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

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At least 433 records · Page 24

ExaAM: Metal additive manufacturing simulation at the fidelity of the microstructure

Additive manufacturing (AM), or 3D printing, of metals is transforming the fabrication of components, in part by dramatically expanding the design space, allowing optimization of shape and topology. However, although the physical processes involved in AM are similar to those of welding, a field with decades of experimental, modeling, simulation, and characterization experience, qualification of AM parts remains a challenge. The availability of exascale computational systems, particularly when combined with data-driven approaches such as machine learning, enables topology and shape optimization as well as accelerated qualification by providing process-aware, locally accurate microstructure and mechanical property models. We describe the physics components comprising the Exascale Additive Manufacturing simulation environment and report progress using highly resolved melt pool simulations to inform part-scale finite element thermomechanics simulations, drive microstructure evolution, and determine constitutive mechanical property relationships based on those microstructures using polycrystal plasticity. We report on implementation of these components for exascale computing architectures, as well as the multi-stage simulation workflow that provides a unique high-fidelity model of process–structure–property relationships for AM parts. In addition, we discuss verification and validation through collaboration with efforts such as AM-Bench, a set of benchmark test problems under development by a team led by the National Institute of Standards and Technology.

3D printing↗

Range 7 Scanner Integration with PaR Robot Scanning System

An interface bracket and coordinate transformation matrices were designed to allow the Range 7 scanner to be mounted on the PaR Robot detector arm for scanning the heat shield or other object placed in the test cell. A process was designed for using Rapid Form XOR to stitch data from multiple scans together to provide an accurate 3D model of the object scanned. An accurate model was required for the design and verification of an existing heat shield. The large physical size and complex shape of the heat shield does not allow for direct measurement of certain features in relation to other features. Any imaging devices capable of imaging the entire heat shield in its entirety suffers a reduced resolution and cannot image sections that are blocked from view. Prior methods involved tools such as commercial measurement arms, taking images with cameras, then performing manual measurements. These prior methods were tedious and could not provide a 3D model of the object being scanned, and were typically limited to a few tens of measurement points at prominent locations. Integration of the scanner with the robot allows for large complex objects to be scanned at high resolution, and for 3D Computer Aided Design (CAD) models to be generated for verification of items to the original design, and to generate models of previously undocumented items. The main components are the mounting bracket for the scanner to the robot and the coordinate transformation matrices used for stitching the scanner data into a 3D model. The steps involve mounting the interface bracket to the robot's detector arm, mounting the scanner to the bracket, and then scanning sections of the object and recording the location of the tool tip (in this case the center of the scanner's focal point). A novel feature is the ability to stitch images together by coordinates instead of requiring each scan data set to have overlapping identifiable features. This setup allows models of complex objects to be developed even if the object is large and featureless, or has sections that don't have visibility to other parts of the object for use as a reference. In addition, millions of points can be used for creation of an accurate model [i.e. within 0.03 in. (=0.8 mm) over a span of 250 in. (=635 mm)].

Schuler, Jason↗

Three-Dimensional Bubble Fluidics in Architected Porous Media

Gas bubble flows in porous media often exhibit complex and seemingly unpredictable behaviors that are difficult to control. This lack of control limits the ability to design effective devices which manage multiphase flows. Here, we show how the design of 3D printed pores can deterministically control the flow path of an injected gas stream. Open cell structures can be designed to shape the gas/liquid interface with fidelity to control how the two phases are distributed throughout a porous material. The distributed gas volume is free to interact physically and chemically with the surrounding liquid phase, an effect we exploit to create a logical control gate to redirect flows within a lattice. This also allows us to design architectures for reactive capture and aerating bioreactors, resulting in patterned boundaries which can make more effective use of the liquid and gas reagents.

