Search NASA⌕ Search

SEARCH · Search NASA

Results for “Casting Optimization”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Laser Powder Deposition Parametric Optimization and Property Development for Ti-6Al-4V Alloy

In this study, Ti6Al4V alloy was produced via laser powder deposition (LPD). To obtain Ti6Al4V alloy with maximum density, LPD parameters for preparing Ti6Al4V samples were optimized using the Taguchi method. Results were analyzed on the basis of the signal-to-noise (S/N) ratios and analyses of variance. A high energy density should be used to achieve higher levels of densification. The optimal combination of parameters for density was a scanning speed of 550 mm/min, laser power of 160 W, powder feeding rate of 0.99 g/min, and shield gas flow of 8 L/min. An almost fully dense Ti6Al4V sample was prepared using the optimized LPD process, and the relative density was greater than 99%. In addition, the microstructure and properties of Ti6Al4V samples prepared by optimized LPD process were investigated. The microstructure investigation revealed that the LPD-prepared Ti6Al4V sample was predominantly composed of fine acicular α phase and lath-type α phase. Tensile and microhardness tests indicated that the LPD sample had higher mechanical properties than the traditional cast Ti6Al4V alloy because of the acicular martensitic phase and smaller grain size.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Materials for Automotive Lightweighting

Reducing the weight of automobiles is a major contributor to increased fuel economy. The baseline materials for vehicle construction, low-carbon steel and cast iron, are being replaced by materials with higher specific strength and stiffness: advanced high-strength steels, aluminum, magnesium, and polymer composites. We find that the key challenge is to reduce the cost of manufacturing structures with these new materials. Maximizing the weight reduction requires optimized designs utilizing multimaterials in various forms. This use of mixed materials presents additional challenges in joining and preventing galvanic corrosion.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Electropolishing of a Full-Sized U-10Mo Plate

Electropolishing is used to remove material from the surface of a metal using electric potential and current. U-10Mo fuel is produced from a low enriched uranium plate alloyed with 10% molybdenum (U-10Mo). Electropolishing is being considered in two steps of the process of fabricating this U-10Mo fuel. First, it could be used as a means initially improving the surface finish of the cast plate while removing smut from the casting process from the surface prior to homogenization. Second, it could be used again after homogenization to remove oxidation and continue to improve the surface finish prior to hot rolling. The purpose of this work is to demonstrate the process on full-size ingots and optimize the process. A depleted uranium U-10Mo plate was electropolished three times: the first two times were prior to homogenization and the third after a homogenization step. The first two polishes decreased the overall roughness, as measured by laser confocal microscopy. After each polish, a smoother and shinier blue-gold surface was left on the plate. Upon homogenization, the surface had a more matte appearance and the surface roughness increased back to the pre-homogenization values obtained prior to the initial polish. After electropolishing the homogenized pieces, the changes in surface roughness increased, as measured by laser confocal microscopy. The final polishing step was not long enough to return the surface roughness to pre-homogenization conditions, implying less polishing is needed before the homogenization versus afterwards. Heat generation during the polish was addressed by circulating the electrolyte solution through an external heat exchanger; however, solubility and anodization challenges require further study.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Effect of isotropic and anisotropic porous microstructure on electrochemical performance of Li ion battery cathodes: An experimental and computational study

Liquid electrolyte mass transport is a major limitation affecting high-power Li ion batteries. Fast discharging causes Li salt depletion in the current collector region of the cathode which produces overpotential in the electrolyte and consequently a drop of cell voltage to below the cut-off voltage, especially at higher electrode thickness and discharge rate. In this study, through experiment and simulation, we have investigated the effect of electrode thickness, mass loading, discharge rate and tortuosity on electrolyte mass transport and final derived areal capacity and specific energy for electrodes having isotropic (normal tape casting) and anisotropic (freeze tape casting) porous microstructure. Furthermore, the macroporous channels in freeze tape cast electrodes facilitate Li salt transport and reduce the Li salt mass transport limitations even at high electrode thickness and discharge rates, and high electrode tortuosity. In our results, computer simulations show that freeze tape cast electrodes may be fully discharged up to 750 μm thickness at 1 C rate compared to 300 μm for normal tape cast electrodes with the same mass loading. Freeze tape cast electrodes also show stable maximum areal capacity for C rates about double the maximum C rates of their normal tape cast electrode counterparts with the same mass loading.

