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At least 343 records · Page 19

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DOE OSTI2025

Electrified vapour deposition at ultrahigh temperature and atmospheric pressure for nanomaterials synthesis

Vapour-phase synthesis methods have shown promise for the scalable synthesis of nanomaterials and coatings. However, the vaporization of different precursors for the synthesis of a broad nanomaterial space, particularly at atmospheric pressure, while maintaining compositional and structural control of the final product is challenging. Here we report the generation of an ultrahigh-temperature atomic vapour at atmospheric pressure based on electrified heating, for the growth of multi-elemental nanomaterials and thin films. This process relies on a reactor design whereby solid-state precursors are vaporized within a semi-confined space beneath an electrified heater that can reach ~3,000 K. The proximity of the heater rapidly breaks down the bonds of metal salt precursors and decomposes them into an atomic vapour that expands into a high-temperature (>2,000 K), highly reactive and high-flux vapour (10 21 –10 22 atoms per cm 2 per second) that travels upwards in a directional flow. When mixed with entrained ambient gases, the highly reactive atomic species rapidly nucleate and grow into the desired final products, including alloys, oxides, sulfides and thin films, which can be deposited on a low-temperature substrate. This EVD approach can synthesize a broad range of functional nanomaterials at atmospheric pressure, including single-phase multi-elemental nanomaterials formed under thermodynamically non-equilibrium conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Equilipy: a python package for calculating phase equilibria

The CALPHAD (CALculation of PHAse Diagram) approach (Nigel Saunders & Miodownik, 1998) provides predictions for thermodynamically stable phases in multicomponent-multiphase materials across a wide range of temperatures. Consequently, the CALPHAD calculations became an essential tool in materials and process design (Luo, 2015). Such design tasks frequently require navigating a high-dimensional space due to multiple components involved in the system. This increasing complexity demands high-throughput CALPHAD calculations, especially in the rapidly evolving field of alloy design. In response to the need, we developed Equilipy an open-source Python package designed for calculating phase equilibria of multicomponent-multiphase systems. Equilipy is specifically tailored for high-throughput CALPHAD calculations, offering parallel computations across multiple processors and nodes with the given NPT input conditions namely elemental compositions (N), pressure (P), and temperature (T). Equilipy utilizes the program structure and Gibbs energy functions from the Fortran-based program, Thermochimica (Piro et al., 2013), with incorporating a new Gibbs energy minimization algorithm. This algorithm, originally developed by Capitani and Brown in 1987 (Capitani & Brown, 1987), has been revised and implemented to enhance the stability and performance of calculations. The Fortran codes are precompiled and interfaced with Python via F2PY, ensuring high computation speed. Benchmark tests shown in Figure 1 demonstrate that Equilipy’s computation speed is comparable to those of established commercial software, TC-Python and PanPython. This result highlights its efficiency and potential applications in various scientific and industrial fields.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1990

A generic interface between COSMIC/NASTRAN and PATRAN (R)

Despite its powerful analytical capabilities, COSMIC/NASTRAN lacks adequate post-processing adroitness. PATRAN, on the other hand is widely accepted for its graphical capabilities. A nonproprietary, public domain code mnemonically titled CPI (for COSMIC/NASTRAN-PATRAN Interface) is designed to manipulate a large number of files rapidly and efficiently between the two parent codes. In addition to PATRAN's results file preparation, CPI also prepares PATRAN's P/PLOT data files for xy plotting. The user is prompted for necessary information during an interactive session. Current implementation supports NASTRAN's displacement approach including the following rigid formats: (1) static analysis, (2) normal modal analysis, (3) direct transient response, and (4) modal transient response. A wide variety of data blocks are also supported. Error trapping is given special consideration. A sample session with CPI illustrates its simplicity and ease of use.

Roschke, Paul N.↗

NASA NTRS2002

Advancements in Binder Systems for Solid Freeform Fabrication

Paper will present recent developments in advanced material binder systems for solid freeform fabrication (SFF) technologies. The advantage of SFF is the capability to custom fabricate complex geometries directly from computer aided design data in layer- by-layer fashion, eliminated the need for traditional fixturing and tooling. Binders allow for the low temperature processing of 'green' structural materials, either metal, ceramic or composite, in traditional rapid prototyping machines. The greatest obstacle comes when green parts must then go through a sintering or burnout process to remove the binders and fully densify the parent material, without damaging or distorting the original part geometry. Critical issues and up-to-date assessments will be delivered on various material systems.

