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DOE OSTI2021

A Novel Laser-Aided Machining and Polishing Process for Additive Manufacturing Materials with Multiple Endmill Emulating Scan Patterns

In additive manufacturing (AM), the surface roughness of the deposited parts remains significantly higher than the admissible range for most applications. Additionally, the surface topography of AM parts exhibits waviness profiles between tracks and layers. Therefore, post-processing is indispensable to improve surface quality. Laser-aided machining and polishing can be effective surface improvement processes that can be used due to their availability as the primary energy sources in many metal AM processes. While the initial roughness and waviness of the surface of most AM parts are very high, to achieve dimensional accuracy and minimize roughness, a high input energy density is required during machining and polishing processes although such high energy density may induce process defects and escalate the phenomenon of wavelength asperities. In this paper, we propose a systematic approach to eliminate waviness and reduce surface roughness with the combination of laser-aided machining, macro-polishing, and micro-polishing processes. While machining reduces the initial waviness, low energy density during polishing can minimize this further. The average roughness (Ra=1.11μm) achieved in this study with optimized process parameters for both machining and polishing demonstrates a greater than 97% reduction in roughness when compared to the as-built part.

42 ENGINEERING↗

NASA NTRS1975

Geologic structure of shallow maria

Isopach maps and structural contour maps of the eastern mare basins (30 deg N to 30 deg S; 0 deg to 100 deg E), constructed from measurements of partially buried craters, are presented and discussed. The data, which are sufficiently scattered to yield gross thickness variations, are restricted to shallow maria with less than 1500-2000 m of mare basalts. The average thickness of basalt in the irregular maria is between 200 and 400 m. Correlations between surface topography, basalt thickness, and basin floor structure are apparent in most of the basins that were studied. The mare surface is commonly depressed in regions of thick mare basalts; mare ridges are typically located in regions of pronounced thickness changes; and arcuate mare rilles are confined to thin mare basalts. Most surface structures are attributed to shallow stresses developed within the mare basalts during consolidation and volume reduction.

Dehon, R. A.↗

NASA NTRS1981

Earth Survey Applications Division

Accomplishments of research and data analysis conducted to study physical parameters and processes inside the Earth and on the Earth's surface, to define techniques and systems for remotely sensing the processes and measuring the parameters of scientific and applications interest, and the transfer of promising operational applications techniques to the user community of Earth resources monitors, managers, and decision makers are described. Research areas covered include: geobotany, magnetic field modeling, crustal studies, crustal dynamics, sea surface topography, land resources, remote sensing of vegetation and soils, and hydrological sciences. Major accomplishments include: production of global maps of magnetic anomalies using Magsat data; computation of the global mean sea surface using GEOS-3 and Seasat altimetry data; delineation of the effects of topography on the interpretation of remotely-sensed data; application of snowmelt runoff models to water resources management; and mapping of snow depth over wheat growing areas using Nimbus microwave data.

Carpenter, L.↗

DOE OSTI2025

Predictive numerical modeling of plasma-induced surface roughness and wettability evolution in LM-PAEK/CF tape

Plasma surface modification effectively enhances adhesion in thermoplastic composites, yet its impacts on high-performance polymers like low-melting polyaryletherketone (LM-PAEK) remain inadequately quantified. Here, this study integrates experimental analysis and numerical modeling to characterize surface roughness and wettability changes in LM-PAEK/carbon fiber composites treated with atmospheric plasma. Atomic Force Microscopy quantified surface topography (n = 10 per condition for contact angles), while static contact-angle assessments measured wettability. Roughness rapidly increased from ∼0.2 nm to 1.6 nm, and contact angle reduced from ∼90° to 24°, both stabilizing after 25–30 s of exposure. A semi-empirical, physics-informed framework was calibrated to these data, coupling surface chemistry via the Owens–Wendt decomposition with topography via the Wenzel roughness factor, and evaluated using out-of-sample (cross-validated) tests, while static contact angle assessments measured wettability. Numerical predictions matched experimental results closely (RMSE <5%, R 2 > 0.95). Incorporating material-specific parameters, the calibrated model supports plasma-treatment optimization and provides quantitative guidance for improving interfacial adhesion in thermoplastic composite manufacturing.

