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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 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Quantifying Trapped Powder in Electron Beam Powder Bed Fusion

Abstract Electron beam powder bed fusion (PBF-EB) shows great potential for manufacturing complex parts including those with internal cavities for heat exchanger, manifold systems, or energy absorption purposes. PBF-EB allows for the manufacture of channel geometries without the need for support structures. Due to the nature of the powder spreading process, powder feedstock is often trapped in intentionally manufactured cavities. This trapped powder can often be difficult to remove and can disturb the intended flow of fluid through the cavity or damage downstream components in its use case. These trapped powder particles present a risk of contamination and component failure if not completely evacuated. Ti6Al4V is a choice material for aerospace applications due to its high strength to weight ratio and its composition as a nonferrous metal; however, in weight sensitive applications excess entrapped powders or powders loosely attached to the surface could cause undesirable weight increases. The inherent spreading process of PBF-EB is different than laser powder bed fusion (PBF-LB) in its operational temperature, sintering. In addition, PBF-EB is less commonly studied in literature compared to its PBF-LB counterpart, and as a result the complexity of the semi-sintered powder and its spreading behavior are not well understood. Prior work has investigated the difficulty in removing trapped powder from PBF-EB, but these studies do not address how to quantify the amount of trapped powder in the cavity. Thus, an accurate method to measure the amount of trapped powder in the cavity must be investigated. In this work, Ti6Al4V coupons were manufactured with horizontal and vertical cavities of three different sizes. Archimedes testing allows for the determination of density differences caused by porosity and trapped powders by measuring mass and volumetric dispersion. Computed tomography (CT) is well suited for segmenting the internal structure and features of a part and has been studied for applications including voids, porosity, and dross. Thus, CT was explored as a method for evaluating trapped powder content in this work. The volumetric representation of the segmentation of the reconstructed CT volume can vary greatly depending on the input filter and thresholding methods. In this study, four different types of segmentation approaches were evaluated to determine the best approach for segmenting the volume as compared to an operator labeled ground truth. The percentage density results from the Archimedes testing were compared to the volumetric percent density from the computed tomography approach. Differences in packing density between two different internal channel features were investigated. Overall, this work sought to validate the use of computed tomography for the detection of trapped powders and present a framework for volumetric segmentation.

Johnstone, Brian↗
DOE OSTI2023

In-process volumetric sensing of defects in multiple parts during powder bed fusion using ultrasound

This letter reports on the integration of eight ultrasonic transducers into a build substrate for individual in-process monitoring of eight parts fabricated using powder bed fusion additive manufacturing. Ultrasound is shown to be able to sense poor fusion of parts to the substrate and also sensitivity to porosity. This technique demonstrates the utility of ultrasound as one of a few techniques able to interrogate the volume of additively manufactured parts during the process. Additionally, the ability to measure several parts during a single build can be used for efficient process parameter development studies, as the ultrasonic measurements can offer rapid information about part quality and integrity.

Kizer, Nathan J.↗
DOE OSTI2021

Search for charged Higgs bosons produced in vector boson fusion processes and decaying into vector boson pairs in proton–proton collisions at $\sqrt{s} = 13\,{\text {TeV}} $

A search for charged Higgs bosons produced in vector boson fusion processes and decaying into vector bosons, using proton–proton collisions at √s = 13 TeV at the LHC, is reported. The data sample corresponds to an integrated luminosity of 137 fb -1 collected with the CMS detector. Events are selected by requiring two or three electrons or muons, moderate missing transverse momentum, and two jets with a large rapidity separation and a large dijet mass. No excess of events with respect to the standard model background predictions is observed. Model independent upper limits at 95% confidence level are reported on the product of the cross section and branching fraction for vector boson fusion production of charged Higgs bosons as a function of mass, from 200 to 3000GeV. The results are interpreted in the context of the Georgi–Machacek model.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Search for light long-lived neutral particles from Higgs boson decays via vector-boson-fusion production from pp collisions at $\sqrt{s}=13$ TeV with the ATLAS detector