Cooper, Ken↗

NASA NTRS2006

Electron Beam Freeform Fabrication (EBF3) for Cost Effective Near-Net Shape Manufacturing

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cubic centimeters per hour (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M.↗

NASA NTRS2006

Electron Beam Freeform Fabrication for Cost Effective Near-Net Shape Manufacturing

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cm3/hr (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M.↗

NASA NTRS2006

Simulating Humans as Integral Parts of Spacecraft Missions

The Collaborative-Virtual Environment Simulation Tool (C-VEST) software was developed for use in a NASA project entitled "3-D Interactive Digital Virtual Human." The project is oriented toward the use of a comprehensive suite of advanced software tools in computational simulations for the purposes of human-centered design of spacecraft missions and of the spacecraft, space suits, and other equipment to be used on the missions. The C-VEST software affords an unprecedented suite of capabilities for three-dimensional virtual-environment simulations with plug-in interfaces for physiological data, haptic interfaces, plug-and-play software, realtime control, and/or playback control. Mathematical models of the mechanics of the human body and of the aforementioned equipment are implemented in software and integrated to simulate forces exerted on and by astronauts as they work. The computational results can then support the iterative processes of design, building, and testing in applied systems engineering and integration. The results of the simulations provide guidance for devising measures to counteract effects of microgravity on the human body and for the rapid development of virtual (that is, simulated) prototypes of advanced space suits, cockpits, and robots to enhance the productivity, comfort, and safety of astronauts. The unique ability to implement human-in-the-loop immersion also makes the C-VEST software potentially valuable for use in commercial and academic settings beyond the original space-mission setting.

Bruins, Anthony C.↗

NASA NTRS2018

Modeling-Driven Damage Tolerant Design of Graphene Nanoplatelet/Carbon Fiber/Epoxy Hybrid Composite Panels for Full-Scale Aerospace Structures

The objective of this study is to design a new nano graphenecarbon fiberpolymer hybrid composite that can be used for the NASA SLS Composite Exploration Upper Stage (CEUS) forward skirt structure. The new material will improve the resistance to open-hole compression failure of the structure relative to traditional polymer fiber composites. The material is designed rapidly and with little cost using the Integrated Computational Materials Engineering (ICME) approach. Multiscale modeling and experiments are used to synergistically optimize the material design to yield improved properties and performance by controlling key processing parameters for manufacturing nano-enhanced materials. Specifically, the nanocomposite panel showed a 22 reduction in mass relative to the traditional composite panel, while both designs are equal in terms of ease of manufacture. This potential mass savings corresponds to an estimated 45 savings in materials and manufacturing costs. The multiscale ICME workflow developed for this project can be readily applied to the development of nano-enhanced composite materials and large aerospace structures. In addition, all key aspects of ICME were employed to complete this project including multiscale modeling, experimental characterization and visualization, data management, visualization, error and uncertainty quantification, and education. The results presented herein indicate a dramatic level of success, as well as the power and potential of ICME approach and multiscale modeling for composite materials.

computational mechanics↗

DOE OSTI2025

Accelerating Discovery of Solid‐State Thin‐Film Metal Dealloying for 3D Nanoarchitecture Materials Design through Laser Thermal Gradient Treatment

Thin‐film solid‐state metal dealloying (thin‐film SSMD) is a promising method for fabricating nanostructures with controlled morphology and efficiency, offering advantages over conventional bulk materials processing methods for integration into practical applications. Although machine learning (ML) has facilitated the design of dealloying systems, the selection of key thermal treatment parameters for nanostructure formation remains largely unknown and dependent on experimental trial and error. To overcome this challenge, a workflow enabling high‐throughput characterization of thermal treatment parameters is demonstrated using a laser‐based thermal treatment to create temperature gradients on single thin‐film samples of Nb‐Al/Sc and Nb‐Al/Cu. This continuous thermal space enables observation of dealloying transitions and the resulting nanostructures of interest. Through synchrotron X‐ray multimodal and high‐throughput characterization, critical transitions and nanostructures can be rapidly captured and subsequently verified using electron microscopy. The key temperatures driving chemical reactions and morphological evolutions are clearly identified. While the oxidation may influence nanostructure formation during thin‐film treatment, the dealloying process at the dealloying front involves interactions solely between the dealloying elements, highlighting the availability and viability of the selected systems. Further, this approach enables efficient exploration of the dealloying process and validation of ML predictions, thereby accelerating the discovery of thin‐film SSMD systems with targeted nanostructures.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

