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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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DOE OSTI2024

Intelligent Manufacturing for Extreme Environments Conference Proceedings

The Intelligent Manufacturing for Extreme Environments (IMEE) workshop was held at the Center for Advanced Energy Studies (CAES) in Idaho Falls, Idaho, May 2–3, 2023, in support of the United States (U.S.) National Science Foundation (NSF) Established Program to Stimulate Competitive Research: Workshop Opportunities (EPSCoR-WO) program. This workshop featured keynote speakers, panels, and breakout sessions with 58 participants. Nuclear reactors need to operate under extreme service conditions, such as high temperatures, corrosive environments, and high-radiation doses. Hence, reactor components must be able to withstand those conditions. The participants envision a future where on demand manufacture of components for small modular reactors (SMRs), microreactors, and other advanced reactor designs are possible. In this future, regulatory bodies accept validated manufacturing processes and standardized feedstocks, thus eliminating the need for individual component testing. However, the necessary technologies and regulatory policies needed for this future do not exist today. Successful innovation would revolutionize the nuclear power sector, enable fast commercial development, create economic opportunities in the U.S., reduce the carbon footprint and associated risks, and promote a skilled and highly competitive workforce. The objective of the workshop was to convene world-class experts, researchers, educators, and students to identify gaps and envision solutions for five interrelated challenges for intelligent manufacturing in extreme environments. The key outcomes of the conference were: (1) to take the opportunity for researchers and educators to network and form collaborations; and (2) to produce a full report to inform policy-makers, industry, and the academic community of various challenges and opportunities in the nuclear energy sector.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Friction and oxidative wear of 440C ball bearing steels under high load and extreme bulk temperatures

Unlubricated sliding friction and wear of 440C steels in an oxygen environment have been studied under a variety of load, speed, and temperature ranging from approximately -185 to 675 deg C. A specially designed test apparatus with a ball-on-flat geometry has been used for this purpose. The observed dependencies of the initial coefficient of friction, the average dynamic coefficient of friction, and the wear rate on load, speed, and test temperatures have been examined from the standpoint of existing theories of friction and wear. High contact temperatures are generated during the sliding friction, causing rapid oxidation and localized surface melting. A combination of fatigue, delamination, and loss of hardness due to tempering of the martensitic structure is responsible for the high wear rate observed and the coefficient of friction.

Chaudhuri, Dilip K.↗
DOE OSTI2026

High pressure effects on EBC systems in high temperature environments

Environmental barrier coatings (EBCs) are designed to protect SiCfiber/SiCmatrix ceramic matrix composites (CMCs) in turbine engines by mitigating wear in high-temperature water vapor environments. The failure of EBCs is frequently attributed to the accelerated oxidation of the silicon bond coating layer when exposed to high-temperature steam, leading to the formation of a thickened thermally grown oxide (TGO). TGO growth increases interfacial stress, weakens adhesion, and results in coating spallation. Understanding the impact of high-temperature oxidation of EBC systems is essential for developing accurate lifespan models for turbine components, although pressurized oxidation testing is extremely sparse in the open literature. In this work, oxidation tests were performed on rare earth silicate EBCs coated onto SiC substrates under increased pressure conditions. The coated specimens were tested at 1100°C, 1200°C, and 1300°C at both 1 atm and 10 atm total pressure in steam environments. Subsequent characterization focused on the microstructural evolution of the EBC/Si/SiC system. The experimental findings indicated that TGO behavior is dependent on high-pressure conditions, with elevated pressure leading to an increase in oxide scale thickness and modifications in its morphology.

