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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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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Reduction of baseplate distortion during directed energy deposition using compliant features

Distortion in additive manufacturing (AM) remains a barrier to its adoption in precision industries. Baseplate warpage is one such issue which compromises the feasibility of post-process precision machining. The restriction to thermal contraction of the deposited part, imposed by the baseplate, generates bending moments, that in turn causes warpage. A novel distortion mitigation strategy using baseplates with integrated compliant features, which enables thermal contraction of the build is presented. Six unique design concepts are evaluated, including a solid reference, using two deposition geometries. A laser, hot-wire, directed energy deposition (DED) process is used to deposit a symmetric cylindrical part (C-part) and a T-shaped asymmetric part (T-part). Flatness deviation of baseplates is measured using structured light 3D scanning. Measurements reveal a reduction in net flatness deviation of 58.8% for the C-part and 40.9% for the T-part, compared to the solid reference. While most designs yielded reductions exceeding 30% and 20% for the C- and T-parts, respectively, one configuration resulted in increased deviation. Finite element (FE) simulations are performed to elucidate the underlying mechanisms affecting distortion of compliant baseplates during DED. Despite variations between predictions and measurements, agreement in the general trend is observed. It also revealed that initial flatness errors in baseplates significantly affect its deviation during deposition. Predictions indicate that compliant features significantly affect the thermal distribution as well as the evolution of flatness deviation in the baseplate during deposition. Notably, one design exhibited a reduction in distortion during cooling, following its initial increase during deposition. FE predictions show a maximum reduction of 60.9% and 38.8% in net flatness deviation for the C- and T-parts, respectively. The performance of compliant baseplates is found to be governed by both its the thermal and mechanical characteristics, which are crucial factors to be considered during design.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗
DOE OSTI2024

Digital bead modeling for wire-arc directed energy deposition

Prediction of 2D cross-section and full 3D geometry for stacked weld beads is critical for the outcome of wire-arc directed energy deposition (DED) parts; however, most additive path planning software packages model beads as extrusions of a rectangle. Weld beads are not rectangular, and the resulting shape is dependent upon physics effects at the moment of deposition. Physics phenomena such as the geometry of the underlying surface, the heat input of the welding mode, and the direction of gravity contribute to bead shape. Here, this paper presents a novel implicit modeling method that discretizes a 2D area or 3D volume of space into pixels or voxels and constructs fields based on these physics phenomena. The fields are combined using a weighting scheme trained on 3D scan measurements of welds and wire-arc DED prints. Pixels or voxels are added until the known amount of deposited volume has been achieved. Thereby, a strong conservation of mass principle is applied to the process. Utilizing machine learning techniques, the present model can be trained on a database of scans allowing for the representation of a wide variety of prints. Results show that this method can produce predictions with realistic bead morphology and sub-millimeter form error.

Bead geometry modeling↗
DOE OSTI2023

4D structural changes and pore network model of biomass during pyrolysis

Biochar is an engineered carbon-rich substance used for soil improvement, environmental management, and other diverse applications. To date, the understanding of how biomass affects biochar microstructure has been limited due to the complexity of analysis involved in tracing the changes in the physical structure of biomass as it undergoes thermochemical conversion. In this study, we used synchrotron x-ray micro-tomography to visualize changes in the internal structure of biochar from diverse feedstock (miscanthus straw pellets, wheat straw pellets, oilseed rape straw pellets, and rice husk) during pyrolysis by collecting a sequence of 3D scans at 50 °C intervals during progressive heating from 50 °C to 800 °C. The results show a strong dependence of biochar porosity on feedstock as well as pyrolysis temperature, with observed porosity in the range of 7.41–60.56%. Our results show that the porosity, total surface area, pore volume, and equivalent diameter of the largest pore increases with increasing pyrolysis temperature up to about 550 °C. The most dramatic development of pore structure occurred in the temperature range of 350–450 °C. This understanding is pivotal for optimizing biochar’s properties for specific applications in soil improvement, environmental management, and beyond. By elucidating the nuanced variations in biochar’s physical characteristics across different production temperatures and feedstocks, this research advances the practical application of biochar, offering significant benefits in agricultural, environmental, and engineering contexts.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

In-Situ Detection and Prediction of WAAM Cross Feature Geometry

Abstract Wire arc additive manufacturing (WAAM) is increasingly used by manufacturers due to its relatively low cost and high deposition rate compared to other metal AM methods, but the parts produced by WAAM can be subject to localized variations in part quality. One such variation is the cross-feature defect, whereby a localized part height increase occurs due to the crossing of deposition toolpaths. Mitigation of this defect is typically achieved using manual path planning strategies, but closed-loop control is underutilized. Since the nature of this defect and of the WAAM process is such that the previous layer’s geometry influences that of the subsequent layer’s, the cross-feature defect geometry changes throughout the deposition. Therefore, any closed-loop control strategy will need to incorporate the dynamic trait of this defect. The present work seeks to implement an in-situ process modeling approach where a regression model can be continuously updated to predict the defect geometry of the subsequent deposition layer based on the historical process data. Several multi-layer cross-feature geometries are deposited and current, voltage, and optical camera data is taken for each layer. The resulting cross-feature geometries are characterized using 3D scanning and the performance and accuracy of the in-situ modeling approach is evaluated.