A New Concurrent Engineering Tool for the New Mission Design Center at NASA Ames Research Center

The NASA Ames Mission Design Center (MDC) has undergone a significant transformation process in recent years, culminating in becoming a true Concurrent Engineering Center. The underlying goal of this transformation is to better serve the Ames PI community in a cost-effective and rapidly-responsive way, providing quality products pivotal to the decision-making proposal strategy of our center. The four pillars of the change focus on four areas: personnel, physical places, tools, and training. Personnel: the MDC switched from using a dedicated pool of engineers—mostly entry-level career—for a matrixed approach with more experienced Subject Matter Experts, usually involved in spaceflight projects. These SMEs get detailed to the MDC for the duration of the study on a part-time or full-time basis. Physical places: The physical aspect pertains mostly to the layout of the new Engineering building and the dedicated concurrent engineering layout to foster collaboration. The current plan includes a dedicated space for concurrent engineering sessions as well as dedicated project rooms for concept studies. Tool: the MDC team is developing a new in-house concurrent engineering tool to facilitate concurrent engineering sessions. The team leveraged the many lessons learned and insight gained from using the current concurrent engineering tool, in use since 2007. SMEs have been involved throughout its design and development, ensuring accuracy and providing validity to the implementation approach. This new tool is database-driven and allows a team to work concurrently on the same model of a mission concept. “Workspaces” are provided for each of the traditional spacecraft mission design disciplines, including cost accounting and systems engineering. There are multiple tiers of fidelity available within each workspace, which can be completed parametrically or independently from the other disciplines as needed or synchronously with the other disciplines. A “commit” step synchronizes a workspace with the mission database and identifies any potential conflicts, along with the user who entered the conflicting data. A Mission Summary workspace enables a Study Lead to run an effective CE session, displaying key graphics, workspace status information, and technical and monetary budget information. This new CE tool will be undergoing Beta Testing with its primary user base and a limited Parts database in the summer of 2020. The team plans to release the first fully operational version in December 2020. Training: working in early concept development and maturation for a space mission requires a unique mindset and being comfortable with uncertainties in an environment where requirements are not yet fully developed, and where changes and trade-offs happen at a high tempo. The MDC started a weekly training program to ensure a common knowledge base on how do develop and mature early concept studies, as well as how to operate in a concurrent engineering environment. In conclusion, the MDC transformation will provide the overall PI community focused on cost-effective small satellite scientific missions with a powerful tool to address and mature early concepts more effectively and efficiently.

David Mauro↗

NASA NTRSDate not supplied

Expanding the Time Dimension of Hyperspectral Infrared Sounding Observations: Designing the NUCAPS-Forecast System

Low Earth orbit (LEO) hyper-spectral infrared (IR) sounders have significant yet untapped potential for characterizing thermodynamic environments of convective initiation and ongoing convection. While LEO soundings are of enormous value to weather forecasters, they cannot provide the temporal resolution needed to resolve the rapidly evolving thermodynamics of the convective environment. A novel methodology was developed to extend snapshots of LEO soundings forward in time up to six hours into the future and has been made available within the NOAA National Weather Service Advanced Weather Interactive Processing System (AWIPS) for testing in a quasi-operational setting. This methodology is based on parcel forward-trajectory calculations from the satellite observing time to recreate future soundings of temperature and moisture at regularly gridded intervals in space and time. The soundings are based on NOAA-Unique Combined Atmospheric Processing System (NUCAPS) retrievals from the Suomi NPP and NOAA-20 satellite platforms to allow for rapid near-real time product processing. Science code was transitioned to operational production in 2019 and the product, NUCAPS-Forecast, was tested at the NOAA Hazardous Weather Testbed Spring Experiment in 2019 and 2021. Forecaster feedback has led to improving the product and processing system to address product limitations and improve its applicability for pre-convective forecasting. This presentation highlights the design of the NUCAPS-Forecast system. Solutions were tested and implemented to remove excess moisture and conjoin forward-trajected parcels into vertical profiles for calculating grids of stability indices. Additionally, use cases that explore the tendencies of derived convective available potential energy (CAPE) and convective inhibition (CIN) were investigated. When evaluated against gridded, hourly accumulated rainfall obtained from the Multi-Radar Multi-Sensor (MRMS) observational data set areas with elevated CAPE (reduced CIN) are shown to be associated with areas of precipitation and increase confidence the LEO soundings advected forward in time physically represent atmospheric processes. These results suggest that adiabatic parcel advection of LEO satellite sounding snapshots forward in time exhibits skill in discriminating locations and times that are more likely to lead to convective initiation. Leveraging trajectory modeling to increase the spatial and temporal resolution of LEO IR sounding observations today demonstrates the value of these observations from the future constellation of JPSS satellites and GeoXO mission.