Ardrey, Kristyn [ORNL] (ORCID:0000000184407796)↗
NASA NTRS2004

Robotic Subsurface Analyzer and Sample Handler for Resource Reconnaissance and Preliminary Site Assessment for ISRU Activities at the Lunar Cold Traps

Since the 1960s, claims have been made that water ice deposits should exist in permanently shadowed craters near both lunar poles. Recent interpretations of data from the Lunar Prospector-Neutron Spectrometer (LP- NS) confirm that significant concentrations of hydrogen exist, probably in the form of water ice, in the permanently shadowed polar cold traps. Yet, due to the large spatial resolution (45-60 Ian) of the LP-NS measurements relative to these shadowed craters (approx.5-25 km), these data offer little certainty regarding the precise location, form or distribution of these deposits. Even less is known about how such deposits of water ice might effect lunar regolith physical properties relevant to mining, excavation, water extraction and construction. These uncertainties will need to be addressed in order to validate fundamental lunar In Situ Resource Utilization (ISRU) precepts by 2011. Given the importance of the in situ utilization of water and other resources to the future of space exploration a need arises for the advanced deployment of a robotic and reconfigurable system for physical properties and resource reconnaissance. Based on a collection of high-TRL. designs, the Subsurface Analyzer and Sample Handler (SASH) addresses these needs, particularly determining the location and form of water ice and the physical properties of regolith. SASH would be capable of: (1) subsurface access via drilling, on the order of 3-10 meters into both competent targets (ice, rock) and regolith, (2) down-hole analysis through drill string embedded instrumentation and sensors (Neutron Spectrometer and Microscopic Imager), enabling water ice identification and physical properties measurements; (3) core and unconsolidated sample acquisition from rock and regolith; (4) sample handling and processing, with minimized contamination, sample containerization and delivery to a modular instrument payload. This system would be designed with three mission enabling goals, including: (1) a self-contained, low power, low mass, "black box'' configuration for operations from a lander, various classes of rovers or a surface-based platform with human assistance or robotic anchoring mechanisms; (2) reconfigurable and scalable sample handling for delivery to various types of instrumentation, depending on mission requirements; and (3) the use of advanced automation control and diagnostic techniques that will afford local human deployed, remote teleoperation and fully autonomous intelligent operations. Though a great deal of technology has been advanced toward these objectives, the SASH system faces significant design challenges, including the low gravity environment, various levels of autonomy in operations, radiation exposure, dust contamination, and temperature extremes and deltas. Significant input from the scientific and engineering communities, as well as a significant environmental testing program, will be required to guide the design process.

Gorevan, S. P.↗
NASA NTRS2016

Physics of the Cosmos: Program Annual Technology Report

From ancient times, humans have looked up at the night sky and wondered: Are we alone? How did the universe come to be? How does the universe work? PCOS focuses on that last question. Scientists investigating this broad theme use the universe itself as their laboratory, investigating its fundamental laws and properties. They test Einstein's General Theory of Relativity to see if our current understanding of space-time is borne out by observations. They examine the behavior of the most extreme environments - supermassive black holes, active galactic nuclei, and others - and the farthest reaches of the universe, to expand our understanding. With instruments sensitive across the spectrum, from radio, through infrared (IR), visible light, ultraviolet (UV), to X rays and gamma rays, as well as gravitational waves (GWs), they peer across billions of light-years, observing echoes of events that occurred instants after the Big Bang. The Laser Interferometer Gravitational-Wave Observatory (LIGO) recently recorded the first direct measurement of long-theorized GWs. Another surprising recent discovery is that the universe is expanding at an ever-accelerating rate, the first hint of so-called "dark energy," estimated to account for 75% of mass-energy in the universe. Dark matter, so called because we can only observe its effects on regular matter, accounts for another 20%, leaving only 5% for regular matter and energy. Scientists now also search for special polarization in the cosmic microwave background to support the notion that in the split-second after the Big Bang, the universe inflated faster than the speed of light! The most exciting aspect of this grand enterprise today is that we can finally develop the tools needed for such discoveries.

