Low-Rate Cycling Regeneration Sustains NMC811–Graphite Battery Performance through Extreme Ultrafast Charging

Urban air mobility (UAM) systems, such as electric vertical takeoff and landing (eVTOL) aircraft, require batteries capable of extreme ultrafast charging to support high-frequency operations. Here, in this work, we evaluate the electrochemical stability of NMC811–graphite full cells using a complex mixed-modal protocol designed to simulate the aggressive turnaround demands of UAM missions. We demonstrate that incorporating a periodic low-rate (0.3C) “regeneration” cycle enables cells to maintain 96% capacity retention over 900 cycles, despite repeated exposure to ultrafast pulses. To validate the efficacy of this regeneration mechanism, we performed simplified control experiments comparing continuous 10C charging against a 10C–0.3C interleaved protocol. Advanced characterization reveals that while mechanical particle fracture is pervasive at these rates, the regeneration cycles decelerate the electrochemical degradation by resolving spatially heterogeneous Ni oxidation states and relaxing lithium-ion concentration gradients. These findings provide a vital mechanistic framework for battery operation, proving that restorative charging can effectively delay and mitigate failure in demanding UAM applications.

batteries↗
DOE OSTI2024

Fragmentation in Collisions of Snow with Graupel/Hail: New Formulation from Field Observations

Abstract Secondary ice production (SIP) has been attributed to the generation of most ice particles observed in precipitating clouds with cloud tops warmer than −36°C, from various aircraft- and ground-based field observations across the globe. One of the known SIP mechanisms is fragmentation during collisions among ice particles. It has been studied with our theoretical formulation, which has been applied in microphysical schemes of atmospheric models in a few studies. These have predicted an extensive impact on cloud glaciation and radiative properties. However, there has been a lack of experimental field studies, especially involving naturally falling snowflakes, to better understand this particular mechanism of SIP. This study reports the first field measurements with modern technology for fragmentation during collisions between naturally falling snowflakes and graupel/hail particles. This was observed with an innovatively designed portable chamber that was deployed outdoors in northern Sweden. Applying the observations from this field-based study, we optimized the existing formulation for predicting numbers of fragments from collisions of snow with graupel/hail. The observations show the average numbers of fragments per collision for dendritic (3–12 mm) and nondendritic (1–3 mm) snow were about 12 and 1, respectively. This represents a boost of predicted fragment numbers relative to our original formulation published in 2017. The updated formulation for breakup in ice–ice collisions can be implemented in the microphysical schemes of atmospheric models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Strong Sensitivity of Simulated Biomass Burning Aerosol Transport and Radiative Effects Over the South Atlantic to Carbonaceous Aerosol Aging and Particle Density

Biomass burning aerosol (BBA) impacts climate through aerosol‐cloud‐radiation interactions, but models disagree on the sign and magnitude of BBA radiative effects. We quantify the sensitivity of BBA radiative effects and transport to three BBA‐relevant processes and properties: parameterized oxidative aging of organic aerosol (OA), a combined change to black carbon (BC) density and the method for calculating aerosol refractive index, and reduction in OA density. We evaluate Unified Model simulations against two aircraft campaigns from summer 2017 over the Southeast Atlantic. The model generally performs well, such that discrepancies between the observational data sets may sometimes limit the precision of the evaluation. Our newly developed aging parameterization reproduces observed OA:BC mass ratios well and allows modeled OA:BC to decrease with smoke age, but increases bias in aerosol extinction and changes the BBA radiative effect little (+0.12 W m -2 ). We calculate aerosol refractive index using either a volume‐weighted component average or the Maxwell‐Garnett (MG) mixing assumption, which represents BC as small inclusions in a host material. Compared to MG mixing, the volume‐weighted average refractive index and reduced BC density increase aerosol absorption, substantially increasing the total BBA radiative effect (+2.66 W m -2 ) and amount of BBA transported across the ocean through BC self‐lofting. Reducing OA density to better match literature values changes the total BBA radiative effect by −1.96 W m -2 . Changes to direct radiative effects exceed changes to cloud radiative effects. Our findings emphasize the sensitivity of aerosol radiative effects and transport to these processes and properties, which we suggest could be improved in climate models.