25 ENERGY STORAGE↗
DOE OSTI2026

Influence of the as-built microstructure on the recrystallization of an additively manufactured Inconel939 Ni-based superalloy

This study investigates the influence of the as-built microstructure on the recrystallization (RX) behavior and mechanical properties of the Ni-based superalloy Inconel 939 produced by laser powder bed fusion (PBF-LB/M). Two distinct as-built microstructures were obtained by varying the hatch distance (h d ): a columnar, strongly textured condition (h d =50, termed h d 50) and an equiaxed, weakly textured condition (h d =70, termed h d 70)). Both were subjected to nine solution treatments combining three temperatures (1100, 1150, and 1200 °C) and three holding times (1, 4, and 8 h). Comprehensive microstructural characterization was conducted to assess grain morphology, texture, grain boundary character, dislocation density, and precipitate distribution. Recrystallization was found to be significantly slower than in cast counterparts, requiring higher temperatures and longer times for completion. The initial microstructure plays a decisive role: full RX was achieved only in hd70 specimens after treatment at 1200 °C for 8 h, whereas hd50 samples exhibited delayed and incomplete RX under identical conditions. This behavior is attributed to the finer grain size and higher fraction of high-angle grain boundaries in hd70, which promote recrystallization. Mechanical testing revealed that hd70 samples subjected to a 1200 °C/8 h treatment followed by standard double ageing show higher yield and tensile strengths across the investigated temperature range than both printed and cast Inconel939 processed under conventional conditions, albeit with slightly reduced ductility. The enhanced mechanical performance is attributed to the larger grain size, which limits grain boundary sliding. These results demonstrate the critical importance of controlling the as-built microstructure and tailoring post-processing strategies to optimize high-temperature performance of PBF-LB/M Inconel939.

Inconel939↗
DOE OSTI2021

Intentional Uranium Tagging for Material Provenance and Pathway Forensics (LA19-Intentional-Forensics-NDD3Bb) (Annual Report for FY21)

This report describes the outcomes of the third and final year of a project to research the feasibility of tagging uranium materials, especially nuclear fuels. The experimental focus remained on metallic uranium forms under prospective surface and bulk tagging scenarios. Overall, the results showed that the tags could be successfully imparted and characterized in both as-built and degraded conditions. This was in line with expectations coming into this project, indicating promise for both surface and bulk tagging of metallic forms of uranium. Multiple surface tagging techniques and detection strategies were explored in FY21, with an emphasis on improving tag quality, readability, and detection in the field. Non-radioactive materials were used as a testbed. Selective deposition via laser beam was determined to be successful in imparting a readable titanium deposit on a stainless steel base plate, and can be read with high resolution characterization techniques (e.g., scanning electron microscopy) and field capable tools (e.g., eddy current testing). Other deposition techniques, such as selective deposition via electron beam and photoluminescent tags, were explored in FY21, and while success for these techniques would be dependent on additional work, these techniques showed potential for surface tagging applications. To survey bulk taggant elements for bulk uranium metal, 16 tagging elements were spread among 18 depleted uranium castings (4 baseline, 3 mix, 1 dilution, and 10 recycle). Most of these were made and characterized in FY21. Taggant acceptability was based upon manufacturability, detectability, and persistence from the standpoint of two detection options: bulk chemical analysis (for “chemical taggants”) and microstructural analysis (for “second phase taggants”). Taggant detection in both up-front manufacturing and in the face of “degradations” such as dilution, mixing, and recycling was generally good. Two independent laboratories carried out chemical analysis on most of the castings, and often at several locations within a casting, and the results are discussed. Scanning electron microscopy+EDS microanalysis revealed the second phases mostly contained the expected tagging elements. The shapes and 2 spatial distributions of these micron-sized carbides, oxides, and intermetallic particles offers opportunities for further science-based investigation and tagging optimization. Overall, V and Co currently appear as the best choices for chemical taggants while Al, Ti, Mn, Co, Pd, and Tb all look good as second phase taggants. The other elements considered here – Sc, Ni, Ge, Nb, Ce, Ta, W, Ir, and Au – while not being ruled out, require more study to become viable options. It is of special note that in the recycling study only one of the 12 elements fell out of detection even after 10 meltings, demonstrating their persistence. An Appendix tabulates all chemical analysis results to enable more quantitative and statistical studies of detection opportunities and limitations, as a part of a related project.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Multi-point Adjoint-Based Design of Tilt-Rotors in a Noninertial Reference Frame

Optimization of tilt-rotor systems requires the consideration of performance at multiple design points. In the current study, an adjoint-based optimization of a tilt-rotor blade is considered. The optimization seeks to simultaneously maximize the rotorcraft figure of merit in hover and the propulsive efficiency in airplane-mode for a tilt-rotor system. The design is subject to minimum thrust constraints imposed at each design point. The rotor flowfields at each design point are cast as steady-state problems in a noninertial reference frame. Geometric design variables used in the study to control blade shape include: thickness, camber, twist, and taper represented by as many as 123 separate design variables. Performance weighting of each operational mode is considered in the formulation of the composite objective function, and a build up of increasing geometric degrees of freedom is used to isolate the impact of selected design variables. In all cases considered, the resulting designs successfully increase both the hover figure of merit and the airplane-mode propulsive efficiency for a rotor designed with classical techniques.