COR↗
NASA NTRS2017

Program Annual Technology Report: Physics of the Cosmos Program Office

From ancient times, humans have looked up at the night sky and wondered: Are we alone? How did the universe come to be? How does the universe work? PCOS focuses on that last question. Scientists investigating this broad theme use the universe as their laboratory, investigating its fundamental laws and properties. They test Einstein’s General Theory of Relativity to see if our current understanding of space-time is borne out by observations. They examine the behavior of the most extreme environments – supermassive black holes, active galactic nuclei, and others – and the farthest reaches of the universe, to expand our understanding. With instruments sensitive across the spectrum, from radio, through infrared (IR), visible light, ultraviolet (UV), to X rays and gamma rays, as well as gravitational waves (GWs), they peer across billions of light-years, observing echoes of events that occurred instants after the Big Bang. Last year, the LISA Pathfinder (LPF) mission exceeded expectations in proving the maturity of technologies needed for the Laser Interferometer Space Antenna (LISA) mission, and the Laser Interferometer Gravitational-Wave Observatory (LIGO) recorded the first direct measurements of long-theorized GWs. Another surprising recent discovery is that the universe is expanding at an ever-accelerating rate, the first hint of so-called “dark energy,” estimated to account for 75% of mass-energy in the universe. Dark matter, so called because we can only observe its effects on regular matter, is thought to account for another20%, leaving only 5% for regular matter and energy. Scientists now also search for special polarization in the cosmic microwave background to support the notion that in the split-second after the Big Bang, the universe inflated faster than the speed of light! The most exciting aspect of this grand enterprise today is the extraordinary rate at which we can harness technologies to enable these key discoveries.

COR↗
NASA NTRSDate not supplied

Next Generation Big Data Storage for Long Space Missions

This paper presents the results of the HELIOS (Hardened Extremely Long Life In-formation Optical Storage) mission on the International Space Station (ISS) which tested a unique solution for the long-term storage and retrieval of data in space. For this mission Creative Technology (CTech) developed test media—termed WORF (Write Once, Read Forever)—to validate whether this patented technology will survive all critical parameters for harsh space-based environments including microgravity and ionizing radiation. The HELIOS experiment confirmed that the WORF media is impervious to ionizing radiation, microgravity, solar (plasma) eruptions, and the stress from 8 Gs of the launch including extreme temperature expo-sure. The principal results indicate that there has been no discernible degradation of the media after 8 months on the ISS as compared to a control set of media stored on the ground. This data validated the media’s survivability for harsh space environments for long-term and deep space missions. In addition to the space environment, we are confident that WORF technology can be used for data storage where space-related and other long-term or archival integrity is critical such as: geospatial collections from satellites; space weather archives; past, ongoing, and future space mission media and documentation files; the deep space Gate-way program; as well as Big Data applications such as the Vera C. Rubin astronomical observatory (formerly the LSST). WORF technology for the HELIOS experiment uses a proven archival media, redesigned, re-purposed and patented by CTech to store digital data for long periods, measured in decades and possibly centuries. The media stores standing waves embedded in a substrate that capture the precise col-ors or wavelengths projected onto the media. The colors represent numerical data, with each data location storing multiple superimposed wavelengths, which facilitate the storage of multiple data bytes (rather than just zeros and ones); advanced mathematical permutations allow for extremely large data density equal to or greater than contemporary data storage de-vices. These colors cannot fade or degrade over time since the standing waves are physically stabilized (fully oxidized) metallic silver; no dyes are embedded for this storage system, and silver ions resist micro-bacterial and fungal contamination

Rodney Grubbs↗
NASA NTRS2012

Alterations of Cellular Immune Reactions in Crew Members Overwintering in the Antarctic Research Station Concordia