Atomic Force Microscopy↗

DOE OSTI2021

Determining Spatial Scales of Soil Moisture—Cloud Coupling Pathways Using Semi-Idealized Simulations

The spatial scales of land-atmosphere interactions over heterogeneous, realistic soil moisture patterns are critical to improve our understanding of land-atmosphere interactions. However, these scales are poorly quantified. We use high-resolution numerical experiments to quantify the spatial scales for a selected day during the Holistic Interactions of Shallow Clouds, Aerosols, and Land-Ecosystems (HI-SCALE) campaign in Oklahoma. A semi-idealized approach (removing background winds and surface topography while retaining the real-world data for other boundary conditions) enables examination of the local influence from the surface. Simulations that apply uniform surface, variable land cover with uniform soil moisture, and variable land cover with variable soil moisture are then compared. Land cover variations, especially water and urban surfaces, create two variance peaks in the surface sensible heat flux in the scales >10 km (meso-β) and <6 km (meso-γ). Both peaks are enhanced by the observation-based soil moisture distribution that has most of its variance in the meso-β scale. Atmospheric response in the meso-β scale is hydrostatic with weak vertical motion. The land cover variations induce secondary circulations in the scales of 2.5–6 km. The additional soil moisture variability intensifies extreme circulations over dry soil patches and sharp sensible heat flux gradients, slightly extending the characteristic scales to 2.5–9 km. While their areal coverage is small, soil moisture variations on such “hotspots” lead to substantially larger convective cloud structure and domain-mean rainfall, calling for a consideration of their non-linear effect in large-scale models.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1991

Pretreatment of lubricated surfaces with sputtered cadmium oxide

Cadmium oxide is used with a dry solid lubricant on a surface to improve wear resistance. The surface topography is first altered by photochemical etching to a predetermined pattern. The cadmium oxide is then sputtered onto the altered surface to form an intermediate layer to more tightly hold the dry lubricant, such as graphite.

Fusaro, Robert L.↗

NASA NTRS2008

Utilizing Mars Global Reference Atmospheric Model (Mars-GRAM 2005) to Evaluate Entry Probe Mission Sites

Engineering-level atmospheric model widely used for diverse mission applications. Mars-GRAM s perturbation modeling capability is commonly used, in a Monte-Carlo mode, to perform high fidelity engineering end-to-end simulations for entry, descent, and landing (EDL)1. Traditional Mars-GRAM options for representing the mean atmosphere along entry corridors include: a) TES Mapping Years 1 and 2, with Mars-GRAM data coming from MGCM model results driven by observed TES dust optical depth; and b) TES Mapping Year 0, with user-controlled dust optical depth and Mars-GRAM data interpolated from MGCM model results driven by selected values of globally-uniform dust optical depth. From the surface to 80 km altitude, Mars-GRAM is based on NASA Ames Mars General Circulation Model (MGCM). Mars-GRAM and MGCM use surface topography from Mars Global Surveyor Mars Orbiter Laser Altimeter (MOLA), with altitudes referenced to the MOLA areoid, or constant potential surface. Mars-GRAM 2005 has been validated2 against Radio Science data, and both nadir and limb data from the Thermal Emission Spectrometer (TES)

Justh, Hilary L.↗

NASA NTRS2008

Evaluating Mars Science Laboratory Landing Sites with the Mars Global Reference Atmospheric Model (Mars-GRAM 2005)

