Process Defects Knowledge Modeling in Laser Powder Bed Fusion Additive Manufacturing: An Ontological Framework
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Nazmul Hasan↗
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Improved Modeling in a Matlab-Based Navigation System
An innovative approach to autonomous navigation is available for low earth orbit satellites. The system is developed in Matlab and utilizes an Extended Kalman Filter (EKF) to estimate the attitude and trajectory based on spacecraft magnetometer and gyro data. Preliminary tests of the system with real spacecraft data from the Rossi X-Ray Timing Explorer Satellite (RXTE) indicate the existence of unmodeled errors in the magnetometer data. Incorporating into the EKF a statistical model that describes the colored component of the effective measurement of the magnetic field vector could improve the accuracy of the trajectory and attitude estimates and also improve the convergence time. This model is identified as a first order Markov process. With the addition of the model, the EKF attempts to identify the non-white components of the noise allowing for more accurate estimation of the original state vector, i.e. the orbital elements and the attitude. Working in Matlab allows for easy incorporation of new models into the EKF and the resulting navigation system is generic and can easily be applied to future missions resulting in an alternative in onboard or ground-based navigation.
Deutschmann, Julie↗
Transatmospheric vehicle research
Research was conducted into the alternatives to the supersonic combustion ramjet (scramjet) engine for hypersonic flight. A new engine concept, the Oblique Detonation Wave Engine (ODWE) was proposed and explored analytically and experimentally. Codes were developed which can couple the fluid dynamics of supersonic flow with strong shock waves, with the finite rate chemistry necessary to model the detonation process. An additional study was conducted which compared the performance of a hypersonic vehicle powered by a scramjet or an ODWE. Engineering models of the overall performances of the two engines are included. This information was fed into a trajectory program which optimized the flight path to orbit. A third code calculated the vehicle size, weight, and aerodynamic characteristics. The experimental work was carried out in the Ames 20MW arc-jet wind tunnel, focusing on mixing and combustion of fuel injected into a supersonic airstream. Several injector designs were evaluated by sampling the stream behind the injectors and analyzing the mixture with an on-line mass spectrometer. In addition, an attempt was made to create a standing oblique detonation wave in the wind tunnel using hydrogen fuel. It appeared that the conditions in the test chamber were marginal for the generation of oblique detonation waves.
Adelman, Henry G.↗
Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification
The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.
Laser Powder Bed Fusion↗
Improved Treatment of Snow Over Ice Sheets in the NASA GISS Climate Model: Towards Ice Sheet–Climate Coupling
Representing the interactions between ice sheets and climate is essential for more accurate prediction of climate change and sea level rise. Ice sheets interact with the overlying atmosphere via the accumulation of snow and its compaction into firn, then ice, as well as the melting of surface snow and ice and the creation of runoff water. Getting an adequate representation of heat transfer, compaction, and melting processes is essential for an accurate representation of snow on land ice in global climate models. We are implementing an improved snow model on top of land ice as part of an effort to couple the NASA GISS climate model with the PISM ice sheet model. The new snow model includes additional layers and processes that are not currently incorporated (e.g., liquid water retention, percolation and refreezing, and snow densification), and mass and energy transfer methods that are consistent with both static ice sheets (with implicit iceberg fluxes) and interactive ice sheets (with explicit dynamics). We are tuning the densification scheme of this snow model with temperature and density data from common FirnCover and SumUp observations at locations in the accumulation zone of Greenland, and we compare the resulting density profiles to other SumUp density profiles in Greenland and Antarctica. We will assess the impact of this new snow model in climate model simulations with a static ice sheet compared with the previous (simpler) 2-layer snow model. Finally, we aim to use the non-coupled simulations as a baseline to assess the impact of dynamic coupling with an interactive ice sheet model.