Background: Concordia Station is located inside Antarctica about 1000km from the coast at an altitude of 3200m (Dome C). Hence, individuals living in this harsh environment are exposed to two major conditions: 1.) hypobaric hypoxia and 2.) confinement and extreme isolation. Both hypoxia and confinement can affect human immunity and health, and are likely to be present during exploration class space missions. This study focused on immune alterations measured by a new global immunity test assay, similar to the phased out delayed type hypersensitivity (DTH) skin test. Methods: After informed written consent 14 healthy male subjects were included to the CHOICE-study (Consequences-of-longterm-Confinement-and-Hypobaric-HypOxia-on-Immunity-in-the Antarctic-Concordia-Environment). Data collection occurred during two winter-over periods lasting each one year. During the first campaign 6 healthy male were enrolled followed by a second campaign with 8 healthy males. Blood was drawn monthly and incubated for 48h with various bacterial, viral and fungal antigens followed by an analysis of plasma cytokine levels (TNF-alpha, IL2, IFN-gamma, IL10). As a control, blood was incubated without stimulation ("resting condition"). Goals: The scope of this study was to assess the consequences of hypoxia and confinement on cellular immunity as assessed by a new in vitro DTH-like test. Results: Initial results indicate that under resting conditions the in vitro DTH-like test showed low cytokine levels which remained almost unchanged during the entire observation period. However, cytokine responses to viral, bacterial and fungal antigens were remarkably reduced at the first month after arrival at Concordia when compared to levels measured in Europe prior to departure for Antarctica. With incrementing months of confinement this depressed DTH-like response tended to reverse, and in fact to show an "overshooting" immune reaction after stimulation. Conclusion: The reduced in vitro DTH-like test response in the early phase of Antarctic wintering over con rms distinct immune suppressive effects seen after (sub-)acute hypobaric hypoxia. The reversal and overshooting reaction of cellular immune responses upon stimulation, but not the resting state, indicate either a) priming of immune answers and/or b) an uncoupled or disregulated control of cellular immune answers by auto-, para- and endocrine pathways. Further analyses and correlations are warranted. Acknowledgement: Supported by the European Space Agency (ESA), the French (IPEV) and Italian (PNRA) polar institutes, the German National Space Program (DLR, 50WB0719/WB0919), by BELSPO/PROEDEX/ESA (C90-380/-391), NASA and by the Concordia crews who have participated with great enthusiasm.

Crucian, Brian↗
NASA NTRS2016

Post-Launch Calibration and Testing of Space Weather Instruments on GOES-R Satellite

The Geostationary Operational Environmental Satellite - R (GOES-R) is the first of a series of satellites to be launched, with the first launch scheduled for October 2016. The three instruments Solar UltraViolet Imager (SUVI), Extreme ultraviolet and X-ray Irradiance Sensor (EXIS), and Space Environment In-Situ Suite (SEISS) provide the data needed as inputs for the product updates National Oceanic and Atmospheric Administration (NOAA) provides to the public. SUVI is a full-disk extreme ultraviolet imager enabling Active Region characterization, filament eruption, and flare detection. EXIS provides inputs to solar back-ground-sevents impacting climate models. SEISS provides particle measurements over a wide energy-and-flux range that varies by several orders of magnitude and these data enable updates to spacecraft charge models for electrostatic discharge. EXIS and SEISS have been tested and calibrated end-to-end in ground test facilities around the United States. Due to the complexity of the SUVI design, data from component tests were used in a model to predict on-orbit performance. The ground tests and model updates provided inputs for designing the on-orbit calibration tests. A series of such tests have been planned for the Post-Launch Testing (PLT) of each of these instruments, and specific parameters have been identified that will be updated in the Ground Processing Algorithms, on-orbit parameter tables, or both. Some of SUVI and EXIS calibrations require slewing them off the Sun, while no such maneuvers are needed for SEISS. After a six-month PLT period the GOES-R is expected to be operational. The calibration details are presented in this paper.