3D microfluidics↗

Three-dimensional reconstruction of inertial confinement fusion hot-spot plasma from x-ray and nuclear diagnostics on OMEGA

Multidimensional effects degrade the neutron yield and the compressed areal density of laser-direct-drive inertial confinement fusion implosions of layered deuterium–tritium cryogenic targets on the OMEGA Laser System with respect to 1D radiation-hydrodynamic simulation predictions. A comprehensive physics-informed 3D reconstruction effort is under way to infer hot-spot and shell conditions at stagnation from four x-ray and seven neutron detectors distributed around the OMEGA target chamber. Neutron diagnostics, providing measurements of the neutron yield, hot-spot flow velocity, and apparent ion-temperature distribution, are used to infer the mode-1 perturbation at stagnation. The x-ray imagers record the shape of the hot-spot plasma to diagnose mode-1 and mode-2 perturbations. A deep-learning convolutional neural network trained on an extensive set of 3D radiation-hydrodynamic simulations is used to interpret the x-ray and nuclear measurements to infer the 3D profiles of the hot-spot plasma conditions and the amount of laser energy coupled to the hot-spot plasma. A 3D simulation database shows that larger mode-1 asymmetries are correlated with higher hot-spot flow velocities and reduced laser-energy coupling and neutron yield. Three-dimensional hot-spot reconstructions from x-ray measurements indicate that higher amounts of residual kinetic energy are correlated with higher measured hot-spot flow velocities, consistent with 3D simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

High-Energy X-ray Tomographic Analysis of Precursor Metal Powders (Ti-6Al-4V) Used for Additive Manufacturing

We utilized high-energy x-ray tomography to characterize Ti-6Al-4V metal powders (both as-received and recycled) used in powder-bed additive manufacturing process. The image processing workflow was developed to process and analyze large amount of data objectively by computer program. The distribution of size and shape of the metal particles as well as defect (mainly porosity) inside the particles was analyzed with the statistical representation and resolution in micrometer. The result revealed that circular-shaped porosity with various sizes could be embedded in the powder particles. These porosities could potentially be transferred to the 3D printed part and critically affect the mechanical performance of the component. The present study shows the effectiveness of characterizing metal powders using x-ray imaging techniques where sufficient number of particles can be sampled within tens of minutes with a minimum sample preparation and high accuracy. Clear structural differences in the as-received and recycled powders were delineated that helps in determining the feasibility of using the recycled powders.

36 MATERIALS SCIENCE↗

LLRF System Analysis for the Fermilab PIP-II LINAC

Developing long-lived quantum processing units (QPUs) capable of supporting high-fidelity quantum operations is a crucial challenge on the path toward fault-tolerant quantum computing. TESLA-shaped superconducting RF (SRF) cavities, known for photon relaxation times on the order of seconds, provide an excellent foundation for 3D QPUs and quantum memory. This talk presents a novel design that leverages TESLA cavity modes coupled to ancillary transmon qubits, optimized to preserve coherence and control. By carefully engineering the package geometry, optimizing Hamiltonian parameters, and minimizing lossy participation ratios, we achieve photon relaxation times of over 16 ms and 20 ms for the two cavity modes, representing a significant improvement over previous multimode quantum memories. Despite the reduced coupling between the qubit and cavity modes, which is necessary to preserve long lifetimes, the platform supports robust and universal control schemes that are not limited by low coupling strength. We will also discuss how this architecture can lead to scalable, modular quantum computing systems.

Varghese, P. [Fermilab]↗

Liquid Crystal Orientation and Shape Optimization for the Active Response of Liquid Crystal Elastomers

Liquid crystal elastomers (LCEs) are responsive materials that can undergo large reversible deformations upon exposure to external stimuli, such as electrical and thermal fields. Controlling the alignment of their liquid crystals mesogens to achieve desired shape changes unlocks a new design paradigm that is unavailable when using traditional materials. While experimental measurements can provide valuable insights into their behavior, computational analysis is essential to exploit their full potential. Accurate simulation is not, however, the end goal; rather, it is the means to achieve their optimal design. Such design optimization problems are best solved with algorithms that require gradients, i.e., sensitivities, of the cost and constraint functions with respect to the design parameters, to efficiently traverse the design space. In this work, a nonlinear LCE model and adjoint sensitivity analysis are implemented in a scalable and flexible finite element-based open source framework and integrated into a gradient-based design optimization tool. To display the versatility of the computational framework, LCE design problems that optimize both the material, i.e., liquid crystal orientation, and structural shape to reach a target actuated shapes or maximize energy absorption are solved. Multiple parameterizations, customized to address fabrication limitations, are investigated in both 2D and 3D. The case studies are followed by a discussion on the simulation and design optimization hurdles, as well as potential avenues for improving the robustness of similar computational frameworks for applications of interest.