weather↗

NASA NTRS1987

Artificial Intelligence (AI), Operations Research (OR), and Decision Support Systems (DSS): A conceptual framework

In recent years there has been increasing interest in applying the computer based problem solving techniques of Artificial Intelligence (AI), Operations Research (OR), and Decision Support Systems (DSS) to analyze extremely complex problems. A conceptual framework is developed for successfully integrating these three techniques. First, the fields of AI, OR, and DSS are defined and the relationships among the three fields are explored. Next, a comprehensive adaptive design methodology for AI and OR modeling within the context of a DSS is described. These observations are made: (1) the solution of extremely complex knowledge problems with ill-defined, changing requirements can benefit greatly from the use of the adaptive design process, (2) the field of DSS provides the focus on the decision making process essential for tailoring solutions to these complex problems, (3) the characteristics of AI, OR, and DSS tools appears to be converging rapidly, and (4) there is a growing need for an interdisciplinary AI/OR/DSS education.

Parnell, Gregory S.↗

NASA NTRS1988

Hormone purification by isoelectric focusing in space

The objective of the program was the definition and development of optimal methods for electrophoretic separations in microgravity. The approach is based on a triad consisting of ground based experiments, mathematical modeling and experiments in microgravity. Zone electrophoresis is a rate process, where separation is achieved in uniform buffers on the basis of differences in electrophoretic mobilities. Optimization and modeling of continuous flow electrophoresis mainly concern the hydrodynamics of the flow process, including gravity dependent fluid convection due to density gradients and gravity independent electroosmosis. Optimization of focusing requires a more complex model describing the molecular transport processes involved in electrophoresis of interacting systems. Three different focusing instruments were designed, embodying novel principles of fluid stabilization. Fluid stability was achieved by: (1) flow streamlining by means of membrane elements in combination with rapid fluid recycling; (2) apparatus rotation in combination with said membrane elements; and (3) shear stress induced by rapid recycling through a narrow gap channel.

Bier, M.↗

NASA NTRS2001

Reducing Bolt Preload Variation with Angle-of-Twist Bolt Loading

Critical high-pressure sealing joints on the Space Shuttle reusable solid rocket motor require precise control of bolt preload to ensure proper joint function. As the reusable solid rocket motor experiences rapid internal pressurization, correct bolt preloads maintain the sealing capability and structural integrity of the hardware. The angle-of-twist process provides the right combination of preload accuracy, reliability, process control, and assembly-friendly design. It improves significantly over previous methods. The sophisticated angle-of-twist process controls have yielded answers to all discrepancies encountered while the simplicity of the root process has assured joint preload reliability.