On-orbit Calibration↗
NASA NTRS2016

Post-Launch Calibration and Testing of Space Weather Instruments on GOES-R Satellite

The Geostationary Operational Environmental Satellite - R (GOES-R) is the first of a series of satellites to be launched, with the first launch scheduled for October 2016. The three instruments - Solar Ultra Violet Imager (SUVI), Extreme ultraviolet and X-ray Irradiance Sensor (EXIS), and Space Environment In-Situ Suite (SEISS) provide the data needed as inputs for the product updates National Oceanic and Atmospheric Administration (NOAA) provides to the public. SUVI is a full-disk extreme ultraviolet imager enabling Active Region characterization, filament eruption, and flare detection. EXIS provides inputs to solar backgrounds/events impacting climate models. SEISS provides particle measurements over a wide energy-and-flux range that varies by several orders of magnitude and these data enable updates to spacecraft charge models for electrostatic discharge. EXIS and SEISS have been tested and calibrated end-to-end in ground test facilities around the United States. Due to the complexity of the SUVI design, data from component tests were used in a model to predict on-orbit performance. The ground tests and model updates provided inputs for designing the on-orbit calibration tests. A series of such tests have been planned for the Post-Launch Testing (PLT) of each of these instruments, and specific parameters have been identified that will be updated in the Ground Processing Algorithms, on-orbit parameter tables, or both. Some of SUVI and EXIS calibrations require slewing them off the Sun, while no such maneuvers are needed for SEISS. After a six-month PLT period the GOES-R is expected to be operational. The calibration details are presented in this paper.

On-orbit Calibration↗
NASA NTRS2002

Low Temperature Reliability of Electronic Packages/Assemblies for Space Missions

A NASA-wide team, funded under the NASA Electronic Parts and Packaging Program (NEPP), was formed to collaborate and to establish reliability of various electronic parts/packaging and assemblies for operation under extreme cold temperatures. One of the primary objectives of the NEPP is to expedite the infusion of cutting edge technologies into the present and future NASA missions. Commercial-off-the-shelf (COTS) emerging electronic parts/packages due to their lower weight, increased functionality, and lower cost are excellent candidates for space missions if they are characterized to show that they will meet the stringent reliability and quality requirements. Characterizations, especially for the extreme cold temperatures, are required since very limited data are available by manufacturers or users. For severe military environments, the temperature conditions to -65 C are the lowest temperature for which these parts/packages and assemblies are qualified. New data beyond this relatively benign cold temperature are required for numerous NASA missions. Several parts/packages, based on the project recommendation for their immediate and future needs, were selected for detailed characterization to cold temperature regimes down to liquid nitrogen (-196 C), covering both Mars cold temperature (-125 C) and asteroid (- 180 C) lander environmental requirements. Numerous parts/packages and assemblies were characterized during extreme temperature environmental tests. Several electrical parameters were characterized at discrete temperatures to -185 C to determine if they remain within their specification ranges. Both packages and circuit boards were subjected to nondestructive testing including optical, X-ray, and acoustic microscopy to document their integrity prior to environment exposure. Package/board assemblies were also subjected to X-ray to characterize solder joint integrity including void levels. Both parts and assemblies were subjected to thermal cycling with a large temperature swing enveloping numerous NASA missions. Details of the performed tests and the results obtained are presented.

Patterson, Richard L.↗
NASA NTRS1989

Making on-orbit structural repairs to Space Station

One of the key factors dictating the safety and durability of the proposed U.S. Space Station is the ability to repair structural damage while remaining in orbit. Consequently, studies are conducted to identify the engineering problems associated with accomplishing structural repairs on orbit, due to zero gravity environment and exposure to extreme temperature variations. There are predominant forms of structural failure, depending on the metallic or composite material involved. Aluminum is the primary metallic material used in space vehicle applications. Welding processes on aluminum alloy structures were tested, resulting in final selection of electron beam welding as the primary technique for metallic material repair in Space. Several composite structure repair processes were bench-tested to define their applicability to on-orbit EVA requirements: induction heating prevailed. One of the unique problems identified as inherent in the on-orbit repair process is that of debris containment. The Maintenance Work Station concept provides means to prevent module contamination from repair debris and ensure the creation of a facility for crew members to work easily in a microgravity environment. Different technologies were also examined for application to EVA repair activities, and the concept selected was a spring-loaded, collapsible, box-like Debris Containement and Collection Device with incorporated fold-down tool boards and handholes in the front panel.

