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Results for “Additive Process Modeling”

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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Wintertime nitric acid chemistry - Implications from three-dimensional model calculations

A three-dimensional simulation of the evolution of HNO3 has been run for the winter of 1979. Winds and temperatures are taken from a stratospheric data assimilation analysis, and the chemistry is based on Limb Infrared Monitor of the Stratosphere (LIMS) observations. The model is compared to LIMS observations to investigate the problem of 'missing' nitric acid chemistry in the winter hemisphere. Both the model and observations support the contention that a nitric acid source is needed outside of the polar vortex and north of the subtropics. Observations suggest that HNO3 is not dynamically controlled in middle latitudes. The model shows that given the time scales of conventional chemistry, dynamical control is expected. Therefore, an error exists in the conventional chemistry or additional processes are needed to bring the model and data into agreement. Since the polar vortex is dynamically isolated from the middle latitudes, and since the highest HNO3 values are observed in October and November, a source associated solely with polar stratospheric clouds cannot explain the deficiencies in the chemistry. The role of heterogeneous processes on background aerosols is reviewed in light of these results.

Rood, Richard B.↗
NASA NTRS1992

Linear-quadratic-Gaussian synthesis with reduced parameter sensitivity

We present a method for improving the tolerance of a conventional LQG controller to parameter errors in the plant model. The improvement is achieved by introducing additional terms reflecting the structure of the parameter errors into the LQR cost function, and also the process and measurement noise models. Adjusting the sizes of these additional terms permits a trade-off between robustness and nominal performance. Manipulation of some of the additional terms leads to high gain controllers while other terms lead to low gain controllers. Conditions are developed under which the high-gain approach asymptotically recovers the robustness of the corresponding full-state feedback design, and the low-gain approach makes the closed-loop poles asymptotically insensitive to parameter errors.

Lin, J. Y.↗
NASA NTRSDate not supplied

Modeling Pore Closure in the Hot Isostatic Pressing of Additively Manufactured Inconel 718 Samples

Additive manufacturing provides opportunity for a new world of possibilities for metallic component design and fabrication; however, as-built part quality is notoriously variable, anisotropic, and degraded by porous defects. To improve quality, parts are commonly post processed using a variety of techniques including hot isostatic pressing (HIP). During HIP, high temperature and pressure is employed to improve microstructure and reduce pore volume by inducing visco-plastic deformation in the metallic substrate. Validated computational capabilities can provide predictions to guide the selection of processing condition, expected pore reduction, and the effects of varying entrapped gas in the pores. This discussion describes a micro-scale finite element structural model developed to predict pore closure due to HIP in as-built additively manufactured Inconel 718 samples produced by the laser powder bed fusion process. The model accounts for plastic deformation, creep, and internal pressure for a single pore. Pores are characterized in physical samples before and after HIP, and model predictions are compared to this measured data.

defect model prediction↗
NASA NTRS1994

Re-engineering the mission life cycle with ABC and IDEF

The theory behind re-engineering a business process is to remove the non-value added activities thereby lowering the process cost. In order to achieve this, one must be able to identify where the non-value added elements are located which is not a trivial task. This is because the non-value added elements are often hidden in the form of overhead and/or pooled resources. In order to be able to isolate these non-value added processes from among the other processes, one must first decompose the overall top level process into lower layers of sub-processes. In addition, costing data must be assigned to each sub-process along with the value the sub-process adds towards the final product. IDEF0 is a Federal Information Processing Standard (FIPS) process-modeling tool that allows for this functional decomposition through structured analysis. In addition, it illustrates the relationship of the process and the value added to the product or service. The value added portion is further defined in IDEF1X which is an entity relationship diagramming tool. The entity relationship model is the blueprint of the product as it moves along the 'assembly line' and therefore relates all of the parts to each other and the final product. It also relates the parts to the tools that produce the product and all of the paper work that is used in their acquisition. The use of IDEF therefore facilitates the use of Activity Based Costing (ABC). ABC is an essential method in a high variety, product-customizing environment, to facilitate rapid response to externally caused change. This paper describes the work being done in the Mission Operations Division to re-engineer the development and operation life cycle of Mission Operations Centers using these tools.