A search is reported for long-lived dark photons with masses between 0.1 GeV and 15 GeV, from exotic decays of Higgs bosons produced via vector-boson-fusion. Events that contain displaced collimated Standard Model fermions reconstructed in the calorimeter or muon spectrometer are probed. This search uses the full LHC Run 2 (2015–2018) data sample collected in proton–proton collisions at $\sqrt{s}=13$ TeV, corresponding to an integrated luminosity of 139 fb –1 . Dominant backgrounds from Standard Model processes and non-collision sources are estimated using data-driven techniques. The observed event yields in the signal regions are consistent with the expected background. Upper limits on the Higgs boson to dark photon branching fraction are reported as a function of the dark photon mean proper decay length or of the dark photon mass and the coupling between the Standard Model and the potential dark sector. This search is combined with previous ATLAS searches obtained in the gluon–gluon fusion and WH production modes. A branching fraction above 10% is excluded at 95% CL for a 125 GeV Higgs boson decaying into two dark photons for dark photon mean proper decay lengths between 173 and 1296 mm and mass of 10 GeV.

Aad, G. (ORCID:0000000266654934)↗
DOE OSTI2024

Orchard: Heterogeneous Parallelism and Fine-grained Fusion for Complex Tree Traversals

Many applications are designed to perform traversals ontree-likedata structures. Fusing and parallelizing these traversals enhance the performance of applications. Fusing multiple traversals improves the locality of the application. The runtime of an application can be significantly reduced by extracting parallelism and utilizing multi-threading. Prior frameworks have tried to fuse and parallelize tree traversals using coarse-grained approaches, leading to missed fine-grained opportunities for improving performance. Other frameworks have successfully supported fine-grained fusion on heterogeneous tree types but fall short regarding parallelization. We introduce a new frameworkOrchardbuilt on top ofGrafter.Orchard’s novelty lies in allowing the programmer to transform tree traversal applications by automatically applyingfine-grainedfusion and extractingheterogeneousparallelism.Orchardallows the programmer to write general tree traversal applications in a simple and elegant embedded Domain-Specific Language (eDSL). We show that the combination of fine-grained fusion and heterogeneous parallelism performs better than each alone when the conditions are met.

Computer Science↗
DOE OSTI2020

Semi-analytic model of magnetized liner inertial fusion

The code that was developed is called SAMM (Semi-Analytic MagLIF Model). In 2015, McBride and Slutz published all of the equations that are solved by the code in the original SAMM paper: R. D. McBride and S. A. Slutz, ?A semi-analytic model of magnetized liner inertial fusion?, Phys. Plasmas 22, 052708 (2015); http://doi.org/10.1063/1.4918953. The SAMM code is now implemented in both the MATLAB and Python programming languages. Students from multiple universities have requested copies of the code so that they can become more familiar with the MagLIF concept. We would like to seek an open-source solution. There is no market value to this code, as there are plenty of more sophisticated simulation codes already available; SAMM is merely a simplified model that is purely for educational purposes. In fact, at least one graduate student (from the University of California, San Diego) has already implemented and published his own modified version of the model: J. Narkis, H. U. Rahman, J. C. Valenzuela, F. Conti, R. D. McBride, D. Venosa, and F. N. Beg, ?A semi-analytic model of gas-puff liner-on-target magneto-inertial fusion?, Phys. Plasmas 26, 032708 (2019); https://doi.org/10.1063/1.5086056. SAND2020-12244 M Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Moore, Thomas↗
DOE OSTI2025

In situ Visible Light and Thermal Imaging Data from a Laser Powder Bed Fusion Additive Manufacturing Process Co-Registered to X-ray Computed Tomography and Fatigue Data

