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Outline - Process-Structure-Performance Framework - Process-Specific Defects in selective laser melting (SLM) additive manufacturing (AM) process - Idealized Keyhole/Entrapped gas pores - Idealized Lack of Fusion (LoF) pores - Influence of Pore Geometry on Strain Localization - 3D Model of LoF pores - Partial validation of the 3D LoF 2 model
Composite materials have tremendous potential in the design and manufacture of commercial aircraft due to their high strength-to-weight and stiffness-to-weight properties. However, the use of composite materials is currently limited by high cost and long manufacturing time. The National Aeronautics and Space Administration (NASA) initiated the Hi-rate Composite Aircraft Manufacturing (HiCAM) project to investigate promising composite processing technologies with a goal of vastly improving composite commercial aircraft manufacturing rate (4-6x faster than current production rates). Laser assisted automated fiber placement (AFP) of thermoplastics is a key technology that could increase speed of composite manufacturing, but the technology has not been fully developed. In-situ consolidation AFP of thermoplastics (ICAT) could reduce time and cost even further by eliminating the time and equipment required for post-consolidation. In this work, the thermal response of laser heated ICAT was investigated using forward looking infrared (FLIR) and embedded thermocouples (TCs) to better understand fusion between layers (autohesion). Detailed explanation of the algorithm to combine FLIR and TC data will be presented. In addition, the effect of robot speed on time above melting temperature was quantified.
Most fusion propulsion concepts that have been investigated in the past employ some form of inertial or magnetic confinement separately, and are encumbered by the need for advanced drivers (e.g. laser) or steady-state magnetic confinement systems (e.g. superconductors) that have historically resulted in large, massive spacecraft designs. Here we present a comparatively new approach, Magnetized Target Fusion (MTF), which offers a nearer-term avenue for realizing the tremendous performance benefits of fusion propulsion. MTF attempts to combine the favorable attributes of both inertially and magnetically confined fusion to achieve both efficient and low-cost compressional plasma heating and energy confinement. The key advantage of MTF is its less demanding requirements for driver energy and power processing. Additional features include: 1) very low system masses and volumes, 2) high gain and relatively low waste heat, 3) substantial utilization of energy from product neutrons, 4) efficient, low peak-power drivers based on existing pulsed power technology, and 5) very high I(sub sp), specific power and thrust. MTF overcomes many of the problems associated with traditional fusion techniques, thus making it particularly attractive for space applications. I(sub sp) greater than 50,000 seconds and specific powers greater than 20 kilowatts/kilogram appear feasible using relatively near-term pulse power and plasma gun technology.
Most fusion propulsion concepts that have been investigated in the past employ some form of inertial or magnetic confinement separately, and are encumbered by the need for advanced drivers (e.g. laser) or steady-state magnetic confinement systems (e.g. superconductors) that have historically resulted in large, massive spacecraft designs. Here we present a comparatively new approach, Magnetized Target Fusion (MTF), which offers a nearer-term avenue for realizing the tremendous performance benefits of fusion propulsion. MTF attempts to combine the favorable attributes of both inertially and magnetically confined fusion to achieve both efficient and low-cost compressional plasma heating and energy confinement. The key advantage of MTF is its less demanding requirements for driver energy and power processing. Additional features include: 1) very low system masses and volumes, 2) relatively low waste heat, 3) substantial utilization of energy from product neutrons, 4) efficient, low peak-power drivers based on existing pulsed power technology, 5) very high Isp , specific power and thrust, and 6) relatively affordable R&D pathways. MTF overcomes many of the problems associated with traditional fusion techniques, thus making it particularly attractive for space applications. Isp greater than 50,000 seconds and specific powers greater than 20 kilowatts/kilogram appear feasible using relatively near-term pulse power and plasma gun technology.
