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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Review of in situ process monitoring for metal hybrid directed energy deposition

Hybrid manufacturing, or the combination of additive and subtractive manufacturing within a single build volume is transforming the way products are being fabricated. Additive manufacturing confers unprecedented freedom of design and reduced material usage while enabling serial customization. Subtractive manufacturing provides superior surface finish and improved dimensional accuracies. Interwoven, these two digital manufacturing paradigms are enabling the rapid manufacturing of complex, highly accurate, and customized geometries in a diversity of high-performance alloys. In situ monitoring, heavily relied upon in either additive or subtractive, becomes even more crucial with the interplay of the two processes in a single combined build sequence. Moreover, challenges that do not exist in either process alone can now have a dramatic impact on final part quality: (1) a large amount of heat is generated during additive manufacturing deposition, which is primarily dissipated into the machine tooling and impacts accuracy by deforming the material and causing misaligned machining; (2) microstructure, mechanical properties, and residual stresses are the result of the complex thermal histories generated by additive manufacturing and can impact subsequent cutting performance. This comprehensive review considers previous research in monitoring and providing closed-loop control in both additive and subtractive manufacturing separately and then considers the implications of the effectiveness of these monitoring techniques when additive and subtractive processes are integrated together.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Sampling and resolution characteristics in reduced order models of shallow water equations: Intrusive vs nonintrusive

We investigate the sensitivity of reduced order models (ROMs) to training data spatial resolution as well as sampling rate. In particular, we consider proper orthogonal decomposition (POD), coupled with Galerkin projection (POD-GP), as an intrusive reduced order modeling technique. For non-intrusive ROMs, we consider two frameworks. The first is using dynamic mode decomposition (DMD), and the second is based on artificial neural networks (ANNs). For ANN, we utilized a residual deep neural network, and for DMD we have studied two versions of DMD approaches; one with hard thresholding and the other with sorted bases selection. Also, we highlight the differences between mean-subtracting the data (centering) and using the data without mean-subtraction. We tested these ROMs using a system of 2D shallow water equations for four different numerical experiments, adopting combinations of sampling rates and spatial resolutions. For these cases, we found that the DMD basis obtained with hard threshodling is sensitive to sampling rate. The sorted DMD algorithm helps to mitigate this problem and yields more stabilized and converging solution. Furthermore, we demonstrate that both DMD approaches without mean subtraction provide significantly more accurate results than DMD with mean-subtracting the data. On the other hand, POD is relatively insensitive to sampling rate and yields better representation of the flow field. Meanwhile, spatial resolution has little effect on both POD and DMD performances. Here, the numerical results reveal that an ANN on POD subspace (POD-ANN) performs remarkably better than POD-GP and DMD in capturing system dynamics, even with a small number of modes.

42 ENGINEERING↗
DOE OSTI2023

Pileup and Infrared Radiation Annihilation (PIRANHA): a paradigm for continuous jet grooming

Jet grooming is an important strategy for analyzing relativistic particle collisions in the presence of contaminating radiation. Most jet grooming techniques introduce hard cutoffs to remove soft radiation, leading to discontinuous behavior and associated experimental and theoretical challenges. In this paper, we introduce Pileup and Infrared Radiation Annihilation (Piranha), a paradigm for continuous jet grooming that overcomes the discontinuity and infrared sensitivity of hard-cutoff grooming procedures. We motivate Piranha from the perspective of optimal transport and the Energy Mover’s Distance and review Apollonius Subtraction and Iterated Voronoi Subtraction as examples of Piranha-style grooming. We then introduce a new tree-based implementation of Piranha, Recursive Subtraction, with reduced computational costs. Finally, we demonstrate the performance of Recursive Subtraction in mitigating sensitivity to soft distortions from hadronization and detector effects, and additive contamination from pileup and the underlying event.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Non-Intrusive Measurements Using Femtosecond Laser in Atmospheric Pressure Plasma Jet

