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DOE OSTI2024

Integrated top-down process and voxel-based microstructure modeling for Ti-6Al-4V in laser wire direct energy deposition process

Laser-wire metal additive manufacturing (AM) is one of the ideal direct energy deposition (DED) processes for creating large-scale parts with a medium level of complexity. However, the DED process involves complex thermal signatures and wide length scales making the fabrication of realistic AM components and part qualification often reliant on experimental trial-and-error optimization. While experimental measurements over the full volume of a part are valuable and necessary, measuring the entire area of a part is significantly laborious and practically infeasible, particularly for large parts in terms of cost and rapid qualification. Therefore, in this work, we developed an effective thermal and microstructure modeling framework based on the Johnson–Mehl-Avrami-Kolmogorov (JMAK) and Koistinen & Marburger (KM) models through a top-down approach that considers plate distortion-affected thermal profiles. A voxel-by-voxel simulation method is used to predict individual phase fractions of Ti-6Al-4 V. The predicted results were validated through detailed metallurgical measurements. A combined voxel-by-voxel approach with a sparse data reconstruction technique produced a near-perfect reconstruction of the original data. This approach anticipates a significant reduction in data points and computation time and resources. Lastly, we conclude with potential extensions of this work to other modeling efforts.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Role of gas surface interactions in the reduction of OGO-6 neutral gas particle mass spectrometer data

The gas-surface interaction effects observed by the quadrupole mass spectrometer are described, and the technique developed to account for them in determining ambient neutral densities is summarized. The total ion current and the ion currents for ions with molecular weights 2, 4, 16, 28, and 32 are sampled for 1.125 sec once every 9.216 sec, for 258 sec out of a 368 sec cycle. An equation is given for the number density of any constituent in the ion source region, and source density data are discussed. The mass 28 background gas is considered to be CO rather than N2, and a CO model is developed. A quasi-equilibrium model of the atomic oxygen interactions is constructed, and a set of surface parameters is determined which provides a reasonable fit to the mass 16 and 32 source densities consistent with the predicted ambient atomic oxygen.

Hedin, A. E.↗

NASA NTRS1978

A Multi-Band Far-Infrared Survey with a Balloon-Borne Telescope

Nine additional radiation sources, above a 3-sigma confidence level of 1300 Jy, were identified at 100 microns by far infrared photometry of the galactic plane using a 0.4 meter aperture, liquid helium cooled, multichannel far infrared balloon-borne telescope. The instrument is described, including its electronics, pointing and suspension systems, and ground support equipment. Testing procedures and flight staging are discussed along with the reduction and analysis of the data acquired. The history of infrared astronomy is reviewed. General infrared techniques and the concerns of balloon astronomers are explored.

Jacobson, M. R.↗

NASA NTRS2017

Cryogenic Thermal Conductivity Measurements on Candidate Materials for Space Missions

Spacecraft and instruments on space missions are built using a wide variety of carefully-chosen materials. In addition to having mechanical properties appropriate for surviving the launch environment, these materials generally must have thermal conductivity values which meet specific requirements in their operating temperature ranges. Space missions commonly propose to include materials for which the thermal conductivity is not well known at cryogenic temperatures. We developed a test facility in 2004 at NASAs Goddard Space Flight Center to measure material thermal conductivity at temperatures between 4 and 300 Kelvin, and we have characterized many candidate materials since then. The measurement technique is not extremely complex, but proper care to details of the setup, data acquisition and data reduction is necessary for high precision and accuracy. We describe the thermal conductivity measurement process and present results for several materials.

thermal conductivity↗

NASA NTRS2017

Cryogenic Thermal Conductivity Measurements on Candidate Materials for Space Missions

Spacecraft and instruments on space missions are built using a wide variety of carefully-chosen materials. It is common for NASA engineers to propose new candidate materials which have not been totally characterized at cryogenic temperatures. In many cases a material's cryogenic thermal conductivity must be known before selecting it for a specific space-flight application. We developed a test facility in 2004 at NASA's Goddard Space Flight Center to measure the longitudinal thermal conductivity of materials at temperatures between 4 and 300 Kelvin, and we have characterized many candidate materials since then. The measurement technique is not extremely complex, but proper care to details of the setup, data acquisition and data reduction is necessary for high precision and accuracy. We describe the thermal conductivity measurement process and present results for ten engineered materials, including alloys, polymers, composites, and a ceramic.