Autogenous welds in 304 stainless steel were performed by Nd-YAG laser heating in a simulated space environment. Simulation consists of welding on the NASA KC-135 aircraft to produce the microgravity and by containing the specimen in a vacuum chamber. Experimental results show that the microgravity welds are stronger, harder in the fusion zone, have deeper penetration and have a rougher surface rippling of the weld pool than one-g welds. To perform laser welding in space, a solar-pumped laser concept that significantly increases the laser conversion efficiency and makes welding viable despite the limited power availability of spacecraft is proposed.
Large-scale applications of high-power lasers are considered (special experiments are described to confirm the feasibility of these applications) to achieve also large-scale environmental advantages. The possibility of producing electric energy by Laser-Solar Power Satellites in the near future is discussed. A full-scale experimental L-SPS satellite is suggested as a module of a global space energy network. Electric power of about 10 MW at the surface of the Earth is achievable as a result of energy conversion of laser radiation. L-SPS is based on the greatest advantages of present optics and laser techniques. Specialized-scale experiments are carried out and described. L-SPS project could provide real electricity for consumers not later than by highly developed fusion techniques, and the environmental aftereffects are quite favorable. A new method of power supply for satellites is suggested, based on the connection of an on-board electric circuit directly with the ground-based power grid by means of laser beams.
JBK-75 is an iron-nickel derivative alloy of A-286 that has been of interest to NASA’s propulsion community for use in fuel injectors and other components that are used in hot, corrosive environments. To enable the rapid production of these components in JBK-75, Marshall Space Flight Center has developed parameters for manufacturing fully dense JBK-75 components using powder bed fusion additive manufacturing (PBFAM). These parameters were developed in a two-step development. First, the depth of laser penetration in the powdered material was measured across a spectrum of laser powers to determine the optimal power necessary for generating the desired meltpool depth. The parameter set’s vector-to-vector spacing was then then tailored to guarantee the full densification of the desired area. The results of this development was a readily implementable parameter that produced 99.6% dense material when using a 147W power running at 600mm/s with a 85μm(32%) vector-to-vector spacing.
NASA is considering a mission to explore near-interstellar space early in the next decade as the first step toward a vigorous interstellar exploration program. A key enabling technology for such an ambitious science and exploration effort is the development of propulsion systems capable of providing fast trip times; mission duration should not exceed the professional lifetime of the investigative team. Advanced propulsion technologies that might support an interstellar precursor mission early in the next century include some combination of solar sails, nuclear electric propulsion systems, and aerogravity assists. Follow-on missions to far beyond the heliopause will require the development of propulsion technologies that are only at the conceptual stage today. These include 1) matter-antimatter annihilation, 2) beamed-energy sails, and 3) fusion systems. For years, the scientific community has been interested in the development of solar sail technology to support exploration of the inner and outer planets. Progress in thin-film technology and the development of technologies that may enable the remote assembly of large sails in space are only now maturing to the point where ambitious interstellar precursor missions can be considered. Electric propulsion is now being demonstrated for planetary exploration by the Deep Space 1 mission. The primary issues for it's adaptation to interstellar precursor applications include the nuclear reactor that would be required and the engine lifetime. For further term interstellar missions, matter-antimatter annihilation propulsion system concepts have the highest energy density of any propulsion systems using onboard propellants. However, there are numerous challenges to production and storage of antimatter that must be overcome before it can be seriously considered for interstellar flight. Off-board energy systems (laser sails) are candidates for long-distance interstellar flight but development of component technologies and necessary infrastructure have not begun.. Fusion propulsion has been studied extensively. However, fusion technology is still considered immature, even after many decades of well-funded research. Furthermore, fusion alone does not offer high enough energy density to make it a viable candidate for interstellar propulsion unless propellant can be collected in situ, as was considered by R. Bussard for his interstellar ramjet concept. The current research in investigating these propulsion systems will be described, and the range of application of each technology will be explored.
The physical processes occurring in plasma focus devices were studied. These devices produce dense high temperature plasmas, which emit X rays of hundreds of KeV energy and one to ten billion neutrons per pulse. The processes in the devices seem related to solar flare phenomena, and would also be of interest for controlled thermonuclear fusion applications. The high intensity, short duration bursts of X rays and neutrons could also possibly be used for pumping nuclear lasers.
