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At least 325 records · Page 18

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DOE OSTI2025

HPC for Optimizing Process Parameters to Control Material Evolution in Seamless Induction Hardening of Wind Turbine Main Shaft Bearings

Work proposed in this project focused on understanding the effect of martensitic transformation in the steel on the potential for cracking during seamless induction hardening (SIH) as a function of process conditions to allow the process to optimally scale up. Large-scale, three-dimensional phase-field simulations of martensitic transformation were performed using MEUMAPPS-SS (Microstructure Evolution Using Massively Parallel Phase-field Simulations – Solid State) code developed at Oak Ridge National Laboratory. The simulations were guided by location-specific thermal history generated by experimental measurements of time-temperature history generated at The Timken Company. The simulations were able to capture the morphological evolution of the martensite variants in an Fe-1.0C-1.5Cr steel based on the Nishiyama-Wasserman (NW) orientation relationship. The simulations were also able to quantify the stress-state at the interface between impinging martensite variants. The simulations indicated that the magnitude of the various stress and strain components were dependent on the sizes of the impinging plates with a reduction in these quantities with reduced plate size in agreement with experimental findings. The results obtained from the simulations will be used to guide the optimization of the alloy thermal conditions to eliminate quench cracking during SIH of bearing steels.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

HPC for optimizing process parameters to control material evolution in seamless induction hardening of wind turbine main shaft bearings

17 WIND ENERGY↗

NASA NTRS1993

Development of a CFD code for casting simulation

Because of high rejection rates for large structural castings (e.g., the Space Shuttle Main Engine Alternate Turbopump Design Program), a reliable casting simulation computer code is very desirable. This code would reduce both the development time and life cycle costs by allowing accurate modeling of the entire casting process. While this code could be used for other types of castings, the most significant reductions of time and cost would probably be realized in complex investment castings, where any reduction in the number of development castings would be of significant benefit. The casting process is conveniently divided into three distinct phases: (1) mold filling, where the melt is poured or forced into the mold cavity; (2) solidification, where the melt undergoes a phase change to the solid state; and (3) cool down, where the solidified part continues to cool to ambient conditions. While these phases may appear to be separate and distinct, temporal overlaps do exist between phases (e.g., local solidification occurring during mold filling), and some phenomenological events are affected by others (e.g., residual stresses depend on solidification and cooling rates). Therefore, a reliable code must accurately model all three phases and the interactions between each. While many codes have been developed (to various stages of complexity) to model the solidification and cool down phases, only a few codes have been developed to model mold filling.

Murph, Jesse E.↗

NASA NTRS2002

High Precision Wavelength Monitor for Tunable Laser Systems

A solid-state apparatus for tracking the wavelength of a laser emission has a power splitter that divides the laser emission into at least three equal components. Differing phase shifts are detected and processed to track variations of the laser emission.

Mark E Froggatt↗

NASA NTRSDate not supplied

NDE Methods and Capabilities Handbook – Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. NDE techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delamination, voids, AFP defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency (speed & cost), and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members to the NDE community is discussed.

Patricia A Howell↗

NASA NTRSDate not supplied

NDE Methods and Capabilities Handbook - Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. Techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delaminations, voids, Automated Fiber Placement (AFP) defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability to the NDE community of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members is discussed.

Nondestructive Evaluation↗

NASA NTRSDate not supplied

NDE Methods and Capabilities Handbook - Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. Techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delaminations, voids, Automated Fiber Placement (AFP) defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency and limitations. This paper describes key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability to the NDE community of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members is discussed.

nondestructive evaluation↗

NASA NTRS1992

On the relative importance of magnetospheric and ionospheric processes during substorm onset and expansion: A case study

The question of whether substorm onset is triggered in the magnetotail or the ionosphere is presented. The possible influence of the ionosphere in the subsequent development of a substorm is discussed. Theoretical considerations involved are reviewed and a case study to address this question is examined. The evidence indicates that magnetotail processes initiate the sequence of events called a substorm, while the ionosphere appears to play a critical role in the subsequent evolution of the substorm expansion phase. However, the necessary observations, in particular high time resolution coordinated observations in the ionosphere and magnetotail are relatively rare. Continued examination of existing ground and space based data sets, in particular underutilized observations such as the Scatha data, may provide a more solid foundation for clarifying this issue and determining the relative importance of magnetospheric and ionospheric processes during substorms.

