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DOE OSTI2024

Evaluation of In-Situ AM Process Monitoring Techniques and Potential for Detecting Process Anomalies and Undesirable Microstructures

The US Department of Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing rapid qualification of new materials for fabrication of nuclear relevant components using advanced manufacturing techniques. Particular interest is placed on code-qualifying stainless steel (SS) 316H processed by laser powder bed fusion (LPBF) additive manufacturing. A paradigm that incorporates data from in-situ sensing during the printing, ex-situ characterization, and advanced artificial intelligence–based models was established under the Transformation Challenge Reactor (TCR) program to develop a pedigree for each fabricated component that could be tracked from the feedstock to the component’s release for application. Under the TCR program, the Peregrine software was developed as a tool for incorporating the vast amounts of in-situ and ex-situ characterization data collected; all data stored on a rapidly growing digital platform. The digital platform allows for users to link site-specific process anomalies to the macro- and microstructure. The platform will eventually be able to predict component performance, which will be crucial to qualifying materials and components in risk-averse industries such as those supporting and building nuclear reactors. Current in-situ process monitoring techniques that are already integrated with software like Peregrine are advantageous for identifying process anomalies including powder spatter, component edge swelling, recoating-build interactions, and so on. However, additional data are required to fully predict the resulting microstructures needed for identifying relationships to component performance. The rapid cooling rates observed in LPBF are some of the highest of any bulk manufacturing process, resulting in heterogenous microstructures and typically causing anisotropy in mechanical properties. Moreover, evolved residual thermal stresses are high, which can cause severe defects such as delamination or cracking. Therefore, other in-situ monitoring methods are warranted for exploration to measure and map the thermal history, and potentially the stress state, of each build. This report summarizes different in-situ monitoring strategies proposed for LPBF with a focus on the more developed sensor systems. Novel capabilities for measuring melt pool temperatures are also addressed to better inform modeling efforts.

36 MATERIALS SCIENCE↗

NASA NTRS2011

Development of a Real-Time Pulse Processing Algorithm for TES-Based X-Ray Microcalorimeters

We report here a real-time pulse processing algorithm for superconducting transition-edge sensor (TES) based x-ray microcalorimeters. TES-based. microca1orimeters offer ultra-high energy resolutions, but the small volume of each pixel requires that large arrays of identical microcalorimeter pixe1s be built to achieve sufficient detection efficiency. That in turn requires as much pulse processing as possible must be performed at the front end of readout electronics to avoid transferring large amounts of data to a host computer for post-processing. Therefore, a real-time pulse processing algorithm that not only can be implemented in the readout electronics but also achieve satisfactory energy resolutions is desired. We have developed an algorithm that can be easily implemented. in hardware. We then tested the algorithm offline using several data sets acquired with an 8 x 8 Goddard TES x-ray calorimeter array and 2x16 NIST time-division SQUID multiplexer. We obtained an average energy resolution of close to 3.0 eV at 6 keV for the multiplexed pixels while preserving over 99% of the events in the data sets.

Tan, Hui↗

DOE OSTI2020

Oxidation states of iron and manganese in lignocellulose altered by the brown rot fungus Gloeophyllum trabeum measured in-situ using X-ray absorption near edge spectroscopy (XANES)

Brown rot fungi utilize iron as part of a chelator-mediated Fenton (CMF) reaction during wood biodegradation. Research suggests these fungi reduce Fe 3+ to promote oxygen radical generation resulting in depolymerization of the wood cell wall. High levels of Mn are also found in wood decayed by brown rot fungi. However, little is known about the oxidation states of Fe and Mn during the decay process. X-ray absorption near edge spectroscopy (XANES) can be used to examine metal oxidation states and coordination chemistry. In this work, XANES experiments were conducted on wood decayed by Gloeophyllum trabeum over 2–8 weeks with results showing that Mn 2+ and Fe 3+ predominated for metal oxidation states. However, Fe 2+ was present at sites of greater fungal growth In certain cases, the μXANES measurements showed that the fraction of Fe 2+ in the wood samples was as high as 50%. Localized areas of reduced iron corresponded with areas of greater fungal hyphal mass which is in agreement with how brown rot fungi decay wood via the CMF reaction. The limited change in oxidation state of Mn observed in wood with active fungal activity suggests that the role of manganese in CMF biodegradation chemistry should be further explored.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2006