James Tuttle↗

NASA NTRS2020

Ensemble PM2.5 Forecasting during the 2018 Camp Fire Event Using the HYSPLIT Transport and Dispersion Model

Biomass burning releases a vast amount of aerosols into the atmosphere, often leading to severe air quality and health problems. Prediction of the air quality effects from biomass burning emissions is challenging due to uncertainties in fire emission, plume rise calculation, and other model inputs/processes. Ensemble forecasting is increasingly used to represent model uncertainties. In this paper, an ensemble forecast was conducted to predict surface PM2.5 during the 2018 California Camp Fire event using the NOAA HYSPLIT dispersion model at 0.1- degree horizontal resolution. Different combinations of four satellite-based fire emission datasets (FEER, FLAMBE, GBBEPx and GFAS), two plume rise schemes (Briggs and Sofiev), various meteorology inputs and model setup options were used to create the forecast ensemble, for a total of 112 experiments. The performance of each ensemble member and the ensemble mean were evaluated using ground-based observations, with four statistical metrics and an overall rank. The ensemble spread of the 112 members reached 1000 μg/m3, highlighting the large uncertainty in wildfire forecast. The ensemble mean displayed the best performance. Each fire emission product contributed to one or more members among the top ten performers, revealing the forecasting dependence on both the quality of fire emissions data and model representation of emission, transport and removal processes. In addition, an ensemble size reduction technique was introduced. With the help of this technique, the ensemble size was reduced from 112 to 28 members and still produced an ensemble mean that yielded comparable or even better performance to that of the full ensemble.

Biomass Burning↗

DOE OSTI2024

Deep Learning-based Parameterization of Complex 3D CO2 Saturation Data in Large-scale Geological Carbon Storage

In deep learning (DL), dimension reduction plays a pivotal role in improving training efficiency and minimizing overfitting, especially when working with complex datasets like three-dimensional (3D) saturation data. In the context of geological carbon storage (GCS), 3D saturation data introduces unique challenges due to its sparse nature and sharp transitions at plume boundaries, known as shock fronts. To tackle these challenges, we developed a novel DL framework that combines dimension reduction with advanced 3D reconstruction techniques. Our approach utilizes latent variables derived from 2D average saturation fields to efficiently capture the essential features of high-dimensional data while reducing the number of variables. This enhances both the robustness and accuracy of DL models, making the framework more practical for real-world applications. By offering a tailored solution for modeling complex 3D saturation dynamics, this framework holds significant potential for environmental monitoring, energy storage, and other geological applications.

Wang, Hongsheng [University of Texas at Austin]↗

NASA NTRS2018

Analysis of Simulated and Experimental Noise Sources of Boeing 777 Main Gear Model via CLEAN in 3D

Previously obtained experimental and simulated phased microphone array data for the NASA 26%-scale model of a six-wheel main landing gear, with and without a toboggan-shaped noise reduction fairing, were analyzed using the CLEAN technique in three dimensions. The model is a high-fidelity representation of the Boeing 777-200 aircraft main landing gear. The reprocessing of the acoustic data was undertaken to address the deficiencies encountered in the source localization (beamform) maps and the integrated farfield spectra at mid to high frequencies in our previous study, where conventional array processing techniques were applied to the same data sets. Application of the CLEAN approach resulted in higher quality beamform maps with many of the previously observed side lobes either eliminated or suppressed significantly. As a result, integration of the experimentally and computationally based maps showed substantial improvement in the quality of the high-frequency spectral content relative to the corresponding spectra generated via conventional array processing, thus extending the good agreement achieved between the measured and predicted farfield spectra from 8 kHz to 14 kHz in model-scale frequencies. In addition, an examination of the simulated surface pressure fluctuations, off-surface flow field, and three-dimensionally constructed noise sources was conducted to determine the cause of the subtle discrepancies between measured and predicted sound pressure levels that occur in the 1,800 Hz to 4,000 Hz model-scale frequency range.

