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DOE OSTI2024

Preliminary Results on Process Modeling Tools for Determining Variability in Additively Manufactured Stainless Steel 316 Parts

The Advanced Materials and Manufacturing Technologies program aims to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. However, the distinct characteristics of additive manufacturing (AM) materials, stemming from their unique processing history, microstructure, and properties, pose significant challenges for the qualification and certification of nuclear components. These challenges primarily arise from component-scale variations in microstructure and properties influenced by local process conditions and geometry, which affect thermal history, melt pool dynamics, and microstructure evolution. Computational modeling tools can play a crucial role in predicting and controlling this variability. This report presents preliminary results on process modeling tools designed to predict microstructure variability in additively manufactured stainless steel 316 parts. It details the software packages and physical modeling approaches employed to simulate an AM component within an automated process modeling workflow. Initial results are demonstrated through comparisons between predicted microstructures and experimental measurements across various representative processing conditions. The report concludes by discussing the challenges inherent in process modeling of AM components and outlines a plan for future development needs.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Plants for water recycling, oxygen regeneration and food production

During long-duration space missions that require recycling and regeneration of life support materials the major human wastes to be converted to usable forms are CO2, hygiene water, urine and feces. A Controlled Ecological Life Support System (CELSS) relies on the air revitalization, water purification and food production capabilities of higher plants to rejuvenate human wastes and replenish the life support materials. The key processes in such a system are photosynthesis, whereby green plants utilize light energy to produce food and oxygen while removing CO2 from the atmosphere, and transpiration, the evaporation of water from the plant. CELSS research has emphasized the food production capacity and efforts to minimize the area/volume of higher plants required to satisfy all human life support needs. Plants are a dynamic system capable of being manipulated to favour the supply of individual products as desired. The size and energy required for a CELSS that provides virtually all human needs are determined by the food production capacity. Growing conditions maximizing food production do not maximize transpiration of water; conditions favoring transpiration and scaling to recycle only water significantly reduces the area, volume, and energy inputs per person. Likewise, system size can be adjusted to satisfy the air regeneration needs. Requirements of a waste management system supplying inputs to maintain maximum plant productivity are clear. The ability of plants to play an active role in waste processing and the consequence in terms of degraded plant performance are not well characterized. Plant-based life support systems represent the only potential for self sufficiency and food production in an extra-terrestrial habitat.

NASA Discipline Life Support Systems↗

NASA NTRS2001

Dynamic Fatigue of ULE Glass

Ultra Low Expansion (ULE) glass is used in a number of applications which require a low thermal expansion coefficient. One such application is telescope mirror elements. An allowable stress can be calculated for this material based upon modulus of rupture data; however, this does not take into account the problem of delayed failure. Delayed failure, due to stress corrosion can significantly shorten the lifetime of a glass article. Knowledge of the factors governing the rate of subcritical flaw growth in a given environment enables the development of relations between lifetime, applied stress and failure probability for the material under study. Dynamic fatigue is one method of obtaining the necessary information to develop these relationships. In this study, the dynamic fatigue method was used to construct time-to-failure diagrams for both 230/270 ground and optically polished samples. The grinding and polishing process reduces the surface flaw size and subsurface damage, and relieves residual stress by removing materials with successively smaller grinding media. This resulted in an increase in the strength of the optic during the grinding and polishing sequence. There was also an increase in the lifetime due to grinding and polishing. It was found that using the fatigue parameters determined from the 230/270 grit surface are not significantly different from the optically polished values. Although the lower bound of the polished samples is more conservative, neither time-to-failure curves lie beyond the upper or lower bound of the confidence limits. Therefore, designers preferring conservative limits could use samples without residual stress present (polished samples) to determine the fatigue parameters and inert Weibull parameters from samples with the service condition surface, to determine time-to-failure of the optical element.

Tucker, Dennis S.↗

DOE OSTI2025

Characterization of Infrasonic Signatures of Earth-Grazing Fireballs as Analogues to Hypersonic Vehicles (Final Report)

Accurate detection, discrimination, and characterization of high-altitude hypersonic events using infrasonic monitoring are critical to planetary defense and global strategic surveillance. This report synthesizes recent advances achieved through rigorous analysis of infrasonic signatures from natural meteoroids, emphasizing shallow entry-angle meteoroids as essentially proxies for artificial hypersonic systems. Meteoroids naturally encompass diverse velocities, trajectories, altitudes, and fragmentation behaviors, enabling systematic validation of empirical period–yield relationships, waveform morphology classifiers, and trajectory-induced back-azimuth deviation models. Integration of adaptive array-processing enhancements within Cardinal software further extends infrasonic detection sensitivity and signal classification reliability. Collectively these advances, based solely on infrasonic signatures or limited optical data, offer robust methodologies for distinguishing natural from artificial hypersonic sources, significantly reducing event geolocation uncertainties and refining source-function determination. The outcomes detailed herein lay foundational groundwork for improved global hypersonic event-surveillance frameworks, supporting improved security preparedness and informing strategic monitoring and defense policies.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1982

