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DOE OSTI2024

3D Reconstruction of a High-Energy Diffraction Microscopy Sample Using Multi-modal Serial Sectioning with High-Precision EBSD and Surface Profilometry

High-energy diffraction microscopy (HEDM) combined with in situ mechanical testing is a powerful nondestructive technique for tracking the evolving microstructure within polycrystalline materials during deformation. This technique relies on a sophisticated analysis of X-ray diffraction patterns to produce a three-dimensional reconstruction of grains and other microstructural features within the interrogated volume. However, it is known that HEDM can fail to identify certain microstructural features, particularly smaller grains or twinned regions. Characterization of the identical sample volume using high-resolution surface-specific techniques, particularly electron backscatter diffraction (EBSD), can not only provide additional microstructure information about the interrogated volume but also highlight opportunities for improvement of the HEDM reconstruction algorithms. In this study, a sample fabricated from undeformed “low solvus, high refractory” nickel-based superalloy was scanned using HEDM. The volume interrogated by HEDM was then carefully characterized using a combination of surface-specific techniques, including epi-illumination optical microscopy, zero-tilt secondary and backscattered electron imaging, scanning white light interferometry, and high-precision EBSD. Custom data fusion protocols were developed to integrate and align the microstructure maps captured by these surface-specific techniques and HEDM. The raw and processed data from HEDM and serial sectioning have been made available via the Materials Data Facility (MDF) at https://doi.org/10.18126/4y0p-v604 for further investigation.

36 MATERIALS SCIENCE↗

NASA NTRS2001

Sources of Variability in the Stratospheric Column of Nitrogen Dioxide

Instruments such as the Global Ozone Monitoring Experiment (GOME, on the European Remote Sensing Satellite (ERS-2), launched 1995), the Scanning Imaging Absorption Spectrometer for Atmospheric Chartography (SCIAMACHY, on ENVISAT, to be launched July 2001) and the Ozone Monitoring Instrument (OMI on EOS Aura, to be launched 2003) make measurements of the total column of NO2. There is interest in separating the stratospheric and tropospheric contributions to the column, as the tropospheric column provides a measure of pollution. We are using a 3D chemistry and transport model driven by winds from the Goddard Space Flight Center Data Assimilation System to examine variability in the stratospheric NO2 column. Model results for NOx = NO + NO2 + 2N2O5 will be shown to compare well with sunset observations from the Halogen Occultation Experiment on the Upper Atmosphere Research Satellite, and to exhibit similar temporal and spatial dependence. Partitioning between NO, NO2, and N2O5 is also shown to compare well with observations. This good agreement supports the use of simulated fields in the stratosphere to derive the tropospheric column from the total column. Preliminary comparisons of the tropospheric column with model simulations for the troposphere will also be shown.

Douglass, Anne↗

NASA NTRS2019

Bounding Methods for Heterogeneous Lidar-derived Navigational Geofences

Safe Unmanned Aerial Vehicle (UAV) operations near the ground require navigation methods that avoid fixed obstacles such as buildings, power lines and trees. Aerial lidar surveys of ground structures are available with the precision and accuracy to geolocate obstacles, but the high volume of raw survey data can exceed the compute power of onboard processors and the rendering ability of ground-based flight planning maps. Representing ground structures with bounding polyhedra instead of point clouds greatly reduces the data size and can enable effective obstacle avoidance, as long as the bounding geometry envelopes the structures with high spatial fidelity. This report describes in detail four methods to compute bounding geometries of ground obstacles from lidar point clouds. The four methods are: 1) 2.5D Maximum Elevation Box, 2) 2.5D Ground Map Extrusion, 3) 3D Bounding Cylinder, and 4) 3D Bounding Box. The methods are applied to five point cloud datasets from lidar surveys of UAV flight research sites in Georgia and Virginia with an average point spacing that ranges from 0.1m to 0.6m. The methods are assessed using survey areas with geometrically heterogeneous ground structures: buildings, vegetation, power lines, and sub-meter structures such as road signs and guy wires. The 2.5D Maximum Elevation Box method is useful for simple structures. The 2.5D Ground Map Extrusion method efficiently encloses vegetation, but requires handdrawn ground footprints. The 3D Bounding Cylinder method excels at enclosing linear structures such as power lines and fences. The 3D Bounding Box method excels at enclosing planar structures such as buildings. The methods are compared on the basis of data compression and boundary fidelity on selected areas. The 2.5D methods yield the highest data compression but the polyhedra produced by them enclose significant amounts of empty space. Boundary fidelity is superior for the 3D methods, though this fidelity comes at the cost of a roughly thirtyfold lower data compression ratio than the 2.5D Maximum Elevation Box method. A mix of these output geometries is proposed for autonomous UAV navigation with limited on-board computing. Both the accuracy and spatial detail of emerging satellite-based survey technology lower than that of aerial lidar scanning survey technology. Sub-meter structures and thin linear structures are not reliably mapped at present by satellite-based surveys.