Thien, Austen↗
DOE OSTI2025

Influence of gradation on failure mode of saturated sand at particle scale

Extensive research has been reported in the literature to characterize the failure mode of dry sand using various experimental techniques such as surface optical imaging, photo-elastic materials, three-dimensional (3D) computed tomography (CT), and 3D synchrotron micro-computed tomography (SMT). However, there is a limited literature about the behavior of saturated sand. This paper presents the results of axisymmetric triaxial compression (ATC) experiments that were conducted on saturated sand specimens. The behavior of specimens composed of a uniform sand with grain size between US sieves #40 and #50 is compared to specimens conducted on the same sand that has a wider gradation. 3D SMT technique was used to acquire 3D scans while shearing the specimens to probe localized events that are completely missed or misinterpreted when analyzing ATC measurements based on global standard measurements. The results show a higher effective principal stress ratio (EPSR) for the non-uniform specimen and a thicker shear band when compared to uniform specimen.

Elnur, Mohammed [University of Tennessee]↗
DOE OSTI2025

Flexible Fuel Electric Hybrid Glass Furnace Demonstration

The furnace contractor completed General Arrangement (GA) layouts and Piping and Instrumentation Diagrams (P&ID) for both furnaces during this reporting period. Preliminary equipment lists accompanied this work. Control system architecture in progress. Key furnace design elements and deliverables on track to be complete by end of phase. The facilities design and integration contractor completed a 3D scan and modeling of the facility. The work during this period focused on preliminary design with a focus on overall project scope and feasibility. This key work supports the overall project deliverables for 30% preliminary engineering and Preliminary Design Report (PDR) which are on track to be complete by the end of the phase. These deliverables are approximately 50% complete through the end of this reporting period. The batch house operations design contractor continues development of site plan and General Arrangement (GA) layout to support the 30% preliminary engineering and design package. This work is 60% complete by the end of this reporting period and is on track to be complete by the end of the phase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Study of shortwave spectra in fully 3D environment: synergy between scanning radars and spectral radiation measurements (final Report)

Overview of 3D atmospheric radiative transfer in cloudy atmosphere for Reports on Progress in Physics. We surveyed the 3D atmospheric radiative transfer literature over the past 50 years and identify three concurrent and intertwining themes: first, how to assess the damage (bias) caused by 3D effects in the operational 1D radiative transfer models? Second, how to mitigate this damage? Third, can we exploit 3D radiative transfer phenomena to invent new observation methods and technologies? Two equally important application areas for atmospheric radiative transfer in general, and 3D in particular, were identified: broadband radiative energy budget estimation and wavelength-specific optical remote sensing signal modeling. As illustrations, both satellite and ARM observations were highly used.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

3D Reality Energy Modeling Software

The team will combine Bentley Systems’ ContextCapture and extend Oak Ridge National Laboratory’s building energy modeling capabilities in order to create digital twins of buildings that allow simulation-informed improvement for energy efficiency and demand response in the design and operation of the built environment. Bentley Systems’ ContextCapture software processes data from 3D laser scanning and photographs (through photogrammetry) to create a photorealistic, 3D mesh with a scale of individual objects to building to city-sized. This capability easily provides city-level visualization models and platforms where sustainable design alternatives are readily evaluated. Oak Ridge National Laboratory (ORNL) serves the U.S. Dept. of Energy (DOE) as one of three core laboratories developing building energy modeling tools EnergyPlus and OpenStudio. ORNL’s AutoBEM software (bit.ly/AutoBEM) can process imagery (satellite, aerial, and street level), LiDAR, cartographic layers, tax assessor’s data, and other data sources to extract building footprints, height, window-to-wall ratio, building type, vintage, and other building properties. AutoBEM has created 178,368 building energy models that were empirically validated with 15-minute whole-building electrical data from a utility.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Three-dimensional broadband nonlinear phased array imaging

System include an ultrasonic transducer configured to couple to a nondestructive testing (NDT) sample and configured to produce and direct an ultrasonic probe wave at a selected frequency into a subsurface region of the NDT sample, a 3D laser scanning vibrometer configured to direct a detection beam in a scan area on a surface of the NDT sample and to receive a return beam from the scan area, and to detect, based on the return beam, a 3D motion of the surface across a wideband frequency range, and a processor, and a memory configured with instructions that, when executed by the processor, cause the processor to produce sub-surface image data of the NDT sample at multiple harmonics of the selected frequency in the wideband frequency range based on the detected 3D surface motion, wherein the sub-surface image data describes a nonlinear defect response produced in the NDT sample by interaction of the ultrasonic probe wave with the subsurface region.