Measurement and visualization of skin friction on the leeside of delta wings in supersonic flow

The reported investigation was conducted with the aid of the NASA Ames High Reynolds Number Wind Tunnel. The flow conditions considered involved free stream Mach numbers of 2 and 3, and a Reynolds number of approximately 10,000,000 p. m. The employed model was a delta wing with an angle of 70 deg. A method reported by Tanner (1977) was used for the measurement of the skin friction. This method involves the use of a laser interferometer to determine the change in the thickness of an oil film. The procedure can also be employed for a visualization of skin friction in the form of interferograms. The investigation shows that skin friction measurements can provide a significant contribution to a physical understanding of the flow processes at the delta wing.

Szodruch, J.↗

NASA NTRS1993

Intelligent neuroprocessors for in-situ launch vehicle propulsion systems health management

Efficacy of existing on-board propulsion systems health management systems (HMS) are severely impacted by computational limitations (e.g., low sampling rates); paradigmatic limitations (e.g., low-fidelity logic/parameter redlining only, false alarms due to noisy/corrupted sensor signatures, preprogrammed diagnostics only); and telemetry bandwidth limitations on space/ground interactions. Ultra-compact/light, adaptive neural networks with massively parallel, asynchronous, fast reconfigurable and fault-tolerant information processing properties have already demonstrated significant potential for inflight diagnostic analyses and resource allocation with reduced ground dependence. In particular, they can automatically exploit correlation effects across multiple sensor streams (plume analyzer, flow meters, vibration detectors, etc.) so as to detect anomaly signatures that cannot be determined from the exploitation of single sensor. Furthermore, neural networks have already demonstrated the potential for impacting real-time fault recovery in vehicle subsystems by adaptively regulating combustion mixture/power subsystems and optimizing resource utilization under degraded conditions. A class of high-performance neuroprocessors, developed at JPL, that have demonstrated potential for next-generation HMS for a family of space transportation vehicles envisioned for the next few decades, including HLLV, NLS, and space shuttle is presented. Of fundamental interest are intelligent neuroprocessors for real-time plume analysis, optimizing combustion mixture-ratio, and feedback to hydraulic, pneumatic control systems. This class includes concurrently asynchronous reprogrammable, nonvolatile, analog neural processors with high speed, high bandwidth electronic/optical I/O interfaced, with special emphasis on NASA's unique requirements in terms of performance, reliability, ultra-high density ultra-compactness, ultra-light weight devices, radiation hardened devices, power stringency, and long life terms.

Gulati, S.↗

NASA NTRS1993

Molecular line emission models of Herbig-Haro objects. II - HCO(+) emission

We present time-dependent models of the chemistry and temperature of interstellar molecular gas clumps that are exposed to the radiation from propagating stellar-jet shocks. The X-ray, EUV, and FUV radiation from the shock initiates ion chemistry and also heats the gas in the clumps. Using representative parameters, we show that, on the shock transit time between the clumps, the abundances of the ionized molecular species that are produced in the clumps can exceed the values determined from steady state models by several orders of magnitude. Collisional excitation by the heated gas can lead to measurable line emission from several ionized species; as in previous investigations of X-ray-irradiated molecular gas, we find that electron impacts contribute significantly to this process. We apply these results to the interpretation of the HCO(+) line emission that has already been detected in several Herbig-Haro objects. We demonstrate that this picture provides a natural explanation of the fact that the line intensity typically peaks ahead of the associated shock, as well as of the reported low line-center velocities and narrow line widths. We tabulate several diagnostic line intensities of HCO(+) and other molecular species that may be used to infer the physical conditions in the emitting gas.