Moore, Andrew J.↗

DOE OSTI2025

Advanced Interactive 3D Visualization Tool for Customizable Analyses of Tomography Datasets in Material Science

Current methods for visualizing and analyzing 3D tomography datasets in materials science often lack the interactivity and depth required for detailed structural insights. This limitation restricts a researchers' ability to accurately interpret complex data, which is critical for advancing material innovations and understanding structural properties. To address this issue, we have developed a novel, web-based interactive 3D visualization and analysis tool from the Trame framework that offers customizable features to enhance data interpretability. The tool allows users to adjust parameters such as visible range, slice planes, data rotation, and layering, providing a more detailed and dynamic view of complex structures. Its user-friendly web interface increases the accessibility and ease of use for both novice and experienced researchers, to visualize large volumetric datasets. The tool supports a diverse range of data formats, making it versatile for various research applications. Unique capabilities include real-time data manipulation, automated feature detection, context-sensitive feedback, and real-time volume calculations and distributions per sliced region or layer, alongside the ability to quickly generate high-quality screenshots and videos for presentations and reports. These advancements offer a comprehensive solution for enhanced 3D data exploration, significantly improving the analysis process and communication of results in materials science.

36 - MATERIALS SCIENCE↗

NASA NTRS2001

C-Coupon Studies of CMCS: Fracture Behavior and Microstructural Characterization

A curved beam 'C-coupon' was used to assess fracture behavior in a Sylramic(tm)/melt infiltration (MI) SiC matrix composite. Failure stresses and fracture mechanisms, as determined by optical and scanning electron microstructural analysis, are compared with finite element stress calculations to analyze failure modes. Material microstructure was found to have a strong influence on mechanical behavior. Fracture occurs in interlaminar tension (ILT), provided that the ratio of ILT to tensile strength for the material is less than the ratio of radial to hoop stresses for the C-coupon geometry. Utilization of 3D architectures to improve interlaminar strength requires significant development efforts to incorporate through thickness fibers in regions with high curvatures while maintaining uniform thickness, radius, and microstructure.

Hurwitz, Frances I.↗

NASA NTRS2002

Visions of our Planet's Atmosphere, Land & Oceans

The NASA/NOAA Electronic Theater presents Earth science observations and visualizations in a historical perspective. Fly in from outer space to South Africa, Cape Town and Johannesburg using NASA Terra MODIS data, Landsat data and 1m IKONOS "Spy Satellite" data. Zoom in to any place South Africa using Earth Viewer 3D from Keyhole Inc. and Landsat data at 30 m resolution. Go back to the early weather satellite images from the 1960s and see them contrasted with the latest US and international global satellite weather movies including hurricanes & "tornadoes". See the latest visualizations of spectacular images from NASA/NOAA remote sensing missions like Terra, GOES, TRMM, SeaWiFS, Landsat 7 including 1 - min GOES rapid scan image sequences of Nov 9th 2001 Midwest tornadic thunderstorms and have them explained. See how High-Definition Television (HDTV) is revolutionizing the way we present science to the public. See dust storms and flooding in Africa and smoke plumes from fires in Mexico. See visualizations featured on the covers of Newsweek, TIME, National Geographic, Popular Science & on National & International Network TV. New computer software tools allow us to roam & zoom through massive global images e.g. Landsat tours of the US, and Africa, showing desert and mountain geology as well as seasonal changes in vegetation. See animations of the north and south polar ice packs and with icebergs on the coasts of Greenland and off the coast of Antarctica. Spectacular new visualizations of the global land, atmosphere & oceans are shown. Listen to the pulse of our planet. See how land vegetation, ocean plankton, clouds and temperatures respond to the sun & seasons. See vortexes and currents in the global oceans that bring up the nutrients to feed tiny algae and draw the fish, whales and fisherman. See the how the ocean blooms in response to these currents and El Nino/La Nina climate changes. See the city lights, fishing fleets, gas flares and biomass burning of the Earth at night observed by the "night-vision" DMSP military satellite. The presentation will be made using the latest HDTV and video projection technology that is now done from a laptop computer through an entirely digital path.