Lopez, Ramon E.↗

NASA NTRS1990

Survival of carbon grains in shocks

Supernova shocks play a significant part in the life of an interstellar grain. In a typical 10 to the 9th power year lifetime, a grain will be hit by an average of 10 shocks of 100 km s(sup -1) or greater velocity, and even more shocks of lower velocity. Evaluation of the results of this frequent shock processing is complicated by a number of uncertainties, but seems to give about 10 percent destruction of silicate grains and about half that for graphite grains. Because of the frequency of shocking, the mineralogy and sizes of the grain population is predominately determined by shock processing effects, and not by the initial grain nucleation and growth environment. One consequence of the significant role played by interstellar shocks is that a certain fraction (up to 5 percent) of the carbon should be transformed into the diamond phase. Diamond transformation is observed in the laboratory at threshold shock pressures easily obtainable in grain-grain collisions in supernova shocks. Yields for transforming graphite, amorphous carbon, glassy carbon, and other nearly pure carbon solids into diamond are quite high. Impurities up to at least the 10 percent level (for oxygen) are tolerated in the process. The typical size diamond expected from shock transformation agrees well with the observed sizes in the Lewis et al. findings in meteoritic material. Isotropic anomalies already contained in the grain are likely to be retained through the conversion process, while others may be implanted by the shock if the grain is close to the supernova. The meteoritic diamonds are likely to be the results of transformation of carbon grains in grain-grain collisions in supernova shock waves.

Seab, C. Gregory↗

NASA NTRS1995

Chemical Evolution of Interstellar Dust into Planetary Materials

Comets are believed to retain some interstellar materials, stored in fairly pristine conditions since-their formation. The composition and properties of cometary dust grains should reflect those of grains in the outer part of the protosolar nebula which, at least in part, were inherited from the presolar molecular cloud. However, infrared emission features in comets differ from their interstellar counterparts. These differences imply processing of interstellar material on its way to incorporation in comets, but C and N appear to be retained. Overall dust evolution from the interstellar medium (ISM) to planetary materials is accompanied by an increase in proportion of complex organics and a decrease in pure carbon phases. The composition of cometary dust grains was measured in situ during fly-by missions to comet Halley in 1986. The mass spectra of about 5000 cometary dust grains with masses of 5 x 10(exp -17) - 5 x 10(exp -12) g provide data about the presence and relative abundances of the major elements H, C, N, O,Na, Mg, Al, Si, S, Cl, K, Ca, Ti, Cr, Fe, Ni. The bulk abundances of major rock-forming elements integrated over all spectra were found to be solar within a factor of 2, while the volatile elements H, C, N, O in dust are depleted in respect to their total cosmic abundances. The abundances of C and N in comet dust are much closer to interstellar than to meteoritic and are higher than those of dust in the diffuse ISM. In dense molecular clouds dust grains are covered by icy mantles, the average composition of which is estimated to be H:C:N:O = 96:14:1:34. Up to 40% of elemental C and O may be sequestered in mantles. If we use this upper limit to add H, C, N and O as icy mantle material to the abundances residing in dust in the diffuse ISM, then the resulting values for H. C, and N match cometary abundances. Thus, ice mantles undergoing chemical evolution on grains in the dense ISM appear to have been transformed into less volatile and more complex organic residues wherein the H, C and N are largely retained and ultimately accreted in cometary dust. The abundance of O is about the same for cometary dust, meteorites and interstellar dust. In all these samples, most of O in a solid phase is bonded to silicates. In dense molecular clouds, the abundance of O in dust+mantles is significantly higher then in cometary dust. This difference may reflect the greater lability of oxygenated species toward astrophysical processing. Laboratory studies show that O-bearing functional groups in organic compounds tend to be relatively easily removed by heating and/or UV and particle irradiation . In Halley's coma, O-containing organic grains, being unstable, were located closest to the nucleus. The decomposition of the organic grain component in the coma provided a significant extended source contribution to O-containing gaseous species such as CO and H2CO.