The Mars Global Reference Atmospheric Model (Mars-GRAM) is an engineering-level atmospheric model widely used for diverse mission applications. Mars-GRAM s perturbation modeling capability is commonly used, in a Monte-Carlo mode, to perform high fidelity engineering end-to-end simulations for entry, descent, and landing (EDL) [1]. From the surface to 80 km altitude, Mars-GRAM is based on the NASA Ames Mars General Circulation Model (MGCM). Mars-GRAM and MGCM use surface topography from Mars Global Surveyor Mars Orbiter Laser Altimeter (MOLA), with altitudes referenced to the MOLA areoid, or constant potential surface. Traditional Mars-GRAM options for representing the mean atmosphere along entry corridors include: (1) Thermal Emission Spectrometer (TES) mapping years 1 and 2, with Mars-GRAM data coming from NASA Ames Mars General Circulation Model (MGCM) results driven by observed TES dust optical depth or (2) TES mapping year 0, with user-controlled dust optical depth and Mars-GRAM data interpolated from MGCM model results driven by selected values of globally-uniform dust optical depth. Mars-GRAM 2005 has been validated [2] against Radio Science data, and both nadir and limb data from TES [3]. There are several new features included in Mars-GRAM 2005. The first is the option to use input data sets from MGCM model runs that were designed to closely simulate conditions observed during the first two years of TES observations at Mars. The TES Year 1 option includes values from April 1999 through January 2001. The TES Year 2 option includes values from February 2001 through December 2002. The second new feature is the option to read and use any auxiliary profile of temperature and density versus altitude. In exercising the auxiliary profile Mars-GRAM option, values from the auxiliary profile replace data from the original MGCM databases. Some examples of auxiliary profiles include data from TES nadir or limb observations and Mars mesoscale model output at a particular location and time. The final new feature is the addition of two Mars-GRAM parameters that allow standard deviations of Mars-GRAM perturbations to be adjusted. The parameter rpscale can be used to scale density perturbations up or down while rwscale can be used to scale wind perturbations.

Justh, H. L.↗

NASA NTRS2010

Modeling Martian Dust Using Mars-GRAM

Engineering-level atmospheric model widely used for diverse mission applications. Mars-GRAM s perturbation modeling capability is commonly used, in a Monte-Carlo mode, to perform high fidelity engineering end-to-end simulations for entry, descent, and landing (EDL). From the surface to 80 km altitude, Mars-GRAM is based on NASA Ames Mars General Circulation Model (MGCM). Mars-GRAM and MGCM use surface topography from Mars Global Surveyor Mars Orbiter Laser Altimeter (MOLA), with altitudes referenced to the MOLA areoid, or constant potential surface. Traditional Mars-GRAM options for representing the mean atmosphere along entry corridors include: TES Mapping Years 1 and 2, with Mars-GRAM data coming from MGCM model results driven by observed TES dust optical depth TES Mapping Year 0, with user-controlled dust optical depth and Mars-GRAM data interpolated from MGCM model results driven by selected values of globally-uniform dust optical depth. Mars-GRAM 2005 has been validated against Radio Science data, and both nadir and limb data from the Thermal Emission Spectrometer (TES).

Justh, Hilary L.↗

NASA NTRS1984

An estimate of global absolute dynamic topography

The absolute dynamic topography of the world ocean is estimated from the largest scales to a short-wavelength cutoff of about 6700 km for the period July through September, 1978. The data base consisted of the time-averaged sea-surface topography determined by Seasat and geoid estimates made at the Goddard Space Flight Center. The issues are those of accuracy and resolution. Use of the altimetric surface as a geoid estimate beyond the short-wavelength cutoff reduces the spectral leakage in the estimated dynamic topography from erroneous small-scale geoid estimates without contaminating the low wavenumbers. Comparison of the result with a similarly filtered version of Levitus' (1982) historical average dynamic topography shows good qualitative agreement. There is quantitative disagreement, but it is within the estimated errors of both methods of calculation.

Tai, C.-K.↗

NASA NTRS2023

A Framework for Estimating Global River Discharge From the Surface Water and Ocean Topography Satellite Mission

The Surface Water and Ocean Topography (SWOT) mission will vastly expand measurements of global rivers, providing critical new data sets for both gaged and ungaged basins. SWOT discharge products (available approximately 1 year after launch) will provide discharge for all river that reaches wider than 100 m. In this paper, we describe how SWOT discharge produced and archived by the US and French space agencies will be computed from measurements of river water surface elevation, width, and slope and ancillary data, along with expected discharge accuracy. We present for the first time a complete estimate of the SWOT discharge uncertainty budget, with separate terms for random (standard error) and systematic (bias) uncertainty components in river discharge time series. We expect that discharge uncertainty will be less than 30% for two-thirds of global reaches and will be dominated by bias. Separate river discharge estimates will combine both SWOT and in situ data; these “gage-constrained” discharge estimates can be expected to have lower systematic uncertainty. Temporal variations in river discharge time series will be dominated by random error and are expected to be estimated within 15% for nearly all reaches, allowing accurate inference of event flow dynamics globally, including in ungaged basins. We believe this level of accuracy lays the groundwork for SWOT to enable breakthroughs in global hydrologic science.