Southeast Atlantic↗
DOE OSTI2026

A Model Intercomparison Study to Investigate Mixing Characteristics in Non‐Precipitating Stratocumulus Clouds

Recent aircraft observations of marine stratocumulus clouds consistently showed that cloud microphysical relationships vary with altitude, indicating inhomogeneous mixing characteristics near cloud top and homogeneous mixing characteristics in mid-levels of clouds. Here, we conduct model intercomparison of an idealized, non-precipitating stratocumulus cloud to evaluate model consistency and examine whether simulations can reproduce the observed mixing characteristics. The results show that eleven large-eddy simulations with various dynamics and microphysics schemes show good agreement on the thermodynamical, microphysical, and dynamical properties of the stratocumulus-topped boundary layer in a steady state. The inter-model spread in steady-state liquid water path is significantly reduced compared to previous model intercomparison studies. This improvement might be due to better models and more consistent initial conditions than those used decades ago. In addition, most simulations, including a low-dimensional simulation, capture inhomogeneous mixing characteristics near the cloud top and homogeneous mixing characteristics inside the cloud. Moreover, simulations using Lagrangian microphysics schemes agree better with the observed mixing characteristics compared with those using the bin microphysics schemes. Since most simulations do not fully resolve the entrainment process, the apparent mixing characteristics arise from the variations in the resolved cloud properties. Our results support the vertical circulation mixing hypothesis, which suggests that homogeneous mixing characteristics in mid-levels of clouds are due to the vertical circulation of entrainment-affected and diluted parcels from the cloud top moved to lower levels.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

CACTI ARM Aerial Facility Measurements of Ice Nucleating Particles

The dataset comprises measures, using Colorado State University's Ice Spectrometer (IS, an immersion freezing device with a range from 0°C down to -26 to -29°C) of atmospheric ice nucleating particle (INP) concentrations taken on the Atmospheric Radiation Measurement (ARM) program Aerial Facilty (AAF) G-1 aircraft. INP measurements on the G-1 were collected from varied altitudes on different flights over the region of the Sierras de Córdoba mountain range of north-central Argentina, centred over ARM's Mobile Facility (AMF-1) near Villa Yacanto, where ground-based INP measures were being taken concurrently. Both studies took place as part of the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) Experiment. A filter sampling system was deployed on the G-1 to collect aerosol particles for post-processing of INPs collected on filters (measuring their immersion freezing ability) once returned to Colorado State University (CSU). Filter holders used were pre-cleaned aluminum in-line units loaded with pre-cleaned and pre-sterilized 47 mm dia. Nuclepore polycarbonate filters (0.2 mm pore size). Filters were drawn for varied times, resulting in varied volumes collected (51 to 1667 SL). Mass flow rate was recorded in real-time so that total sampled volume (at standard temperature and pressure) could be determined. A total of 34 sample filters were collected over the IOP, including 5 blanks. Filters were stored at -20°C freezer prior to frozen return to Colorado State University (CSU). . Processing to obtain spectra of INP number concentration active via the immersion freezing mechanism versus temperature was conducted using CSU's IS instrument (McCluskey et al., 2018). For measurment of INPs, collected aerosol particles were re-suspended in 7 mL of 0.02 µm-filtered deionized water. Aliquots of each suspension, and serial dilutions, were dispensed into trays which were fit into aluminum blocks in the IS. Samples are cooled at 0.33°C min-1 and the freezing temperatures of wells recorded automatically. Cumulative INP concentrations were determined by first calculating the INPs per mL of suspension based on Vali (1971) and then converting to concentration per standard liter of air using the proportion of the total liquid sample dispensed and the air sample volumes. Aliquots of suspensions from selected samples were also heat treated (95°C for 20 min) to denature and deactivate biological INPs, and digested in 10% H2O2 at 95°C under UV-B to remove all organic carbon INPs. McCluskey, C. S., J. Ovadnevaite, M. Rinaldi, J. Atkinson, F. Belosi, D. Ceburnis, S. Marullo, T. C. J. Hill, U. Lohmann, Z. A. Kanji, C. O’Dowd, S. M. Kreidenweis, P. J. DeMott, 2018: Marine and Terrestrial Organic Ice Nucleating Particles in Pristine Marine to Continentally-Influenced Northeast Atlantic Air Masses, Journal of Geophysical Research: Atmospheres, 123, 6196–6212, https://doi.org/10.1029/2017JD028033. Vali, G., 1971: Quantitative evaluation of experimental results on the heterogeneous freezing nucleation of supercooled liquids. J. Atmos. Sci., 28, 402–409.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Coupled Air Quality and Boundary-Layer Meteorology in Western U.S. Basins during Winter: Design and Rationale for a Comprehensive Study