Fomenkova, M. N.↗

DOE OSTI2025

Exploring the Nucleon Structure via Deep Electroproduction Processes

Understanding the internal structure of the nucleon is a fundamental goal of modern physics, which aims at a comprehensive framework describing the internal dynamics of quarks and gluons. Among other structure functions, Generalized Parton Distributions (GPDs) offer a powerful framework for describing the nucleon dynamics by correlating the longitudinal momentum and the transverse position of its internal partons. Such a correlation provides a three-dimensional picture of the nucleon and enables access to fundamental properties, including the internal pressure distributions and the parton’s angular momentum contribution to the nucleon's total spin, thereby playing a central role in resolving the nucleon spin puzzle. At the Thomas Jefferson National Facility (JLab), polarized electron beam experiments allow for probing GPDs through the measurement of hard exclusive processes. Among the cleanest experimental channels, we find the electro-production of a real photon through the Deeply Virtual Compton Scattering (DVCS) mechanism. The first data-taking period of the CLAS12 program, taking place in 2018, allowed for unique DVCS Beam Spin Asymmetry (BSA) measurements in the phase space covered by a 10.6 GeV polarized electron beam impinging on an unpolarized liquid hydrogen target. Although detecting all final-state particles ensures exclusivity of the process, conservation laws indicate that it is not mandatory. I adopt an approach omitting the direct detection of the recoil proton, providing a simplified yet effective event selection strategy that boosts statistics and gives access to a larger phase space sensitive to the underlying GPD dynamics through BSA and cross section measurements. The Double DVCS (DDVCS) process promises a dedicated mapping of GPDs. Contributing to the electro-production of a lepton pair cross-section, the DDVCS reaction extends DVCS by allowing the final-state photon to be virtual, enriching the kinematic phase space and providing unique access to the internal correlations encoded by GPDs. A feasibility study is conducted to assess the potential of future DDVCS measurements at Jefferson Lab and the future Electron-Ion Collider (EIC). While Jefferson Lab will provide DDVCS measurements in the valence region through the SoLID$\mu$ and $\mu$CLAS12 experimental projects, in the long term, the EIC will provide complementary measurements in the sea region, both accessing unprecedented information about GPDs in a phase space region otherwise inaccessible. Taken together, these investigations demonstrate both the current capabilities and future opportunities for probing GPDs through exclusive processes. The experimental analysis of DVCS at CLAS12 provides precise measurements within an established framework, while the phenomenological study of DDVCS opens the door to richer and more comprehensive explorations with future detectors and facilities.

Alvarado, Juan [Université Paris-Saclay: Gif-sur-Y↗

NASA NTRS1976

Studies of the exhaust products from solid propellant rocket motors

This study was undertaken to determine the feasibility of conducting environmental chamber tests on the physical processes which occur when a solid rocket motor exhaust mixes with the ambient atmosphere. Of particular interest was the interaction between hydrogen chloride, aluminum oxide, and water vapor. The program consisted of three phases: (1) building a small rocket motor and using it to provide the exhaust species in a controlled environment; (2) evaluating instruments used to detect and measure HCl concentrations and if possible determining whether the HCl existed in the gaseous state or as an acid aerosol; (3) monitoring a series of 6.4-percent scale space shuttle motor tests and comparing the results to the environmental chamber studies. Eighteen firings were conducted in an environmental chamber with the initial ambient relative humidity set at values from 29 to 100 percent. Two additional firings were made in a large shed, and four were made on an open concrete apron. Six test firings at MSFC were monitored, and the ground level concentrations are reported. Evidence is presented which shows that the larger Al2O3 (5 to 50 micrometers) particles from the rocket motor can act as condensation nuclei. Under appropriate ambient conditions where there is sufficient water vapor this results in the formation of an acid aerosol. Droplets of this acid were detected both in the environmental chamber and in the scaled shuttle engine tests.

Dawbarn, R.↗

NASA NTRS1982

Containerless processing of Nb-Ge alloys in a long drop tube

The thirty-two meter drop tube at the Marshall Space Flight Center was used to study the effect of zero gravity containerless processing on the structure and properties of materials. The concept involves the suppression of heterogeneous nucleation of solid in liquid and, therefore, solidification accompanied by large degrees of undercooling. Under these conditions metastable phases can be formed or, at the very least, unique nonequilibrium microstructures (containing equilibrium phases) with unique properties can be produced. The drop tube solidification was applied to niobium base alloys with emphasis on the Nb-Ge binary system in an effort to produce metastable phases with high superconducting transition temperatures in bulk specimens. In the past, only lower Ge alloys (Nb-13 a/o, Nb-18 a/o, and Nb-22 a/o) could be undercooled. Higher Ge alloys (e.g., Nb-25 a/o Ge and Nb-27 a/o Ge) can now be undercooled on a routine basis.

Bayuzick, R. J.↗

NASA NTRS1991

A major advance in powder metallurgy

Ultramet has developed a process which promises to significantly increase the mechanical properties of powder metallurgy (PM) parts. Current PM technology uses mixed powders of various constituents prior to compaction. The homogeneity and flaw distribution in PM parts depends on the uniformity of mixing and the maintenance of uniformity during compaction. Conventional PM fabrication processes typically result in non-uniform distribution of the matrix, flaw generation due to particle-particle contact when one of the constituents is a brittle material, and grain growth caused by high temperature, long duration compaction processes. Additionally, a significant amount of matrix material is usually necessary to fill voids and create 100 percent dense parts. In Ultramet's process, each individual particle is coated with the matrix material, and compaction is performed by solid state processing. In this program, Ultramet coated 12-micron tungsten particles with approximately 5 wt percent nickel/iron. After compaction, flexure strengths were measured 50 percent higher than those achieved in conventional liquid phase sintered parts (10 wt percent Ni/Fe). Further results and other material combinations are discussed.