snow↗
Test Capability Enhancements to the NASA Langley 8-Foot High Temperature Tunnel
The NASA Langley 8-Foot High Temperature Tunnel produces true enthalpy environments simulating flight from Mach 4 to Mach 7, primarily for airbreathing propulsion and aerothermal/thermo-structural testing. Flow conditions are achieved through a methane-air heater and nozzles producing aerodynamic Mach numbers of 4, 5 or 7 and have exit diameters of 8 feet or 4.5 feet. The 12-ft long free-jet test section, housed inside a 26-ft vacuum sphere, accommodates large test articles. Recently, the facility underwent significant upgrades to support hydrocarbon fueled scramjet engine testing and to expand flight simulation capability. The upgrades were required to meet engine system development and flight clearance verification requirements originally defined by the joint NASA-Air Force X-43C Hypersonic Flight Demonstrator Project and now the Air Force X-51A Program. Enhancements to the 8-Ft. HTT were made in four areas: 1) hydrocarbon fuel delivery; 2) flight simulation capability; 3) controls and communication; and 4) data acquisition/processing. The upgrades include the addition of systems to supply ethylene and liquid JP-7 to test articles; a Mach 5 nozzle with dynamic pressure simulation capability up to 3200 psf, the addition of a real-time model angle-of-attack system; a new programmable logic controller sub-system to improve process controls and communication with model controls; the addition of MIL-STD-1553B and high speed data acquisition systems and a classified data processing environment. These additions represent a significant increase to the already unique test capability and flexibility of the facility, and complement the existing array of test support hardware such as a model injection system, radiant heaters, six-component force measurement system, and optical flow field visualization hardware. The new systems support complex test programs that require sophisticated test sequences and precise management of process fluids. Furthermore, the new systems, such as the real-time angle of attack system and the new programmable logic controller enhance the test efficiency of the facility. The motivation for the upgrades and the expanded capabilities is described here.
Harvin, S. F.↗
Computer Modeling of Direct Metal Laser Sintering
A computational approach to modeling direct metal laser sintering (DMLS) additive manufacturing process is presented. The primary application of the model is for determining the temperature history of parts fabricated using DMLS to evaluate residual stresses found in finished pieces and to assess manufacturing process strategies to reduce part slumping. The model utilizes MSC SINDA as a heat transfer solver with imbedded FORTRAN computer code to direct laser motion, apply laser heating as a boundary condition, and simulate the addition of metal powder layers during part fabrication. Model results are compared to available data collected during in situ DMLS part manufacture.
Cross, Matthew↗
Progress of Aircraft System Noise Assessment with Uncertainty Quantification for the Environmentally Responsible Aviation Project
Aircraft system noise predictions have been performed for NASA modeled hybrid wing body aircraft advanced concepts with 2025 entry-into-service technology assumptions. The system noise predictions developed over a period from 2009 to 2016 as a result of improved modeling of the aircraft concepts, design changes, technology development, flight path modeling, and the use of extensive integrated system level experimental data. In addition, the system noise prediction models and process have been improved in many ways. An additional process is developed here for quantifying the uncertainty with a 95% confidence level. This uncertainty applies only to the aircraft system noise prediction process. For three points in time during this period, the vehicle designs, technologies, and noise prediction process are documented. For each of the three predictions, and with the information available at each of those points in time, the uncertainty is quantified using the direct Monte Carlo method with 10,000 simulations. For the prediction of cumulative noise of an advanced aircraft at the conceptual level of design, the total uncertainty band has been reduced from 12.2 to 9.6 EPNL dB. A value of 3.6 EPNL dB is proposed as the lower limit of uncertainty possible for the cumulative system noise prediction of an advanced aircraft concept.
Thomas, Russell H.↗
IMPACT: Design of Integrated Multiphysics Producible Additive Components for Turbomachinery
The overall objective of the IMPACT program was to enable a dramatic reduction in design maturation time for an additive hot-section turbomachinery component through the following: • A fast crack-risk producibility surrogate model generated from machine learning applied to additive process simulation data generated via exascale computing, • Linking this surrogate model to multi-physics topology optimization (TO) to enable the creation of producible, near-optimal structural/thermal designs for additive hot-section components, • Maturing this toolset to reduce hot-section component design-for-manufacturing iterations by a large fraction, and eventually, • Using these tools to develop more efficient gas turbines in much shorter design cycle times.