Femto-second (fs) lasers offer state-of-the art non-intrusive diagnostic capabilities in plasma flow environments. The diagnostics in plasma flows using a fs-laser that are relevant to this proposal include Two-photon Absorption Laser Induced Fluorescence (TALIF) for measuring the number density of an atomic species, and Femto-second Laser Electronic Excitation Tagging (FLEET) for performing velocity measurements in plasma flows. Various aspects of these diagnostics using fs-lasers are still an active domain of research. The TALIF technique has been used to measure the number density of atomic species in various plasma flow environments like atmospheric pressure plasma jet (APPJ) and arc-jet flows. This technique utilizes a fs-laser to excite an atomic species and the subsequent relaxation process through fluorescence is recorded to make measurements. A narrow band-pass filter is used to isolate the fluorescence signal that is in the infra-red regime. However, broad-band background emissions can potentially pass through the filter and induce noise in the TALIF signal. Particularly, arc-jet plasma flows inherently contain background emissions. In such plasma flow environments, in addition to the filter, the background-subtraction technique will play an important role in reducing the noise that is induced in the number density measurements using TALIF. The proposed research focuses on evaluating the effectiveness of a background-subtraction technique by measuring atomic oxygen using a femtosecond (fs) TALIF in APPJ with induced background emissions and comparing measurements obtained without inducing the emissions. Therefore, by quantifying the changes in the signal-to-noise ratio caused by a background-subtraction technique applied for APPJ, it will enable a better understanding of the uncertainties in the background subtracted fs-TALIF measurements for arc-jet plasma flows. In addition to this, FLEET will be used to obtain velocity in the APPJ, and the impact of background emissions will be analyzed. Under this effort, the experimenters and research personnel will gain the technical know-how in the operational and theoretical aspects of the advanced fs-laser-based diagnostic techniques. The knowledge gained in this process will then also directly be applied to a separate ONR funded project at the Aerodynamics Research Center (ARC), UT Arlington, related to arc-jet flow characterization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Manufacturing Demonstration Facility: Development and Evaluation of Hybrid Manufacturing Toolpaths

The integration of additive manufacturing (AM) capabilities on Computer Numerical Control (CNC) systems allows for the expansion of additive manufacturing to a wide range of part and tool repair operations. This multi-tasking integration, termed hybrid manufacturing, has been researched by others in the past, and Autodesk has been critical in developing process planning and toolpath algorithms for hybrid systems. Objectives and Tasks: Hybrid manufacturing systems enable both additive and subtractive capabilities in a single manufacturing workcell. These systems have the potential to impact a variety of industries, including the tool and die industry due to their repair, refurbishment, and complex geometry manufacturing capabilities. While there has been significant development of toolpath planning for both subtractive and additive processes independently, there has been little, if any, development of hybrid toolpath planning to integrate both processes during the manufacturing design and toolpath generation stage of a product’s lifecycle. Furthermore, additive toolpath planning has been limited to planar manufacturing, but this limitation could be overcome as hybrid CNC machines have multi-axis control. The objectives of this research include: - Development and demonstration of independent three-, four-, and five-axis toolpath generation algorithms for both additive and subtractive processes, and - Development, demonstration, and integration of three-, four-, and five-axis hybrid process planning and toolpath generation algorithms for hybrid additive and subtractive processes. The team will leverage the widely used Autodesk Fusion 360 product design and manufacturing (CAD/CAM) platform to achieve these objectives. Autodesk will provide the expertise in CAD tools, as well as access to their new CAD/CAM manufacturing tools (3-, 4-, and 5-axis milling, additive toolpath generation). ORNL will provide expertise in additive manufacturing toolpath generation, process planning, and manufacturing validation. By the end of the program, the team will have developed and validated multi-axis milling, additive manufacturing, and hybrid manufacturing on an industrial hybrid CNC system (Mazak 500-VC).

42 ENGINEERING↗
DOE OSTI2022

The Stability of Fiber Spectrographs in the Faint-source Regime

The use of optical fibers in astronomical instrumentation offers high-multiplex and light-gathering flexibility. However, with most previous fiber spectrographs optimized for large fields of view on modest-aperture telescopes, the performance of fibers in the context of faint targets on large telescopes remains largely untested. In this paper, we evaluate aspects of fiber stability, especially as they apply in the context of precision sky subtraction of faint sources at modest spectral resolution ($R$ ~ 3000). After introducing a framework for describing potential systematic errors, we use publicly available data from existing instruments, including instrumentation used by the fourth-generation Sloan Digital Sky Survey’s MaNGA project (MaNGA: Mapping Nearby Galaxies at Apache Point Observatory) and the Very Large Telescope’s FLAMES: Fiber Large Array Multi Element Spectrograph. We isolate sources of fiber systematics and estimate the observed amplitude of persistent residuals as well as stochastic noise contributions resulting from changing fiber stresses. Comparing these levels against their impact on various sky subtraction schemes demonstrates that 0.1% precision sky subtraction with fiber instruments is possible. As a demonstration, we show that the MaNGA instrument can deliver 0.2% residuals on bright near-IR sky lines with nonlocal sky subtraction, if pseudo-slit limitations are addressed by allocating 50% of its fibers to sky. We further highlight recently published deep exposures that achieved a 1$σ$ background level of 27.6 AB per square arc second, equivalent to a precision of 0.2% of the sky background continuum.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Dark Photon Dark Matter and Low-frequency Gravitational-wave Detection with Gaia-like Astrometry

