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At least 37 records · Page 2

An instrument for in situ characterization of powder spreading dynamics in powder-bed-based additive manufacturing processes

In powder-bed-based metal additive manufacturing (AM), the visualization and analysis of the powder spreading process are critical for understanding the powder spreading dynamics and mechanisms. Unfortunately, the high spreading speeds, the small size of the powder, and the opacity of the materials present a great challenge for directly observing the powder spreading behavior. In this study, we report a compact and flexible powder spreading system for in situ characterization of the dynamics of the powders during the spreading process by high-speed x-ray imaging. The system enables the tracing of individual powder movement within the narrow gap between the recoater and the substrate at variable spreading speeds from 17 to 322 mm/s. The instrument and method reported here provide a powerful tool for studying powder spreading physics in AM processes and for investigating the physics of granular material flow behavior in a confined environment.

47 OTHER INSTRUMENTATION↗

Geometry definition and grid generation for a complete fighter aircraft

Recent advances in computing power and numerical solution procedures have enabled computational fluid dynamicists to attempt increasingly difficult problems. In particular, efforts are focusing on computations of complex three-dimensional flow fields about realistic aerodynamic bodies. To perform such computations, a very accurate and detailed description of the surface geometry must be provided, and a three-dimensional grid must be generated in the space around the body. The geometry must be supplied in a format compatible with the grid generation requirements, and must be verified to be free of inconsistencies. This paper presents a procedure for performing the geometry definition of a fighter aircraft that makes use of a commercial computer-aided design/computer-aided manufacturing system. Furthermore, visual representations of the geometry are generated using a computer graphics system for verification of the body definition. Finally, the three-dimensional grids for fighter-like aircraft are generated by means of an efficient new parabolic grid generation method. This method exhibits good control of grid quality.

Edwards, T. A.↗

Cycle life machine for AX-5 space suit

In order to accurately test the AX-5 space suit, a complex series of motions needed to be performed which provided a unique opportunity for mechanism design. The cycle life machine design showed how 3-D computer images can enhance mechanical design as well as help in visualizing mechanisms before manufacturing them. In the early stages of the design, potential problems in the motion of the joint and in the four bar linkage system were resolved using CAD. Since these problems would have been very difficult and tedious to solve on a drawing board, they would probably not have been addressed prior to fabrication, thus limiting the final design or requiring design modification after fabrication.

Schenberger, Deborah S.↗

NASA System-Wide Safety Wildland Firefighting Operations Workshop Report

On March 9-11, 2022, NASA’s System-Wide Safety Wildland Firefighting Operations Workshop engaged the broader wildland firefighting management ecosystem in a safety-oriented discussion via a virtual platform. This enabled a better understanding of how NASA and community expertise can be leveraged in the safe development of current and future firefighting systems and operations. The goals of the workshop were to: (1) identify and prioritize the top safety-oriented risks, gaps in capabilities, and emerging technologies to enhance wildland firefighting for both near-term and far-term concepts, with a specific focus on aviation operations and (2) engage the stakeholder community in defining emergent safety-oriented scope, roles, responsibilities, and procedures for agents undergoing increasingly complex wildland firefighting operations in information-rich, but uncertain environments. Workshop participants were solicited from wildland firefighting stakeholders across government, industry, and academia. All levels of government were engaged, as NASA sought attendees from federal, state, local, and tribal government agencies. Industry participants from traditional wildland firefighting domains such as data visualization and equipment manufacturers were invited, and corporate attendees from novel application domains such as aerial robotics and autonomous systems were present as well. The top three findings were as follows: (1) Enhancing situation awareness is a safety priority, especially in the use of aerial assets; (2) Timely access to information along with data fusion and integrated displays will enhance safety-critical decision-making both inside and outside aviation contexts; and (3) Tailorable standards and common operating pictures in the field will enhance inter-agency cooperation in the wildland firefighting lifecycle and enable the optimal use of limited resources such as aerial assets. The workshop helped inform NASA of the relevant safety-related wildland firefighting concerns and aided the broader ecosystem in understanding the potential safety-oriented role NASA might play in this community. Increased engagement with crucial governmental stakeholders (e.g., U.S. Forest Service, CAL FIRE, etc.) along with industry partners in cutting- edge information -centric domains is a fundamental next step. Additionally, the workshop findings will help define the first of a series of operationally challenging demonstrations, held in concert with strategic ecosystem partners, known as the Safety Demonstrator Series for NASA’s System-Wide Safety project. The first demonstration is set in the wildland firefighting application domain and will: (1) examine high risk operational scenarios to reduce their overall risk via services, functions or capabilities that act as risk mitigators (or transfer that risk to automated systems better able to tolerate it) and (2) explore novel tools and technologies that will enhance safety margins by enabling non-traditional or neoteric operational paradigms.

wildland firefighting↗

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA's Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aid in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI.