SiC Composite Turbine Vanes

Turbine inlet guide vanes have been fabricated from composites of silicon carbide fibers in silicon carbide matrices. A unique design for a cloth made from SiC fibers makes it possible to realize the geometric features necessary to form these vanes in the same airfoil shapes as those of prior metal vanes. The fiber component of each of these vanes was made from SiC-fiber cloth coated with boron nitride. The matrix was formed by chemical-vapor infiltration with SiC, then slurry-casting of SiC, followed by melt infiltration with silicon. These SiC/SiC vanes were found to be capable of withstanding temperatures 400 F (222 C) greater than those that can be withstood by nickel-base-superalloy turbine airfoils now in common use in gas turbine engines. The higher temperature capability of SiC/SiC parts is expected to make it possible to use them with significantly less cooling than is used for metallic parts, thereby enabling engines to operate more efficiently while emitting smaller amounts of NOx and CO. The SiC/SiC composite vanes were fabricated in two different configurations. Each vane of one of the configurations has two internal cavities formed by a web between the suction and the pressure sides of the vane. Each vane of the other configuration has no web (see Figure 1). It is difficult to fabricate components having small radii, like those of the trailing edges of these vanes, by use of stiff stoichiometric SiC fibers currently preferred for SiC/SiC composites. To satisfy the severe geometric and structural requirements for these vanes, the aforementioned unique cloth design, denoted by the term Y-cloth, was conceived (see Figure 2). In the regions away from the trailing edge, the Y-cloth features a fiber architecture that had been well characterized and successfully demonstrated in combustor liners. To form a sharp trailing edge (having a radius of 0.3 mm), the cloth was split into two planes during the weaving process. The fiber tows forming the trailing-edge section were interlocked, thereby enhancing through-thickness strength of the resulting composite material. For vanes of the webless configuration, each made from a layup of six plies of Ycloth, the length of each Y-cloth layer was cut so that the two strips corresponding to the aforementioned two planes would wrap around the perimeter of a graphite vane preform tool with a 10-mm overlap. The overlap was used to join the two strips in a fringe splice. To make the external sixth ply, a standard woven cloth was cut to the required final length and a fringe splice joined the two ends of the cloth at the trailing edge. The cloth was then prepregged. The entire assembly was then placed into an aluminum compaction tool designed to form the outer net shape of the vane. After the prepreg material was allowed to dry, the preform was removed from the aluminum tooling and placed into an external graphite tool before being shipped to a vendor for matrix infiltration. To make the SiC fiber preform for a vane having an internal web, a slightly different initial approach was followed. Each of two sections forming the internal cavities (and ultimately the web) was created by first slipping two concentric layers of a two-dimensional, 2-by-2, 45 - braided tube around a net-shape graphite mandrel. The tubes on both mandrels were prepregged and allowed to dry. The resulting two subassemblies were put together, then four additional plies were wrapped around them in the same fashion as that described above for the six plies of the vaneless configuration. The consolidation of the SiC fiber preforms into SiC/SiC composite parts was performed by commercial vendors using their standard processes. The capability of two of the webless SiC/SiC turbine vanes was demonstrated in tests in a turbine environment. The tests included 50 hours of steady-state operation and 102 two-minute thermal cycles. A surface temperature of 1,320 C was reached during the tests.