Astrometric surveys offer us a method for searching for elusive cosmic signatures, such as ultralight dark photon dark matter and gravitational waves (GWs), by observing the temporal change of stars’ apparent locations. The detection capabilities of such surveys rapidly decrease at low frequencies, because the signals become hardly distinguishable from the background motion of stars. In this work, we find that the background motion can be well described by a linear model over time, based on which we propose a linear background subtraction scheme. Compared to the conventional quadratic subtraction, the advantage of linear subtraction emerges within the frequency range below 6 × 10 −9 Hz. Taking dark photons with purely gravitational interactions, dark photons with additional U(1) B or U(1) B−L gauge interactions, and low-frequency GWs as examples, we illustrate that the linear subtraction scheme can result in an enhancement of more than 1 order of magnitude in the exclusion limits of Gaia-like experiments in the low-frequency range.

Astrometry↗
DOE OSTI2024

Toolpath considerations for hybrid additive manufacturing

Hybrid additive manufacturing combines both additive and subtractive manufacturing processes to fabricate geometrically complex, dimensionally accurate parts that are difficult to make using either additive or subtractive manufacturing alone. Industrial applications for hybrid additive manufacturing include direct manufacturing (building whole parts), feature addition (adding onto existing parts), and remanufacturing or repair operations. To coordinate the additive and subtractive processes, computer-aided manufacturing (CAM) software must generate distinct toolpaths for each process. Each application requires different considerations and inputs when generating the toolpaths. For example, when building a part with an internal cavity that would otherwise be unmanufacturable due to reach or access limitations, a CAM must determine which layer(s) of deposition are appropriate to machine to create the internal cavity. This chapter explores the area of toolpath generation for hybrid manufacturing by discussing the necessary considerations that are unique to a hybrid process.

Feldhausen, Thomas↗
DOE OSTI2024

Hybrid metal additive/subtractive machine tools and applications

Additive manufacturing creates parts by depositing a preform, typically layer by layer. Subtractive manufacturing involves removing material from a preform to create parts. Hybrid machine tools combine both additive and subtractive processes in the same workspace. They can be used to create parts that meet functional tolerance and surface finish requirements, or to create features that are difficult to produce using additive or subtractive processes alone. Here, this paper describes hybrid metal additive/subtractive machine tools. It covers design considerations, sensors and controls, process management, programming and software, and the impact on the design space. It also identifies future research challenges.

42 ENGINEERING↗
DOE OSTI2021

Measurements of dihadron correlations relative to the event plane in Au+Au collisions at $\sqrt{s_{NN}} =200$ GeV*

Dihadron azimuthal correlations containing a high transverse momentum ($ p_{T} $) trigger particle are sensitive to the properties of the nuclear medium created at RHIC through the strong interactions occurring between the traversing parton and the medium, i.e. jet-quenching. Previous measurements revealed a strong modification to dihadron azimuthal correlations in Au+Au collisions with respect to p+p and d+Au collisions. The modification increases with the collision centrality, suggesting a path-length or energy density dependence to the jet-quenching effect. This paper reports STAR measurements of dihadron azimuthal correlations in mid-central (20%-60%) Au+Au collisions at $ \sqrt{s_{\rm{NN}}} = 200 $ GeV as a function of the trigger particle's azimuthal angle relative to the event plane, $ \phi_{s} = | \phi_{t}- \psi_{{\rm{EP}}}| $. The azimuthal correlation is studied as a function of both the trigger and associated particle $ p_{T} $. The subtractions of the combinatorial background and anisotropic flow, assuming Zero Yield At Minimum (ZYAM), are described. The correlation results are first discussed with subtraction of the even harmonic (elliptic and quadrangular) flow backgrounds. The away-side correlation is strongly modified, and the modification varies with $ \phi_{s} $, with a double-peak structure for out-of-plane trigger particles. The near-side ridge (long range pseudo-rapidity $ \Delta\eta $ correlation) appears to drop with increasing $ \phi_{s} $ while the jet-like component remains approximately constant. The correlation functions are further studied with the subtraction of odd harmonic triangular flow background arising from fluctuations. It is found that the triangular flow, while responsible for the majority of the amplitudes, is not sufficient to explain the $ \phi_{s} $-dependence of the ridge or the away-side double-peak structure. The dropping ridge with $ \phi_{s} $ could be attributed to a $ \phi_{s} $-dependent elliptic anisotropy; however, the physics mechanism of the ridge remains an open question. Even with a $ \phi_{s} $-dependent elliptic flow, the away-side correlation structure is robust. These results, with extensive systematic studies of the dihadron correlations as a function of $ \phi_{s} $, trigger and associated particle $ p_{T} $, and the pseudo-rapidity range $ \Delta\eta $, should provide stringent inputs to help understand the underlying physics mechanisms of jet-medium interactions in high energy nuclear collisions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Neutron detection efficiency measurements of organic glass scintillator arrays