Babai, Majid↗

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA.s Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aide in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing simulation support. This paper highlights the accomplishments of this task agreement, while also introducing the capabilities of simulation software.

Babai, Majid↗

Monte Carlo modeling and simulations of the High Definition (HD120) micro MLC and validation against measurements for a 6 MV beam

Purpose: The most recent Varian micro multileaf collimator (MLC), the High Definition (HD120) MLC, was modeled using the BEAMNRC Monte Carlo code. This model was incorporated into a Varian medical linear accelerator, for a 6 MV beam, in static and dynamic mode. The model was validated by comparing simulated profiles with measurements. Methods: The Varian Trilogy (2300C/D) accelerator model was accurately implemented using the state-of-the-art Monte Carlo simulation program BEAMNRC and validated against off-axis and depth dose profiles measured using ionization chambers, by adjusting the energy and the full width at half maximum (FWHM) of the initial electron beam. The HD120 MLC was modeled by developing a new BEAMNRC component module (CM), designated HDMLC, adapting the available DYNVMLC CM and incorporating the specific characteristics of this new micro MLC. The leaf dimensions were provided by the manufacturer. The geometry was visualized by tracing particles through the CM and recording their position when a leaf boundary is crossed. The leaf material density and abutting air gap between leaves were adjusted in order to obtain a good agreement between the simulated leakage profiles and EBT2 film measurements performed in a solid water phantom. To validate the HDMLC implementation, additional MLC static patterns were also simulated and compared to additional measurements. Furthermore, the ability to simulate dynamic MLC fields was implemented in the HDMLC CM. The simulation results of these fields were compared with EBT2 film measurements performed in a solid water phantom. Results: Overall, the discrepancies, with and without MLC, between the opened field simulations and the measurements using ionization chambers in a water phantom, for the off-axis profiles are below 2% and in depth-dose profiles are below 2% after the maximum dose depth and below 4% in the build-up region. On the conditions of these simulations, this tungsten-based MLC has a density of 18.7 g cm{sup -3} and an overall leakage of about 1.1 {+-} 0.03%. The discrepancies between the film measured and simulated closed and blocked fields are below 2% and 8%, respectively. Other measurements were performed for alternated leaf patterns and the agreement is satisfactory (to within 4%). The dynamic mode for this MLC was implemented and the discrepancies between film measurements and simulations are within 4%. Conclusions: The Varian Trilogy (2300 C/D) linear accelerator including the HD120 MLC was successfully modeled and simulated using the Monte Carlo BEAMNRC code by developing an independent CM, the HDMLC CM, either in static and dynamic modes.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Techno-economics of hydrocarbon fuel production and recyclables recovery from landfill-destined municipal solid waste: AI-enhanced materials recovery facility design

Sustainable aviation fuels (SAF) production from cellulosic paper fractions of municipal solid waste (MSW) destined for landfills has strong potential to advance environmental, social, and economic sustainability across the aviation and waste sectors. This study proposes an artificial intelligence-enabled material recovery facility (AI-MRF) design to efficiently characterize, separate, process, and convert recovered paper waste from MSW into intermediate chemicals and SAF. The AI-MRF, designed to process 233,091 metric tons of MSW annually, integrates smart manufacturing technologies including AI, visual and hyperspectral imaging, multi-sensor data, and traditional sorting systems. Well-characterized and sorted cellulosic paper waste was utilized for chemical and fuel production scenarios, while clean plastics, metals, and glass were considered for recycling. Conversion of paper waste into intermediate sugars achieved a net present value (NPV) of up to $\$67$ million. For sugar-to-SAF production scenarios, the minimum fuel selling price (MFSP) was calculated at $\$6.11$ per gasoline gallon equivalent (GGE) when excluding recyclable revenue, and $\$4.03$ per GGE when halving recyclable revenue. The MFSP was further reduced to $\$1.96$ per GGE when accounting for SAF sales and recyclables. Nationally, this approach could yield about 2 billion GGE of hydrocarbon fuel annually from available MSW in the United States.