Haber, Harry S.↗
NASA NTRSDate not supplied

Maturation of In-space Welding in Reduced Gravity and Reduced Pressure Environments Through Progression to Suborbital Flight Experiments

Development of in-space welding (ISW) is a key and enabling manufacturing technology as welding is currently involved in producing approximately 90% of durable goods, and this trend is expected to hold for in-space manufacturing as well. ISW is critical to a sustainable space economy. To mature in-space welding, numerous gaps must be closed since NASA has not made a weld in space in 50 years. Advancing laser beam welding (LBW) towards a suborbital flight demonstration will help mature the process for in-space assembly & manufacturing (ISAM) through demonstration in relevant environments and achieving technology readiness milestones. LBW technologies and science improved by this work will benefit in-space manufacturing, long-term sustainability of space structures & operations, and the overall space economy. Ground-based welding of aerospace hardware requires an Edisonian approach to qualify a welding process; however, this approach is infeasible for ISW qualification due to mass, volume, logistic, and cost challenges inherent to the space environment. To address this challenge, we are conducting ground and suborbital tests with partners performing parabolic flights to gather data on LBW processes and infuse them into NASA & partner missions. This progression from ground to flight experiments will elucidate relevant physics during LBW: 1) reduced gravity, 2) reduced pressure, and 3) extreme temperature. Data from post-flight evaluation and in situ instrumentation will feed integrated computational materials engineering (ICME) tools to reduce the burden of ISW infusion by establishing a link between space and terrestrial environments, ultimately accelerating the qualification of LBW in space.

in-space welding↗
DOE OSTI2021

AOI [1]: Passive Wireless Sensor Systems Fabricated by Direct-Writing for Temperature and Health Monitoring of Energy Systems in Harsh-Environments (Final Report)

Researchers at West Virginia University (WVU) propose to demonstrate a wireless, high-temperature sensor system for monitoring the temperature and health of energy-system components. The active sensor and electronics for wireless communication will be composed entirely of an electroceramic materials (conductive ceramics) which are capable of withstanding the harsh-environments required for fossil energy-based technologies. This work will focus primarily on the fabrication and testing of temperature (thermocouples and thermistors) and health (strain/stress and crack propagation sensors) that function at extreme temperatures (up to 700-1700ºC). The electronics will accompany the high-temperature sensor, which will include a passive wireless communication circuit that allows the transmission of the data based on the LCR resonance principle to a near-by reader antenna. This passive transmission of data will reduce the need for interconnect wires near the active, and possibly rotating, energy-system component. The research will include process development to permit the 2D/3D direct-writing of the entire sensor and communication circuit onto the energy-system component. The direct-writing will be facilitated by using silicon-based polymer-derived precursors to form the high-temperature, stable electroceramic compositions. In addition, methods for direct-writing the circuit onto a fugitive carrier substrate will be completed, which will permit a “peel-and-stick”-like transfer of the sensor circuit to the energy-system component. This feature will allow the economical and precise placement of the sensor circuit onto components of various shapes and locations, without altering the geometry and active features of the manufactured component, or the removal (or decommissioning) of the component for installation. The proposed work will be directed at the following areas: 1) Investigation of phase formation, sintering/grain growth, and electrical properties of polymer-derived electroceramic composites; 2) Definition of processes to direct-write through ink-jet and robo-casting the polymer-derived electroceramic composites onto oxide and polymer surfaces; 3) Development of methods to form monolithic "peel-and-stick" preforms that will efficiently transfer the sensor circuit to ceramic surfaces after thermal treatment; 4) Design of passive wireless LCR circuits and receiver (reader) antennas for communication and testing at high temperatures; 5) Investigation of the passive wireless sensor system developed (and method of transferring sensor system) for temperature and stress/strain measurements on a SOFC repeat unit and a singular gas turbine blade prototype as example applications.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2015

Unsteady Three-Dimensional Simulation of a Shear Coaxial GO2/GH2 Rocket Injector with RANS and Hybrid-RAN-LES/DES Using Flamelet Models