Calomino, Anthony M.↗

NASA NTRS2005

Unraveling the Processing Parameters in Friction Stir Welding

In friction stir welding (FSW), a rotating threaded pin tool is translated along a weld seam, literally stirring the edges of the seam together. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path or paths is required. In this study, various markers are used to trace the flow paths of the metal. X-ray radiographs record the segmentation and position of the wire. Several variations in the trajectories can be differentiated within the weld zone.

Schneider, Judy↗

DOE OSTI2024

ARM shortwave spectrometers to study the clear-cloud transition zone and mixing processes

The proposed research is a collaborative effort between NASA/Goddard Space Flight Center and the Hebrew University of Jerusalem. While the NASA team focused on analyzing ground-based hyper-spectral radiance observations to understand cloud edge properties and their connection to mixing processes, the Hebrew University team tackled the problem through cloud modeling activities. By approximating the shortwave spectra in the cloud-clear transition zone as a linear combination of purely clear and purely cloudy spectra we can characterize the variations of cloud optical thickness and cloud droplet effective radius in the transition zone. When applying this method to the measurements of a ground-based shortwave spectroradiometer at the ARM’s SGP site, representing continental conditions, and MAGIC field campaign between Log Angeles, California and Honolulu, Hawaii, representing maritime scenarios, we found that cloud optical depth consistently decreases in both cases, but droplet size decreases much more substantially for the continental regime, suggesting different mixing processes for the continental and maritime conditions. The investigation and measurements of radiation clouds were coupled with a unique cloud modeling. A novel spectral bin microphysics was developed and implemented to the System of Atmospheric Modeling (SAM). In order to resolve cloud transition zones with high spatial gradients of microphysical variables a unique high resolution (10 m) was used in simulations. The model calculates droplet size distributions in each grid point. The model output was transferred to the NASA/GSFC team for utilization in radiative calculations and testing of both radiative algorithm and model representation.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Shallow Cumulus Properties as Captured by Adiabatic Fraction in High-Resolution LES Simulations

Abstract Shallow convective clouds are important players in Earth’s energy budget and hydrological cycle, and are abundant in the tropical and subtropical belts. They greatly contribute to the uncertainty in climate predictions due to their unresolved, complex processes that include coupling between the dynamics and microphysics. Analysis of cloud structure can be simplified by considering cloud motions as a combination of moist adiabatic motions like adiabatic updrafts and turbulent motions leading to deviation from adiabaticity. In this work, we study the sizes and occurrence of adiabatic regions in shallow cumulus clouds during their growth and mature stages, and use the adiabatic fraction (AF) as a continuous metric to describe cloud processes and properties from the core to the edge. To do so, we simulate isolated trade wind cumulus clouds of different sizes using the System of Atmospheric Modeling (SAM) model in high resolution (10 m) with the Hebrew University spectral bin microphysics (SBM). The fine features in the clouds’ dynamics and microphysics, including small near-adiabatic volumes and a thin transition zone at the edge of the cloud (∼20–40 m in width), are captured. The AF is shown to be an efficient measure for analyzing cloud properties and key processes determining the droplet-size distribution formation and shape during the cloud evolution. Physical processes governing the properties of droplet size distributions at different cloud regions (e.g., core, edge) are analyzed in relation to AF. Significance Statement 1) This study investigates the evolution of cumulus clouds (Cu) using a 10-m-resolution LES model with spectral bin microphysics. 2) The study improves the understanding of the mutual effects of adiabatic updrafts and lateral entrainment and mixing. 3) The study demonstrates the existence of an adiabatic core in nonprecipitating Cu. 4) Shapes of the droplet size distributions are closely related to the adiabatic fraction values. 5) Utilization of high resolution reveals the existence of physically significant small features in the cloud structure, such as a narrow cloud interface zone and small adiabatic volumes.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRSDate not supplied

Enabling Open and Interoperable Science: Multi-Omics Data Processing Platform with NASA GeneLab Standardized Bioinformatics Workflows for Space and Earth Research

