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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Revisiting the Hail Radar Reflectivity–Kinetic Energy Flux Relation by Combining T-Matrix and Discrete Dipole Approximation Calculations to Size Distribution Observations

The retrieval of hail kinetic energy with weather radars or its simulation in numerical models is challenging because of the shape complexity and variable density of hailstones. We combine 3D scans of individual hailstones with measurements of the particle size distributions (PSD) and T-matrix calculations to understand how hail reflectivity Z changes when approximating hailstones as spheroids, as compared to the realistic shapes obtained by 3D scanning technology. Additionally, recent terminal velocity relations are used to compare Z to the hail kinetic energy flux E ˙ . We parameterize the hail backscattering cross sections at L, S, C, and X bands as a function of size between 0.5 and 5.0 cm, matching the range of the observed PSDs. The scattering calculations use the T-matrix method for size parameters below 1.0 and the discrete dipole approximation (DDA) method otherwise. The DDA calculations are done for 48 digital models of realistic hailstones of sizes between 1 and 5 cm. The DDA cross sections are calculated for multiple orientations and averaged assuming a fully random orientation distribution to provide a single value per hailstone. The T-matrix reflectivity assuming solid ice spheres presents negligible differences to DDA results for size parameters below 1.0. Therefore, T matrix was used to fill in the gaps left by the DDA calculations. The results are mapped to the same size bins of the observed PSDs, allowing the calculation of the radar reflectivity. This is then correlated to E ˙ , allowing a potential improvement of past retrieval methods of E ˙ from Z in multiple wavelengths.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2014

Design Visualization Internship Overview

This is a report documenting the details of my work as a NASA KSC intern for the Summer Session from June 2nd to August 8th, 2014. This work was conducted within the Design Visualization Group, a Contractor staffed organization within the C1 division of the IT Directorate. The principle responsibilities of the KSC Design Visualization Group are the production of 3D simulations of NASA equipment and facilities for the purpose of planning complex operations such as hardware transportation and vehicle assembly. My role as an intern focused on aiding engineers in using 3D scanning equipment to obtain as-built measurements of NASA facilities, as well as using CATIA and DELMIA to process this data. My primary goals for this internship focused on expanding my CAD knowledge and capabilities, while also learning more about technologies I was previously unfamiliar with, such as 3D scanning. An additional goal of mine was to learn more about how NASA operates, and how the U.S. Space Program operates on a day-to-day basis. This opportunity provided me with a front-row seat to the daily maneuvers and operations of KSC and NASA as a whole. Each work day, I was able to witness, and even take part of, a small building block of the future systems that will take astronauts to other worlds. After my experiences this summer, not only can I say that my goals have been met, but also that this experience has been the highlight of my experience in higher education.

Telescience↗
DOE OSTI2025

Parametric Finite Element Analysis of Naturally Corroded Steel Specimens Using 3D Surface Laser Scans

Corrosion is considered a uniform thickness reduction design guideline of the maritime industry. However, additionally, the corroded and irregular morphology of the surface affects the steel's load-bearing capacity and its impact on the strength and elongation behaviour of the steel is not yet fully understood. These effects on the local behaviour of steel structures under tensile loading were investigated with tensile tests on naturally corroded steel specimens and nonlinear finite element simulations including the corroded surface morphology with a uniform surface idealation. The models also include the deformed specimen shape. The developed approach led to highly accurate parametric finite element models predicting the ultimate tensile strength and longitudinal position of fracture. The results show that all included aspects are essential for accurate simulations, while solely the maximum available surface resolution was not as decisive.

corrosion↗
NASA NTRS2015

3D-Laser-Scanning Technique Applied to Bulk Density Measurements of Apollo Lunar Samples