Hasler, Arthur F.↗

NASA NTRS2002

Visions of our Planet's Atmosphere, Land and Oceans

Hasler, A. F.↗

NASA NTRS2006

Improved Hurricane Boundary Layer Observations with the Imaging Wind and Rain Airborne Profiler

During the NOAA/NESDIS 2005 Hurricane Season (HS2005) and the 2006 Winter Experiment, the University of Massachusetts (UMass) installed two instruments on the NOAA N42RF WP-3D research aircraft: the Imaging Wind and Rain Airborne Profiler (IWRAP) and the Simultaneous Frequency Microwave Radiometer (SFMR). IWRAP is a dual-band (C- and Ku), dual-polarized pencil-beam airborne radar that profiles the volume backscatter and Doppler velocity from rain and that also measures the ocean backscatter response. It simultaneously profiles along four separate incidence angles while conically scanning at 60 RPM. SFMR is a C-band nadir viewing radiometer that measures the emission from the ocean surface and intervening atmosphere simultaneously at six frequencies. It is designed to obtain the surface wind speed and the column average rain rate. Both instruments have previously been flown during the 2002, 2003 and 2004 hurricane seasons. For the HS2005, the IWRAP system was modified to implement a raw data acquisition system. The importance of the raw data system arises when trying to profile the atmosphere all the way down to the surface with a non-nadir looking radar system. With this particular geometry, problems arise mainly from the fact that both rain and ocean provide a return echo coincident in time through the antenna s main lobe. This paper shows how this limitation has been removed and presents initial results demonstrating its new capabilities to derive the atmospheric boundary layer (ABL) wind field within the inner core of hurricanes to much lower altitudes than the ones the original system was capable of, and to analyze the spectral response of the ocean backscatter and the rain under different wind and rain conditions.

tropical cyclones↗

NASA NTRS1995

Full resolution hologram-like autostereoscopic display

Under this program, Dimension Technologies Inc. (DTI) developed a prototype display that uses a proprietary illumination technique to create autostereoscopic hologram-like full resolution images on an LCD operating at 180 fps. The resulting 3D image possesses a resolution equal to that of the LCD along with properties normally associated with holograms, including change of perspective with observer position and lack of viewing position restrictions. Furthermore, this autostereoscopic technique eliminates the need to wear special glasses to achieve the parallax effect. Under the program a prototype display was developed which demonstrates the hologram-like full resolution concept. To implement such a system, DTI explored various concept designs and enabling technologies required to support those designs. Specifically required were: a parallax illumination system with sufficient brightness and control; an LCD with rapid address and pixel response; and an interface to an image generation system for creation of computer graphics. Of the possible parallax illumination system designs, we chose a design which utilizes an array of fluorescent lamps. This system creates six sets of illumination areas to be imaged behind an LCD. This controlled illumination array is interfaced to a lenticular lens assembly which images the light segments into thin vertical light lines to achieve the parallax effect. This light line formation is the foundation of DTI's autostereoscopic technique. The David Sarnoff Research Center (Sarnoff) was subcontracted to develop an LCD that would operate with a fast scan rate and pixel response. Sarnoff chose a surface mode cell technique and produced the world's first large area pi-cell active matrix TFT LCD. The device provided adequate performance to evaluate five different perspective stereo viewing zones. A Silicon Graphics' Iris Indigo system was used for image generation which allowed for static and dynamic multiple perspective image rendering. During the development of the prototype display, we identified many critical issues associated with implementing such a technology. Testing and evaluation enabled us to prove that this illumination technique provides autostereoscopic 3D multi perspective images with a wide range of view, smooth transition, and flickerless operation given suitable enabling technologies.

Eichenlaub, Jesse B.↗

NASA NTRS2013

Terahertz Lasers Reveal Information for 3D Images

After taking off her shoes and jacket, she places them in a bin. She then takes her laptop out of its case and places it in a separate bin. As the items move through the x-ray machine, the woman waits for a sign from security personnel to pass through the metal detector. Today, she was lucky; she did not encounter any delays. The man behind her, however, was asked to step inside a large circular tube, raise his hands above his head, and have his whole body scanned. If you have ever witnessed a full-body scan at the airport, you may have witnessed terahertz imaging. Terahertz wavelengths are located between microwave and infrared on the electromagnetic spectrum. When exposed to these wavelengths, certain materials such as clothing, thin metal, sheet rock, and insulation become transparent. At airports, terahertz radiation can illuminate guns, knives, or explosives hidden underneath a passenger s clothing. At NASA s Kennedy Space Center, terahertz wavelengths have assisted in the inspection of materials like insulating foam on the external tanks of the now-retired space shuttle. "The foam we used on the external tank was a little denser than Styrofoam, but not much," says Robert Youngquist, a physicist at Kennedy. The problem, he explains, was that "we lost a space shuttle by having a chunk of foam fall off from the external fuel tank and hit the orbiter." To uncover any potential defects in the foam covering, such as voids or air pockets, that could keep the material from staying in place, NASA employed terahertz imaging to see through the foam. For many years, the technique ensured the integrity of the material on the external tanks.