Multi-omics biological data continues to be generated at an astounding pace. Genomics, transcriptomics, metabolomics, and proteomics, or collectively known as multi-omics data, are used to assess biological functions, and provide invaluable insights into human, animal, plant, and environmental health both on Earth and in Space. Despite the abundance of these valuable data, the need for bioinformatics expertise, particularly as it relates to the niche filed of space biology, and a lack of accessible resources for processing these data limit their usefulness in deriving biological insights. The NASA Open Science Data Repository (OSDR) provides access to omics data from various spaceflight and analog studies. To enhance the accessibility and reusability of these data, GeneLab (part of OSDR) designs and implements standardized, community-driven, open-source bioinformatics workflows to transform raw omics data into standardized processed data. Currently, GeneLab-processed data from hundreds of space studies have been reused for meta-analyses. This has led to new insights and scientific publications that extend beyond the initial research, thereby enriching our understanding of molecular-scale biological responses to the space environment. To make these bioinformatics workflows open and accessible, GeneLab teamed up with DOE-funded initiatives, including the National Microbiome Data Collaborative (NMDC), to create the NASA EDGE [Empowering the Development of Genomics Expertise] Bioinformatics web-based platform. NASA EDGE utilizes shared compute resources to run the GeneLab standardized bioinformatics workflows, which eliminates the need for researchers to have their own high performance computing cluster. The web-based platform makes complicated biological analyses incredibly easy to perform, thus expanding the reach of these analyses to bioinformatics novices, students, and even citizen scientists enabling them to contribute to scientific discoveries and progress. The authors will demonstrate how the NASA EDGE platform can be used to process microbial omics data hosted on OSDR as well as user-generated omics datasets using GeneLab’s standard workflows.

Amanda M. Saravia-Butler↗

NASA NTRS2016

Aeroelastic Response of the Adaptive Compliant Trailing Edge Transition Section

This presentation describes an unconventional process for analyzing and validating non-linear aerostructures.

aircraft stability↗

NASA NTRS1996

Probabilistic Simulation of Progressive Fracture in Bolted-Joint Composite Laminates

This report describes computational methods to probabilistically simulate fracture in bolted composite structures. An innovative approach that is independent of stress intensity factors and fracture toughness was used to simulate progressive fracture. The effect of design variable uncertainties on structural damage was also quantified. A fast probability integrator assessed the scatter in the composite structure response before and after damage. Then the sensitivity of the response to design variables was computed. General-purpose methods, which are applicable to bolted joints in all types of structures and in all fracture processes-from damage initiation to unstable propagation and global structure collapse-were used. These methods were demonstrated for a bolted joint of a polymer matrix composite panel under edge loads. The effects of the fabrication process were included in the simulation of damage in the bolted panel. Results showed that the most effective way to reduce end displacement at fracture is to control both the load and the ply thickness. The cumulative probability for longitudinal stress in all plies was most sensitive to the load; in the 0 deg. plies it was very sensitive to ply thickness. The cumulative probability for transverse stress was most sensitive to the matrix coefficient of thermal expansion. In addition, fiber volume ratio and fiber transverse modulus both contributed significantly to the cumulative probability for the transverse stresses in all the plies.

Minnetyan, L.↗

NASA NTRS1989

Image wavelet decomposition and applications

The general problem of computer vision has been investigated for more that 20 years and is still one of the most challenging fields in artificial intelligence. Indeed, taking a look at the human visual system can give us an idea of the complexity of any solution to the problem of visual recognition. This general task can be decomposed into a whole hierarchy of problems ranging from pixel processing to high level segmentation and complex objects recognition. Contrasting an image at different representations provides useful information such as edges. An example of low level signal and image processing using the theory of wavelets is introduced which provides the basis for multiresolution representation. Like the human brain, we use a multiorientation process which detects features independently in different orientation sectors. So, images of the same orientation but of different resolutions are contrasted to gather information about an image. An interesting image representation using energy zero crossings is developed. This representation is shown to be experimentally complete and leads to some higher level applications such as edge and corner finding, which in turn provides two basic steps to image segmentation. The possibilities of feedback between different levels of processing are also discussed.