Michael Durand↗

DOE OSTI2022

Boiling Transitions During Droplet Contact on Superheated Nano/Micro-Structured Surfaces

Manipulating surface topography is one of the most promising strategies for increasing the efficiency of numerous industrial processes involving droplet contact with superheated surfaces. In such scenarios, the droplets may immediately boil upon contact, splash and boil, or could levitate on their own vapor in the Leidenfrost state. In this work we report the outcomes of water droplets coming in gentle contact with designed nano/micro-textured surfaces at a wide range of temperatures as observed using high-speed optical and X-ray imaging. Further, we report a paradoxical increase in the Leidenfrost temperature ($T_{\text{LFP}}$) as the texture spacing is reduced below a critical value (~10 μm) that represents a minima in $T_{\text{LFP}}$. Although droplets on such textured solids appear to boil upon contact, our studies suggest that their behavior is dominated by hydrodynamic instabilities implying that the increase in $T_{\text{LFP}}$ may not necessarily lead to enhanced heat transfer. On such surfaces, the droplets display a new regime characterized by splashing accompanied by a vapor jet penetrating through the droplets before they transition to the Leidenfrost state. We provide a comprehensive map of boiling behavior of droplets over a wide range of texture spacings that may have significant implications towards applications such as electronics cooling, spray cooling, nuclear reactor safety and containment of fire calamities.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1995

Ice flow dynamics of the Greenland ice sheet from SAR interferometry

Synthetic-aperture radar (SAR) interferograms produced from ESA's ERS-1 satellite, provide the first synoptic view of ice flow dynamics of the western sector of the Greenland Ice Sheet. Glacial motion is detected in the radar ranging direction at millimetric scales, across a complete sequence of snow accumulation and melting regimes, despite significant varations in their radar scattering properties. Ice flow evolves from a slow, regular motion at the higher elevations. At lower elevations, motion is strongly convoluted by meter-scale undulations in surface topography, which have a unique interferometric signature that enables a novel approach for retrieving flow direction. Inferred flow directions, combined with surface displacements in the radar ranging direction, yield ice velocity estimates that are within 6% of in-situ measurements gathered along a 40 km survey line. Application of repeat-pass SAR interferometry to the entire Greenland Ice Sheet should enable precise mapping of its ice flow dynamics at an unprecedented level of spatial detail.

Rignot, E.↗

DOE OSTI2024

Investigation of the cesium activation of Ga⁢N photocathodes by low-energy electron microscopy

Low-energy electron microscopy (LEEM) was performed on p-Ga⁢N samples during in situ cesium deposition. LEEM images of electron reflectivity recorded as a function of the incident electron energy at different Cs coverages allowed to spatially resolve the evolution of the local work function (WF) during the activation process. While the average WF drops by more than 3 eV, the local WF remains quite uniform across the surface throughout the activation process. Maximum fluctuations of less than 0.2 eV were observed in the WF maps for Cs coverage of a fraction of a monolayer. These fluctuations are mainly related to the surface topography, in particular, to the atomic steps’ structure, which replicates the substrate miscut. Apart from these weak spatial fluctuations, no Cs clusters that would induce strong local WF contrast were observed at the scale of the 20-nm resolution of the measurements. These observations agree with the simple model of semiconductor activation to negative electron affinity that describes the formation of a dipole layer as responsible for the lowering of the WF. Additionally, at complete Cs coverage, the WF becomes fully homogeneous over the surface, smoothing out features originating from defects and topography.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

AFM Microcantilever With a Collocated AlN Sensor-Actuator Pair: Enabling Efficient Q-Control for Dynamic Imaging