We characterize the neutron detection efficiency of pixelated organic glass scintillator (OGS) arrays manufactured in two ways: an additive method in which the OGS is cast in place in a pixelated mold, and a subtractive method in which the scintillator is first cast as a large block before being cut in bars and bonded together to form the array. The cast-in-place array utilizes a mixture of “bis(9,9-dimethyl-9H-fluoren-2-yl)diphenylsilane” (P2), “tri([1,1'-biphenyl]-4-yl)(phenyl)silane” (PB3), and “4-bis(2-methylstyryl)benzene” (MSB), and 50% by weight of polystyrene is added to the mixture for subtractive manufactured array. We compare the performance of the OGS arrays to that of an EJ-299-33M plastic scintillator array that was manufactured using a subtractive process similar to that of the second OGS array.

Neutron detectors (cold, thermal, fast neutrons)↗
DOE OSTI2025

Distinguishing isotropic and anisotropic signals for X-ray total scattering using machine learning

Understanding structure–property relationships is essential for advancing technologies based on thin films. X-ray pair distribution function (PDF) analysis can access relevant atomic structure details spanning local-, mid- and long-range structure. While X-ray PDF has been adapted for thin films on amorphous substrates, measurements on single-crystal substrates are necessary to accurately determine structure origins for some thin film materials, especially those for which the substrate changes the accessible structure and properties. However, when measuring films on single-crystal substrates, high-intensity anisotropic Bragg spots saturate 2D detector images, overshadowing the thin films' isotropic scattering signal. This renders previous data processing methods for films on amorphous substrates unsuitable for films on single-crystal substrates. To address this measurement need, we developed IsoDAT2D, an innovative data processing approach using unsupervised machine learning algorithms. The program combines dimensionality reduction and clustering algorithms to separate thin film and single-crystal substrate X-ray scattering signals. We use SimDAT2D , a program we developed to generate simulated thin film data, to validate IsoDAT2D . Here we also use IsoDAT2D to isolate X-ray total scattering signal from a thin film on a single-crystal substrate. The resulting PDF data are compared with similar data processed using previous methods, especially substrate subtraction for single-crystal and amorphous substrates. PDF data from IsoDAT2D -identified X-ray total scattering data are significantly better than from single-crystal substrate subtraction, but not as reliable as PDF data from amorphous substrate subtraction. With IsoDAT2D , there are new opportunities to expand PDF to a wider variety of thin films, including those on single-crystal substrates, with which new structure–property relationships can be elucidated to enable fundamental understanding and technological advances.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Positioning Accuracy in a Concurrent Robot-CNC Hybrid Manufacturing System

Abstract Additive manufacturing (AM) has gained notoriety for offering advantages over traditional manufacturing methods, such as increased design complexity and flexibility. However, it has not found widespread use beyond rapid prototyping. One hindrance to the acceptance of AM processes in industry is the time and cost of fabrication per component. While metal AM by itself can be inexpensive, extra manufacturing steps in the form of subtractive manufacturing (SM) may need to be performed to reach final part tolerances, leading to hybrid additive-subtractive manufacturing (HASM) of a part, which increases time and cost. A potential area to reduce cost is through increasing the efficiency of the HASM process by conducting additive and subtractive manufacturing simultaneously. Usually, HASM is performed in a process where AM is completed in one machine or cell and transferred to another machine or cell for SM in a sequential assembly line process. This efficiency decreases part cost, but high aspect ratio parts or parts with internal geometry that require interleaved additive deposition and machining cannot be produced. One unexplored solution to simultaneous HASM that allows for interleaved operations is to operate the deposition head and machining spindle concurrently within the same machine envelope, known as concurrent HASM (CHASM). In this type of process, both AM and SM occur simultaneously on a batch of small parts or a single large part, maintaining a high efficiency without sacrificing the full range of complex geometries that AM allows for. A potential approach to the single-machine method could be to combine a robot and mill within the same envelope. A challenge to this approach, however, is control of both systems. Most machine controllers have limited external communication or, if a robot has been integrated, only offer movement of either the robot or mill at any given time. As a result, systems must pause either the AM or SM process to switch between them rather than working simultaneously. The present work investigates the positional accuracy of such a CHASM system comprised of a robotic arm and a 3-axis mill. Open-loop tests with limited communication between machines are performed on the system to verify positional error during concurrent robot-mill movements. Under certain conditions, it is demonstrated that position error can stay within 2 mm for the duration of a single layer; however, these tests show that, generally, the open-loop positioning performance of the system is inadequate for CHASM without part-specific hand-tuning of parameters. Based on these results, a set of requirements for successful robot-CNC CHASM is proposed for future integrations.