Wolfire, Mark G.↗

NASA NTRS2011

Operational Phase Life Cycle Assessment of Select NASA Ground Test Facilities

NASA's Aeronautics Test Program (ATP) is responsible for many large, high-energy ground test facilities that accomplish the nation s most advanced aerospace research. In order to accomplish these national objectives, significant energy and resources are consumed. A select group of facilities was analyzed using life-cycle assessment (LCA) to determine carbon footprint and environmental impacts. Most of these impacts stem from electricity and natural gas consumption, used directly at the facility and to generate support processes such as compressed air and steam. Other activities were analyzed but determined to be smaller in scale and frequency with relatively negligible environmental impacts. More specialized facilities use R-134a, R-14, jet fuels, or nitrogen gas, and these unique inputs can have a considerable effect on a facility s overall environmental impact. The results of this LCA will be useful to ATP and NASA as the nation looks to identify its top energy consumers and NASA looks to maximize research output and minimize environmental impact. Keywords: NASA, Aeronautics, Wind tunnel, Keyword 4, Keyword 5

Sydnor, George H.↗

NASA NTRS2014

Impact-Induced Chondrule Deformation and Aqueous Alteration of CM2 Murchison

Deformed chondrules in CM2 Murchison have been found to define a prominent foliation [1,2] and lineation [3] in 3D using X-ray computed tomography (XCT). It has been hypothesized that chondrules in foliated chondrites deform by "squeezing" into surrounding pore space [4,5], a process that also likely removes primary porosity [6]. However, shock stage classification based on olivine extinction in Murchison is consistently low (S1-S2) [4-5,7] implying that significant intracrystalline plastic deformation of olivine has not occurred. One objective of our study is therefore to determine the microstructural mechanisms and phases that are accommodating the impact stress and resulting in relative displacements within the chondrules. Another question regarding impact deformation in Murchison is whether it facilitated aqueous alteration as has been proposed for the CMs which generally show a positive correlation between degree of alteration and petrofabric strength [7,2]. As pointed out by [2], CM Murchison represents a unique counterpoint to this correlation: it has a strong petrofabric but a relatively low degree of aqueous alteration. However, Murchison may not represent an inconsistency to the proposed causal relationship between impact and alteration, if it can be established that the incipient aqueous alteration post-dated chondrule deformation. Methods: Two thin sections from Murchison sample USNM 5487 were cut approximately perpendicular to the foliation and parallel to lineation determined by XCT [1,3] and one section was additionally polished for EBSD. Using a combination of optical petrography, SEM, EDS, and EBSD several chondrules were characterized in detail to: determine phases, find microstructures indicative of strain, document the geometric relationships between grain-scale microstructures and the foliation and lineation direction, and look for textural relationships of alteration minerals (tochilinite and Mg-Fe serpentine) that indicate timing of their formation relative to deformation event(s). Preliminary Results: Deformed chondrules are dominated by forsterite and clinoenstatite with lesser amounts of Fe-Mg serpentine, sulfides, and low calcium pyroxene. Olivine grains are commonly fractured but generally show sharp optical extinction. The pyroxene, in contrast, is not only fractured but also often displays undulose extinction. In addition, the clinoenstatite is frequently twinned but it is unclear whether the twins are the result of mechanical deformation or inversion from protoenstatite [8]. EBSD work is currently ongoing to determine if areas of higher crystallographic strain can be imaged and mapped, and to determine the pyroxene twin orientations. In regards to alteration, we have found evidence for post-deformation formation of tochilinite and Mg-Fe serpentine indicating that aqueous alteration has indeed post-dated the deformation of the chondrules.

Hanna, R. D.↗

NASA NTRS2011

TPSAS-NF1676L-12284-DND

A much desired capability for conceptual design of aircraft is the ability to rapidly and accurately evaluate new concepts to avoid adverse trade decisions that can hinder the development in the later stages of design. For the conceptual design of supersonic aircraft, it is important to evaluate the robustness of a new low-boom concept. Here, robustness means that the aircraft configuration has low-boom ground signatures at both under-track and off-track locations. An integration process for off-track boom analysis is developed to facilitate robust design of low-boom supersonic aircraft. The integrated off-track analysis can also be used to study sonic boom impact on flight corridors where flight conditions and ground elevation might have a significant effect on ground signatures. The key for off-track sonic boom analysis is accurate solutions for off-body pressure distribution along the lower region of a cylinder cut around the aircraft. To ensure the numerical accuracy of the off-body pressure distribution, a mesh study is performed to determine the mesh requirements for off-track analysis as well as comparisons between Cart3D and USM3D off-track sonic boom results for various low-boom concepts. The integrated and automated process makes it possible to study the environmental impact of future supersonic concepts in the early design phases and support the planning of future flight corridors to mitigate sonic boom effects.