Thompson, Bryce↗

NASA NTRS2010

Rapid Active Sampling Package

A field-deployable, battery-powered Rapid Active Sampling Package (RASP), originally designed for sampling strong materials during lunar and planetary missions, shows strong utility for terrestrial geological use. The technology is proving to be simple and effective for sampling and processing materials of strength. Although this originally was intended for planetary and lunar applications, the RASP is very useful as a powered hand tool for geologists and the mining industry to quickly sample and process rocks in the field on Earth. The RASP allows geologists to surgically acquire samples of rock for later laboratory analysis. This tool, roughly the size of a wrench, allows the user to cut away swaths of weathering rinds, revealing pristine rock surfaces for observation and subsequent sampling with the same tool. RASPing deeper (.3.5 cm) exposes single rock strata in-situ. Where a geologist fs hammer can only expose unweathered layers of rock, the RASP can do the same, and then has the added ability to capture and process samples into powder with particle sizes less than 150 microns, making it easier for XRD/XRF (x-ray diffraction/x-ray fluorescence). The tool uses a rotating rasp bit (or two counter-rotating bits) that resides inside or above the catch container. The container has an open slot to allow the bit to extend outside the container and to allow cuttings to enter and be caught. When the slot and rasp bit are in contact with a substrate, the bit is plunged into it in a matter of seconds to reach pristine rock. A user in the field may sample a rock multiple times at multiple depths in minutes, instead of having to cut out huge, heavy rock samples for transport back to a lab for analysis. Because of the speed and accuracy of the RASP, hundreds of samples can be taken in one day. RASP-acquired samples are small and easily carried. A user can characterize more area in less time than by using conventional methods. The field-deployable RASP used a Ni/Cad rechargeable battery. Power usage was less than 1 Wh/ cm3 even when sampling strong basalts, so many samples could be taken on a single battery charge.

Peters, Gregory↗

NASA NTRSDate not supplied

Exploring Multimodal Interactions in Human-Autonomy Teaming Using a Natural User Interface

The creation of a multimodal, natural user interface to facilitate multi-agent interaction is essential to establishing trust among human and machine teammates in multi-agent systems. Trust is being researched, along with trustworthiness, as a path to certification of autonomous systems by the Autonomy Teaming and TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR) project at NASA. The Autonomous Mission Experimental Logistics Interactive Assistant (AMELIA) is a natural user interface that enables multimodal interaction and is designed for rapid mission planning. AMELIA is an intelligent system that considers the user’s preferred communication strategies, as well as the time-critical aspect of the multi-agent system decision-making process. Twenty-four participants planned a multi-agent search and rescue mission, with the aid of an intelligent assistant. The results show that while the combined use of touch and speech was faster than speech alone, the single modality, touch, was still the most efficient. Future research should investigate additional input technologies.

Lisa R Le Vie↗

NASA NTRSDate not supplied

Exploring Multimodal Interactions in Human-Autonomy Teaming Using a Natural User Interface

Lisa Renee Le Vie↗

DOE OSTI2024

Rapid Assessment of Sulfate Resistance in Mortar and Concrete

Extensive research has been conducted on the sulfate attack of concrete structures; however, the need to adopt the use of more sustainable materials is driving a need for a quicker test method to assess sulfate resistance. This work presents accelerated methods that can reduce the time required for assessing the sulfate resistance of mixtures by 70%. Class F fly ash has historically been used in concrete mixtures to improve sulfate resistance. However, environmental considerations and the evolving energy industry have decreased its availability, requiring the identification of economically viable and environmentally friendly alternatives to fly ash. Another challenge in addressing sulfate attack durability issues in concrete is that the standard sulfate attack test (ASTM C1012) is time-consuming and designed for only standard mortars (not concrete mixtures). To expedite the testing process, accelerated testing methods for both mortar and concrete mixtures were adopted from previous work to further the development of the accelerated tests and to assess the feasibility of testing the sulfate resistance of mortar and concrete mixtures rapidly. This study also established criteria for interpreting sulfate resistance for each of the test methods used in this work. A total of 14 mortar mixtures and four concrete mixtures using two types of Portland cement (Type I and Type I/II) and various supplementary cementitious materials (SCMs) were evaluated in this study. The accelerated testing methods significantly reduced the evaluation time from 12 months to 21 days for mortar mixtures and from 6 months to 56 days for concrete mixtures. The proposed interpretation method for mortar accelerated test results showed acceptable consistency with the ACI 318-19 interpretations for ASTM C1012 results. The interpretation methods proposed for the two concrete sulfate attack tests demonstrated excellent consistency with the ASTM C1012 results from mortar mixtures with the same cementitious materials combinations. Metakaolin was shown to improve sulfate resistance for both mortar and concrete mixtures, while silica fume and natural pozzolan had a limited impact. Using 15% metakaolin in mortar or concrete mixtures with Type I/II cement provided the best sulfate resistance.

Chemistry↗