This dataset is comprised of in situ sensing data collected during a laser-based powder bed fusion additive manufacturing process, as well as rasterized scan path information, post-build X-ray computed tomography (XCT), and fatigue test results. A total of 64 cylinders, approximately 15 mm in diameter and 102 mm tall, were printed out of stainless steel 316H on a Colibrium Additive Concept Laser M2 Series 5 machine. Parameters known to produce dense material were used to construct 56 of these cylinders, while the remaining 8 cylinders were printed with relatively high energy density parameters prone to producing keyhole pores. In addition, two spatter generation blocks were constructed upstream of the 64 cylinders such that ejecta produced during the melting of the spatter generators were stochastically seeded onto the 64 cylinders. Based on previous experiments, these spatter particles were theorized to produce stochastic lack-of-fusion pores. During the construction of the build, high-resolution images of reflected light in the visible spectrum were captured both before and after recoating for each print layer. Additionally, temporally integrated thermal imaging in the near infrared spectrum produced integrated sum and max images on a layerwise basis. The multimodal in situ data has been co-registered to the build plate coordinate system, allowing for identification of process anomalies (e.g., spatter particles) apparent in the two sensors. Following construction of the build, the cylinders were subjected to XCT to identify internal flaws, and the resulting data have also been registered to the build plate coordinate system. Finally, 60 of the 64 cylinders were machined into fatigue coupons conforming to ASTM E466 and subsequently subjected to either high- or -low-cycle fatigue testing. The results of the fatigue tests have also been included in the dataset, and the XCT data corresponded to the approximate location of the gauge sections of the machine fatigue specimen geometry.

42 ENGINEERING↗
DOE OSTI2020

Open Source Scalable Data Services and Data Fusion for Biological and Environmental Sciences (SBIR Phase I Final Scientific/ Technical Report)

The overarching goal of the project is to develop an integrated open-source scientific data management system (Apache V2 license), ResonantEco, that meets the need of biological and environmental researchers and developers for data management, curation, and data processing for analyses with a wide range of scale and complexity. ResonantEco will provide web enabled data services with features such as unified data interfaces and federated views of data and metadata for heterogeneous data sources with an interactive web client for data exploration. Our use of the term fusion is taken from geospatial (GIS) domain where data fusion is often synonymous with data integration. In particular, data integration in ResonantEco involves combining data residing in different sources and providing users with a unified view of them.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

Multimodal Data Fusion via Entropy Minimization

The use of gradient-based data-driven models to solve a range of real-world remote sensing problems can in practice be limited by the uniformity of available data. Use of data from disparate sensor types, resolutions, and qualities typically requires compromises based on assumptions that are made prior to model training and may not necessarily be optimal given over-arching objectives. For example, while deep neural networks (NNs) are state-of-the-art in a variety of target detection problems, training them typically requires either limiting the training data to a subset over which uniformity can be enforced or training independent models which subsequently require additional score fusion. The method we introduce here seeks to leverage the benefits of both approaches by allowing correlated inputs from different data sources to co-influence preferred model solutions, while maintaining flexibility over missing and mismatching data. In this work we propose a new data fusion technique for gradient updated models based on entropy minimization and experimentally validate it on a hyperspectral target detection dataset. We demonstrate superior performance compared to currently available techniques using a range of realistic data scenarios, where available data has limited spacial overlap and resolution.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Leading magnetic fusion energy science into the big-and-fast data lane

To crack the code of unlimited clean energy from magnetic fusion, researchers collaborate among numerous facilities that are scattered around the globe. Probing hot fusion plasmas with sophisticated diagnostics, they routinely generate fast streams of high-dimensional time-series data. We present the adaptation of a production code-base for a plasma diagnostic to the big-and-fast data lane. The new code-base is used to stream measurements, made in Korea, into a Top-15 computing facility in the US for remote analysis. We discuss software and design choices made for this new HPC-enabled scientific workflow.

Kube, Ralph↗
DOE OSTI2022

Porosity Determination and Classification of Laser Powder Bed Fusion AlSi10Mg Dogbones Using Machine Learning [Slides]

Angular pores (lack of fusion) pores are more detrimental to the health of the part due to induced stress concentrations. Three types of porosity found in AM parts: keyhole porosity, gas porosity, and lack of fusion porosity. In this research, we address the question, "Which machine learning and/or machine vision techniques work best to segment porosity and determine the type of porosity observed in the sample?"