Mandl, Daniel↗
NASA NTRS2019

Kepler Data Validation II–Transit Model Fitting and Multiple-Planet Search

This paper discusses the transit model-fitting and multiple-planet search algorithms and performance of the Kepler Science Data Processing Pipeline, developed by the Kepler Science Operations Center (SOC). Threshold crossing events (TCEs), which are transit candidate events, are generated by the Transiting Planet Search (TPS) component of the pipeline and subsequently processed in the data validation (DV) component. The transit model is used in DV to fit TCEs to characterize planetary candidates and to derive parameters that are used in various diagnostic tests to classify them. After the signature associated with the TCE is removed from the light curve of the target star, the residual light curve goes through TPS again to search for additional TCEs. The iterative process of transit model fitting and multiple-planet search continues until no TCE is generated from the residual light curve or an upper limit is reached. The transit model-fitting and multiple-planet search performance of the final release (9.3, 2016January) of the pipeline is demonstrated with the results of the processing of four years (17 quarters) of flight data from the primary Kepler Mission. The transit model-fitting results are accessible from the NASA Exoplanet Archive. The final version of the SOC codebase is available through GitHub.

Threshold crossing events (TCEs↗
NASA NTRS1979

Development of a model and computer code to describe solar grade silicon production processes

Mathematical models, and computer codes based on these models were developed which allow prediction of the product distribution in chemical reactors in which gaseous silicon compounds are converted to condensed phase silicon. The reactors to be modeled are flow reactors in which silane or one of the halogenated silanes is thermally decomposed or reacted with an alkali metal, H2 or H atoms. Because the product of interest is particulate silicon, processes which must be modeled, in addition to mixing and reaction of gas-phase reactants, include the nucleation and growth of condensed Si via coagulation, condensation, and heterogeneous reaction.

Srivastava, R.↗
NASA NTRS1985

On-orbit Systems Identification of Flexible Spacecraft Technol., 1984, Pt. 2 p 465-481

Future spacecraft include configurations which are too flexible to be adequately tested prior to flight and which will require on-orbit systems identification to ensure safe operation of the flight control system. The structural dynamics model will evolve and its accuracy will improve in stages as ground tests of full-scale components and replica-scale models are performed. State Space Modeling and Conditional Maximum Likelihood Parameter Estimation methodology can provide the formal probability-based framework for the process of upgrading a model as additional test results are obtained. Although the number of unknown parameters can be reduced by the use of canonical forms for the stability matrix, the number of unknown model parameters quickly becomes unmanageable unless advantage is taken of the relationship of a much fewer number of global model parameters. Distributed parameter systems or partial differential equation models are one way to take advantage of such global parameters to reduce the number of unknown model parameters.

Taylor, L.↗
NASA NTRS1986

Thermal-capillary analysis of Czochralski and liquid encapsulated Czochralski crystal growth

Results are presented from finite element analysis of the Czochralski (CZ) and Liquid Encapsulated Czochralski (LEC) crystal growth processes based on a thermal-capillary model which governs the heat transfer in the system simultaneously with setting the shapes of the melt/solid interface, the melt and encapsulant menisci, and the radius of a steadily growing crystal. Calculations are performed for the small-scale growth of silicon (CZ) and gallium arsenide (LEC). The effects of melt volume and crucible position relative to the heater on the radius of the crystal and the shape of the melt/solid interface are predicted for the CZ system, and the importance of including an accurate representation of the melt meniscus for modeling the process is demonstrated. The additional effect of an encapsulant layer on heat transfer is treated for the LEC method for the cases of totally transparent and opaque encapsulant. The responses of these LEC prototype systems are examined for changes in pull rate and encapsulant volume.

Derby, J. J.↗
NASA NTRS2020

Narrowing Uncertainties in the Effects of Elevated CO2 on Crops

Plant responses to rising atmospheric carbon dioxide (CO2) concentrations, together with projected variations in temperature and precipitation will determine future agricultural production. Estimates of the impacts of climate change on agriculture provide essential information to design effective adaptation strategies, and develop sustainable food systems. Here, we review the current experimental evidence and crop models on the effects of elevated CO2 concentrations. Recent concerted efforts have narrowed the uncertainties in CO2-induced crop responses so that climate change impact simulations omitting CO2 can now be eliminated. To address remaining knowledge gaps and uncertainties in estimating the effects of elevated CO2 and climate change on crops, future research should expand experiments on more crop species under a wider range of growing conditions, improve the representation of responses to climate extremes in crop models, and simulate additional crop physiological processes related to nutritional quality.