Remillieux, Marcel↗
DOE OSTI2024

Automatic Digitization and Orientation of Scanned Mesh Data for Floor Plan and 3D Model Generation

This paper describes a novel approach for generating accurate floor plans and 3D models of building interiors using scanned mesh data. Unlike previous methods, which begin with a high resolution point cloud from a laser range-finder, our approach begins with triangle mesh data, as from a Microsoft HoloLens. It generates two types of floor plans, a “pen-and-ink” style that preserves details and a drafting-style that reduces clutter. It processes the 3D model for use in applications by aligning it with coordinate axes, annotating important objects, dividing it into stories, and removing the ceiling. Its performance is evaluated on commercial and residential buildings, with experiments to assess quality and dimensional accuracy. Our approach demonstrates promising potential for automatic digitization and orientation of scanned mesh data, enabling floor plan and 3D model generation in various applications such as navigation, interior design, furniture placement, facilities management, building construction, and HVAC design.

Sharma, Ritesh↗
DOE OSTI2022

A reliable workflow for improving nanoscale X-ray fluorescence tomographic analysis on nanoparticle-treated HeLa cells

Abstract Scanning X-ray fluorescence (XRF) tomography provides powerful characterization capabilities in evaluating elemental distribution and differentiating their inter- and intra-cellular interactions in a three-dimensional (3D) space. Scanning XRF tomography encounters practical challenges from the sample itself, where the range of rotation angles is limited by geometric constraints, involving sample substrates or nearby features either blocking or converging into the field of view. This study aims to develop a reliable and efficient workflow that can (1) expand the experimental window for nanoscale tomographic analysis of local areas of interest within a laterally extended specimen, and (2) bridge 3D analysis at micrometer and nanoscales on the same specimen. We demonstrate the workflow using a specimen of HeLa cells exposed to iron oxide core and titanium dioxide shell (Fe3O4/TiO2) nanocomposites. The workflow utilizes iterative and multiscale XRF data collection with intermediate sample processing by focused ion beam (FIB) sample preparation between measurements at different length scales. Initial assessment combined with precise sample manipulation via FIB allows direct removal of sample regions that are obstacles to both incident X-ray beam and outgoing XRF signals, which considerably improves the subsequent nanoscale tomography analysis. This multiscale analysis workflow has advanced bio-nanotechnology studies by providing deep insights into the interaction between nanocomposites and single cells at a subcellular level as well as statistical assessments from measuring a population of cells.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2026

3D printed water-stable Cd-doped Cs 4 MnBi 2 Cl 12 /polylactic acid perovskite/polymer composites for high-flux X-ray scintillation

Stable and efficient X-ray scintillators are crucial for medical diagnostics, industrial, and defense applications. However, conventional scintillator technologies face a trade-off between stability, optimal performance, and sustainability. Herein, we introduce 3D-printed Cs 4 MnBi 2 Cl 12 (Pero1) and Cs 4 Cd 0.68 Mn 0.32 Bi 2 Cl 12 (Pero2) perovskite microcrystals embedded within a polylactic acid (PLA) polymer composite as X-ray scintillators, combining efficiency, stability, and sustainability. The orange luminescent perovskite powder phosphors exhibited poor water stability, which was successfully addressed through incorporation into PLA via filament extrusion and fused deposition modeling (FDM) 3D printing. The resulting composite films demonstrated remarkable water stability while maintaining uniform orange emission throughout the polymer matrix, as confirmed by 3D topography scanning and X-ray fluorescence mapping. Structural characterization revealed minimal chemical interaction between the perovskite and PLA matrix, with the composites retaining their crystalline properties. The PLA-Pero2 composite exhibited superior optical properties, with a photoluminescence quantum yield of 47%, nearly 17 times higher than that of PLA-Pero1 (2.8%), attributed to the effective suppression of non-radiative decay pathways through Cd 2+ doping. Under hard X-ray irradiation at synchrotron beamlines, both composites exhibited excellent radioluminescence, with emission peaks at 605 nm, a linear response across a wide X-ray flux range, and remarkable radiation stability, showing less than 3% intensity degradation after 600 seconds of continuous high-dose exposure. The PLA-Pero2 composite achieved a spatial resolution of 5 line pairs per millimeter and a contrast ratio of 0.255. These performance metrics, combined with the polymer's biodegradability and scalability through additive manufacturing, position PLA-based composites as a more sustainable alternative to conventional petroleum-based polymer scintillators for next-generation medical imaging, radiation monitoring, and industrial radiography applications.