The wintertime episodes of high aerosol concentrations occur frequently in urban and agricultural basins and valleys worldwide. These episodes often arise following development of persistent cold-air pools (PCAPs) that limit mixing and modify chemistry. While field campaigns targeting either basin meteorology or wintertime pollution chemistry have been conducted, coupling between interconnected chemical and meteorological processes remains an insufficiently studied research area. Gaps in understanding the coupled chemical–meteorological interactions that drive high-pollution events make identification of the most effective air-basin specific emission control strategies challenging. To address this, a September 2019 workshop occurred with the goal of planning a future research campaign to investigate air quality in western U.S. basins. Approximately 120 people participated, representing 50 institutions and five countries. Workshop participants outlined the rationale and design for a comprehensive wintertime study that would couple atmospheric chemistry and boundary layer and complex-terrain meteorology within western U.S. basins. Participants concluded the study should focus on two regions with contrasting aerosol chemistry: three populated valleys within Utah (Salt Lake, Utah, and Cache Valleys) and the San Joaquin Valley in California. This paper describes the scientific rationale for a campaign that will acquire chemical and meteorological datasets using airborne platforms with extensive range, coupled to surface-based measurements focusing on sampling within the near-surface boundary layer, and transport and mixing processes within this layer, with high vertical resolution at a number of representative sites. No prior wintertime basin-focused campaign has provided the breadth of observations necessary to characterize the meteorological–chemical linkages outlined here, nor to validate complex processes within coupled atmosphere–chemistry models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Observationally constrained analysis on the distribution of fine- and coarse-mode nitrate in global models

Nitrate plays an important role in the Earth system and air quality. A key challenge in simulating the life cycle of nitrate aerosol in global models is to accurately represent mass size distribution of nitrate aerosol. In this study, we evaluate the performance of the Energy Exascale Earth System Model version 2 (E3SMv2) and the Community Earth System Model version 2 (CESM2), along with Aerosol Comparisons between Observations and Models (AeroCom) phase III models, in simulating spatial distribution of fine-mode nitrate, the mass size distribution of fine- and coarse-mode nitrate, and the gas–aerosol partitioning between nitric acid gas and nitrate, using long-term ground-based observations and measurements from multiple aircraft campaigns. We find that most models underestimate the annual mean PM 2.5 (particulate matter with diameter less than 2.5 µm) nitrate surface concentration averaged over all sites. The observed nitrate PM 2.5 / PM 10 and PM 1 / PM 4 ratios are influenced by the relative contribution of fine sulfate or organic particles and coarse dust or sea salt particles. Overall, the ground-based observations give an annual mean surface nitrate PM 2.5 / PM 10 ratio of 0.7. Most models underestimate the annual mean PM 2.5 / PM 10 ratio in all regions. There are large spreads in the modeled nitrate PM 1 / PM 4 ratios, which span the full range from 0 to 1. Most models underestimate the surface molar ratio of nitrate to total inorganic nitrate averaged across all sites. Our study indicates the importance of gas–aerosol partition parameterization and the simulation of dust and sea salt in correctly simulating the mass size distribution of nitrate.

Nitrate↗
DOE OSTI2025

The NASA ACTIVATE Mission

The NASA Aerosol Cloud Meteorology Interactions over the Western Atlantic Experiment (ACTIVATE) conducted 162 joint flights with two aircraft over the northwest Atlantic to study aerosol–cloud interactions (ACIs), which represent the largest uncertainty in estimating total anthropogenic radiative forcing. The combination of a high-flying King Air and low-flying HU-25 Falcon, equipped with remote sensing and in situ instruments, characterized trace gases, aerosol particles, clouds, and meteorological variables with data collected nearly simultaneously below, within, and above marine boundary layer (MBL) clouds. Flights spanning warm and cold seasons across 3 years (2020–22) provided a broad range of conditions associated with aerosol particles, cloud properties (including particle size and phase), and meteorology, ideally suited for robust ACI calculations and assessing how well models simulate a wide range of MBL clouds from stratiform to cumulus. ACTIVATE data suggest that drivers of cloud droplet number concentration N d , including aerosol particles and MBL dynamics, vary between winter and summer months with a stronger potential to convert aerosol particles into cloud droplets in winter. Models of varying complexity not only highlight some skills in simulating winter and summer cloud types but also identify challenges that still need to be addressed such as treatment of turbulence, wet scavenging, and mesoscale organization. Remote sensing advances range from new retrieval methods for N d , cloud phase classification, vertically resolved aerosol and cloud condensation nuclei number concentration, and ocean surface wind speed. This work describes these scientific and technological advances along with efforts in outreach and open data science.

aerosol indirect effect↗
DOE OSTI2024

Quantifying the Turbulent Entrainment‐Mixing Processes Based on Z ‐LWC Relationships of Cloud Droplets