42 ENGINEERING↗

An overview of vertebrate mineralization with emphasis on collagen-mineral interaction

The nucleation, growth, and development of mineral crystals through their interaction principally with collagen in normal bone and calcifying tendon have been elaborated by applying a number of different techniques for analysis of the inorganic and organic constituents of these tissues. The methods have included conventional and high voltage electron microscopy, electron diffraction, microscopic tomography and 3D image reconstruction, and atomic force microscopy. This summary presents results of these studies that have now characterized the size, shape, and aspects of the chemical nature of the crystals as well as their orientation, alignment, location, and distribution with respect to collagen. These data have provided the means for understanding more completely the formation and strength of the collagen-mineral composite present in most vertebrate calcifying tissues and, from that information, a basis for the adaptation of such tissues under mechanical constraints. In the context of the latter point, other data are given showing effects on collagen in bone cell cultures subjected to the unloading parameters of spaceflight. Implications of these results may be particularly relevant to explaining loss of bone by humans and other vertebrate animals during missions in space, during situations of extended fracture healing, long-term bedrest, physical immobilization, and related conditions. In a broader sense, the data speak to the response of bone and mineralized vertebrate tissues to changes in gravitational loading and applied mechanical forces in general.

Non-NASA Center↗

Alcock-Paczynski Blinding Scheme for the Ly-$α$ Forest Analysis

We present and validate a blinding method for the Lyman-$α$ (Ly$α$) forest analysis based on a modification of the Alcock-Paczynski test. In order to hide the background expansion history, the method employs a geometrical shift of each quasar (QSO) forest in wavelength space, once the quasar continuum has been fitted and the fluctuation field is extracted. The redshift positions for the QSO sample are also changed in a consistent manner. We show that the method remains effective when applied to real data, where contamination from metals and Lyman-$β$ is intrinsically mixed with the Lyman-$α$ forest. This limitation is primarily visible in the 1D correlation function, where other blinding strategies can mitigate the effect. To assess its effectiveness, the prescription is tested against a series of datasets of increasing complexity: from idealized low-noise mocks, to realistic DESI year one synthetic datasets, and finally to data from DESI first data release (DR1), using both the auto (Ly$α\times$Ly$α$) and cross (Ly$α\times$ QSO) correlations. We find that the method robustly shifts the BAO peak position from the 3D correlation functions to the expected value for cosmology changes of around 5% in the matter content, without altering the shape of the posteriors in the model parameters. In conclusion, this catalog-level blinding strategy is a viable method for cosmological inference with the Lyman-$α$ forest, particularly if a cross-analysis with other tracers using the same blinding strategy is pursued.

Perez-Sanchez, G. [Guanajuato U.] (ORCID:000900096↗

Predicting 3D moisture sorption behavior of materials from 1D investigations

Abstract Moisture in materials can be a source of future outgassing and exacerbate unwanted changes in physical and chemical properties. Here, we investigate the effect of sample size and shape on the moisture transport phenomena through a combined experimental and modeling approach. Several different materials varying in size and shape were investigated over a wide range of relative humidities (0–90%) and temperatures ( $$30{-}70^{\,\circ } \hbox {C}$$ 30 - 70 ∘ C ) using gravimetric type dynamic vapor sorption (DVS). A dynamic triple-mode sorption model, developed previously, was employed to describe the experimental results with good success; the model includes absorption, adsorption, pooling (clustering) of species, and molecular diffusion. Here we show that the full triple-mode sorption model is robust enough to predict the dynamic uptake and outgassing of 3-dimensional (3D) samples using parameters derived from quasi-1D samples. This successful demonstration on three different materials (filled polydimethylsiloxane (PDMS), unfilled PDMS, and ceramic inorganic composite) illustrates that the model is robust at describing the scale-independent physics and chemistry of moisture sorption and diffusion materials. This work demonstrates that while sorption mechanisms manifest in testing of all sample sizes, some of these mechanisms were so subtle that they were overlooked in our initial modeling and assessment, illustrating the importance of multi-scale experiments in the development of robust predictive capabilities. Our study also outlines the challenges and viable solutions for global optimization of a multi-parameter model. The ability to quantify moisture sorption and diffusion, independent of scale, using 1D lab-scale experiments enables prediction of long-term bulk materials behavior in real applications.