Jones, William T.↗
DOE OSTI2026

CTRL-STEER: Closed-Loop Neuron Activation Control in Vision-Language-Action Models

Vision-Language-Action (VLA) models enable test-time behavioral steering via neuron-level interventions, but existing methods use fixed strengths and operate in open loop. This static modulation fails under evolving task dynamics, leading to overcorrection, oscillations, and reduced task success—especially for temporal attributes like speed. We propose CTRL-STEER, a control-theoretic framework that casts activation steering as closed-loop feedback with adaptive, time-varying interventions. Instead of assuming neurons encode temporal concepts, we steer along motion-aligned residual directions and regulate intervention magnitude via feedback. We instantiate this with both PID and reinforcement learning controllers that jointly optimize concept adherence and task success. Experiments on fine-tuned OpenVLA policies across four LIBERO suites show improved stability and a better steering–success trade-off over fixed-coefficient baselines, without retraining the base model.

Babu, Abhijith [Florida International University, ↗
DOE OSTI2018

Additive Manufacturing of High-Entropy Alloys: A Review

Owing to the reduced defects, low cost, and high efficiency, the additive manufacturing (AM) technique has attracted increasingly attention and has been applied in high-entropy alloys (HEAs) in recent years. It was found that AM-processed HEAs possess an optimized microstructure and improved mechanical properties. However, no report has been proposed to review the application of the AM method in preparing bulk HEAs. Hence, it is necessary to introduce AM-processed HEAs in terms of applications, microstructures, mechanical properties, and challenges to provide readers with fundamental understanding. Specifically, we reviewed (1) the application of AM methods in the fabrication of HEAs and (2) the post-heat treatment effect on the microstructural evolution and mechanical properties. Compared with the casting counterparts, AM-HEAs were found to have a superior yield strength and ductility as a consequence of the fine microstructure formed during the rapid solidification in the fabrication process. The post-treatment, such as high isostatic pressing (HIP), can further enhance their properties by removing the existing fabrication defects and residual stress in the AM-HEAs. Furthermore, the mechanical properties can be tuned by either reducing the pre-heating temperature to hinder the phase partitioning or modifying the composition of the HEA to stabilize the solid-solution phase or ductile intermetallic phase in AM materials. Moreover, the processing parameters, fabrication orientation, and scanning method can be optimized to further improve the mechanical performance of the as-built-HEAs.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS1983

Convair 990 transonic flow-field simulation about the forward fuselage

A three-dimensional, viscous flow code was used to calculate the transonic flow about the forebody of the Convair CV-990 (Galileo II) research aircraft stationed at NASA Ames Research Center. The computations were used to determine the location for a differential pressure system. In addition, attitude sensor placements were verified. These instruments comprise a meteorological measurement system, which will be used for global determination of three-dimensional wind data. The code solves the thin layer form of the Reynolds-averaged Navier-Stokes equations using an implicit numerical procedure. The governing equations are written in a generalized, nonorthogonal coordinate system, and are cast in a strong conservation law form. Laminar boundary layer results are presented for free stream Mach number of 0.8 and angles of attack of zero and 2 deg. Use of this computational tool reduced the development time for the location of the sensors and aided in the optimal placement on the aircraft of these devices.

Chaussee, D. S.↗
NASA NTRS1994

Hybrid near-optimal aeroassisted orbit transfer plane change trajectories

In this paper, a hybrid methodology is used to determine optimal open loop controls for the atmospheric portion of the aeroassisted plane change problem. The method is hybrid in the sense that it combines the features of numerical collocation with the analytically tractable portions of the problem which result when the two-point boundary value problem is cast in the form of a regular perturbation problem. Various levels of approximation are introduced by eliminating particular collocation parameters and their effect upon problem complexity and required number of nodes is discussed. The results include plane changes of 10, 20, and 30 degrees for a given vehicle.

