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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 55 records · Page 3

Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Interest in multi-axis additive manufacturing has grown significantly in recent years due to associated benefits that range from improved quality to support for greater geometric complexity. A method of 5-axis Laser Hot-Wire Directed Energy Deposition is developed and demonstrated in this study using an 8-axis industrial robot, comprised of a 6-axis serial link robot and a 2 degree-of-freedom positioner. Coordinated 5-axis motion is used to print Ti-6Al-4V objects predominantly through build plate rotation. Methods of slicing and toolpath generation are presented, including the use of an alternating toolpath direction philosophy and the manipulation of the CAD model surface normal vectors for determining the required build plate tilt angles for maintaining consistent deposition orientations relative to gravity. Another objective of the study was to determine the limits of conventional slicing and layer height control techniques for printing geometries with significant unsupported overhangs. A comparison is made between the behavior of normal and conformal bead alignment in this regard, and the performance of the layer height controller is reported as it relates to process stability and the limits of printing overhang geometries. Unsupported overhangs were successfully printed at 35° without build plate tilt and 45° with build plate tilt. Toolpath velocity and net-shape printing performance are reported as well, with 3D scans of the printed surfaces used for net-shape characterization. In all, the printing of three geometries is presented, including the overhang geometry, a 5-axis toolpath geometry, and a large-scale, multi-bead demonstrator part, which exceeded 500 mm in height and weighed 44 kg (97 lbs).

36 MATERIALS SCIENCE↗

Reduction of baseplate distortion during directed energy deposition using compliant features

Distortion in additive manufacturing (AM) remains a barrier to its adoption in precision industries. Baseplate warpage is one such issue which compromises the feasibility of post-process precision machining. The restriction to thermal contraction of the deposited part, imposed by the baseplate, generates bending moments, that in turn causes warpage. A novel distortion mitigation strategy using baseplates with integrated compliant features, which enables thermal contraction of the build is presented. Six unique design concepts are evaluated, including a solid reference, using two deposition geometries. A laser, hot-wire, directed energy deposition (DED) process is used to deposit a symmetric cylindrical part (C-part) and a T-shaped asymmetric part (T-part). Flatness deviation of baseplates is measured using structured light 3D scanning. Measurements reveal a reduction in net flatness deviation of 58.8% for the C-part and 40.9% for the T-part, compared to the solid reference. While most designs yielded reductions exceeding 30% and 20% for the C- and T-parts, respectively, one configuration resulted in increased deviation. Finite element (FE) simulations are performed to elucidate the underlying mechanisms affecting distortion of compliant baseplates during DED. Despite variations between predictions and measurements, agreement in the general trend is observed. It also revealed that initial flatness errors in baseplates significantly affect its deviation during deposition. Predictions indicate that compliant features significantly affect the thermal distribution as well as the evolution of flatness deviation in the baseplate during deposition. Notably, one design exhibited a reduction in distortion during cooling, following its initial increase during deposition. FE predictions show a maximum reduction of 60.9% and 38.8% in net flatness deviation for the C- and T-parts, respectively. The performance of compliant baseplates is found to be governed by both its the thermal and mechanical characteristics, which are crucial factors to be considered during design.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗

Digital bead modeling for wire-arc directed energy deposition

Prediction of 2D cross-section and full 3D geometry for stacked weld beads is critical for the outcome of wire-arc directed energy deposition (DED) parts; however, most additive path planning software packages model beads as extrusions of a rectangle. Weld beads are not rectangular, and the resulting shape is dependent upon physics effects at the moment of deposition. Physics phenomena such as the geometry of the underlying surface, the heat input of the welding mode, and the direction of gravity contribute to bead shape. Here, this paper presents a novel implicit modeling method that discretizes a 2D area or 3D volume of space into pixels or voxels and constructs fields based on these physics phenomena. The fields are combined using a weighting scheme trained on 3D scan measurements of welds and wire-arc DED prints. Pixels or voxels are added until the known amount of deposited volume has been achieved. Thereby, a strong conservation of mass principle is applied to the process. Utilizing machine learning techniques, the present model can be trained on a database of scans allowing for the representation of a wide variety of prints. Results show that this method can produce predictions with realistic bead morphology and sub-millimeter form error.