This manuscript presents a novel microcantilever with an embedded piezoelectric sensor-actuator pair for dynamic atomic force microscopy (AFM). The transducer pair is constructed from a two-layered AlN stack. Stacking the piezoelectric transducers in this manner leads to a minimal feedthrough from actuation to sense electrode, granting a high dynamic range frequency response for dynamic mode AFM. The cantilever's design allows for dual mode operation at 1 st and 2 nd resonance modes. High resolution tapping mode imaging results are reported, while the cantilever is operated at these modes. A feedback control loop is used to modify quality factor of the 1 st mode of the cantilever, using a positive position feedback (PPF) controller. Here, a faster response time is achieved by reducing the Q-factor, enabling the cantilever to track the topography at a higher scan rate. Results of bimodal AFM imaging are reported, using amplitude changes of the 1 st mode for surface topography, while material properties are encoded in phase changes of the 2 nd mode.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Characterization of Incremental Markings in the Sagittal Otolith of the Pacific Sardine ( Sardinops sagax ) Using Different Imaging Modalities

Teleost fish possess calcium carbonate otoliths located in separate chambers (utriculus, sacculus, and lagena) of their membranous labyrinth. This study analyzed the surface topography of the sagittal otolith of the Pacific sardine (Sardinops sagax) and the daily and annual increments in these otoliths. The otolith surface, characterized by laser scanning confocal microscopy for the first time, consisted of a system of prominent ridges and valleys (grooves), but it is unclear whether these structures are functional or represent time-resolving markings reflecting growth periodicity. Within the first-year volume, daily increments, each consisting of an incremental (more mineralized) and a discontinuous (less mineralized) zone, were resolved by optical microscopy and backscattered electron (BSE) imaging in the scanning electron microscope (SEM). Daily growth increments could, however, not be resolved in volumes formed after the first year, presumably because otolith growth markedly slows down and spacing of incremental markings narrows in older fish. Throughout otolith growth, the crystalline network continues across the discontinuous zones. Fluorochrome labeling provides additional information on growth after the first year. Compared with optical and BSE imaging, synchrotron microComputed Tomography of intact otoliths (with 0.69 µm volume elements) was less able to resolve daily increments; X-ray phase contrast reconstructions provided more detail than reconstructions with absorption contrast. Future research directions are proposed.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1990

Interannual differences of Geosat altimeter heights and sea level - The importance of a datum

Sea surface height data from the Geosat altimeter are compared with island sea level data from 18 gages in the western and central tropical Pacific during December 1986 to November 1987. Care was taken to ensure that the two data sets are referenced to the same mean surface. This was done by requiring that both data sets have a zero mean sea level over the period April 1985 to April 1986. When the annual means are computed at each station in the later time period, it is found that the annual mean sea surface height values have drifted away from the corresponding sea level values by as much as 16 cm. Further, the pattern of differences that develop between the two data sets is not random but is spatially coherent with a strong east-west gradient. These observations illustrate the necessity for sea surface height data to be referred to a well-defined zero point, a datum, in order to reliably monitor interannual changes in the sea surface topography. Until these differences can be eliminated, it will be necessary to use tide gage data as benchmarks for the altimeter sea surface height data.

Wyrtki, Klaus↗

NASA NTRS2000

Future Applications Using Return-Pulse Correlation from Imaging Laser Altimeters

The Laser Vegetation Imaging Sensor (LVIS) is an airborne, wide-swath, digitization-only laser altimeter capable of collecting full return waveforms (i.e. echoes) from laser footprints ranging in diameter from 1 to 80 m across up to a 1 km wide data swath. The return waveform can be used to enhance the accuracy of laser ranging and to provide information about the vertical structure of vegetation and topography within each laser footprint. Although extremely small laser footprints (< 1 0 cm diameter) generally return simple, impulse responses to their target surface, larger footprints typically exhibit complex returns representing the diverse vertical distributions of surfaces contained in each footprint. Only a handful of airborne and spaceborne laser altimeters record the return echo or return pulse that is reflected from the Earth's surface (i.e. NASA's LVIS, SLA, VCL, and GLAS laser altimeters). Waveforms are currently interpreted to extract a timing or ranging point or points to represent the mean ground elevation or the vertical height of vegetation. But, recent progress using pulse shape correlation techniques shows promise for a variety of science applications involving change detection of surface topography and vegetation as well as potential for improving data processing by correlating images or crossovers to solve systematic biases. We show example correlation images from LVIS and discuss instrument design implications and potential science applications.

Blair, J. Bryan↗