3D Printing↗
DOE OSTI2023

Element-Specific Study of Magnetic Anisotropy and Hardening in SmCo 5– x Cu x Thin Films

This work investigates the effect of copper substitution on the magnetic properties of SmCo 5 thin films synthesized by molecular beam epitaxy. A series of thin films with varying concentrations of Cu were grown under otherwise identical conditions to disentangle structural and compositional effects on the magnetic behavior. The combined experimental and theoretical studies show that Cu substitution at the Co 3g sites not only stabilizes the formation of the SmCo 5 structure but also enhances magnetic anisotropy and coercivity. Density functional theory calculations indicate that Sm(Co 4 Cu 3g ) 5 possesses a higher single-ion anisotropy as compared to pure SmCo 5 . In addition, X-ray magnetic circular dichroism reveals that Cu substitution causes an increasing decoupling of the Sm 4f and Co 3d moments. Scanning transmission electron microscopy confirms predominantly SmCo 5 phase formation and reveals nanoscale inhomogeneities in the Cu and Co distribution. Our study based on thin film model systems and advanced characterization as well as modeling reveals novel aspects of the complex interplay of intrinsic and extrinsic contributions to magnetic hysteresis in rare-earth-based magnets, i.e., the combination of increased intrinsic anisotropy due to Cu substitution and the extrinsic effect of inhomogeneous elemental distribution of Cu and Co.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Evaluation of Electron Tomography Capabilities for Shale Imaging

Despite the advantageous resolution of electron tomography (ET), reconstruction of three-dimensional (3D) images from multiple two-dimensional (2D) projections presents several challenges, including small signal-to-noise ratios, and a limited projection range. This study evaluates the capabilities of ET for thin sections of shale, a complex nanoporous medium. A numerical phantom with 1.24 nm pixel size is constructed based on the tomographic reconstruction of a Barnett shale. A dataset of 2D projection images is numerically generated from the 3D phantom and studied over a range of conditions. First, common reconstruction techniques are used to reconstruct the shale structure. The reconstruction uncertainty is quantified by comparing overall values of storage and transport metrics, as well as the misclassification of pore voxels compared to the phantom. We then select the most robust reconstruction technique and we vary the acquisition conditions to quantify the effect of artifacts. We find a strong agreement for large pores over the different acquisition workflows, while a wider variability exists for nanometer-scale features. Furthermore, the limited projection range and reconstruction are identified as the main experimental bottlenecks, thereby suggesting that sample thinning, advanced holders, and advanced reconstruction algorithms offer opportunities for improvement.

3D scanning transmission electron microscopy↗
DOE OSTI2021

Keras CT Segmentation v.1

SAND2020-14119 O A Tensorflow and Keras-backed framework for learned segmentation methods of 3D CT scan volumes. Supported functionality includes training models, running inference and quantifying uncertainty. The main underlying model architecture is V-Net. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Ganter, Tyler↗
DOE OSTI2024

General Testing Setup for Hyperelastic Transducers-DEEC-Tec & Marine Renewable Energy: Preprint

Distributed embedded energy conversion technologies (DEEC-Tec), an emerging domain for ocean wave energy conversion technology, is showing promise for a range of applications. Research is being conducted at the National Renewable Energy Laboratory that leverages this domain to investigate the potential of ocean wave energy converters (WECs) constructed from hyperelastic forms of distributable and embeddable energy transducers. These transducers are available in forms such as disks, rectangles, or hexagons and can be combined in various ways to form energy-producing metamaterials and flexible WECs. DEEC-Tec, therefore, could open doors that enhance ocean wave energy conversion in ways not previously thought possible by allowing for many WEC topologies and morphologies. However, the same diversity and adaptability pose challenges for the development of these DEEC-Tec-oriented hyperelastic transducers. A commercial tensile testing setup was not found that was adaptable enough to accommodate the varied transducers while providing precise force control, range of motion, and noncontact data collection. Because of this lack, a comprehensive test rig was designed in house to be used with a 3D laser scanning device-providing contactless measurements while also allowing for different geometries and various uniaxial loadings. This paper and presentation will discuss these unique challenges and the processes for overcoming them to provide a robust and general testing setup for hyperelastic transducers, of any form, for the DEEC-Tec marine renewable energy domain.

DEEC-Tec↗