42 ENGINEERING↗
Simulation of 1986 South China Sea Monsoon with a Regional Climate Model
A Regional Land-Atmosphere Climate Simulation System (RELACS) project is being developed at NASA Goddard Space Flight Center. One of the major goals of RELACS is to use a regional scale model with improved physical processes and in particular land-related processes, to understand the role of the land surface and its interaction with convection and radiation as well as the water/energy cycles in the IndoChina/South China Sea (SCS) region. The Penn State/NCAR MM5 atmospheric modeling system, a state of the art atmospheric numerical model designed to simulate regional weather and climate, has been successfully coupled to the Parameterization for Land-Atmosphere-Cloud Exchange (PLACE) land surface model. The original MM5 model (without PLACE) includes the option for either a simple slab soil model or a five-layer soil model (MRF) in which the soil moisture availability evolves over time. However, the MM5 soil models do not include the effects of vegetation, and thus important physical processes such as evapotranspiration and interception are precluded. The PLACE model incorporates vegetation type and has been shown in international comparisons to accurately predict evapotranspiration and runoff over a wide variety of land surfaces. The coupling of MM5 and PLACE creates a numerical modeling system with the potential to more realistically simulate atmosphere and land surface processes including land-sea interaction, regional circulations such as monsoons, and flash flood events. In addition, the Penn State/NCAR MM5 atmospheric modeling system has been: (1) coupled to the Goddard Ice Microphysical scheme; (2) coupled to a turbulent kinetic energy (TKE) scheme; (3) modified to ensure cloud budget balance; and (4) incorporated initialization with the Goddard EOS data sets at NASA/Goddard Laboratory for Atmospheres. The improved MM5 with two nested domains (60 and 20 km horizontal resolution) was used to simulate convective activity over IndoChina and the South China Sea, during the monsoon season, from May 6 to May 20, 1986. The model results captured several dominant observed features, such as twin cyclones, a depression system over the Bay of Bengal, strong south-westerly winds over IndoChina before and during the on-set of convection over the SCS, and a vortex over the SCS. Two additional MM5 runs with different land process models, Blackadar and MRF, were performed, and their results are compared to the run with PLACE. The preliminary results indicate that the MM5 results using PLACE and Blackadar are in very good agreement, but the results using MRF do not contain the south-westerly wind over IndoChina prior to the on-set of convection over the SCS.
Tao, W. -K.↗
Navigation of the TSS-1 mission
The Tethered Satellite System Mission was analyzed to determine its impacts on the Mission Control Center (MCC) Navigation section's ability to maintain an accurate state vector for the Space Shuttle during nominal and off-nominal flight operations. Tether dynamics expected on the Shuttle introduces new phenomena when determining the best estimation of its position and velocity. In the analysis, emphasis was placed on determining the navigation state vectors accuracies resulting when the tether induced forces were and were not modeled as an additional acceleration upon processing tracking measurements around a TSS-1 trajectory. Results of the analyses show that when the forces are not modeled in the state vector generation process, the resulting solution state reflects a solution about the center of gravity of the tethered system and not that of the orbiter. The Navigation team's ability to provide accurate state vector estimates necessary for trajectory planning are impeded. In addition to this consequent, is an impact on Onboard Navigation state vector accuracies. These analyses will show that in order to preserve an accurate state onboard the orbiter a new operational procedure would have to be adopted.
Jackson, Timothy C.↗
No constraint on long-term tropical land carbon-climate feedback uncertainties from interannual variability
Unraveling drivers of the interannual variability of tropical land carbon cycle is critical for understanding land carbon-climate feedbacks. Here we utilize two generations of factorial model experiments to show that interannual variability of tropical land carbon uptake under both present and future climate is consistently dominated by terrestrial water availability variations in Earth system models. The magnitude of this interannual sensitivity of tropical land carbon uptake to water availability variations under future climate shows a large spread across the latest 16 models (2.3 ± 1.5 PgC/yr/Tt H 2 O), which is constrained to 1.3 ± 0.8 PgC/yr/Tt H 2 O using observations and the emergent constraint methodology. However, the long-term tropical land carbon-climate feedback uncertainties in the latest models can no longer be directly constrained by interannual variability compared with previous models, given that additional important processes are not well reflected in interannual variability but could determine long-term land carbon storage. Our results highlight the limited implication of interannual variability for long-term tropical land carbon-climate feedbacks and help isolate remaining uncertainties with respect to water limitations on tropical land carbon sink in Earth system models.