Goodwin, Jesse↗
DOE OSTI2022

Structural basis for receptor selectivity and inverse agonism in S1P5 receptors

This dataset contains a subset of raw diffraction images for the serial femtosecond crystallography data of S1P5-ONO-5430608 complex. The diffraction data contain a strong systematic background as described in Lyapina et al. No additional background subtraction was applied to the data. In order to avoid its effects, the background subtraction implemented in CrystFEL, was applied (--rings-grad subtraction). The final stream, supplemented with this dataset, was obtained with: indexamajig 0.8.0 Respectively, the hkl file was obtained with: partialator 0.8.0

Human sphingosine-1-phosphate receptor 5 (S1P5) in↗
DOE OSTI2021

Two and three-dimensional near infrared subcutaneous structure imager using realtime nonlinear video processing

A method includes placing an imaging device in contact with a sample, irradiating the sample via an illuminator such that radiation scatters off of the structure, and providing the scattered radiation to a detector to generate a digital video signal. A processor then performs various operations including subtracting a sum of a black state value and a user-defined black level clamping value from the digital video signal to create subtracted image data, substituting negative values in the subtracted image data with a reference value to create modified image data, and amplifying the modified image data by a user-defined gain to create contrast enhanced image data.

Krasowski, Michael J.↗
DOE OSTI2020

Mechanical properties and microstructure of 316L stainless steel produced by hybrid manufacturing

Hybrid manufacturing is a combination of additive (deposition) and subtractive (machining) manufacturing in a single machine tool. Such a system can be used for near net shape manufacturing and component repair using either similar or dissimilar materials. Integrated into a single system, transition between additive and subtractive manufacturing can occur immediately and be leveraged to generate large components by alternating between the processes. In this investigation, we show how the interleaved capabilities can reduce overall cycle time by up to 68 %, improve average relative elongation to failure by 71 %, and reduce the average relative porosity fraction by 83 % when compared to traditional additive manufactured components. Results from this investigation builds the foundation needed for hybrid manufacturing to be applicable towards the manufacture of large complex components such as nosecones and marine propulsors.

36 MATERIALS SCIENCE↗
DOE OSTI2022

General bounds on holographic complexity

We prove a positive volume theorem for asymptotically AdS spacetimes: the maximal volume slice has nonnegative vacuum-subtracted volume, and the vacuum-subtracted volume vanishes if and only if the spacetime is identically pure AdS. Under the Complexity=Volume proposal, this constitutes a positive holographic complexity theorem. The result features a number of parallels with the positive energy theorem, including the assumption of an energy condition that excludes false vacuum decay (the AdS weak energy condition). Our proof is rigorously established in broad generality in four bulk dimensions, and we provide strong evidence in favor of a generalization to arbitrary dimensions. Our techniques also yield a holographic proof of Lloyd’s bound for a class of bulk spacetimes. We further establish a partial rigidity result for wormholes: wormholes with a given throat size are more complex than AdS-Schwarzschild with the same throat size.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2026

Quantum calculations of the cavity shift in electron magnetic moment measurements

The measurement of the anomalous electron magnetic moment g – 2 through quantum transitions of a single trapped electron is the most stringent test of quantum field theory. These experiments are now so precise that they must account for the effects of the cavity containing the electron. Classical calculations of this “cavity shift” must subtract the electron’s divergent self-field, and thus require knowledge of the exact Green’s function for the cavity’s electromagnetic field. We perform the first fully quantum calculation of the cavity shift in a closed cavity, which instead involves subtracting linearly divergent cavity mode sums and integrals. Using contour integration methods, we find perfect agreement with existing classical results for both spherical and cylindrical cavities, justifying their current use. Moreover, our mode-based results can be naturally generalized to account for systematic effects, necessary to push future measurements to the next order of magnitude in precision.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