Williams, Brian E.↗

NASA NTRS2000

Ultra-High Density Holographic Memory Module with Solid-State Architecture

NASA's terrestrial. space, and deep-space missions require technology that allows storing. retrieving, and processing a large volume of information. Holographic memory offers high-density data storage with parallel access and high throughput. Several methods exist for data multiplexing based on the fundamental principles of volume hologram selectivity. We recently demonstrated that a spatial (amplitude-phase) encoding of the reference wave (SERW) looks promising as a way to increase the storage density. The SERW hologram offers a method other than traditional methods of selectivity, such as spatial de-correlation between recorded and reconstruction fields, In this report we present the experimental results of the SERW-hologram memory module with solid-state architecture, which is of particular interest for space operations.

Markov, Vladimir B.↗

DOE OSTI2026

Conversion of real-world aluminum scrap streams into high-performance Al–Mg–Si–Cu automotive alloys using shear assisted processing and extrusion

The conversion of post-consumer aluminum (Al) scrap into usable Al alloys without adding primary Al is challenging because of excess impurities. In this work, >99% post-consumer Twitch, used beverage cans (UBCs), and remelt scrap ingots (RSIs) were used as feedstock materials. As-cast and solution heat-treated feedstock billets were extruded using Shear Assisted Processing and Extrusion (ShAPE) at ~510°C, followed by press quenching. To explore the development of the microstructure, texture, and underlying mechanisms and how they contribute to the overall strengthening in as-extruded and artificially aged samples, scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) were used to collect microstructure and texture data. The enhanced strength and ductility were corroborated with the microstructural features and crystallographic texture. Simple shear $\textrm{A}/\bar{\textrm{A}}$, $\textrm{A}_1^*/\textrm{A} _2^*$ texture components along with weak $\textrm{C}$ and $\textrm{B}/\bar{\textrm{B}}$ texture components were formed during extrusion; the texture was strengthened after heat treatment. The refined second-phase particles helped to retain the deformed microstructure and texture. The contributions of dislocation and precipitate strengthening were maximized when billets were solution-heat-treated prior to extrusion. This is attributed to the formation of effective supersaturated solid solutions during the ShAPE process, which precipitate out during the peak age treatment. Overall, the highest yield strength of 305 MPa, ultimate tensile strength of 350 MPa, and elongation of 12% were achieved in artificially aged samples, which are comparable to those of Al 6082-T6.

Al alloy↗

DOE OSTI2025

Pushing the Limits: Maximizing Energy Density in Silicon Sulfide Solid‐State Batteries

Here, for the first time, we demonstrate a silicon solid-state battery (SSB) architecture that achieves >400 Wh kg −1 , approaching the theoretical limit for silicon-based SSBs. This configuration features a 99.9 wt% micro-Si, a thin sulfide solid electrolyte (SSE), and a high-loading NMC811. Key to these results is strategically selecting and evaluating the processing techniques, whether wet or dry, for the negative electrode, positive electrode and thin sheet-type SSE. Excessive lithium incorporation into the silicon host, beyond the Li 3.75 +Si phase to form a LiSi composite, is essential to match the high capacity of the positive electrode. This SSB achieves over 1000 cycles for a 2 mAh cm −2 with ≈80% capacity retention and 94% capacity retention for 3 mAh cm −2 over 500 cycles at 25 °C. Post analysis identifies the primary capacity decay mechanisms as oxidation at the NMC/SSE interface and structural disruptions within NMC. Meanwhile, the Si electrode maintains a robust solid-electrolyte interphase layer, minimizing capacity decay. This study highlights the necessity for improved NMC coatings, lattice oxygen stabilization, and a durable positive electrode-electrolyte interface to improve the long-term stability of SSBs. Strategies leading to a single-layer pouch cell SSB exceeding 400 Wh kg −1 are developed.

25 ENERGY STORAGE↗

NASA NTRS1987

Synthetic estimation filters for a control system

Hybrid optical correlators, which use spatial light modulators and solid state imagers to interface computers and optical Fourier correlators, will allow the rapid changing of filters and digital pre- or post-correlation processing in vision systems. However, optical correlation (particulary with phase-only filtration) is notoriously sensitive to mismatches of rotation and magnification between the reference image and the input image. Such sharpness is not always desirable if the correlation pattern is to be used in a control system. Two methods of conforming the response of an inherently sharp-response optical correlation to an in plane rotation between reference and object images are discussed. The objective is to condition the correlation for better suitability to a vision-controlled system. The first method is controlled convolutional blurring of a reference image followed by construction of a matched filter (perhaps implemented as a phase-only filter). An alternative is discussed in more detail: it is a synthesis from sharp filters, so weighted as to produce a specified off-center behavior.

Juday, Richard D.↗