carbon dioxide (CO2)↗
NASA NTRS2000

Motion coherence affects human perception and pursuit similarly

Pursuit and perception both require accurate information about the motion of objects. Recovering the motion of objects by integrating the motion of their components is a difficult visual task. Successful integration produces coherent global object motion, while a failure to integrate leaves the incoherent local motions of the components unlinked. We compared the ability of perception and pursuit to perform motion integration by measuring direction judgments and the concomitant eye-movement responses to line-figure parallelograms moving behind stationary rectangular apertures. The apertures were constructed such that only the line segments corresponding to the parallelogram's sides were visible; thus, recovering global motion required the integration of the local segment motion. We investigated several potential motion-integration rules by using stimuli with different object, vector-average, and line-segment terminator-motion directions. We used an oculometric decision rule to directly compare direction discrimination for pursuit and perception. For visible apertures, the percept was a coherent object, and both the pursuit and perceptual performance were close to the object-motion prediction. For invisible apertures, the percept was incoherently moving segments, and both the pursuit and perceptual performance were close to the terminator-motion prediction. Furthermore, both psychometric and oculometric direction thresholds were much higher for invisible apertures than for visible apertures. We constructed a model in which both perception and pursuit are driven by a shared motion-processing stage, with perception having an additional input from an independent static-processing stage. Model simulations were consistent with our perceptual and oculomotor data. Based on these results, we propose the use of pursuit as an objective and continuous measure of perceptual coherence. Our results support the view that pursuit and perception share a common motion-integration stage, perhaps within areas MT or MST.

NASA Center ARC↗
NASA NTRSDate not supplied

The Additive Manufacturing Moment Measure (AM3) Approach to Predictions of Solid Cooling Rate and Time Above Melt

Qualification of a laser powder bed fusion additive manufacturing (LPBF-AM) process requires knowledge of the multi-scale material physics during the process, per part. As the LPBF-AM build occurs, each moment is influenced by the process history. Knowledge of the build sequence can be used to generate a discretized time-space-condition point field that when coupled with a nearest neighbors’ calculation results in a generalized and fully parallel process model computation. This GPU accelerated approach was developed for part-scale analysis of build files along with in-situ process monitoring sensor data and is termed the “Additive Manufacturing Moment Measure” (AM3). The AM3 approach will be presented and then used to evaluate an AM Bench relevant geometry with synchronized in-situ process data, ex-situ nondestructive evaluation, and optical microscopy observations. These comparisons permit a better understanding of how the process actions can affect the LPBF-AM build quality and the signals generated during in-situ process monitoring.

Additive Manufacturing↗
NASA NTRS2015

Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗
NASA NTRS1980

Software reliability: A comparison of results obtained from established software reliability models

Two models of the software error detection process are compared, the Jelinski-Moranda model and a Bayes inference model. Simulation techniques are used to generate software related system failure data which is analyzed by both models. Point estimates and confidence limits are compared. It is demonstrated that uncertainty may be considerable for reasonable samples sizes and should be considered in any application of these techniques. The Jelinski-Moranda model is sensitive to the failure of data to follow internal assumptions of the model, often not providing any point estimates, a factor which may limit its usefulness in many real world situations. The Bayes model is shown to respond to the introduction of additional errors in the software correction process, a condition where error counting models such as the Jelinski-Moranda generally fail to converge.

Horn, M. H.↗
NASA NTRSDate not supplied

A Novel Additive Manufacturing Process Metric for Predicting Spatter-related Porosity in Laser Powder Bed Fusion

Components fabricated using the powder bed fusion laser beam metallic (PBF) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Porosity defects resulting from weld pass inconsistencies are a concern for PBF materials and have a strong adverse effect on the mechanical properties. In an effort to understand and avoid spatter induced porosity, this work aims to provide a novel computational technique that can be used to quantify and predict the sequence-sensitive impact of spatter upon the PBF process stability and consequential porosity in as-printed material. A novel spatter impact AM model-based process metric (AM-PM) is introduced to model and quantify the impact that spatter has on the PBF process. The occurrence of spatter induced porosity is studied using thermal rise, lack of fusion, and spatter impact AM-PMs synchronized with porosity measured by high-resolution X-ray computed tomography. Six cylindrical specimens were designed to compare the AM-PM correlations with porosity across two different laser powers and three hatch scanning strategies. A point field based computational approach is shown to be effective for testing the influence of the different AM-PMs and interrogating the physical process conditions underlying the porosity formation. Further, characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated with the spatter impact AM-PM, which can be exploited to predict and control spatter related porosity by the hatch strategy. Efforts to predict porosity composition within PBF material should incorporate the PBF process disturbances that can result from spatter. The spatter impact AM-PM can be readily incorporated into the development of defect prediction models at the part scale.