Abstract Turbulent entrainment‐mixing processes profoundly influence the relationship between radar reflectivity factor and liquid water content ( Z ‐LWC) of cloud droplets. However, quantification of the entrainment‐mixing mechanisms based on the Z ‐LWC relationship is still lacking. To address this gap, 12,218 entrainment‐mixing cases are simulated using the Explicit Mixing Parcel Model. We examine the variations of the parameters in the power‐law relationship Z = a LWC b , and the relationship between parameter b and homogeneous mixing degree ( ψ ), a measure quantifying entrainment‐mixing processes. The results indicate that parameter b distributes within the range of 1–2, with a positive correlation between parameter b and ψ . The b ‐ ψ relationship is fitted, which connects the Z ‐LWC relationship for various entrainment‐mixing types. The results suggest the potential for employing a remote sensing approach to investigate the entrainment‐mixing mechanisms of non‐precipitating small cumulus/stratocumulus clouds, thereby overcoming the limitations of traditional observational studies that rely solely on aircraft observations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Evaluation of UKESM aerosol size and composition using ATom measurements indicates missing marine aerosol formation mechanisms

Atmospheric aerosols influence climate through their interactions with radiation and clouds, yet large uncertainties remain in their simulation by global models. This study evaluates the United Kingdom Earth System Model version 1.1 (UKESM1.1) using global-scale aircraft observations from the Atmospheric Tomography (ATom) mission, focusing on aerosol lifecycle processes in the remote marine atmosphere. We assess model performance in simulating aerosol precursor vapours, number size distributions, chemical composition, and environmental conditions. Several process improvements are tested, including sulfuric acid-ammonia nucleation, ammonium nitrate scheme, methanesulfonic acid condensation, and low-temperature isoprene-derived secondary organic aerosol formation. Model biases differ significantly between the upper troposphere (UT) and the marine boundary layer (MBL). In the UT, UKESM1.1 overestimates nucleation and Aitken mode particles while underestimating accumulation mode, indicating insufficient growth. In the MBL, the model overestimates primary aerosols (e.g. seasalt) and precursor gases but underestimates nucleation and Aitken mode particles, even after incorporating updated nucleation and ammonium nitrate scheme. The persistence of low aerosol number concentrations, despite overestimated precursors, suggests missing formation pathways likely involving other species such as iodine, amines, and organic vapours. These limitations result in an unbalanced cloud condensation nuclei budget that over-relies on primary emissions. Sensitivity tests reveal that model outputs are strongly influenced by dimethyl sulfide emissions and vapour condensation schemes. Our results highlight the need for future model development to prioritise mechanistic representation of currently missing aerosol sources, rather than relying on empirical tuning, to improve aerosol-climate interaction estimates.

He, Xu-Cheng [Univ. of Cambridge (United Kingdom);↗
DOE OSTI2023

Spectro-Microscopy Studies of Atmospheric Particles

Our project investigated composition and physical properties of individual atmospheric particles collected in field campaigns organized by the DOE Atmospheric Systems Research and Atmospheric Radiation Measurement (ASR/ARM) programs, such as the Green Ocean Amazon (GoAmazon, 2014/5), the Holistic Interactions of Shallow Clouds, Aerosols, and Land-Ecosystems (HI-SCALE, 2016/7), the Aerosol and Cloud Experiment in the Eastern North Atlantic (ACE-ENA, 2017/8), the Aerosol–Ice Formation Closure Pilot Study (AEROICESTUDY, 2019) and in additional small-scale supporting field experiments focused on the investigation of the light-absorbing (aka brown carbon) atmospheric particles. In these studies, we investigated the contribution of natural and anthropogenic sources to populations of atmospheric particles during representative atmospheric conditions; characterized particle composition and evaluated their hygroscopic properties and propensity to act as cloud condensation nuclei (CCN) and ice nuclei (IN); correlated typical particle-type and mixing state characteristics with real-time measurements in the areas of studies. We used multi-modal spectro-microscopy techniques to examine elemental and molecular composition, mixing state, size, and higher order morphology for individual particles. Specifically, we used computer-controlled scanning electron microscopy and X-ray microanalysis for quantitative analysis of particle elemental composition, and we used transmission electron microscopy to provide additional information on the distribution of different components within individual particles (particle heterogeneity). We used synchrotron-based scanning transmission X-ray microscopy for quantitative description of the mixing state and molecular bonding of carbon in particles. The particle composition, mixing state, and morphology from analyzed periods was then combined with the real-time ARM measurements of aerosol size distribution, CCN concentration, hygroscopicity, and aerosol bulk composition. Combined together, results of our studies allowed us to assess the major particle sources (biogenic vs. anthropogenic, primary vs secondary) and gain insight into the atmospheric processing of aerosol particles resulting from condensation, coagulation, oxidative aging, and cloud processing. In collaboration with other scientists involved in field campaigns, we carried out statistical analysis of particle properties and their source-specific contributions to regional aerosol loading under representative air mass, meteorological, and cloud conditions.

scanning transmission X-ray microscopy↗
DOE OSTI2024

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