Source record↗

DOE OSTI2026

Directing Assembly of Mesoscale Multi‐Shell Morphologies of DNA Origami Crystals

Nature builds hierarchically ordered materials, such as seashells, wood, and bones, through spatially and temporally regulated growth. Mimicking such a level of control in synthetic systems remains challenging, particularly in achieving multiscale organizations with prescribed nanoscale arrangements and desired material morphologies. In this study, we introduce a DNA-based self-assembly strategy for constructing diverse multi-shell mesoscale morphologies from nanoscale lattices, enabling prescribed structural, and compositional 3D material patterns. Using DNA origami frames as modular monomers, we direct anisotropic epitaxial growth through addressable DNA frame binding motifs and encapsulate nanoparticles (NPs) in desired 3D patterns. Sequential monomer addition under thermodynamically favorable conditions enables shell growth through heterogeneous nucleation while minimizing unwanted homogeneous nucleation. Here, we demonstrate that DNA-encoded addressability enables epitaxial shell growth along specific lattice directions, yielding crystals with multilayered mesoscale organization, including tube-like (sushi roll) and plate-like (macaron) morphologies. Shell-specific NP configurations and compositions are achieved through addressable and differentiated placement of NPs within each shell, as validated by small-angle x-ray scattering and cross-sectional scanning transmission electron microscopy. We further demonstrate addressable NP release and reveal that shells modulate release kinetics. Together, these findings establish a platform for fabricating DNA origami crystals with programmable mesoscale morphologies, nanoscale structure, composition, and transport properties.

3D patterning↗

DOE OSTI2025

Altermagnetic Band Splitting in 10 nm Epitaxial CrSb Thin Films

Altermagnets are a newly identified family of collinear antiferromagnets with a momentum-dependent spin-split band structure of non-relativistic origin, derived from spin-group symmetry-protected crystal structures. Among candidate altermagnets, CrSb is attractive for potential applications because of a large spin-splitting near the Fermi level and a high Néel transition temperature of around 700 K. Molecular beam epitaxy is used to synthesize CrSb (0001) thin films with thicknesses ranging from 10 to 100 nm. Structural characterization, using reflection high energy electron diffraction, scanning transmission electron microscopy, and X-ray diffraction, demonstrates the growth of epitaxial films with good crystallinity. Polarized neutron reflectometry shows the absence of any net magnetization, consistent with antiferromagnetic order. In vacuo angle resolved photoemission spectroscopy (ARPES) measurements probe the band structure in a previously unexplored regime of film thickness, down to 10 nm. These ARPES measurements show a bulk-type, 3D momentum-dependent band splitting of up to 0.7 eV with g-wave symmetry, consistent with that seen in prior studies of bulk single crystals. The distinct altermagnetic band structure required for potential spin-transport applications survives down to the ∼10 nm thin film limit at room temperature.

Santhosh, Sandra↗

NASA NTRS2002

Visions of our Planet's Atmosphere, Land and Oceans: Spectacular Visualizations of our Blue Marble

Hasler, A. F.↗

DOE OSTI2024

Elucidating metal–organic framework structures using synchrotron serial crystallography

Metal organic frameworks (MOFs) are porous crystalline materials that display a wide variety of physical and chemical properties. Their single crystal structure determination is often challenging because in most cases micro- or nano-sized crystals spontaneously form upon MOF synthesis, which cannot be recrystallized. The production of larger single crystals for structure determination involves optimizing, and thus modifying, the conditions of synthesis, in which success cannot be guaranteed. Failure to produce crystals suitable for single-crystal X-ray diffraction leaves the 3D structure of the MOF compound unknown, and scientists must resort to more challenging structure solution methods based on X-ray powder or electron diffraction data. These laborious tasks can be avoided by using serial crystallography techniques which merge data collected on many micro-crystals. Here, we report the application of three synchrotron serial crystallography methods. We call these “mesh”, “grid” and “mesh&collect” scans. “Still” images (no rotation) are collected in the mesh scan approach, whereas small rotational wedges are collected in the grid scan method. The third protocol, mesh&collect, combines the acquisition of still images and rotational wedges. Using these means, we determine the ab initio structure of benchmark MOFs, MIL-100(Fe) and ZIF-8, that differ largely in unit cell size. These methods are expected to be widely applicable and facilitate structure determination of many MOF microcrystalline systems.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Effect of Preparation Conditions of Fe@SiO2 Catalyst on Its Structure Using High-Pressure Activity Studies in a 3D-Printed SS Microreactor