Bead geometry modeling↗

4D structural changes and pore network model of biomass during pyrolysis

Biochar is an engineered carbon-rich substance used for soil improvement, environmental management, and other diverse applications. To date, the understanding of how biomass affects biochar microstructure has been limited due to the complexity of analysis involved in tracing the changes in the physical structure of biomass as it undergoes thermochemical conversion. In this study, we used synchrotron x-ray micro-tomography to visualize changes in the internal structure of biochar from diverse feedstock (miscanthus straw pellets, wheat straw pellets, oilseed rape straw pellets, and rice husk) during pyrolysis by collecting a sequence of 3D scans at 50 °C intervals during progressive heating from 50 °C to 800 °C. The results show a strong dependence of biochar porosity on feedstock as well as pyrolysis temperature, with observed porosity in the range of 7.41–60.56%. Our results show that the porosity, total surface area, pore volume, and equivalent diameter of the largest pore increases with increasing pyrolysis temperature up to about 550 °C. The most dramatic development of pore structure occurred in the temperature range of 350–450 °C. This understanding is pivotal for optimizing biochar’s properties for specific applications in soil improvement, environmental management, and beyond. By elucidating the nuanced variations in biochar’s physical characteristics across different production temperatures and feedstocks, this research advances the practical application of biochar, offering significant benefits in agricultural, environmental, and engineering contexts.

54 ENVIRONMENTAL SCIENCES↗

In-Situ Detection and Prediction of WAAM Cross Feature Geometry

Abstract Wire arc additive manufacturing (WAAM) is increasingly used by manufacturers due to its relatively low cost and high deposition rate compared to other metal AM methods, but the parts produced by WAAM can be subject to localized variations in part quality. One such variation is the cross-feature defect, whereby a localized part height increase occurs due to the crossing of deposition toolpaths. Mitigation of this defect is typically achieved using manual path planning strategies, but closed-loop control is underutilized. Since the nature of this defect and of the WAAM process is such that the previous layer’s geometry influences that of the subsequent layer’s, the cross-feature defect geometry changes throughout the deposition. Therefore, any closed-loop control strategy will need to incorporate the dynamic trait of this defect. The present work seeks to implement an in-situ process modeling approach where a regression model can be continuously updated to predict the defect geometry of the subsequent deposition layer based on the historical process data. Several multi-layer cross-feature geometries are deposited and current, voltage, and optical camera data is taken for each layer. The resulting cross-feature geometries are characterized using 3D scanning and the performance and accuracy of the in-situ modeling approach is evaluated.

Thien, Austen↗

Influence of gradation on failure mode of saturated sand at particle scale

Extensive research has been reported in the literature to characterize the failure mode of dry sand using various experimental techniques such as surface optical imaging, photo-elastic materials, three-dimensional (3D) computed tomography (CT), and 3D synchrotron micro-computed tomography (SMT). However, there is a limited literature about the behavior of saturated sand. This paper presents the results of axisymmetric triaxial compression (ATC) experiments that were conducted on saturated sand specimens. The behavior of specimens composed of a uniform sand with grain size between US sieves #40 and #50 is compared to specimens conducted on the same sand that has a wider gradation. 3D SMT technique was used to acquire 3D scans while shearing the specimens to probe localized events that are completely missed or misinterpreted when analyzing ATC measurements based on global standard measurements. The results show a higher effective principal stress ratio (EPSR) for the non-uniform specimen and a thicker shear band when compared to uniform specimen.

Elnur, Mohammed [University of Tennessee]↗

Flexible Fuel Electric Hybrid Glass Furnace Demonstration

The furnace contractor completed General Arrangement (GA) layouts and Piping and Instrumentation Diagrams (P&ID) for both furnaces during this reporting period. Preliminary equipment lists accompanied this work. Control system architecture in progress. Key furnace design elements and deliverables on track to be complete by end of phase. The facilities design and integration contractor completed a 3D scan and modeling of the facility. The work during this period focused on preliminary design with a focus on overall project scope and feasibility. This key work supports the overall project deliverables for 30% preliminary engineering and Preliminary Design Report (PDR) which are on track to be complete by the end of the phase. These deliverables are approximately 50% complete through the end of this reporting period. The batch house operations design contractor continues development of site plan and General Arrangement (GA) layout to support the 30% preliminary engineering and design package. This work is 60% complete by the end of this reporting period and is on track to be complete by the end of the phase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Generation of Performance Model for the Aeolian Wind Tunnel (AWT) Rotor at Reduced Pressure