42 ENGINEERING↗
DOE OSTI2024

Updated ASME design correlations and qualification plan for powder bed fusion 316H stainless steel

This report provides an update on the Advanced Materials and Manufacturing Technologies (AMMT) program effort to qualify Laser-Powder Bed Fusion (L-PBF) 316H stainless steel for use with the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules. The report summarizes progress in testing and characterizing L-PBF material at elevated temperatures by providing preliminary design data for L-PBF 316H and by comparing the elevated temperature performance of the L-PBF material to wrought and conventional fusion welded 316H. The report then updates the initial AMMT qualification plan for L-PBF 316H, originally developed in 2023, to update the accelerated qualification strategy adopted in that plan to account for the new high temperature test data. The report also explores a few methods for further accelerating the qualification process using machine learning techniques to supplement the more conventional, empirical analysis methods typically used by ASME to correlate and extrapolate time-dependent material test data.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Fusion Centers and State Energy Stakeholders: Pathways to Robust Threat Information Sharing

Threats to our nation’s critical infrastructure are escalating in frequency and sophistication. It is essential for public and private sectors to join forces to understand the threats, mitigate risks, and plan to respond and recover from disruption. Fusion centers — organizations purpose-built to facilitate communication and cooperation between federal, state, local, and territorial law enforcement entities — are well-positioned to play a pivotal role in this context. Although fusion centers historically focused on crime and terrorism, there is a need to engage more broadly and build stronger threat information sharing relationships among energy stakeholders within their states.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2022

Fusion Blanket and Fuel Cycle Research at PNNL: FY22 Year-end Report

During the reporting period, research at PNNL focused on two tasks within the DOE Fusion Blanket and Fuel Cycle Program. Research on Task 1, Tritium Extraction from Pb-Li and He Using a Vacuum Permeator, focused on atomistic modeling to better understand tritium transport in Pd-coated V vacuum permeators. As a lower cost alternative to Pd permeators, thin coatings of Pd (or other noble metals) can be deposited over a substrate like V. However, the permeation performance of composite metal membranes degrades over time, due to the formation of intermetallics at the coating-substrate interface. Computational studies were performed to better understand tritium transport through these Pd-V intermetallics. The results of the FY22 Pd-V modeling study were recently submitted for publication in Computational Materials Science and presented at the Technology of Fusion Energy conference. Future work in this area will focus on interdiffusion barriers to prevent intermetallic formation that is deleterious to tritium transport. There are opportunities for collaboration with researchers at the Colorado School of Mines, who are manufacturing and testing candidate interdiffusion barriers. Research on Task 3, Solid Breeder Materials, included ion irradiation and post-irradiation characterization of lithium orthosilicate (Li 4 SiO 4 ) and lithium metasilicate (Li 2 SiO 3 ) to improve fundamental understanding of irradiation effects, in combination with atomistic modeling focused on the energetics of He clustering in these two ceramic phases. The results of the study suggested that the Li 4 SiO 4 phase, which is more desirable as a solid breeder due to its higher Li density, was amorphized during ion irradiation while the Li 2 SiO 3 phase appeared to be more resistant to irradiation damage. It is possible that Li loss contributed to the poor irradiation performance of the Li 4 SiO 4 , and some thoughts are provided regarding coatings that could be applied to solid breeders like this to prevent Li loss at elevated temperature while not hindering tritium diffusion. The results of the FY22 ion irradiation study were recently submitted for publication in Journal of Nuclear Materials and presented at the 22nd International Conference on Ion Beam Modification of Materials. Future work in this area will focus on Li-rich ceramics such as Li 5 AlO 4 and Li 8 ZrO 6 that have high Li density and should provide rapid tritium release based on previous work with less Li-rich ceramics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Portable and Adaptable Neutron Diagnostics for Advancing Fusion Energy Science Addendum

Activation detectors developed at LLNL for measuring real-time neutron fluence from fusion sources are used in the broader fusion community. The recommended fluence operating range of this diagnostic is 5x10 2 – 1x10 6 n/cm2. The upper limit on this fluence range is set by the dead time caused by data transfer between the detector and data acquisition computer. Delaying the start of counting is a possible strategy to operate these detectors in higher fluences.