Additive Manufacturing↗
NASA NTRS2007

Cloud Resolving Modeling

One of the most promising methods to test the representation of cloud processes used in climate models is to use observations together with cloud-resolving models (CRMs). CRMs use more sophisticated and realistic representations of cloud microphysical processes, and they can reasonably well resolve the time evolution, structure, and life cycles of clouds and cloud systems (with sizes ranging from about 2-200 km). CRMs also allow for explicit interaction between clouds, outgoing longwave (cooling) and incoming solar (heating) radiation, and ocean and land surface processes. Observations are required to initialize CRMs and to validate their results. This paper provides a brief discussion and review of the main characteristics of CRMs as well as some of their major applications. These include the use of CRMs to improve our understanding of: (1) convective organization, (2) cloud temperature and water vapor budgets, and convective momentum transport, (3) diurnal variation of precipitation processes, (4) radiative-convective quasi-equilibrium states, (5) cloud-chemistry interaction, (6) aerosol-precipitation interaction, and (7) improving moist processes in large-scale models. In addition, current and future developments and applications of CRMs will be presented.

Tao, Wei-Kuo↗
NASA NTRS2019

New Horizons in Cosmology with Spectral Distortions of the Cosmic Microwave Background

Following the pioneering observations with COBE in the early 1990s, studies of the cosmic mi- crowave background (CMB) have primarily focused on temperature and polarization anisotropies. CMB spectral distortions – tiny departures of the CMB energy spectrum from that of a perfect blackbody – provide a second, independent probe of fundamental physics, with a reach deep into the primordial Universe. The theoretical foundation of spectral distortions has seen major advances in recent years, highlighting the immense potential of this emerging field. Spectral distortions probe a fundamental property of the Universe – its thermal history – thereby providing additional insight into processes within the cosmological standard model(I) (CSM) as well as new physics beyond. Spectral distortions are an important tool for understanding inflation and the nature of dark matter. They shed new light on the physics of recombination and reionization, both prominent stages in the evolution of our Universe, and furnish critical information on baryonic feedback processes, in addition to probing primordial correlation functions at scales inaccessible to other tracers. In principle the range of signals is vast: many orders of magnitude of discovery space can be explored by detailed observations of the CMB energy spectrum. Several CSM signals are predicted and provide clear experimental targets that are observable with present-day technology. Confirmation of these signals would extend the reach of the CSM by orders of magnitude in physical scale as the Universe evolves from the initial stages to its present form. Their absence would pose a huge theoretical challenge, immediately pointing to new physics. Here, we advocate for a dedicated effort to measure CMB spectral distortions at the largest angular scales (greater than approximately 1°) within the ESA Voyage 2050 Program. We argue that an L-class mission with a pathfinder would allow a precise measurement of all the expected CSM distortions. With an M-class mission, the primordial distortions (created at z >~ 10(exp 3)) would still be detected at modest significance, while the late-time distortions will continue to be measured to high accuracy. Building on the heritage of COBE/FIRAS, a spectrometer that consists of multiple, cooled (approximately equal to 0.1 K), absolutely-calibrated Fourier Transform Spectrometers (FTS) with wide frequency coverage (ν approximately equal to 10 GHz to a few x THz) and all-sky spectral sensitivity at the level of 0.1 0.5 Jy/sr would be the starting point for the M-class option. A scaled and further optimized version of this concept is being envisioned as the L-class option. Such measurements can only be done from space and would deliver hundreds of absolutely-calibrated maps of the Universe at large scales, opening numerous science opportunities for cosmology and astrophysics. This will provide independent probes of inflation, dark matter and particle physics, recombination and the energy output of our Universe from at late times, turning the long-standing spectral distortion limits of COBE/FIRAS into clear detections.

Chluba, J.↗
NASA NTRSDate not supplied

Porosity Model Parameter Effects on Metal Additive Manufacturing Simulations

This work investigates the effects of model parameters on thermomechanical simulations of a metal additive manufacturing process. The first half of this work explores the sensitivity and effects of the two porosity parameters used in the evolving constitutive model of the simulation. Varying the two parameters of the model show that for the simulations conducted here, the linear coefficient drives the predicted residual stress results while the constant term has little impact. The second half of the work considers the size, order, and the number of element layers in the finite element mesh. The stress distribution plots show that second-order elements along with a dense mesh marginally improve mesh convergence at a significant cost.

Additive Manufacturing↗