The NASA Jet Propulsion Laboratory (JPL) designed the Mars Helicopter (MH) in collaboration with AeroVironment Inc., NASA Ames Research Center, and NASA Langley Research Center to explore the possibility of a vertical takeoff and landing (VTOL) Unmanned Aerial Vehicle (UAV) for flight on Mars. A 40-inch-diameter Aeolian Wind Tunnel (AWT) rotor, roughly approximating the proposed MH design by JPL, was tested in forward flight at Mars atmospheric pressure at the NASA Ames Planetary Aeolian Laboratory (PAL) in support of MH research efforts. This report describes the generation of the rotor model used to correlate with that experimental effort as reported by Ament and Koning. The 40-inch-diameter rotor was 3D-scanned and transformed into an airfoil deck. The scanned rotor airfoil sections are analyzed using C81 Generator (C81Gen) to generate the sectional aerodynamic coefficients for comprehensive analyses. A mid-fidelity computational fluid dynamics (CFD) simulation using Rotorcraft CFD (RotCFD) is pursued to efficiently estimate rotor hover and forward flight performance. Simulations at two pressures, 7 mbar (approximate Martian atmospheric pressure) and 1018 mbar (1 atmosphere), are performed to gain an understanding of the performance differences and Reynolds number effects observed. Experimental 1-atmosphere thrust for single- and dual-rotor isolated hover cases correlate well with the modeled rotor. Performance results at reduced pressure (7 mbar) show a drastic decrease in lift for equivalent RPMs tested at 1 atmosphere. Although this is primarily due to pressure reduction, Reynolds number effects also contribute to this decrease, as airfoil lift and drag coefficients are affected when compared with 1-atmosphere results. Further, simulated rotor power coefficient shows drastic increases at reduced pressures, attributed to laminar boundary layer separation, as described in Koning et al. for the MH rotor analysis. PAL experimental Martian Surface Wind Tunnel (MARSWIT) results are presented in the paper by Ament and Koning. The very low Reynolds number range is currently not well understood and presents various challenges for both experimentation and simulation.

Koning, Witold J. F.↗

Investigating the History of Aubrites Using X-Ray Computed Tomography and Bulk Partition Coefficients

The aubrites are a unique group of differentiated meteorites that formed on parent bodies with oxygen fugacities (ƒO2) from ~2 to ~6 log units below the iron-wustite buffer. At these highly reduced condi- tions, elements deviate from the geochemical behavior exhibited at terrestrial ƒO2, and may form FeO-poor silicates, Si-bearing metals, and exotic sulfides. Geochemical examinations of aubrites, such as mineral major-element compositions, bulk-rock compositions, O isotopes, and crystallization ages, are crucial to understand their formation and evolution at extreme ƒO2 conditions. In this study, we determine partitioning relationships of elements between bulk silicate, sulfide, and metal phases within aubrites, and compare the results to partition coefficients determined from petrologic experiments run under mercurian conditions. While previous studies have described the petrology and 2D modal abundances of aubrites, this work provides the first 3D view of aubritic mineralogies, which are com- pared to the available 2D data. Constraints of 3D modal abundances will increase the accuracy of computed bulk distribution coefficients; therefore, 3D scans of aubrite samples are imperative. We utilize X-ray computed tomogra- phy (XCT) to non-destructively analyze the distribution and abundances of mineral phases in aubrites and locate composite clasts of sulfide grains for future analysis.