Calise, Anthony J.↗
DOE OSTI2017

Effect of Recrystallization on Gas Bubble Swelling in UMo Fuels

The development of low-enriched uranium (LEU) fuels such as UMo dispersion fuels and monolithic UMo fuels is part of a global effort on nuclear nonproliferation. Although UMo fuels have the advantage of high density, excellent irradiation performance and good thermal conductivity, the volumetric swelling in irradiated metallic fuels is known to be an important design parameter because it affects not only the thermal conductivity of the fuels but also the mechanical integrity of fuel structures. Experiments also show that recrystallization dramatically affects the gas bubble swelling kinetics. A series of materials processes such as casting, mechanical rolling and thermal treatment are used in fuel fabrication. Resulting microstructure, such as grain size, porosity, and second phase, strongly depends on the material processes and process parameters. Therefore, a fundamental understanding how fabricated microstructures and irradiation conditions affect the nucleation of gas bubbles, recrystallization and gas bubble swelling kinetics is essential for optimizing material processes to obtain desired microstructure and fuel performance. Great effort has been made in the development of modeling capability for predicting gas bubble swelling kinetics and fission gas release kinetics in nuclear fuels. However, these models are based on the assumptions that the inter- and intra-granular gas bubble sizes are independent of position and only depend on time or fission density. Therefore, they are applicable to a material with uniform microstructure such as equiaxed grains with homogeneous defect distributions, homogeneous thermodynamic and kinetic properties of defects, and uniform radiation conditions. Very recently, we developed a three dimension (3D) microstructure dependent gas bubble swelling model for investigating the effect of heterogeneous microstructures and inhomogeneous thermodynamic properties of defects on gas bubble swelling in polycrystalline UMo fuels. However, the model doesn't take into account the effect of recrystallization on swelling kinetics. In this work, the spatially dependent rate theory is used to describe the evolution of interstitials and interstitial loop density. Recrystallization is described by a phase-field model with a concept of 'phase transition' when the local interstitial loop density is larger than a critical value. The intra- and inter- granular gas bubble evolution is described by the spatially dependent Booth model. A model integrating all the microstructure evolution enables one to study the effect of heterogeneous microstructures, recrystallization, and the metallic fuel thermodynamic and kinetic properties on gas bubble swelling kinetics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Development of high B s Fe–Ni-based metal amorphous nanocomposite by optimization of glass-forming ability

Thermocalc simulations identified compositions with good glass-forming ability (GFA) by locating minima in liquidus temperature, and solidification range in (Fe 70 Ni 30 ) x (B-Si-Nb) 100-x alloys with x = 82% and x = 85%, increased compared to previously developed x = 80% alloys. 3 compositions in the x = 82% system and 1 in the x = 85% system were successfully cast as amorphous magnetic ribbon. Magnetic properties of as-cast alloys showed improvements in Curie temperature and saturation induction, especially for the 85% alloy. Crystallization behavior in the 85% alloy was determined to occur as a 2-step process. Annealing studies showed (Fe 70 Ni 30 ) 82 Nb 2 Si 0 B 16 and (Fe 70 Ni 30 ) 82 Nb 3 Si 0 B 15 alloys to exhibit low coercivity and high B s with annealing. TEM results show significant crystallization in as-cast ribbon. The (Fe 70 Ni 30 ) 85 Nb 0.5 Si 0 B 14.5 alloy as-cast has small, uniformly distributed grains, allowing a useful nanocrystalline alloy to be produced as cast. Lastly, the parameter ΔT xg , the temperature range in which the material can be thermomechanically processed, was in the range of 12–23 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Graphene oxide coated side polished surface plasmon resonance optical fibre sensor with varying polishing losses

Four batches of side-polished SMF optical fibres with different polishing losses, − 0.5 dBm, − 5 dBm, − 10 dBm and − 15 dBm were coated with a graphene oxide layer of ~ 0.5 μm via drop casting. TE polarized light was propagated through the light during experiments and four different transformer oils with different water contents were dropped onto the sensor. The drop in the power of transmitted light was recorded. The responses of the sensors showed good linearity for all, but the least polished fibre showed the weakest response in terms of power drop towards change in concentration. The − 5 dBm fibre showed the best response per unit concentration change. Additional tests showed the increased response for a GO coated side polished sensor compared to an uncoated side polished sensor. Simulation using COMSOL was performed to show the effects on the electric field of a sensor with and without GO coating. Another set of simulations were performed to show the effects of reducing cladding thickness on the coupling of the electric field. Simulations show that the optimal cladding thickness is not the most polished fibre, coinciding with our results that − 15 dBm loss fibre did not show the most response per unit change in the analyte.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2016