In order to better interpret gravimetric data from orbiters such as GRAIL and LRO to understand the subsurface composition and structure of the lunar crust, it is import to have a reliable database of the density and porosity of lunar materials. To this end, we have been surveying these physical properties in both lunar meteorites and Apollo lunar samples. To measure porosity, both grain density and bulk density are required. For bulk density, our group has historically utilized sub-mm bead immersion techniques extensively, though several factors have made this technique problematic for our work with Apollo samples. Samples allocated for measurement are often smaller than optimal for the technique, leading to large error bars. Also, for some samples we were required to use pure alumina beads instead of our usual glass beads. The alumina beads were subject to undesirable static effects, producing unreliable results. Other investigators have tested the use of 3d laser scanners on meteorites for measuring bulk volumes. Early work, though promising, was plagued with difficulties including poor response on dark or reflective surfaces, difficulty reproducing sharp edges, and large processing time for producing shape models. Due to progress in technology, however, laser scanners have improved considerably in recent years. We tested this technique on 27 lunar samples in the Apollo collection using a scanner at NASA Johnson Space Center. We found it to be reliable and more precise than beads, with the added benefit that it involves no direct contact with the sample, enabling the study of particularly friable samples for which bead immersion is not possible

Macke, R. J.↗
DOE OSTI2021

In-situ Nondestructive Evaluation of In-flight Particle Dynamics and Intrinsic Properties for Directed Energy Deposition

The objective of this exploratory project is to determine the feasibility of using laser diffraction, structured light 3D scanning, and x-ray diffraction for in-situ assessment and inspection of metal directed energy deposition (DED) that is applied to repair components such as engine parts in remanufacturing. During this project, we have successfully published or submitted at least one journal article for each subtask that we identified. One of our conference paper and presentation has won “best paper award” from Manufacturing & Design Division in the Institute of Industrial and Systems Engineers (IISE) Annual Conference 2021. Through this seed grant, we successfully validated the concepts and proved the three in-situ monitoring techniques work well to predict some defects generation during direct energy deposition. We submitted follow-up proposals to continue work on this topic.

36 MATERIALS SCIENCE↗
NASA NTRS2019

A New Look at Aubrites: Investigating 3D Modal Mineralogy with X-Ray Computed Tomography

The aubrites (approximately 30 known meteorites) are a unique group of differentiated meteorites that formed on asteroids with oxygen fugacities (ƒO2) from approximately 2 to approximately 6 log units below the iron-wustite buffer. At these highly reduced conditions, elements deviate from the geochemical behavior exhibited at terrestrial ƒO2, forming FeO-poor silicates and exotic sulfides. While previous studies have described the petrology and 2D modal abundances of aubrites, this work investigates the 3D modal mineralogies of silicate, metal, and sulfide phases in aubrite samples, which are then compared to the available 2D data. In addition to 3D modal mineralogies, we have examined the geochemistry of fourteen aubrites, including mineral major-element compositions, bulk-rock compositions, and oxygen isotopic compositions to understand their formation and evolution at extreme ƒO2 conditions. We utilize X-ray computed tomography (XCT) to non-destructively analyze the distribution and abundances of mineral phases in aubrites and locate composite clasts of sulfide grains for future analytical study. In order to better constrain elemental behavior under reduced conditions, we specifically target minerals phases that comprise moderately volatile elements (i.e. oldhamite [CaS], caswellsilverite [NaCrS2] and djerfisherite [K6Na(Fe,Cu,Ni)25S26Cl]) as it has been shown that their geochemical behavior changes as a function of ƒO2. Currently, we have produced 3D scans of the Norton County aubrite. The results of the XCT data have allowed for the determination of the abundances of silicate groundmass (i.e., enstatite, forsterite, albite, and diopside), light (based on electron density) sulfides (i.e. alabandite [MnS] and daubréelite [FeCr2S4]), heavy (based on electron density) sulfides (i.e., troilite [FeS]), and Fe,Ni metal by segmenting a density histogram in Volume Graphics Studio software. XCT scans of additional aubrites are underway. By combining the 3D representation of the exotic phases found in aubrites with existing 2D characterizations, we are able to better determine modal abundances. By integrating 3D and 2D modal abundances and geochemistry, we can ultimately better constrain aubrite petrogenesis and elemental partitioning under reduced conditions. Furthermore, application of this new 3D approach offers the opportunity to identify and select clasts for future study prior to cutting the sample, which will minimize sample loss of this precious material.