09 BIOMASS FUELS↗

Reactor Engineering: Experimental Investigation of Alpha Convection

This report summarizes the progress on DE-FG07-07ID14806 project funded by the US Department of Energy under Nuclear Engineering Education Research (NEER) program. During the project a test apparatus was designed and manufactured for experimental investigation of Alpha Convection. Benchmark testing of the new apparatus without the neutron radiation was performed and numerical simulations were conducted to validate the experimental results on natural convection. These results were reported in a journal publication. Subsequently, we conducted the experiment at Missouri S&T research reactor in the beam port to investigate the phenomenon of Alpha Convection. Unfortunately, these experiments were inconclusive. No observable effect of neutron beam was noticed. Insufficient neutron flux as it passes through the borated water is responsible for the unsuccessful experiments. A number of new experiments are designed and manufactured to investigate the phenomenon. A new experiment using shadowgraphy is designed and manufactured to investigate and visualize the natural convection and the impact of neutron on the phenomenon. Moreover, to continue with the original and newly designed experiments a neutron generator was needed to supply a vertical beam of neutrons. This new source of neutron is acquired using DOE NEUP General Scientific Infrastructure number DE-FOA-0000321. The new facility is installed and tested but is yet to be licensed by NRC for regular use and continuation of the experiments.

Conduction convection transition.↗

Reliability of Semiconductor Laser Packaging in Space Applications

A typical set up used to perform lifetime tests of packaged, fiber pigtailed semiconductor lasers is described, as well as tests performed on a set of four pump lasers. It was found that two lasers failed after 3200, and 6100 hours under device specified bias conditions at elevated temperatures. Failure analysis of the lasers indicates imperfections and carbon contamination of the laser metallization, possibly from improperly cleaned photo resist. SEM imaging of the front facet of one of the lasers, although of poor quality due to the optical fiber charging effects, shows evidence of catastrophic damage at the facet. More stringent manufacturing controls with 100% visual inspection of laser chips are needed to prevent imperfect lasers from proceeding to packaging and ending up in space applications, where failure can result in the loss of a space flight mission.

Gontijo, Ivair↗

The Mode Localization Phenomenon: Visual Test Results

The high degree of manufacturing precision required in space structures may make them moresusceptible to mode localization. In this demonstration, the mode localization phenomenon isinvestigated using an existing full scale antenna-like structure having the complexity, manufacturingprecision, and dynamic characteristics of space structures. The actual imperfections were measuredand incorporated in a numerical model of the structure. The impact of several parameters thatprovoke the phenomenon were first studied by numerical simulations, then experimentally. Theresults show excellent agreement, thereby confirming the importance of mode localization in thedesign of actual space structure.

Levine-West, M.↗

Concept of Operations Visualization in Support of Ares I Production

Boeing was selected in 2007 to manufacture Ares I Upper Stage and Instrument Unit according to NASA's design which would require the use of the latest manufacturing and integration processes to meet NASA budget and schedule targets. Past production experience has established that the majority of the life cycle cost is established during the initial design process. Concept of Operations (CONOPs) visualizations/simulations help to reduce life cycle cost during the early design stage. Production and operation visualizations can reduce tooling, factory capacity, safety, and build process risks while spreading program support across government, academic, media and public constituencies. The NASA/Boeing production visualization (DELMIA; Digital Enterprise Lean Manufacturing Interactive Application) promotes timely, concurrent and collaborative producibility analysis (Boeing)while supporting Upper Stage Design Cycles (NASA). The DELMIA CONOPs visualization reduced overall Upper Stage production flow time at the manufacturing facility by over 100 man-days to 312.5 man-days and helped to identify technical access issues. The NASA/Boeing Interactive Concept of Operations (ICON) provides interactive access to Ares using real mission parameters, allows users to configure the mission which encourages ownership and identifies areas for improvement, allows mission operations or spacecraft detail to be added as needed, and provides an effective, low coast advocacy, outreach and education tool.