An overview is presented of the broad perspective of all plasma science. Detailed discussions are given of scientific opportunities in various subdisciplines of plasma science. The first subdiscipline to be discussed is the area where the contemporary applications of plasma science are the most widespread, low temperature plasma science. Opportunities for new research and technology development that have emerged as byproducts of research in magnetic and inertial fusion are then highlighted. Then follows a discussion of new opportunities in ultrafast plasma science opened up by recent developments in laser and particle beam technology. Next, research that uses smaller scale facilities is discussed, first discussing non-neutral plasmas, and then the area of basic plasma experiments. Discussions of analytic theory and computational plasma physics and of space and astrophysical plasma physics are then presented.
One of the major advantages of using P-B11 fusion fuel is that the reaction produces only charged particles in the form of three alpha particles and no neutrons. A fusion concept that lends itself to this fuel cycle is the Magnetically Insulated Inertial Confinement Fusion (MICF) reactor whose distinct advantage lies in the very strong magnetic field that is created when an incident particle (or laser) beam strikes the inner wall of the target pellet. This field serves to thermally insulate the hot plasma from the metal wall thereby allowing thc plasma to burn for a long time and produce a large energy magnification. If used as a propulsion device, we propose using antiprotons to drive the system which we show to be capable of producing very large specific impulse and thrust. By way of validating the confinement propenies of MICF we will address a proposed experiment in which pellets coated with P-B11 fuel at the appropriate ratio will be zapped by a beam of antiprotons that enter the target through a hole. Calculations showing the density and temperature of the generated plasma along with the strength of the magnetic field and other properties of the system will be presented and discussed.
Many forestry and earth science applications require spatially detailed forest height data sets. Among the various remote sensing technologies, lidar offers the most potential for obtaining reliable height measurement. However, existing and planned spaceborne lidar systems do not have the capability to produce spatially contiguous, fine resolution forest height maps over large areas. This paper describes a Landsat-lidar fusion approach for modeling the height of young forests by integrating historical Landsat observations with lidar data acquired by the Geoscience Laser Altimeter System (GLAS) instrument onboard the Ice, Cloud, and land Elevation (ICESat) satellite. In this approach, "young" forests refer to forests reestablished following recent disturbances mapped using Landsat time-series stacks (LTSS) and a vegetation change tracker (VCT) algorithm. The GLAS lidar data is used to retrieve forest height at sample locations represented by the footprints of the lidar data. These samples are used to establish relationships between lidar-based forest height measurements and LTSS-VCT disturbance products. The height of "young" forest is then mapped based on the derived relationships and the LTSS-VCT disturbance products. This approach was developed and tested over the state of Mississippi. Of the various models evaluated, a regression tree model predicting forest height from age since disturbance and three cumulative indices produced by the LTSS-VCT method yielded the lowest cross validation error. The R(exp 2) and root mean square difference (RMSD) between predicted and GLAS-based height measurements were 0.91 and 1.97 m, respectively. Predictions of this model had much higher errors than indicated by cross validation analysis when evaluated using field plot data collected through the Forest Inventory and Analysis Program of USDA Forest Service. Much of these errors were due to a lack of separation between stand clearing and non-stand clearing disturbances in current LTSS-VCT products and difficulty in deriving reliable forest height measurements using GLAS samples when terrain relief was present within their footprints. In addition, a systematic underestimation of about 5 m by the developed model was also observed, half of which could be explained by forest growth that occurred between field measurement year and model target year. The remaining difference suggests that tree height measurements derived using waveform lidar data could be significantly underestimated, especially for young pine forests. Options for improving the height modeling approach developed in this study were discussed.