54 ENVIRONMENTAL SCIENCES↗
ASME Code change proposal to implement new universal high temperature constitutive models for Section III, Division 5
This report completes work on a universal high temperature constitutive model suitable for use with the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules for the design by inelastic analysis of Class A nuclear reactor components. The goals of this work are to provide a simple model form that adequately captures the high temperature response of materials and can be applied to any future Code material. Additionally, the report describes an automated process for calibrating a model against test data. The idea is to simplify the effort required to generate a constitutive model for an arbitrary material, provided test data is available. This will accelerate the process of qualifying new Code materials in the future. In addition, the report provides calibrated models and detailed validation comparisons to test data for five currently-qualified or soon-to-be qualified materials: 316H, Grade 91, Alloy 800H, Alloy 617, and Alloy 709. The report surveys the available data for the remaining two ASME Class Materials --- 2.25Cr-1Mo and 304H --- concluding that there is enough data data to generate a model for 2.25Cr-1Mo steel provided some additional sources of non-public data can be included in the test database, but that a dedicated cyclic test campaign would be needed for 304H. Supplemental material includes the full text of an ASME Code change proposal to incorporate the models for the four currently-qualified Class A material, detailed validation comparisons to test data for the five material models, and input files for reference implementations of the constitutive models in the NEML and NEML2 modeling frameworks.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Extending the granularity of representation and control for the MIL-STD CAIS 1.0 node model
The Common APSE (Ada 1 Program Support Environment) Interface Set (CAIS) (DoD85) node model provides an excellent baseline for interfaces in a single-host development environment. To encompass the entire spectrum of computing, however, the CAIS model should be extended in four areas. It should provide the interface between the engineering workstation and the host system throughout the entire lifecycle of the system. It should provide a basis for communication and integration functions needed by distributed host environments. It should provide common interfaces for communications mechanisms to and among target processors. It should provide facilities for integration, validation, and verification of test beds extending to distributed systems on geographically separate processors with heterogeneous instruction set architectures (ISAS). Additions to the PROCESS NODE model to extend the CAIS into these four areas are proposed.
Rogers, Kathy L.↗
Splat Quenching as a High Throughput Rapid Solidification Testing Method for Developing Additive Manufacturing Alloys
Splat quenching as a high throughput rapid solidification screening tool is evaluated. Samples were made using known alloys (SS316, IN625, Ti-5553) to evaluate and establish the microstructures for a variety of alloy systems as well as the predicted cooling rates. The samples are inductively heated and levitated prior to being struck between two platens that produce a high contact pressure and a thin sample resulting in cooling rates on the order of 10 6 to 10 7 K/s. Process parameters were evaluated with analytical models in addition to numerical simulations to provide an effect of process variables such as substrate material, melt superheat, and platen velocity on the resulting solidification. The splat thickness was found to be controlled by platen velocity, melt superheat, as well as the feedstock volume. The sample thickness is the key controlling factor for varying the average cooling rate experienced by the splat quenched sample. The splat quenching techniques can reach regions of rapid solidification space that meet and exceed laser and electron beam techniques across the sample. In conclusion, the results of the study provide a useful foundation in understanding the splat quenching technique and its potential as a low effort tool to explore rapid solidification effects on alloys.
Alloy Design↗
Operations and maintenance manual for a scale-model lunar roving vehicle
A one-sixth scale model of the lunar roving vehicle used in the Apollo 15 mission was built and instrumented to conduct model studies of vehicle mobility. The model was free running under radio control and was equipped with a lightweight telemetry transmitter that allowed 16 channels of data to be gathered simultaneously. String payout and fifth-wheel devices were developed to measure vehicle velocity. Other real-time measurements included wheel torque, wheel speed, center-of-gravity accelerations, and steering forces. Calibration, operations, and maintenance procedures were worked out. Details of the development of the instrumentation, its maintenance, and some of the problems encountered, are recorded serve as a preliminary operations and maintenance manual for this specific model. In addition, information regarding soil processing and testing that may be useful to NASA personnel planning mobility research with the model in soil is furnished.
Lessem, A. S.↗
Feasibility of Additive Manufacturing for Thermal Protection Systems
Thermal Protection Systems (TPS) use advanced materials to protect vehicles from aerodynamic heating during atmospheric entry. Manufacturing of these composite materials is often very time consuming and labor-intensive. Leveraging the additive manufacturing FDM (Fused Deposition Modeling) process enables NASA to design and manufacture advanced ablative TPS materials while reducing manufacturing time and cost. Since additive manufacturing is an automated process, it ensures part consistency over the entire heat shield area. The purpose for this presentation will be three-fold. 1) Introduce novel low-density ablative materials capable of utilizing additive manufacturing capabilities 2) show feasibility of additively manufacturing TPS coupons using the downselected TPS materials 3) Side by side comparison of high temperature test results for printable paste and state of the art low-density ablators
T. Boghozian↗