Wilbur, Z. E.↗

Large-Drop Ice Accretion Test Results for a Large Scale Swept Wing Model

In-flight icing is an important consideration that affects aircraft design, performance and safety. Newer regulations combined with increasing demand to reduce fuel burn, emissions and noise are driving a need for improvements in icing simulation capability. To that end, this paper presents the results of ice accretion testing conducted in the NASA Icing Research Tunnel on a large swept wing section typical of a modern commercial transport. The model was based upon a section of the Common Research Model wing at the 64% semispan station with a streamwise chord length of 136 in. The test conditions were developed with an icing scaling analysis to generate similar conditions for a small MVD = 25 μm and a large MVD = 110 μm. A series of tests were conducted over a range of total temperature from -23.8 ˚C to -1.4 ˚C with all other conditions held constant. The results for the small MVD cloud conditions were consistent with previous work and showed the changing ice morphology from rime ice at colder temperatures to highly 3D scallop ice in the range of -8.7 ˚C to -3.8 ˚C. The results for the large MVD cloud conditions exhibited some differences in the ice accretion morphology from the small MVD conditions. Scallop-like ice features were observed at total temperature of -3.8˚C. The large MVD ice accretion at lower temperatures tended to be smoother than the corresponding ice accretion for small MVD. The thickness of the main ice shape tended to be larger for the small MVD conditions compared to the corresponding large MVD ice shape while the latter had more ice farther downstream. The measured ice mass was approximately equal between the corresponding small and large MVD ice shapes up to a freezing fraction of 0.6. For higher freezing fraction, the large MVD ice shapes weighed more. Cloud MVD variation from 50 μm to 230 μm while holding the scaling parameters constant resulted in very minor differences in the ice shapes, mostly in the upper and lower surface chordwise extents. Ice volume was computed from 3D scan data and used to calculate a ratio of ice mass to volume. The resulting values were in the range of 240 to 455 Kg/m3. While this is consistent with analogous values previously reported in the literature, more data are needed to determine a specific trend in this ratio as a function of freezing fraction and the corresponding governing physical phenomena. This work has resulted in a significant experimental database of ice accretion for small and large MVD conditions applicable to large-scale swept wings.

Icing↗

Large-Drop Ice Accretion Test Results for a Large Scale Swept Wing Section

In-flight icing is an important consideration that affects aircraft design, performance and safety. Newer regulations combined with increasing demand to reduce fuel burn, emissions and noise are driving a need for improvements in icing simulation capability. To that end, this paper presents the results of ice accretion testing conducted in the NASA Icing Research Tunnel on a large swept wing typical of a modern commercial transport. The model was based upon a section of the Common Research Model wing at the 64% semispan station with a streamwise chord length of 136 in. The test conditions were developed with an icing scaling analysis to generate similar conditions for a small MVD = 25 μm and a large MVD = 110 μm. A series of tests were conducted over a range of total temperature from -23.8 ˚C to -1.4 ˚C with all other conditions held constant. The results for the small MVD cloud conditions were consistent with previous work and showed the changing ice morphology from rime ice at colder temperatures to highly 3D scallop ice in the range of -8.7 ˚C to -3.8 ˚C. The results for the large MVD cloud conditions exhibited some differences in the ice accretion morphology. Scallop-like ice features were observed at total temperature of -3.8˚C. The large MVD ice accretion at lower temperatures tended to be smoother than the corresponding ice accretion for small MVD. The thickness of the main ice shape tended to be larger for the small MVD conditions compared to the corresponding large MVD ice shape while the latter had more ice farther downstream. The measured ice mass was approximately equal between the corresponding small and large MVD ice shapes up to a freezing fraction of 0.6. For higher freezing fraction, the large MVD ice shapes weighed more. Cloud MVD variation from 50 μm to 230 μm while holding the scaling parameters constant resulted in very minor differences in the ice shapes, mostly in the upper and lower surface chordwise extents. Ice volume was computed from 3D scan data and used to calculate a ratio of ice mass to volume. The resulting values were in the range of 240 to 455 Kg/m3. While this is consistent with analogous values previously reported in the literature, more data are needed to determine a specific trend in this ratio as a function of freezing fraction and the corresponding governing physical phenomena. This work has resulted in a significant experimental database of ice accretion for small and large MVD conditions applicable to large-scale swept wings.

Icing↗

Astrobee: Five years of Completed, Current, and Future Research on the International Space Station using Free Flying Robots.