Treil, N.↗

NASA NTRS1994

Variability in pigment concentration in warm-core rings as determined by coastal zone color scanner satellite imagery from the Mid-Atlantic Bight

A time series of coastal zone color scanner (CZCS) derived chlorophyll (CZCS-chl) and sea surface temperature (SST) satellite imagery was developed for the Mid-Atlantic Bight (MAB). Warm-core rings (WCR) were identified by both the warmer SST signal as well as the low pigment concentrations of their cores. The variation in pigment concentrations and SST observed in satellite imagery over the geographic range and life span of four WCRs is investigated. The hypotheses are that pigment concentration increase during the lifetime of the WCR is a response to processes such as convective overturn, upwelling, edge enhancement due to increased vertical mixing, active convergence, or lateral exchange. Empirical orthogonal function analysis (EOF) is used to investigate the relationship between SST and pigment patterns observed in the presence of a WCR. The first two EOF modes explain more than 80% of the variability observed in all four WCRs and in both (SST and pigment) data sets. The results of this study show that, at the synoptic scales of staellite data, the variability observed in the WCRs is greater at the periphery of the rings. These results show that advective entrainment, rather than processes at ring center (e.g., shoaling of the pycnocline/nutricline in response to frictional decay) or at the periphery due to other processes such as vertical mixing, is the mechanism responsible for the observed variability.

Garcia-Moliner, Graciela↗

DOE OSTI2020

Measurements of the Flow in the Vicinity of an Additively Manufactured Turbine Leading-Edge Using X-Ray Particle Tracking Velocimetry

X-ray particle tracking velocimetry (PTV) is performed, for the first time, to measure the velocity field inside a leading-edge of a turbine blade made by laser-additive-manufacturing (LAM) process. The traditional showerhead holes were replaced by a porous matrix in the leading-edge. The flow through such a leading-edge piece cannot be faithfully recreated by traditional prototype testing methods due to the surface roughness and imperfections caused by LAM process. Hence, direct measurement is the only option. However, it is difficult to measure flow inside such pieces with traditional velocimetry measurements due to the existence of metallic walls. Moreover, small internal size and high flow speeds call for a measurement technique with high spatial and temporal resolutions. To address these issues, we performed time-resolved X-ray PTV using the Advanced Photon Source (APS) synchrotron facility at the Argonne National Laboratory (ANL). A hydraulic system was constructed to run water, mixed with seeding particles, through the leading-edge piece. A high-speed camera captured the images of the seeding particles, which were later processed to create particle tracks. The time-averaged velocity field showed distinct pairs of vortices located in front of the porous outlet inside the leading-edge piece. The inlet channel showed reversed flow due to partial obstruction by the porous inlet of the test piece. Such knowledge of the flow field inside a leading-edge of a turbine blade will help us to design better cooling paths leading to higher cooling efficiency and increased life-span of a turbine blade.