Hot Rolling Scrap Reduction through Edge Cracking and Surface Defects Control

The design of future aircraft must address the combined demands for fuel efficiency, reduced emissions and lower operating costs. One contribution to these goals is weight savings through the development of new alloys and design techniques for airframe structures. This research contributes to the light-weighting through fabrication of monolithic components from advanced aluminum alloys by making a link between alloy processing history and in-service performance. Specifically, this research demonstrates the link between growing cracks with features of the alloy microstructure that follow from thermo-mechanical processing. This is achieved through a computer model of crack deviation. The model is validated against experimental data from production scale aluminum alloy plate, and demonstration of the effect of changes in processing history on crack growth is made. The model is cast in the open-source finite element code WARP3D, which is freely downloadable and well documented. This project provides benefit along several avenues. First, the technical contribution of the computer model offers the materials engineer a critical means of providing guidance both upstream, to process tuning to achieve optimal properties, and downstream, to enhance fault tolerance. Beyond the fuel savings and emissions reduction inherent in the light-weighting of aircraft structures, improved fault tolerance addresses demands for longer inspection intervals over baseline, and a lower life cycle cost.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

High-Performance AEM LTE with Advanced Membranes, Ionomers and PGM-Free Electrodes

Alkaline low temperature electrolysis (LTE) systems enjoy several potential advantages over acid-based LTE systems including facile oxygen evolution reaction (OER) kinetics and electrodes that can use little to no platinum group metals (PGM). The polymer membranes and membrane electrode assembly (MEA) structures going into alkaline electrochemical systems have seen significant advances in recent years. The objective of this project is to combine state-of-the-art alkaline polymer electrolyzer components into one optimized membrane electrode assembly (MEA) system to achieve DOE low temperature electrolysis (LTE) goals. The benefit of individual component advances cannot be fully appreciated until all aspects and components of the MEA are working at an equally high level of performance. New electrode fabrication methods were developed where solvent cast catalyst/ionomer solutions were used in place of insoluble ionomers to significantly improve adhesion. The membranes were improved in terms of durability and mechanical properties. The OER and HER catalysts were improved and made more durable.

08 HYDROGEN↗
DOE OSTI2018

Prediction of Cooling Curves for Controlled Unidirectional Solidification Under the Influence of Shrinkage: A Semi-analytical Approach

Quality of casting products can be significantly improved by controlling the crystal growth rate. Both dendritic and equiaxed grain structures depend strongly on crystal growth rate along the crystallographic direction. Uncontrolled solidification processes may lead to the formation of porous and columnar material with an extremely non-homogeneous composition distribution. These undesirable micro-structures can be avoided by adopting an optimal cooling rate (K/s) during the crystal growth. The present work focuses on determining suitable cooling curves to obtain desired unidirectional crystal growth rates, by implementing a semi-analytical model. Here, we defined cooling curve as the time history of temperature evolution at the cold boundary. The proposed semi-analytical heat transfer model is diffusion driven and accounts for shrinkage effect during solidification. The proposed model is found capable of predicting cooling curves for prescribed interface velocities. The model is self-sufficient in validating itself by means of solving inverse and forward problems. The cooling curve prediction by the model is validated by using it as the transient boundary condition for an existing enthalpy updating scheme-based numerical model. The proposed model is also applied to empirical data reported in literature, to validate the model against experimental results. All the validations showcased excellent fit. The proposed model will facilitate controlled unidirectional crystal growth rate by providing cooling rate (K/s) as an input for the experiments involving directional solidification.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Minimally Mutated HIV-1 Broadly Neutralizing Antibodies to Guide Reductionist Vaccine Design

An optimal HIV vaccine should induce broadly neutralizing antibodies (bnAbs) that neutralize diverse viral strains and subtypes. However, potent bnAbs develop in only a small fraction of HIV-infected individuals, all contain rare features such as extensive mutation, insertions, deletions, and/or long complementarity-determining regions, and some are polyreactive, casting doubt on whether bnAbs to HIV can be reliably induced by vaccination. We engineered two potent VRC01-class bnAbs that minimized rare features. According to a quantitative features frequency analysis, the set of features for one of these minimally mutated bnAbs compared favorably with all 68 HIV bnAbs analyzed and was similar to antibodies elicited by common vaccines. This same minimally mutated bnAb lacked polyreactivity in four different assays. We then divided the minimal mutations into spatial clusters and dissected the epitope components interacting with those clusters, by mutational and crystallographic analyses coupled with neutralization assays. Finally, by synthesizing available data, we developed a working-concept boosting strategy to select the mutation clusters in a logical order following a germline-targeting prime. We have thus developed potent HIV bnAbs that may be more tractable vaccine goals compared to existing bnAbs, and we have proposed a strategy to elicit them. This reductionist approach to vaccine design, guided by antibody and antigen structure, could be applied to design candidate vaccines for other HIV bnAbs or protective Abs against other pathogens.

59 BASIC BIOLOGICAL SCIENCES↗