After five years on the International Space Station (ISS), the Astrobee Research Facility, has completed over 160 Test Sessions logging over 1200 hours of operations. Managed by the NASA ISS Program OZ office and supported by NASA Ames Research Center (ARC) in California, the Astrobee Team currently maintains two identical free-flying Astrobee robots and a Docking Station for research on the ISS. As a technology demonstration platform, the Astrobee Robots are available for Guest Scientists to use for a spectrum of research capabilities. Using ambient air on the ISS, propelled by battery-operated fans, Astrobee is designed to autonomously operate throughout most of the USOS (US Orbital Segment), with the objective of minimizing the need for astronaut support. Astrobee carries a suite of six cameras, a two degree-of-freedom (DOF) arm with a gripper that can grasp ISS handrails and other objects, and three payload bays that provide power and data for guest science hardware. Astrobee can autonomously execute hours-long flight plans or be tele-operated from the ground. While the Astrobee Team continues to improve mapping and autonomous flight capabilities, one of the main goals of Astrobee Robots is to provide research opportunities for Guest Scientists. The Astrobee Robot Software (ARS) makes extensive use of the open-source Robot Operating System (ROS). The ARS can be used interchangeably with an Astrobee Simulator or as Astrobee’s onboard software. ARS features include autonomous docking and perching, real-time teleoperations from the ground, plan based autonomous tasks, multi Astrobee communication, among other capabilities. Through simulation software and ground testing laboratories, the Astrobee Team is available to support Guest Scientists during development and testing and lead real-time ISS operations. The Astrobee Team and Guest Scientists have completed research including Astrobatics maneuvers, RFID and sound sensing capabilities, Gecko materials studies, student Robotics Programming Challenges, and Free Flyer formation flight investigations. Current science with the Astrobee Robots is investigating new docking capabilities through software only research as well as testing new docking hardware installed on the Astrobees. The Astrobee Team and other researchers at NASA Ames continue to explore robotics applications for future NASA missions such as Gateway and potential experiments involving human-robot interactions. Continued advanced mapping resolution capabilities, and high-resolution panoramic imagery also remains areas of research. Exciting in development research involves docking for rendezvous proximity operation (CLINGERS), multi resolution 3D scanning (MRS), space debris removal in microgravity (REACCH). This presentation will mainly focus on completed research over the past year and current science being performed on the Astrobees. This presentation will also focus on how a Guest Scientist/Researcher progresses from conception to running their science on the Astrobees on the ISS, as well as discuss the Astrobee Facility resources available for supporting ground testing and real-time ISS operations.

Astrobee↗

Physics-based Simulation of Human Posture Using 3D Whole Body Scanning Technology for Astronaut Space Suit Evaluation

Over the past few years high precision three-dimensional (3D) full body laser scanners have been developed to be used as a powerful anthropometry tool for quantification of the morphology of the human body. The full body scanner can quickly extract body characteristics in non-contact fashion. It is required for the Anthropometry and Biomechanics Facility (ABF) to have capabilities for kinematics simulation of a digital human at various postures whereas the laser scanner only allows capturing a single static posture at each time. During this summer fellowship period a theoretical study has been conducted to estimate an arbitrary posture with a series of example postures through finite element (FE) approximation and found that four-point isoparametric FE approximation would result in reasonable maximum position errors less than 5%. Subsequent pilot scan experiments demonstrated that a bead marker with a nominal size of 6 mm could be used as a marker for digitizing 3-D coordinates of anatomical landmarks for further kinematic analysis. Two sessions of human subject testing were conducted for reconstruction of an arbitrary postures from a set of example postures for each joint motion for the forearm/hand complex and the whole upper extremity.

Kim, Kyu-Jung↗

How to Create a 3D Model from Scanned Data in 5 Easy Steps

Additive manufacturing is a cost effective way to generate copies of damaged parts for demonstrations. Integrating scanned data of a damaged area into an existing model may be challenging. However, using the relatively inexpensive Nettfab software (from one can generate a "watertight" model that is easy to print.