Powder bed fusion (PBF) additive manufacturing (AM) enables the creation of parts with complexity and functionality levels that were previously impossible with traditional manufacturing methods. By modifying the laser power, hatch spacing, or the numerous other processing parameters, the PBF process supports the production of a wide set of materials and geometries. However, that same process parameter design flexibility causes the process-design space of PBF to be massive and expensive to explore experimentally. Another challenge is quality variation across a build. As a part is being built, geometric variance between locations, such as at a thin-wall section vs. the bulk material, may cause the specified processing parameters to no longer be acceptable for producing defect-free printing. Furthermore, if the processing parameters deviate during the print process, it is difficult to assess if the part will still perform satisfactorily. Integrated Computational Materials Engineering (ICME) provides a way to understand and address these various challenges. This talk will present advancements in process-structure simulations of PBF at NASA Langley Research Center. The ability to simulate grain-scale PBF microstructures using the Physically Based Monte Carlo method will be demonstrated and compared to experimental measurements. Techniques for simulating three-dimensional lack-of-fusion and keyhole porosity defects based on the specific processing conditions and approaches for integrating the two porosity prediction techniques alongside the computational microstructure evolution models will be shown. Finally, the integration of simulated PBF microstructures, embedded process defects, and crystal plasticity finite element models to elucidate the interaction of porosity and microstructure on micromechanical fields will be demonstrated. These integrated techniques demonstrate an example of using ICME to relate processing to performance for PBF AM materials. With continued maturity, it is hoped that such ICME approaches will lead to next-generation computational-materials supported qualification and certification of AM parts.
This study tests a novel methodology to add value to satellite data sets. This methodology, data fusion, is similar to data assimilation, except that the background modelbased field is replaced by a satellite data set, in this case AIRS (Atmospheric Infrared Sounder) carbon monoxide (CO) measurements. The observational information comes from CO measurements with lower spatial coverage than AIRS, namely, from TES (Tropospheric Emission Spectrometer) and MLS (Microwave Limb Sounder). We show that combining these data sets with data fusion uses the higher spectral resolution of TES to extend AIRS CO observational sensitivity to the lower troposphere, a region especially important for air quality studies. We also show that combined CO measurements from AIRS and MLS provide enhanced information in the UTLS (upper troposphere/lower stratosphere) region compared to each product individually. The combined AIRS-TES and AIRS-MLS CO products are validated against DACOM (differential absorption mid-IR diode laser spectrometer) in situ CO measurements from the INTEX-B (Intercontinental Chemical Transport Experiment: MILAGRO and Pacific phases) field campaign and in situ data from HIPPO (HIAPER Pole-to-Pole Observations) flights. The data fusion results show improved sensitivities in the lower and upper troposphere (20-30% and above 20%, respectively) as compared with AIRS-only version 5 CO retrievals, and improved daily coverage compared with TES and MLS CO data.
Electron beam freeform fabrication (EBF3) is a member of an emerging class of direct manufacturing processes known as solid freeform fabrication (SFF); another member of the class is the laser deposition process. Successful application of the EBF3 process requires precise control of a number of process parameters such as the EB power, speed, and metal feed rate in order to ensure thermal management; good fusion between the substrate and the first layer and between successive layers; minimize part distortion and residual stresses; and control the microstructure of the finished product. This is the only effort thus far that has addressed computer simulation of the EBF3 process. The models developed in this effort can assist in reducing the number of trials in the laboratory or on the shop floor while making high-quality parts. With some modifications, their use can be further extended to the simulation of laser, TIG (tungsten inert gas), and other deposition processes. A solid mechanics-based finite element code, ABAQUS, was chosen as the primary engine in developing these models whereas a computational fluid dynamics (CFD) code, Fluent, was used in a support role. Several innovative concepts were developed, some of which are highlighted below. These concepts were implemented in a number of new computer models either in the form of stand-alone programs or as user subroutines for ABAQUS and Fluent codes. A database of thermo-physical, mechanical, fluid, and metallurgical properties of stainless steel 304 was developed. Computing models for Gaussian and raster modes of the electron beam heat input were developed. Also, new schemes were devised to account for the heat sink effect during the deposition process. These innovations, and others, lead to improved models for thermal management and prediction of transient/residual stresses and distortions. Two approaches for the prediction of microstructure were pursued. The first was an empirical approach involving the computation of thermal gradient, solidification rate, and velocity (G,R,V) coupled with the use of a solidification map that should be known a priori. The second approach relies completely on computer simulation. For this purpose a criterion for the prediction of morphology was proposed, which was combined with three alternative models for the prediction of microstructure; one based on solidification kinetics, the second on phase diagram, and the third on differential scanning calorimetry data. The last was found to be the simplest and the most versatile; it can be used with multicomponent alloys and rapid solidification without any additional difficulty. For the purpose of (limited) experimental validation, finite element models developed in this effort were applied to three different shapes made of stainless steel 304 material, designed expressly for this effort with an increasing level of complexity. These finite element models require large computation time, especially when applied to deposits with multiple adjacent beads and layers. This problem can be overcome, to some extent, by the use of fast, multi-core computers. Also, due to their numerical nature coupled with the fact that solid mechanics- based models are being used to represent the material behavior in liquid and vapor phases as well, the models have some inherent approximations that become more pronounced when dealing with multi-bead and multi-layer deposits.