Ravetta, Patricio↗

DOE OSTI2024

Rapid detection of rare events from in situ X-ray diffraction data using machine learning

High-energy X-ray diffraction methods can non-destructively map the 3D microstructure and associated attributes of metallic polycrystalline engineering materials in their bulk form. These methods are often combined with external stimuli such as thermo-mechanical loading to take snapshots of the evolving microstructure and attributes over time. However, the extreme data volumes and the high costs of traditional data acquisition and reduction approaches pose a barrier to quickly extracting actionable insights and improving the temporal resolution of these snapshots. This article presents a fully automated technique capable of rapidly detecting the onset of plasticity in high-energy X-ray microscopy data. The technique is computationally faster by at least 50 times than the traditional approaches and works for data sets that are up to nine times sparser than a full data set. This new technique leverages self-supervised image representation learning and clustering to transform massive data sets into compact, semantic-rich representations of visually salient characteristics ( e.g. peak shapes). These characteristics can rapidly indicate anomalous events, such as changes in diffraction peak shapes. It is anticipated that this technique will provide just-in-time actionable information to drive smarter experiments that effectively deploy multi-modal X-ray diffraction methods spanning many decades of length scales.

Zheng, Weijian↗

NASA NTRS1991

Software manual for operating particle displacement tracking data acquisition and reduction system

The software manual is presented. The necessary steps required to record, analyze, and reduce Particle Image Velocimetry (PIV) data using the Particle Displacement Tracking (PDT) technique are described. The new PDT system is an all electronic technique employing a CCD video camera and a large memory buffer frame-grabber board to record low velocity (less than or equal to 20 cm/s) flows. Using a simple encoding scheme, a time sequence of single exposure images are time coded into a single image and then processed to track particle displacements and determine 2-D velocity vectors. All the PDT data acquisition, analysis, and data reduction software is written to run on an 80386 PC.

Wernet, Mark P.↗

DOE OSTI2024

AIACHNE's contribution for Nuclear Energy Agency Working Party on International Nuclear Data Evaluation Co-operation Subgroup 50

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

AIACHNE's contribution for Nuclear Energy Agency Working Party on International Nuclear Data Evaluation Co-operation Subgroup 50

The AIACHNE (AI/ML Informed cAlifornium CHi Nuclear data Experiment) project aims at designing an experiment for the 252 Cf Prompt Fission Neutron Spectrum (PFNS) that explores systematic biases in an experimental database retrieved from the EXFOR databases. To that end, machine learning (ML) methods were applied to pint-point measurement features likely related to bia. From that information, we selected a feature that should be explored by the AIACHNE experiment. Measurement features are metadata encapsulating all pertinent information about the physical measurement and analysis techniques. Examples are, for instance, what neutron and fission detectors were used for the physical metadata, and what background reduction techniques were employed for analysis techniques. Such metadata were retrieved both from EXFOR entries as well as the literature of data sets described in detail in Ref. [2]. The prerequisite for applying machine learning techniques is casting the metadata into a format that can be parsed by the algorithm. This step might seem trivial but requires to find a unique language where metadata that carry the same physics meaning across several experiments must have the same identifier. One example is, for instance, the neutron detector. As seen in Figure 1, the machine learning code identified the use of 6 Li detectors as being related to bias in some datasets of the AIACHNE 252 Cf PFNS experimental database. In fact, here are several experiments that used neutron detectors containing 6Li in the database, for instance for the example below. EXFOR format has a unique keywords describing detectors such as “SCIN” or “GLASD”. One may think that these keywords are already sufficient descriptors for ML to uniquely find an issue. However, “SCIN” (used for [3, 4]) and “GLASD” (used for [5]) fail to inform the algorithm what is the active material in the detector. And, the key common issue leading to bias in 252 Cf related to neutron detectors is not whether it is a glass detector or a scintillator. No, the issue is that 6 Li was within both detector types and that even small mistakes in the detector response functions around approximately 200 keV are amplified by the 6 Li(n,α) resonance there leading to bias in data as highlighted in Fig. 1 and Ref. [1]. Hence, the features describing the neutron detector must call out the active material in the detector, rather than the existing EXFOR detector keyword, that the ML algorithm can find physically meaningful features related to bias. The AIACHNE team used a precursor of the WPEC (Working Party on International Nuclear Data Evaluation Co-operation) SG(Subgroup)-50 format to store the metadata for the ML analysis.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1986

Machine vision and the OMV

The orbital Maneuvering Vehicle (OMV) is intended to close with orbiting targets for relocation or servicing. It will be controlled via video signals and thruster activation based upon Earth or space station directives. A human operator is squarely in the middle of the control loop for close work. Without directly addressing future, more autonomous versions of a remote servicer, several techniques that will doubtless be important in a future increase of autonomy also have some direct application to the current situation, particularly in the area of image enhancement and predictive analysis. Several techniques are presentet, and some few have been implemented, which support a machine vision capability proposed to be adequate for detection, recognition, and tracking. Once feasibly implemented, they must then be further modified to operate together in real time. This may be achieved by two courses, the use of an array processor and some initial steps toward data reduction. The methodology or adapting to a vector architecture is discussed in preliminary form, and a highly tentative rationale for data reduction at the front end is also discussed. As a by-product, a working implementation of the most advanced graphic display technique, ray-casting, is described.