36 MATERIALS SCIENCE↗

Self-consistent models for triaxial galaxies with flat rotation curves - The disk case

We examine the possibility of constructing scale-free triaxial logarithmic potentials self-consistently, using Schwarzschild's linear programing method. In particular, we explore the limit of nonaxisymmetric disks. In this case it is possible to reduce the problem to the self-consistent reconstruction of the disk surface density on the unit circle, a considerably simpler problem than the usual 2D or 3D one. Models with surface densities of the form Sigma = (x exp n + (y/q) exp n) exp - 1/n with n = 2 or 4 are investigated. We show that the complicated shapes of the 'boxlet' orbit families (which replace the box orbit family found in potentials with smooth cores) limit the possibility of building self-consistent models, though elliptical disks of axis ratio above 0.7 and a restricted range of boxier models can be constructed. This result relies on using sufficiently fine bins, smaller than the 10 deg bins commonly used in 2D or 3D investigations. It also indicates the need for caution in interpreting N-body models of triaxial halos in which the core of the potential is numerically smoothed.

Kuijken, Konrad↗

On the role of geometrically necessary dislocations in void formation and growth in response to shock loading conditions in wrought and additively manufactured Ta

This study investigates the role of geometrically necessary dislocations (GNDs) and microstructure on void nucleation and growth in wrought and additively manufactured (AM) tantalum subjected to high-strain rate loading. Multi-modal 3D data was collected using TriBeam tomography to calculate GND densities and their spatial relationship to voids. A microstructural comparison between the wrought and AM samples identified distinct void shapes and locations, with intragranular voids and more spherical voids frequently observed in the AM dataset. Results indicate that voids preferentially form at both high-angle grain boundaries and low-angle subgrain boundaries, the latter of which are frequently observed in the AM material. Through a radial distribution analysis of all voids in the datasets, significant GND localization to near-void-surface regions was observed in both samples. 3D crystal plasticity simulations were employed to extend the experimental observations, revealing higher void growth rates in [111] oriented grains when compared to [001] grains. The simulations also suggest that GNDs can be generated as part of the void growth process, with more GND accumulation for growth in a [111] grain than a [001] grain. These findings provide valuable insights into the links between nanoscale void nucleation, mesoscale void growth, and microstructural effects in dynamically loaded tantalum.

36 MATERIALS SCIENCE↗

Fast-, Light-Cured Scintillating Plastic for 3D-Printing Applications

Additive manufacturing techniques enable a wide range of possibilities for novel radiation detectors spanning simple to highly complex geometries, multi-material composites, and metamaterials that are either impossible or cost prohibitive to produce using conventional methods. The present work identifies a set of promising formulations of photocurable scintillator resins capable of neutron-gamma pulse shape discrimination (PSD) to support the additive manufacturing of fast neutron detectors. The development of these resins utilizes a step-by-step, trial-and-error approach to identify different monomer and cross-linker combinations that meet the requirements for 3D printing followed by a 2-level factorial parameter study to optimize the radiation detection performance, including light yield, PSD, optical clarity, and hardness. The formulations resulted in hard, clear, PSD-capable plastic scintillators that were cured solid within 10 s using 405 nm light. The best-performing scintillator produced a light yield 83% of EJ-276 and a PSD figure of merit equaling 1.28 at 450–550 keVee.