Wilbur, Zoe↗
DOE OSTI2024

T staging esophageal tumors with x rays

With histopathology results typically taking several days, the ability to stage tumors during interventions could provide a step change in various cancer interventions. X-ray technology has advanced significantly in recent years with the introduction of phase-based imaging methods. These have been adapted for use in standard labs rather than specialized facilities such as synchrotrons, and approaches that enable fast 3D scans with conventional x-ray sources have been developed. This opens the possibility to produce 3D images with enhanced soft tissue contrast at a level of detail comparable to histopathology, in times sufficiently short to be compatible with use during surgical interventions. In this paper we discuss the application of one such approach to human esophagi obtained from esophagectomy interventions. We demonstrate that the image quality is sufficiently high to enable tumor T staging based on the x-ray datasets alone. Alongside detection of involved margins with potentially life-saving implications, staging tumors intra-operatively has the potential to change patient pathways, facilitating optimization of therapeutic interventions during the procedure itself. Besides a prospective intra-operative use, the availability of high-quality 3D images of entire esophageal tumors can support histopathological characterization, from enabling “right slice first time” approaches to understanding the histopathology in the full 3D context of the surrounding tumor environment.

Optics↗
DOE OSTI2024

Tip-Induced 3D Printing on the Nanoscale with Field Emission Scanning Probes

3D printing down to the nanoscale remains a significant challenge. In this paper, the study explores the use of scanning probes that emit low-energy electrons (<100 eV) coupled with the localized injection and electron-induced decomposition of precursor molecules, for the precise localized deposition of 3D nanostructures. The experiments are performed inside the chamber of a scanning electron microscope (SEM), enabling the use of the in-built gas injector system (GIS) with gaseous naphthalene precursor for carbon deposition, as well as immediate inspection of the deposits by SEM. Substrate materials are planar fused silica with thin conductive coatings and non-planar copper wedges. After investigation of the deposition process parameters, various 2D and 3D carbon deposits are grown. Vertical nanowires several microns in length with a diameter <100 nm are achieved and 3D deposits with a high degree of nanoscale branching are also obtained, presumably due to a charging effect. High aspect ratio carbon nanostructures such as those demonstrated here can be employed as miniaturized electrodes or field emitters. The tip-based approach presented thus paves the way toward 3D nanoscale printing of various materials and functional nanostructures.

3D printing↗
DOE OSTI2021

DEM analysis of the effect of interface transition zone on dynamic splitting tensile behavior of high-strength concrete based on multi-phase model

Highlights: • Crushable aggregates with the real geometry shape are generated by using clump-cluster method. • Flat-Joint Model is adopted as the constitutive law. • The tensile strength is almost not affected by ITZ strength when its strength exceeds 0.8 times that of mortar. • A modified formula that can reflect the functional relationship between the ITZ strength and the TDIF is proposed. The tensile strength is one of the main parameters in the design of concrete structures and has an important influence on the cracking performance and durability of concrete materials. As the weak region in concrete, the strength of the interface transition zone (ITZ) directly affects the dynamic mechanical response of concrete. Meanwhile, considering that the tensile performance of concrete is far weaker than its compressive performance, the study of the strength of ITZ is of great significance to the dynamic tensile fracture characteristics and mechanical properties of concrete. In this paper, a method combining 3D scanning technology and Clump-Cluster was proposed to generate a real geometry shape model of crushable aggregate. On this basis, the 3D discrete element model (DEM) of high-strength concrete was constructed using the Flat-Joint Model (FJM). The effects of the ITZ strength on the failure mode, number of microcracks, tensile strength and strain rate effect of high-strength concrete under strain rates from 0.01/s to 100/s were studied by splitting tensile test. The simulation results indicate that the number of microcracks generated decreases with the increase of ITZ strength, and the proportion of ITZ cracks decreases obviously. When the ITZ strength exceeds the critical value of 0.8 times that of mortar, the tensile strength is almost not affected by ITZ strength. In addition, based on the numerical simulation results, a modified formula that can reflect the functional relationship between the ITZ strength and the dynamic increasing factor of the concrete tensile strength (TDIF) is proposed, and the rationality of the TDIF modified formula is verified.