42 ENGINEERING↗
DOE OSTI2025

Trident Smyth: Near Real Time Sensor Fusion and Track Stitching Application

Sandia’s Sensor Data Fusion application is a NGA sponsored project that fuses tracks from different sensors to provide more accuracy than any single track. The application serves as the unclassified architecture for data ingestion, processing, and near real-time sensor fusion.

Sorroche, Joseph John [Sandia National Laboratorie↗
DOE OSTI2025

Towards a Robust Adaptive Digital Twin for Fusion Applications

The development of a digital twin system for fusion applications is essential for enhancing the prediction, analysis, and optimization of complex plasma processes. Machine learning (ML), particularly deep learning has demonstrated strong capabilities in modeling such highly nonlinear and intricate systems. However, two critical challenges limit the deployment of deep learning-based digital twins: Uncertainty Quantification (UQ) and data drift. UQ is vital for ensuring trustworthy predictions, especially in decision-support scenarios. Additionally, data-driven models are often sensitive to changes in the underlying data distribution, such as shot-to-shot variations in fusion experiments, which can lead to performance degradation over time. To address these challenges, we are developing an uncertainty-aware, adaptive digital twin framework. Our approach incorporates deep learning models enhanced with Gaussian Process approximations for predictive uncertainty estimation, coupled with an online learning mechanism that enables continuous model adaptation to new experimental data. This adaptive capability allows the data driven models to respond effectively to evolving plasma behaviors and equipment conditions. Specifically, to mitigate the effects of shot-to-shot drift, our system updates itself incrementally as new data becomes available, improving both robustness and fidelity. Our vision is to evolve this data driven model into a self-sustaining digital twin system that leverages UQ based feedback to continuously refine itself and potentially support real-time decision making. This presentation will cover a brief background on uncertainty quantification for ML, our ongoing effort on development of UQ capabilities for ML, our data science pipeline from data collection to model development and analysis and online learning framework for modeling coil deflection at DIII-D. I will also briefly touch upon opportunities and challenges in development of digital twin framework.

Sammuli, Brian [General Atomics]↗
DOE OSTI2024

Stability optimization of energetic particle driven modes in nuclear fusion devices: the FAR3d gyro-fluid code

The development of reduced models provide efficient methods that can be used to perform short term experimental data analysis or narrow down the parametric range of more sophisticated numerical approaches. Reduced models are derived by simplifying the physics description with the goal of retaining only the essential ingredients required to reproduce the phenomena under study. This is the role of the gyro-fluid code FAR3d, dedicated to analyze the linear and nonlinear stability of Alfvén Eigenmodes (AE), Energetic Particle Modes (EPM) and magnetic-hydrodynamic modes as pressure gradient driven mode (PGDM) and current driven modes (CDM) in nuclear fusion devices. Such analysis is valuable for improving the plasma heating efficiency and confinement; this can enhance the overall device performance. The present review is dedicated to a description of the most important contributions of the FAR3d code in the field of energetic particles (EP) and AE/EPM stability. FAR3d is used to model and characterize the AE/EPM activity measured in fusion devices as LHD, JET, DIII-D, EAST, TJ-II and Heliotron J. In addition, the computational efficiency of FAR3d facilitates performing massive parametric studies leading to the identification of optimization trends with respect to the AE/EPM stability. This can aid in identifying operational regimes where AE/EPM activity is avoided or minimized. This technique is applied to the analysis of optimized configurations with respect to the thermal plasma parameters, magnetic field configuration, external actuators and the effect of multiple EP populations. In addition, the AE/EPM saturation phase is analyzed, taking into account both steady-state phases and bursting activity observed in LHD and DIII-D devices. The nonlinear calculations provide: the induced EP transport, the generation of zonal structures as well as the energy transfer towards the thermal plasma and between different toroidal/helical families. Finally, FAR3d is used to forecast the AE/EPM stability in operational scenarios of future devices as ITER, CFETR, JT60SA and CFQS as well as possible approaches to optimization with respect to variations in the most important plasma parameters.

Alfv én Eigenmodes↗