Chilton, James H.↗

Additive friction stir deposition induced stress ripples in aluminum alloy

In additive manufacturing, modification of the viscosity of softened or molten metal plays a significant role in the development of mechanical properties distribution. Similar to soft polymers, molten or softened metal usually exhibits vastly different viscoelastic properties. During scratching tests, viscoelastic polymers undergo spatiotemporal stress development and relaxation, causing stress ripples to form on their surfaces. Here, it is observed that friction stir-based solid-state manufacturing can yield similar stress ripples on softened aluminum alloys due to the linear motion of the deposition tool. Softened aluminum alloys exhibit viscoelastic and viscoplastic responses similar to polymeric material during the solid-state deposition process. In the final product, residual stress ripples appear on the surface of the metal alloy due to periodic residual stress relaxation, leading to oscillatory behavior from the bulk mechanical properties of the material. The orientation of the in-built stress pattern formed in the bulk of the additively manufactured metal alloy underneath the visually evident onion ring-like surface pattern formation is diametrically in the opposite direction. The experimentally observed results are consistent with analytical calculation and numerical simulations in terms of behaviors.

36 MATERIALS SCIENCE↗

Web application for machining parameter recommendation using visual analytics

The computer codes create a web application including multiple user interfaces, visualizations, interaction modules between the user, and visualizations. The visualizations will be interactive, allowing users to query the data directly, and they will be arranged in a dashboard. When selections are made in one visualization, filters will be applied to all other visualizations providing a coordinated system for asking questions about the data. The visualization can be utilized for manufacturing data management, analysis, and recommendation.

Chae, Junghoon↗

Imaging transient solidification behavior

Solidification processing offers the first opportunity to control microstructure, properties, and performance in metallic alloy components. Until recently, microstructural evaluations were limited to post-solidification characterization by destructive methods. We review the development of time-resolved, in situimaging techniques capable of capturing solid-liquid interfacial evolution in metallic alloys with high spatial and temporal resolution underdiverse solidification conditions relevant for applications ranging from conventional directional solidification, crystal growth, and casting,to welding and additive manufacturing. These experiments enable direct visualization of transient behaviors that would otherwise remain unknown, uniquely providinginsights into the physics that impact microstructure and defect development and strategies for microstructuralcontrol and defect mitigation. Understanding microstructural evolution and the characteristics that form under various solidification conditions is essential for the development of multiscale, experimentallyinformed predictive modeling. This is highlightedby solidification simulations that utilize in situmeasurements of solidification dynamics from state-of-the-art experimental techniques.

36 MATERIALS SCIENCE↗

Geometry definition and grid generation for a complete fighter aircraft

Recent advances in computing power and numerical solution procedures have enabled computational fluid dynamicists to attempt increasingly difficult problems. In particular, efforts are focusing on computations of complex three-dimensional flow fields about realistic aerodynamic bodies. To perform such computations, a very accurate and detailed description of the surface geometry must be provided, and a three-dimensional grid must be generated in the space around the body. The geometry must be supplied in a format compatible with the grid generation requirements, and must be verified to be free of inconsistencies. A procedure for performing the geometry definition of a fighter aircraft that makes use of a commercial computer-aided design/computer-aided manufacturing system is presented. Furthermore, visual representations of the geometry are generated using a computer graphics system for verification of the body definition. Finally, the three-dimensional grids for fighter-like aircraft are generated by means of an efficient new parabolic grid generation method. This method exhibits good control of grid quality.

Edwards, Thomas A.↗

Image Processing

Images are prepared from data acquired by the multispectral scanner aboard Landsat, which views Earth in four ranges of the electromagnetic spectrum, two visible bands and two infrared. Scanner picks up radiation from ground objects and converts the radiation signatures to digital signals, which are relayed to Earth and recorded on tape. Each tape contains "pixels" or picture elements covering a ground area; computerized equipment processes the tapes and plots each pixel, line be line to produce the basic image. Image can be further processed to correct sensor errors, to heighten contrast for feature emphasis or to enhance the end product in other ways. Key factor in conversion of digital data to visual form is precision of processing equipment. Jet Propulsion Laboratory prepared a digital mosaic that was plotted and enhanced by Optronics International, Inc. by use of the company's C-4300 Colorwrite, a high precision, high speed system which manipulates and analyzes digital data and presents it in visual form on film. Optronics manufactures a complete family of image enhancement processing systems to meet all users' needs. Enhanced imagery is useful to geologists, hydrologists, land use planners, agricultural specialists geographers and others.

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