Hagen, Richard↗

Virtual Fit Assessment: Validation using Historical Spacesuit Fit Data

Virtual fit tests using 3D body scans have provided a cost-effective means to predictively assess spacesuit fit for the current and future astronaut population. However, fit is a complex issue influenced by physical interferences, subjective preference, and many other factors. Fit can substantially differ between the type of hardware, environmental conditions, and tasks being performed. Namely, fit changes across different contexts, such as 3D printed mockup evaluations, pressurized one-g suited test events, neutral buoyancy and other training events, and flight extravehicular activities (EVA). These challenges make it difficult to validate virtual fit frameworks to physical suit sizing. This study proposes a new method of validation using the wealth of historically archived suit fit data. Physically Assessed Fit (PAF) data was assessed from astronauts and test volunteers who wore the legacy Extravehicular Mobility Unit (EMU). The data was collected during the past decades at NASA and considered to be most reliable and dependable. Each participant was 3D scanned for body shape and spacesuit-critical dimensions were measured per NASA guidelines. The participants’ size preference for hard upper torso (HUT) assembly was retrieved from their pressurized suit fit check records. Fit assessments were also updated after one-g EVA training, neutral buoyancy training, and EVA flights. Virtually Assessed Fit (VAF) was done by overlaying the CAD model of a HUT with the 3D body scans of the PAF participants. Each body scan was iteratively adjusted for the position inside the HUT to minimize the suit-to-body contact interference while satisfying a set of prescribed requirements. Then the residual contact area, depth, and volume were quantified as VAF metrics. This process was repeated for the different HUT sizes, including medium, large, and extra-large. Statistical modeling is currently in progress and will be presented at the conference. A statistical classifier will be developed to predict a fit probability for different HUT sizes as a function of the corresponding person’s VAF metrics. The HUT size with the highest fit probability will constitute the most likely size selection for the person, and the prediction will be compared against the corresponding PAF data. The participant data will be randomly pre-grouped into either a model development or validation subset. While the model development subset will be used to build the probability model, the validation subset will be used to assess the model accuracy. Also, the locations and magnitudes of suit-body-contacts will be estimated from VAF. This information can identify the critical suit geometry and body shape features that influence suit fit. The variations found in PAF size selections by subjects with similar VAF metrics will allow for investigations into subjective preferences, for example, tight versus loose fit. Overall, this study is expected to provide a structured validation of a virtual suit fit framework, which has not been possible in the past. The outcome can also provide useful insights and potential limitations for interpreting virtual fit tests for future spacesuit designs and population accommodation.

Han Kim↗

Study of shortwave spectra in fully 3D environment: synergy between scanning radars and spectral radiation measurements (final Report)

Overview of 3D atmospheric radiative transfer in cloudy atmosphere for Reports on Progress in Physics. We surveyed the 3D atmospheric radiative transfer literature over the past 50 years and identify three concurrent and intertwining themes: first, how to assess the damage (bias) caused by 3D effects in the operational 1D radiative transfer models? Second, how to mitigate this damage? Third, can we exploit 3D radiative transfer phenomena to invent new observation methods and technologies? Two equally important application areas for atmospheric radiative transfer in general, and 3D in particular, were identified: broadband radiative energy budget estimation and wavelength-specific optical remote sensing signal modeling. As illustrations, both satellite and ARM observations were highly used.

54 ENVIRONMENTAL SCIENCES↗

Adaptive Wavelength Scanning Lidar (AWSL) for 3D Mapping from Space

We present the design and performance of an adaptive wavelength scanning lidar (AWSL) for highly efficient mapping from low Earth orbit (LEO). Mapping is accomplished by steering a laser beam across 1,200 resolvable spots using wavelength tuning and grating dispersion. Any subset of these 1,200 spots can be selected by wavelength switching. The design is validated with an 1550-nm prototype using a fast wavelength-tuned (500-kHz) pulsed (2-ns) fiber laser with the beam dispersed by gratings for beam steering. Reflected pulses are detected with an eight-pixel detector array with single-photon sensitivity. Eight lidar returns are time-multiplexed to one output that is digitized with a single 1-GSPS-digitizer, to save power. A grating spectrometer rejects solar background noise spatially and spectrally, and images laser footprints on to the detector array. The gratings retain the fiber laser beam quality. We are developing a 1030-nm AWSL intended for a LEO SmallSat platform.

Guangning Yang↗