Mcanulty, M. A.↗

DOE OSTI2021

On single-crystal total scattering data reduction and correction protocols for analysis in direct space

Data reduction and correction steps and processed data reproducibility in the emerging single-crystal total-scattering-based technique of three-dimensional differential atomic pair distribution function (3D-ΔPDF) analysis are explored. All steps from sample measurement to data processing are outlined using a crystal of CuIr 2 S 4 as an example, studied in a setup equipped with a high-energy X-ray beam and a flat-panel area detector. Computational overhead as pertains to data sampling and the associated data-processing steps is also discussed. Various aspects of the final 3D-ΔPDF reproducibility are explicitly tested by varying the data-processing order and included steps, and by carrying out a crystal-to-crystal data comparison. Situations in which the 3D-ΔPDF is robust are identified, and caution against a few particular cases which can lead to inconsistent 3D-ΔPDFs is noted. Although not all the approaches applied herein will be valid across all systems, and a more in-depth analysis of some of the effects of the data-processing steps may still needed, the methods collected herein represent the start of a more systematic discussion about data processing and corrections in this field.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1979

Trends in Materials' Outgassing Technology

Test sample acquisition and chemical analysis techniques for outgassing products from spacecraft, experiment modules, and support equipment is described. The reduction of test data to a computer compatible format to implement materials selection policies is described. A list of the most troublesome outgassing species is given and several materials correlations are discussed. Outgassing from solar panels, thermal blankets, and wire insulation are examined individually.

Colony, J. A.↗

NASA NTRS1994

Optical analysis of crystal growth

Processing and data reduction of holographic images from Spacelab presents some interesting challenges in determining the effects of microgravity on crystal growth processes. Evaluation of several processing techniques, including the Computerized Holographic Image Processing System and the image processing software ITEX150, will provide fundamental information for holographic analysis of the space flight data.

Workman, Gary L.↗

NASA NTRS2012

Quantifying Pilot Visual Attention in Low Visibility Terminal Operations

Quantifying pilot visual behavior allows researchers to determine not only where a pilot is looking and when, but holds implications for specific behavioral tracking when these data are coupled with flight technical performance. Remote eye tracking systems have been integrated into simulators at NASA Langley with effectively no impact on the pilot environment. This paper discusses the installation and use of a remote eye tracking system. The data collection techniques from a complex human-in-the-loop (HITL) research experiment are discussed; especially, the data reduction algorithms and logic to transform raw eye tracking data into quantified visual behavior metrics, and analysis methods to interpret visual behavior. The findings suggest superior performance for Head-Up Display (HUD) and improved attentional behavior for Head-Down Display (HDD) implementations of Synthetic Vision System (SVS) technologies for low visibility terminal area operations. Keywords: eye tracking, flight deck, NextGen, human machine interface, aviation

Ellis, Kyle K.↗

DOE OSTI2018

Fault Detection and Diagnosis In Hall–Héroult Cells Based on Individual Anode Current Measurements Using Dynamic Kernel PCA

Individual anode current signals in aluminum reduction cells provide localized cell conditions in the vicinity of each anode, which contain more information than the conventionally measured cell voltage and line current. One common use of this measurement is to identify process faults that can cause significant changes in the anode current signals. While this method is simple and direct, it ignores the interactions between anode currents and other important process variables. This paper presents an approach that applies multivariate statistical analysis techniques to individual anode currents and other process operating data, for the detection and diagnosis of local process abnormalities in aluminum reduction cells. Specifically, since the Hall–Héroult process is time-varying with its process variables dynamically and nonlinearly correlated, dynamic kernel principal component analysis with moving windows is used. The cell is discretized into a number of subsystems, with each subsystem representing one anode and cell conditions in its vicinity. The fault associated with each subsystem is identified based on multivariate statistical control charts. The results show that the proposed approach is able to not only effectively pinpoint the problematic areas in the cell, but also assess the effect of the fault on different parts of the cell.

36 MATERIALS SCIENCE↗