Frandsen, Brian G. (ORCID:0000000319964320)↗

INTEGRATE - Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements

The INTEGRATE (Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements) project is developing a new inverse-design capability for the aerodynamic design of wind turbine rotors using invertible neural networks. This AI-based design technology can capture complex non-linear aerodynamic effects while being 100 times faster than design approaches based on computational fluid dynamics. This project enables innovation in wind turbine design by accelerating time to market through higher-accuracy early design iterations to reduce the levelized cost of energy. INVERTIBLE NEURAL NETWORKS Researchers are leveraging a specialized invertible neural network (INN) architecture along with the novel dimension-reduction methods and airfoil/blade shape representations developed by collaborators at the National Institute of Standards and Technology (NIST) learns complex relationships between airfoil or blade shapes and their associated aerodynamic and structural properties. This INN architecture will accelerate designs by providing a cost-effective alternative to current industrial aerodynamic design processes, including: - Blade element momentum (BEM) theory models: limited effectiveness for design of offshore rotors with large, flexible blades where nonlinear aerodynamic effects dominate - Direct design using computational fluid dynamics (CFD): cost-prohibitive - Inverse-design models based on deep neural networks (DNNs): attractive alternative to CFD for 2D design problems, but quickly overwhelmed by the increased number of design variables in 3D problems AUTOMATED COMPUTATIONAL FLUID DYNAMICS FOR TRAINING DATA GENERATION - MERCURY FRAMEWORK The INN is trained on data obtained using the University of Marylands (UMD) Mercury Framework, which has with robust automated mesh generation capabilities and advanced turbulence and transition models validated for wind energy applications. Mercury is a multi-mesh paradigm, heterogeneous CPU-GPU framework. The framework incorporates three flow solvers at UMD, 1) OverTURNS, a structured solver on CPUs, 2) HAMSTR, a line based unstructured solver on CPUs, and 3) GARFIELD, a structured solver on GPUs. The framework is based on Python, that is often used to wrap C or Fortran codes for interoperability with other solvers. Communication between multiple solvers is accomplished with a Topology Independent Overset Grid Assembler (TIOGA). NOVEL AIRFOIL SHAPE REPRESENTATIONS USING GRASSMAN SPACES We developed a novel representation of shapes which decouples affine-style deformations from a rich set of data-driven deformations over a submanifold of the Grassmannian. The Grassmannian representation as an analytic generative model, informed by a database of physically relevant airfoils, offers (i) a rich set of novel 2D airfoil deformations not previously captured in the data , (ii) improved low-dimensional parameter domain for inferential statistics informing design/manufacturing, and (iii) consistent 3D blade representation and perturbation over a sequence of nominal shapes. TECHNOLOGY TRANSFER DEMONSTRATION - COUPLING WITH NREL WISDEM Researchers have integrated the inverse-design tool for 2D airfoils (INN-Airfoil) into WISDEM (Wind Plant Integrated Systems Design and Engineering Model), a multidisciplinary design and optimization framework for assessing the cost of energy, as part of tech-transfer demonstration. The integration of INN-Airfoil into WISDEM allows for the design of airfoils along with the blades that meet the dynamic design constraints on cost of energy, annual energy production, and the capital costs. Through preliminary studies, researchers have shown that the coupled INN-Airfoil + WISDEM approach reduces the cost of energy by around 1% compared to the conventional design approach. This page will serve as a place to easily access all the publications from this work and the repositories for the software developed and released through this pr...

aerodynamics↗

Piston geometry and stroke optimization for high efficiency propane spark ignition engines

Propane has unique properties and offers interesting characteristics for high-efficiency spark ignition engines. Its high volatility reduces or completely eliminates fuel-wall wetting and facilitates fuel air mixing. Furthermore, propane has a research octane number of 112 and a high octane sensitivity of 15. Finally, its laminar flame speed is on the same order as that of conventional gasoline, and it exhibits high dilution tolerance. Modern spark ignition internal combustion engines rely on fast combustion rates and high dilution to achieve high brake thermal efficiencies. To accomplish this, high stroke-to-bore ratios and high geometric compression ratios have been used in new engine designs. Therefore, propane’s relatively high laminar flame speeds, high knock resistance, and dilution tolerance make it an excellent candidate fuel for modern spark ignition engines. The objective of this work is to co-optimize the piston geometry and the engine stroke to maximize the efficiency of a spark-ignition engine fueled with propane. 3D computational fluid dynamics (CFD) simulations employing the extended coherent flamelet model were used to study the parametric effects of piston shape and stroke length. A piston geometry based on high performing pistons was parameterized using four controlling parameters. The piston geometry and engine stroke design space was explored using deterministic and quasi-random sampling techniques. In conclusion, a Gaussian process regression model was built using the simulation data to explain the results observed.