Historically, the analysis and design of liquid rocket engines (LREs) has relied on full‐scale testing and one‐dimensional empirical tools. The testing is extremely expensive and the one‐dimensional tools are not designed to capture the highly complex, and multi‐dimensional features that are inherent to LREs. Recent advances in computational fluid dynamics (CFD) tools have made it possible to predict liquid rocket engine performance, stability, to assess the effect of complex flow features, and to evaluate injector‐driven thermal environments, to mitigate the cost of testing. Extensive efforts to verify and validate these CFD tools have been conducted, to provide confidence for using them during the design cycle. Previous validation efforts have documented comparisons of predicted heat flux thermal environments with test data for a single element gaseous oxygen (GO2) and gaseous hydrogen (GH2) injector. The most notable validation effort was a comprehensive validation effort conducted by Tucker et al. [1], in which a number of different groups modeled a GO2/GH2 single element configuration by Pal et al [2]. The tools used for this validation comparison employed a range of algorithms, from both steady and unsteady Reynolds Averaged Navier‐Stokes (U/RANS) calculations, large‐eddy simulations (LES), detached eddy simulations (DES), and various combinations. A more recent effort by Thakur et al. [3] focused on using a state‐of‐the‐art CFD simulation tool, Loci/STREAM, on a two‐dimensional grid. Loci/STREAM was chosen because it has a unique, very efficient flamelet parameterization of combustion reactions that are too computationally expensive to simulate with conventional finite‐rate chemistry calculations. The current effort focuses on further advancement of validation efforts, again using the Loci/STREAM tool with the flamelet parameterization, but this time with a three‐dimensional grid. Comparisons to the Pal et al. heat flux data will be made for both RANS and Hybrid RANSLES/ Detached Eddy simulations (DES). Computation costs will be reported, along with comparison of accuracy and cost to much less expensive two‐dimensional RANS simulations of the same geometry.

Westra, Doug G.↗
DOE OSTI2024

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗
NASA NTRS2005

Java-based Graphical User Interface for MAVERIC-II

A computer program entitled "Marshall Aerospace Vehicle Representation in C II, (MAVERIC-II)" is a vehicle flight simulation program written primarily in the C programming language. It is written by James W. McCarter at NASA/Marshall Space Flight Center. The goal of the MAVERIC-II development effort is to provide a simulation tool that facilitates the rapid development of high-fidelity flight simulations for launch, orbital, and reentry vehicles of any user-defined configuration for all phases of flight. MAVERIC-II has been found invaluable in performing flight simulations for various Space Transportation Systems. The flexibility provided by MAVERIC-II has allowed several different launch vehicles, including the Saturn V, a Space Launch Initiative Two-Stage-to-Orbit concept and a Shuttle-derived launch vehicle, to be simulated during ascent and portions of on-orbit flight in an extremely efficient manner. It was found that MAVERIC-II provided the high fidelity vehicle and flight environment models as well as the program modularity to allow efficient integration, modification and testing of advanced guidance and control algorithms. In addition to serving as an analysis tool for techno logy development, many researchers have found MAVERIC-II to be an efficient, powerful analysis tool that evaluates guidance, navigation, and control designs, vehicle robustness, and requirements. MAVERIC-II is currently designed to execute in a UNIX environment. The input to the program is composed of three segments: 1) the vehicle models such as propulsion, aerodynamics, and guidance, navigation, and control 2) the environment models such as atmosphere and gravity, and 3) a simulation framework which is responsible for executing the vehicle and environment models and propagating the vehicle s states forward in time and handling user input/output. MAVERIC users prepare data files for the above models and run the simulation program. They can see the output on screen and/or store in files and examine the output data later. Users can also view the output stored in output files by calling a plotting program such as gnuplot. A typical scenario of the use of MAVERIC consists of three-steps; editing existing input data files, running MAVERIC, and plotting output results.

Seo, Suk Jai↗