Fischer–Tropsch synthesis (FTS) in a 3D-printed stainless steel (SS) microchannel microreactor was investigated using Fe@SiO2 catalysts. The catalysts were prepared by two different techniques: one pot (OP) and autoclave (AC). The mesoporous structure of the two catalysts, Fe@SiO2 (OP) and Fe@SiO2 (AC), ensured a large contact area between the reactants and the catalyst. They were characterized by N2 physisorption, H2 temperature-programmed reduction (H2-TPR), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), X-ray photoelectron microscopy (XPS), and thermogravimetric analysis–differential scanning calorimetry (TGA-DSC) techniques. The AC catalyst had a clear core–shell structure and showed a much greater surface area than that prepared by the OP method. The activities of the catalysts in terms of FTS were studied in the 200–350 °C temperature range at 20-bar pressure with a H2/CO molar ratio of 2:1. The Fe@SiO2 (AC) catalyst showed higher selectivity and higher CO conversion to olefins than Fe@SiO2 (OP). Stability studies of both catalysts were carried out for 30 h at 320 °C at 20 bar with a feed gas molar ratio of 2:1. The Fe@SiO2 (AC) catalyst showed higher stability and yielded consistent CO conversion compared to the Fe@SiO2 (OP) catalyst.

Biochemistry & Molecular Biology↗

DOE OSTI2025

Multiphoton and Harmonic Imaging of Microarchitected Materials

Microadditive manufacturing has revolutionized the production of complex, nano- to microscale components across various fields. This work investigates two-photon (2P) and three-photon (3P) fluorescence imaging, as well as third-harmonic generation (THG) microscopy, to examine periodic microarchitected lattice structures fabricated using multiphoton lithography (MPL). By immersing the structures in refractive index matching fluids, we demonstrate high-fidelity 3D reconstructions of both fluorescent structures using 2P and 3P microscopy as well as low-fluorescence structures using THG microscopy. These results show that multiphoton fluorescence (MPF) imaging offers reduced signal decay with respect to depth compared to single-photon techniques in the examined structures. We further demonstrate the ability to nondestructively identify intentional internal modifications of the structure that are not immediately visible with scanning electron microscope (SEM) images and compression-induced fractures, highlighting the potential of these techniques for quality control and defect detection in microadditively manufactured components.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Comparison of three measurement modalities for 3D characterization of manufactured features and process-induced porosity in titanium alloy additively manufactured parts

Nondestructive characterization of internal features and defects within complex components is vital for many industrial applications, particularly with the advent of additive manufacturing (AM) technologies. However, community understanding of the limitations of nondestructive methods such as X-ray Computed Tomography (CT) can be limited in certain industrial sectors as these may be emergent applications. In this paper, we investigate the limits of X-ray CT measurements and compare extracted data with mechanical polishing serial sectioning (MPSS) and confocal laser scanning microscopy (CLSM). The test object is an additively manufactured titanium alloy disk that contains both process-induced porosity and machined features, including focused ion beam milled features designed to probe the resolution limits of X-ray CT. Results show that each of these characterization techniques has advantages and disadvantages. We compare data acquisition times, spatial resolution, geometric measurement accuracy and defect visualization fidelity across these modalities to establish a practical framework.

Additive manufacturing↗

NASA NTRS2014

Experimental Evaluation of Fatigue Damage Progression in Postbuckled Single Stringer Composite Specimens

The durability and damage tolerance of postbuckled composite structures are not yet completely understood, and remain difficult to predict due to the nonlinearity of the geometric response and its interaction with local damage modes. A research effort was conducted to investigate experimentally the quasi-static and fatigue damage progression in a single-stringer compression (SSC) specimen. Three specimens were manufactured with a hat-stiffener, and an initial defect was introduced with a Teflon film embedded between one flange of the stringer and the skin. One of the specimens was tested under quasi-static compressive loading, while the remaining two specimens were tested by cycling in postbuckling. The tests were performed at the NASA Langley Research Center under controlled conditions and with instrumentation that allows a precise evaluation of the postbuckling response and of the damage modes. Three-dimensional digital image correlation VIC-3D systems were used to provide full field displacements and strains on the skin and the stringer. Passive thermal monitoring was conducted during the fatigue tests using an infrared camera that showed the location of the delamination front while the specimen was being cycled. The live information from the thermography was used to stop the fatigue tests at critical stages of the damage evolution to allow detailed ultrasonic scans.

Bisagni, Chiara↗