42 ENGINEERING↗

NASA NTRSDate not supplied

The Effect of Trailing Edge Grid Resolution in Large-Eddy Simulations

Ceramic Matrix Composite (CMC) with environmental barrier coating can tolerate significantly higher temperatures compared with the conventional metal alloy blades and thus can help achieve higher thermal efficiency in gas turbine engines. Due to the complex fabrication process of CMC blades, larger blade trailing edge thicknesses and larger leading-edge radii of curvature are expected. These features significantly alter aerodynamic performance especially near the trailing edge and thus the loss profile. In previous studies, the authors used the large eddy simulation (LES) as well as the Reynolds Averaged Navier-Stokes (RANS) coupled with an intermittency function-based transition model to simulate an aerodynamics performance of three different CMC blades and compared the predictions against the data acquired at NASA Glenn Transonic Turbine Blade Cascade Rig. Although we were able to successfully predict different characteristics of aerodynamic performance among three different blades (e.g., pressure loading and integrated losses), LES consistently predicted a small recirculation bubble at the end of the suction side. This was not inconsistent with the physics of the flow, but the pressure loading, locally, near the trailing edge, and as a result, the measured wake profiles did not match the experimental data. To delve further into these issues, a new LES grid with a much finer mesh near the trailing edge was generated where the spanwise extent of the grid was increased by 50%. An LES simulation for the CMC blade with the largest trailing edge thicknesses at the high-freestream turbulence (Tu=13%) condition showed that using such a mesh is necessary for LES to accurately capture the transition phenomena on the suction side. The resulting total pressure coefficient profile and the shift of the wake profile were greatly improved.

CMC↗

NASA NTRSDate not supplied

The Effect of Trailing Edge Grid Resolution in Large-Eddy Simulations

LES↗

DOE OSTI2022

Atomic Edge-Guided Polyethylene Crystallization on Monolayer Two-Dimensional Materials

In this report we combine an advanced synthesis of two-dimensional (2D) materials (MoSe 2 ) having well-defined atomic edge configurations with ab initio and atomistic molecular dynamics (MD) simulations to study how atomic edges interact with polyethylene (HDPE) chains in a dilute solution assembly process. Our results reveal that Mo-terminated zigzag (Mo-ZZ) edges act as preferred nucleation sites and strongly interact with HDPE chains. The HDPE chains align in parallel with the Mo-ZZ edges and form arrays of lamellae that are perpendicular to the edges. Interestingly, atomic edge configurations are observed to dramatically change such interactions. The crystallization discrepancy at different edges was demonstrated on the same piece of MoSe 2 with different types of edges. The ab initio and MD simulations between n-alkane (n = 5 and 25), a segment of HDPE, and MoSe 2 suggest that the atomic structures of MoSe 2 can affect their interactions with n-alkane chains. Following the Mo-ZZ edge preferred nucleation principle, controlled long-range alignment of HDPE lamellae can be realized by creating multilayer MoSe 2 with parallel atomic steps. This research opens a pathway toward an atomic level understanding of polymer–2D nanomaterial interactions. It also bridges the gap between atomic-level and long-range mesoscopic structures and introduces a novel strategy for long-range structural control.

36 MATERIALS SCIENCE↗

NASA NTRS1997

Virtual Collaborative Simulation Environment for Integrated Product and Process Development

Deneb Robotics is a leader in the development of commercially available, leading edge three- dimensional simulation software tools for virtual prototyping,, simulation-based design, manufacturing process simulation, and factory floor simulation and training applications. Deneb has developed and commercially released a preliminary Virtual Collaborative Engineering (VCE) capability for Integrated Product and Process Development (IPPD). This capability allows distributed, real-time visualization and evaluation of design concepts, manufacturing processes, and total factory and enterprises in one seamless simulation environment.

Gulli, Michael A.↗

NASA NTRS1982

Electromigration process for the purification of molten silicon during crystal growth

A process for the purification of molten materials during crystal growth by electromigration of impurities to localized dirty zones. In the Czochralski crystal growing process, the impurities are electromigrated away from the crystallization interface by applying a direct electrical current to the molten silicon for electromigrating the charged impurities away from the crystal growth interface. The edge-defined film-fed crystal growth process, a direct electrical current is applied between the two faces which are used in forming the molten silicon into a ribbon. The impurities, migrated to one side only of the crystal ribbon, may be removed or left in place. If left in place, they will not adversely affect the ribbon when used in solar collectors. The migration of the impurity to one side only of the silicon ribbon is especially suitable for use with asymmetric dies which preferentially crystallize uncharged impurities along one side or face of the ribbon.

Shlichta, P. J.↗