36 MATERIALS SCIENCE↗
DOE OSTI2021

LiDAR For Heliostat Optical Assessment (Final Report)

This project has sought to develop new uses for surveying-quality Light Detecting and Ranging (LiDAR) 3D scanning sensors in the automatic/autonomous assessment of optical errors in largescale concentrating solar power heliostat fields. Past experiments have demonstrated the ability of a 3D-LiDAR to acquire highly accurate point cloud measurements across several Sandia NSTTF heliostats. The goal of this project is to expand upon this work to see if and how it can be used in large commercial heliostat fields.

14 SOLAR ENERGY↗
NASA NTRSDate not supplied

Additional Large-Drop Ice Accretion Test Results for a Large Scale Swept Wing Section from January 2022

In-flight icing is an important consideration that affects aircraft design, performance, certification and safety. Newer regulations combined with increasing demand to reduce fuel burn, emissions and noise are driving a need for improvements in icing simulation capability. To that end, this paper presents the results of additional ice accretion testing conducted in the NASA Icing Research Tunnel in January 2022 with a large swept wing section typical of a modern commercial transport. The model was based upon a section of the Common Research Model wing at the 64% semispan station with a streamwise chord length of 136 in. The test conditions were developed with an icing scaling analysis to generate similar conditions for a small median volumetric diameter (MVD) = 25 μm cloud and a large MVD = 110 μm cloud. A series of tests were conducted over a range of total temperature from -23.8 ˚C to -1.4 ˚C with all other conditions held constant. Another series of tests explored cloud MVD variations from 50 μm to 230 μm while holding constant certain scaling parameters. The variation in ice mass and scanned ice volume across repeat conditions was approximately 50% lower than the uncertainty in the cloud MVD and liquid water content. The measured ice mass and volume calculated from the 3D scans were used to compute the mass to volume ratio that is sometimes referred to as ice density or void fraction. When the ice volume based on the ice shape maximum combined cross section was used to determine this ratio, the resulting values were in the range of 240 to 455 kg/m 3 . This is consistent with analogous values previously reported in the literature. The ice shape mass and volume increased with MVD from 50 to 230 μm at fixed values of the scaling parameters. The ice mass to volume ratio was approximately constant for all of the cases which showed that the accreted mass and volume increased at approximately the same rate. These results demonstrate the significance of cloud MVD on ice shape mass and volume.

Ice accretion, Large drops, Wind tunnel↗
NASA NTRSDate not supplied

Additional Large-Drop Ice Accretion Test Results for a Large Scale Swept Wing Section from January 2022

In-flight icing is an important consideration that affects aircraft design, performance, certification and safety. Newer regulations combined with increasing demand to reduce fuel burn, emissions and noise are driving a need for improvements in icing simulation capability. To that end, this paper presents the results of additional ice accretion testing conducted in the NASA Icing Research Tunnel in January 2022 with a large swept wing section typical of a modern commercial transport. The model was based upon a section of the Common Research Model wing at the 64% semispan station with a streamwise chord length of 136 in. The test conditions were developed with an icing scaling analysis to generate similar conditions for a small median volumetric diameter (MVD) = 25 μm cloud and a large MVD = 110 μm cloud. A series of tests were conducted over a range of total temperature from -23.8 ˚C to -1.4 ˚C with all other conditions held constant. Another series of tests explored cloud MVD variations from 50 μm to 230 μm while holding constant certain scaling parameters. The variation in ice mass and scanned ice volume across repeat conditions was approximately 50% lower than the uncertainty in the cloud MVD and liquid water content. The measured ice mass and volume calculated from the 3D scans were used to compute the mass to volume ratio that is sometimes referred to as ice density or void fraction. When the ice volume based on the ice shape maximum combined cross section was used to determine this ratio, the resulting values were in the range of 240 to 455 kg/m3. This is consistent with analogous values previously reported in the literature. The ice shape mass and volume increased with MVD from 50 to 230 μm at fixed values of the scaling parameters. The ice mass to volume ratio was approximately constant for all of the cases which showed that the accreted mass and volume increased at approximately the same rate. These results demonstrate the significance of cloud MVD on ice shape mass and volume.