Irian Ordaz↗

NASA NTRS2002

LYAPUNOV-Based Sensor Failure Detection and Recovery for the Reverse Water Gas Shift Process

Livingstone, a model-based AI software system, is planned for use in the autonomous fault diagnosis, reconfiguration, and control of the oxygen-producing reverse water gas shift (RWGS) process test-bed located in the Applied Chemistry Laboratory at KSC. In this report the RWGS process is first briefly described and an overview of Livingstone is given. Next, a Lyapunov-based approach for detecting and recovering from sensor failures, differing significantly from that used by Livingstone, is presented. In this new method, models used are in t e m of the defining differential equations of system components, thus differing from the qualitative, static models used by Livingstone. An easily computed scalar inequality constraint, expressed in terms of sensed system variables, is used to determine the existence of sensor failures. In the event of sensor failure, an observer/estimator is used for determining which sensors have failed. The theory underlying the new approach is developed. Finally, a recommendation is made to use the Lyapunov-based approach to complement the capability of Livingstone and to use this combination in the RWGS process.

Haralambous, Michael G.↗

DOE OSTI2024

Experimental analysis of conductive drying of paper and board

The primary heat transfer source in the conventional multi-cylinder drying of paper and board is conduction. Conduction is facilitated by high-tension contact with steam-heated cylinders, while convective drying, the main mass transfer source, operates as heated air flows over the paper web in the pockets. This conduction process occurs at elevated temperatures and contact pressures to ensure effective contact between the wet paper web and the heated cylinders. The contact pressures and temperatures of the hot surface significantly influence the conductive drying characteristics. This research paper presents an experimental study that involves designing a simple lab-scale setup with in-situ and continuous sensing capabilities for various commercially available grades of paper and board. Embedded thermocouples measure the temperatures of the heated platen and the sheet, allowing the collection of flux data to determine heat transfer characteristics. Here, the goal of this study is to ascertain the instantaneous contact coefficients for different basis weights as a function of moisture content. The acquired data will provide valuable insights and information towards process development, design and simulation of the paper drying process.

42 ENGINEERING↗

NASA NTRS2004

Reduced-Order Modeling and Wavelet Analysis of Turbofan Engine Structural Response Due to Foreign Object Damage (FOD) Events

The development of a wavelet-based feature extraction technique specifically targeting FOD-event induced vibration signal changes in gas turbine engines is described. The technique performs wavelet analysis of accelerometer signals from specified locations on the engine and is shown to be robust in the presence of significant process and sensor noise. It is envisioned that the technique will be combined with Kalman filter thermal/health parameter estimation for FOD-event detection via information fusion from these (and perhaps other) sources. Due to the lack of high-frequency FOD-event test data in the open literature, a reduced-order turbofan structural model (ROM) was synthesized from a finite element model modal analysis to support the investigation. In addition to providing test data for algorithm development, the ROM is used to determine the optimal sensor location for FOD-event detection. In the presence of significant noise, precise location of the FOD event in time was obtained using the developed wavelet-based feature.

Turso, James↗

DOE OSTI2026

Mechanistic Studies of an Iron-Catalyzed Intermolecular C–H Amination Reaction under Catalytic Conditions and Having a Large KIE

The conversion of C–H bonds into amines by nitrene insertion is an attractive transformation since it is both atom- and step-economical, and provides a direct route to functionalizing hydrocarbons. Using an iron catalyst [{( tBu pyrr) 2 pyr}Fe(OEt 2 )] (1-OEt 2 ) (( tBu pyrr) 2 pyr 2– = 3,5- t Bu 2 -bis(pyrrolyl)pyridine), we recently demonstrated the catalytic conversion of weak C–H bonds into secondary amines using aryl azides as the nitrene source [Zars, E.; Angew. Chem., Int. Ed. 2023, 62, e202311749]. Here, we describe detailed mechanistic studies of this intermolecular C–H amination reaction under catalytic conditions. We find by Variable Time Normalization Analysis (VTNA) that the conversion of xanthene (2-H 2 ) and 2,4,6-trimethyl-phenyl azide ( Me 3) catalyzed by 1-OEt 2 is an overall 3/2 order process, being 1 st order in 2-H 2 and half order in Me 3. A kinetic isotope effect study (KIE) using 2-d 2 results in a significant decrease in the rate (KIE = 61(15)), which clearly implicates the C–H insertion step as rate-determining. Furthermore, treatment of 1-OEt 2 with one equivalent of N 3 -2,6- i Pr 2 –C 6 H 3 yields the mixed-valence C–N coupled product [( tBu pyrr) 2 pyrFe-N═C(2,6 i Pr 2 –Ph)═N-(2,6 i Pr 2 –Ph))Fe tBu pyrrpyr(2-H-pyrr)] (5 iPr ). Quantum chemical calculations confirm the electronic structure of the mixed-valence dimer in 5 iPr and rationalize the Hammett correlation by a delicate balance in the dinuclearization of the catalytically active monomers. Calculations further indicate significant tunneling for the pivotal H atom abstraction by the iron-imidyl complex. Combining all these results allows us to propose a mechanism consisting of imido formation in equilibrium with a radical-coupled diiron system, followed by stepwise C–H insertion via a linear H atom abstraction transition state and subsequent radical rebound.