33 ADVANCED PROPULSION SYSTEMS↗

Development of inter-grid-cell lateral unsaturated and saturated flow model in the E3SM Land Model (v2.0)

Abstract. The lateral transport of water in the subsurface is important in modulating terrestrial water energy distribution. Although a few land surface models have recently included lateral saturated flow within and across grid cells, it is not a default configuration in the Climate Model Intercomparison Project version 6 experiments. In this work, we developed the lateral subsurface flow model within both unsaturated and saturated zones in the Energy Exascale Earth System Model (E3SM) Land Model version 2 (ELMv2.0). The new model, called ELMlat, was benchmarked against PFLOTRAN, a 3D subsurface flow and transport model, for three idealized hillslopes that included a convergent hillslope, divergent hillslope, and tilted V-shaped hillslope with variably saturated initial conditions. ELMlat showed comparable performance against PFLOTRAN in terms of capturing the dynamics of soil moisture and groundwater table for the three benchmark hillslope problems. Specifically, the mean absolute errors (MAEs) of the soil moisture in the top 10 layers between ELMlat and PFLOTRAN were within 1 %±3 %, and the MAEs of water table depth were within ±0.2 m. Next, ELMlat was applied to the Little Washita experimental watershed to assess its prediction of groundwater table, soil moisture, and soil temperature. The spatial pattern of simulated groundwater table depth agreed well with the global groundwater table benchmark dataset generated from a global model calibrated with long-term observations. The effects of lateral groundwater flow on the energy flux partitioning were more prominent in lowland areas with shallower groundwater tables, where the difference in simulated annual surface soil temperature could reach 0.3–0.4 ∘C between ELMv2.0 and ELMlat. Incorporating lateral subsurface flow in ELM improves the representation of the subsurface hydrology, which will provide a good basis for future large-scale applications.

58 GEOSCIENCES↗

Numerical Simulation of One- And Two-Phase Flows In Propulsion Systems

In this report, we present some results of problems investigated during joint research between the Hampton University (HU) Fluid Mechanics and Acoustics Laboratory (FM&AL), NASA Glenn Research Center (GRC) and the Hyper-X Program of the NASA Langley Research Center (LaRC). This work is supported by joint research between the NASA GRC/HU FM&AL and the Institute of Mechanics at Moscow State University (IM/MSU) in Russia under a Civilian Research and Development Foundation (CRDF) grant, #RE1-2068. The main areas of current scientific interest of the FM&AL include an investigation of the proposed and patented advanced methods for aircraft engine thrust and noise benefits. These methods are based on nontraditional 3D (three dimensional) corrugated and composite nozzle, inlet, propeller and screw designs such as the Bluebell and Telescope nozzles, Mobius-shaped screws, etc. These are the main subject of our other projects, of which one is the NASA MURED's (Minority University Research and Education Division) FAR (Faculty Awards for Research) Award, #NAG-3-2249. Working jointly with this project team, our team also analyzes additional methods for exhaust jet noise reduction. These methods are without essential thrust loss and even with thrust augmentation. The research is focused on a wide regime of problems in the propulsion field as well as in experimental testing and theoretical and numerical simulation analyses for advanced aircraft and rocket engines. The FM&AL Team uses analytical methods, numerical simulations and experimental tests at the Hampton University campus, NASA and IM/MSU. The main results obtained by FM&AL team were published in the papers and patents.

Gilinsky, Mikhail M.↗

Coronal Polarization of Pseudostreamers and the Solar Polar Field Reversal

The reversal of the solar polar magnetic field is notoriously hard to pin down due to the extreme viewing angle of the pole. In Cycle 24, the southern polar field reversal can be pinpointed with high accuracy due to a large-scale pseudostreamer that formed over the pole and persisted for approximately a year. We tracked the size and shape of this structure with multiple observations and analysis techniques including PROBA2/SWAP EUV images, AIA EUV images, CoMP polarization data, and 3D tomographic reconstructions. We find that the heliospheric field reversed polarity in February 2014, whereas in the photosphere, the last vestiges of the previous polar field polarity remained until March 2015. We present here the evolution of the structure and describe its identification in the Fe XII 1074nm coronal emission line, sensitive to the Hanle effect in the corona.

magnetic field↗