Ice accretion↗
NASA NTRS2019

Optimizing the Model of the Viking-400 UAS

This project intends to update and redesign imperfections in the scanned 3D CAD model of the Viking 400 aircraft. This aircraft, similar to the Sierra-B UAS, will carry payloads of scientific instruments for research purposes. The goals of this project are to modify the current scanned model such that it better represents the physical qualities of the aircraft, as well as creating the features that are missing from the model. As the model was imported from a different software, many of the critical surfaces did not accurately reflect the actual aircraft. Those parts of the model were redesigned entirely so that they can be edited for future use, as well as correctly representing the aircraft as it is now. Additionally, parts of the aircraft that did not appear in the scanned model were designed and added to the new model. In order to prioritize ease of use for future missions, the model has been reorganized in a logical fashion that enables modification of specific parts of the aircraft. The organization of this model imitates the drawing tree of the Sierra-B, with the intention of maintaining a functional system of redesign, analysis, and implementation. Ultimately, this project will be a catalyst for making Viking 400 into a functional aircraft and increasing scientific research in airborne vehicles.

Wandrocke, Evan W. J.↗
NASA NTRS2010

Relating Linear and Volumetric Variables Through Body Scanning to Improve Human Interfaces in Space

Designing space suits and vehicles for the diverse human population present unique challenges for the methods of traditional anthropometry. Space suits are bulky and allow the operator to shift position within the suit and inhibit the ability to identify body landmarks. Limited suit sizing options also cause variability in fit and performance between similarly sized individuals. Space vehicles are restrictive in volume in both the fit and the ability to collect data. NASA's Anthropometric and Biomechanics Facility (ABF) has utilized 3D scanning to shift from traditional linear anthropometry to explore and examine volumetric capabilities to provide anthropometric solutions for design. Overall, the key goals are to improve the human-system performance and develop new processes to aid in the design and evaluation of space systems. Four case studies are presented that illustrate the shift from purely linear analyses to an augmented volumetric toolset to predict and analyze the human within the space suit and vehicle. The first case study involves the calculation of maximal head volume to estimate total free volume in the helmet for proper air exchange. Traditional linear measurements resulted in an inaccurate representation of the head shape, yet limited data exists for the determination of a large head volume. Steps were first taken to identify and classify a maximum head volume and the resulting comparisons to the estimate are presented in this paper. This study illustrates the gap between linear components of anthropometry and the need for overall volume metrics in order to provide solutions. A second case study examines the overlay of the space suit scans and components onto scanned individuals to quantify fit and clearance to aid in sizing the suit to the individual. Restrictions in space suit size availability present unique challenges to optimally fit the individual within a limited sizing range while maintaining performance. Quantification of the clearance and fit between similarly sized individuals is critical in providing a greater understanding of the human body's function within the suit. The third case study presented in this paper explores the development of a conformal seat pan using scanning techniques, and details the challenges of volumetric analyses that were overcome in order to develop a universal seat pan that can be utilized across the entire user population. The final case study explores expanding volumetric capabilities through generation of boundary manikins. Boundary manikins are representative individuals from the population of interest that represent the extremes of the population spectrum. The ABF developed a technique to take three-dimensional scans of individuals and manipulate the scans to reflect the boundary manikins' anthropometry. In essence, this process generates a representative three-dimensional scan of an individual from anthropometry, using another individual's scanned image. The results from this process can be used in design process modeling and initial suit sizing work as a three dimensional, realistic example of individuals from the population, maintaining the variability between and correlation to the relevant dimensions of interest.