Laser microsurgery can be used to perform both cell biological manipulations, such as targeted cell ablation, and molecular genetic manipulations, such as genetic transformation and chromosome dissection. In this report, we describe a laser microsurgical method that can be used either to ablate single cells or to ablate a small area (1-3 microns diameter) of the extracellular matrix. In plants and microorganisms, the extracellular matrix consists of the cell wall. While conventional patch clamping of these cells, as well as of many animal cells, requires enzymatic digestion of the extracellular matrix, we illustrate that laser microsurgery of a portion of the wall enables patch clamp access to the plasma membrane of higher plant cells remaining situated in their tissue environment. What follows is a detailed description of the construction and use of an economical laser microsurgery system, including procedures for single cell and targeted cell wall ablation. This methodology will be of interest to scientists wishing to perform cellular or subcellular ablation with a high degree of accuracy, or wishing to study how the extracellular matrix affects ion channel function.
In many organisms muscle formation depends on specialized cells that prefigure the pattern of the musculature and serve as templates for myoblast organization and fusion. These include muscle pioneers in insects and muscle organizing cells in leech. In Drosophila, muscle founder cells have been proposed to play a similar role in organizing larval muscle development during embryogenesis. During metamorphosis in Drosophila, following histolysis of most of the larval musculature, there is a second round of myogenesis that gives rise to the adult muscles. It is not known whether muscle founder cells organize the development of these muscles. However, in the thorax specific larval muscle fibers do not histolyze at the onset of metamorphosis, but instead serve as templates for the formation of a subset of adult muscles, the dorsal longitudinal flight muscles (DLMs). Because these persistent larval muscle fibers appear to be functioning in many respects like muscle founder cells, we investigated whether they were necessary for DLM development by using a microbeam laser to ablate them singly and in combination. We found that, in the absence of the larval muscle fibers, DLMs nonetheless develop. Our results show that the persistent larval muscle fibers are not required to initiate myoblast fusion, to determine DLM identity, to locate the DLMs in the thorax, or to specify the total DLM fiber volume. However, they are required to regulate the number of DLM fibers generated. Thus, while the persistent larval muscle fibers are not obligatory for DLM fiber formation and differentiation, they are necessary to ensure the development of the correct number of fibers.
NASA and the US Navy have demonstrated Lattice Confinement Fusion (LCF) and the Fusion-Fast-Fission of natural uranium and thorium. Both methods build upon decades of research, and the latter benefits from conventional nuclear fission and fusion results. However, this nascent technology doesn’t require fissile isotopes and avoids nuclear weapons proliferation concerns from uranium 235U isotopic enrichment or plutonium 239Pu separation. Of particular note, LCF doesn’t need power hungry magnets, lasers, or particle beams. Potentially, it could provide watts to hundreds of kilowatts of electrical power and process heat suitable for space power and high Isp nuclear electric propulsion (NEP) as well as distributed terrestrial power. Finally, there are indications that LCF fast-fission products are more benign than those of conventional fission reactors. Our goal is to scale the reactions and increase the power output through higher temperature operation and increased material masses.