azides↗

DOE OSTI2025

Self-consistent analysis for the η c → γ γ process

The next-to-next-to-leading-order (NNLO) perturbative QCD (pQCD) predictions for both the decay width and the transition form factor in the η c → γ γ process, based on nonrelativistic QCD (NRQCD), deviate from precise experimental measurements. These significant discrepancies have cast doubt on the applicability of NRQCD to charmonium processes. In this paper, we analyze the η c → γ γ process by applying the principle of maximum conformality (PMC), a systematic method for eliminating renormalization scheme-and-scale ambiguities. The PMC renormalization scales are determined by absorbing the nonconformal β -terms that govern the behavior of the QCD running coupling via the renormalization group equation. We obtain the PMC scale Q ⋆ = 4.49 m c for the η c → γ γ decay width. Even after using the PMC method, the convergence of the pQCD series is still poor, which indicates the importance of uncalculated next-to-next-to-next-to-leading-order and higher-order terms. The resulting value for Γ η c → γ γ is in agreement with the Particle Data Group’s reported value of Γ η c → γ γ = 5.1 ± 0.4 keV within the bounds of uncertainties. Moreover, the transition form factor obtained using the PMC is also in good agreement with precise experimental measurements. The application of the PMC suggests a potential resolution to η c → γ γ puzzle and supports the applicability of NRQCD to charmonium processes. Published by the American Physical Society 2025

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2026

Design and Validation of a Cryogenic Dilatometer

This project focuses on the design and development of a cryogenic dilatometer capable of measuring the thermal expansion of materials at extremely low temperatures. Understanding how materials change dimension with temperature is critical for applications involving cryogenic environments, particularly laminated systems housing superconducting magnets, where small dimensional changes can significantly affect performance and reliability. To address this, a dilatometer system was designed to operate within a liquid nitrogen environment while accurately measuring displacements caused by thermal contraction. The purpose of this device is to determine the coefficient of thermal expansion (CTE) of a material. The design process involved defining functional requirements, developing mechanical and thermal concepts for the measurement apparatus, selecting appropriate materials compatible with cryogenic temperatures, and integrating sensors capable of detecting small dimensional changes. The resulting system aims to provide a practical and repeatable method for evaluating material thermal expansion at cryogenic temperatures, supporting research into composite use in superconducting applications that require accurate characterization of material behavior in low-temperature environments.

Schmitt, Nicholas [Northern Illinois U.]↗

NASA NTRS1973

Vitrification darkening of rock powders - Implications for optical properties of the lunar surface

Laboratory experiments show that albedoes as low as those on the moon can be produced by vacuum vitrification and associated chemical fractionation of ordinary terrestrial basaltic material. Vitrification is established as an unequivocal process that can account for the low albedo and apparent local darkening with age of the lunar surface. The spectral reflectance curves of glass powders are significantly different than those of the parent rock mineralogy; thus, the presence of ubiquitous glass in lunar surface material complicates compositional determinations by interpretation of spectral reflectance curves. Vitrification of rocks on the moon may highly modify the chemical composition of the resulting glass; thus, glass fragments found in lunar fines cannot be assumed to represent bulk parent rock material. Progressive impact vitrification of lunar surface material throughout the moon's history may have led to a fine-grain, opaque, refractory-rich material we call 'ultimate glass.' This unidentified and, at this point, hypothetical component may exist in dark regolith material; if found, it may be a useful indicator of regolith maturity.

Nash, D. B.↗

NASA NTRS1978

The hot corrosion of Co-25Cr-10Ni-5Ta-3Al-0.5Y alloy /S-57/

A cobalt-base alloy, Co-25Cr-10Ni-5Ta-3Al-0.5Y (S-57), was subjected to hot corrosion in Mach 0.3 burner-rig combustion gases at maximum alloy temperatures of 900 and 1000 C. Various salt concentrations were injected into the burner: 0.5, 2,5, and 10 parts per million synthetic sea salt and 4 parts per million sodium sulfate (Na2SO4). The extent of corrosion was determined by measuring the maximum depth of corrosion in the alloy, and the corrosion process was studied by metallography, X-ray diffraction, scanning electron microscopy, and electron microprobe analysis. While S-57 was found to possess only moderate oxidation resistance at these temperatures, this alloy resisted significant hot corrosion attack under all but the most severe test conditions. The process of hot corrosion attack under the most severe conditions of this study was primarily sulfidation.

Santoro, G. J.↗