Margerum, Sarah E.↗
DOE OSTI2020

Use of the Manuela 3D/Radiation Scanning Tool at Nuclear Facilities - 20437

Licensees, facility operators and decommissioning contractors have a need for comprehensive, accurate and precise radiological and topographical data to plan and execute safe and efficient Decontamination and Decommissioning (D and D) projects. Traditional approaches rely greatly upon labor and administratively intensive data collection methods that require considerable time and effort to glean the relevant data to plan and perform work in a radiological work area. Orano Decommissioning Services has developed and utilized at French nuclear facilities a lightweight portable scanning instrument called MANUELA (Mobile Apparatus for Nuclear Expertise Localization Assistance). Recently Orano conducted demonstrations at two United States nuclear facilities using MANUELA that may prove useful in areas of the fuel cycle including: - ALARA (As Low As Reasonably Achievable) planning during facility operations; - Scoping and site characterization during the D and D planning phase; - Remedial action support during active decommissioning work; - Radiation and modeling planning for plant modifications; - Support Final Status Survey and demonstration of 'end state' compliance for license termination. MANUELA is currently being evaluated for use during decommissioning of nuclear facilities and could aide in demonstrating compliance with end state criteria after decommissioning. Of particular interest are decommissioning projects planned for various sites across the United States. Most of these sites present unique challenges and opportunities to safely and efficiently decommission in a regulatory compliant manner. The two demonstration site's current conditions of relatively low radiation levels inside containment proved to be ideal platforms to deploy the MANUELA instrument for evaluation of the complex geometries typically found in a nuclear facility. The MANUELA instrument was able to precisely identify local hot spots of the reactor system's primary equipment and was able to simultaneously overlay the dose information onto the scanned 3D images. Using data like this, a licensee would be able to make informed technical and personnel decisions on methods to remediate, shield or properly dispose of the radioactive source term. MANUELA can be used throughout the decommissioning process to validate progress and continue to refine the work activities to optimize the efforts of the crew which reduces downtime waiting for survey results, whereas traditional survey methodology relies on a physical survey to be performed and the data transcribed onto survey maps that are only two dimensional. The traditional format tends to be inaccurate and difficult to interpret the precise location(s) of hot spots or generalized dose rates. The resultant scan also allows the user to know the exact extent of the survey versus transposing information onto a map with only a portion of the map area scanned. MANUELA also compiles all of the relevant survey data into a downloadable table format which includes the measurement identification number, time stamp, point space location on the XYZ plane, and the dose rate value. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Localized material compression to correct distortion in wire arc additive manufacturing

Wire Arc Additive Manufacturing (WAAM) is an advanced manufacturing technology which utilizes welding systems to generate three dimensional geometries in a layer-by-layer fashion. Distortion or warping of a print substrate and WAAM components due to thermally induced residual stresses is an ongoing challenge limiting the widespread adoption of WAAM technologies for producing components. In this manuscript, a novel approach is described to address thermal distortion in deposited components by applying lateral compressions along the length of the deposited material. To demonstrate this method, a series of single-track walls were printed and compressed at evenly spaced intervals using a modified hydraulic cutter tool. The jaws of the tool were modified to compress material rather than to shear it. A mathematical model was developed to relate the curvature of the deposited material to the volume of compression required to eliminate this distortion. Validation of this model was performed using 3D scan data to compare the change in wall curvature induced by compression to the volume of the applied compressions. Substrate deflection was also compared against a control wall, and implementation of wall compression reduced maximum deflections by 93% across a series of four depositions and subsequent compressions. Wall cross sections were also analyzed to determine the impact of compression on material hardness and grain structure. The results demonstrate that successively placed lateral compressions can effectively control and potentially eliminate bending distortion in printed parts. This methodology can be further developed to form a robust model for correction of thermally-induced distortion in WAAM components.

Additive manufacturing↗