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Results for “in situ processing”

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 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↗
DOE OSTI2023

Summary of Methodology for Mitigating Risks Associated with Licensing and Qualifying AM Nuclear Materials

The US Department of Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program focuses on accelerating the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Laser powder bed fusion (LPBF) is one of the most popular additive manufacturing (AM) processes for fabricating components with intrinsically complex geometries. LPBF was extensively explored for nuclear applications under the previous Transformational Challenge Reactor program. Additionally, Oak Ridge National Laboratory developed and licensed the Peregrine software and larger digital platform that couples machine learning and in situ data collection during AM to detect anomalies and any evolved defects. The digital platform will be critical to (1) the qualification of AM components for nuclear applications that link location-specific data to macroscopic properties and (2) predict final component performance. Current in situ process monitoring tools are valuable for observing the formation of stochastic flaws, but additional data are needed to predict the resulting microstructures and associated material performance. Rapid cooling rates and large thermal gradients have caused large heterogeneities in the microstructure, which cause anisotropy in mechanical performance. The AMMT program is evaluating the best approaches for addressing these heterogeneities and their effect on component performance using a combination of multiscale modeling, enhanced in situ process monitoring, and high throughput experimental testing. This report summarizes strategies for mitigating the risks associated with qualifying AM components, including developing new sensing capabilities for in situ process monitoring and characterizing melt pool solidification and residual stresses to inform multiscale modeling efforts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

A terminology for in situ visualization and analysis systems

The term "in situ processing" has evolved over the last decade to mean both a specific strategy for visualizing and analyzing data and an umbrella term for a processing paradigm. The resulting confusion makes it difficult for visualization and analysis scientists to communicate with each other and with their stakeholders. To address this problem, a group of over 50 experts convened with the goal of standardizing terminology. This paper summarizes their findings and proposes a new terminology for describing in situ systems. An important finding from this group was that in situ systems are best described via multiple, distinct axes: integration type, proximity, access, division of execution, operation controls, and output type. This paper discusses these axes, evaluates existing systems within the axes, and explores how currently used terms relate to the axes.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

A systematic study and framework of fringe projection profilometry with improved measurement performance for in-situ LPBF process monitoring

Fringe Projection Profilometry (FPP) is a cost-effective and non-invasive technology that has been shown to measure finer features. Here, in this work, we developed an in-situ FPP method to measure the dynamic topography of powder bed and printed layer during Laser Powder Bed Fusion (LPBF) additive manufacturing (AM) process. A systematic study towards developing a comprehensive framework of LPBF-specific FPP is demonstrated to enhance and evaluate the performance of applying FPP for in-situ LPBF monitoring, including 1) a modified sensor model with localized correction; 2) improved phase unwrapping with FFT filtering 3) quantitative uncertainty analysis; and 4) experimental validation with ex-situ characterization. The developed LPBF-specific FPP system and methods are implemented on a commercial LPBF-AM machine, achieving better accuracy, more robustness, and increased field of view while maintaining sufficient measurement range and decent resolution, in contrast to literature methods. The established FPP framework will facilitate the development of closed-loop control strategies for advancing LPBF based AM.

42 ENGINEERING↗
NASA NTRS2008

Effect of Processing Pressure on Isolated Pore Formation during Controlled Directional Solidification in Small Channels

Directional solidification experiments were performed, using succinonitrile saturated with nitrogen gas, to examine the effects of in-situ processing pressure changes on the formation growth, and evolution of an isolated, cylindrical gaseous pore. A novel solidification facility, capable of processing thin cylindrical samples (I.D. < 1.0 mm), under controlled pressure conditions, was used for the experiments. A new experimental method for growing the isolated pore from a seed bubble is introduced. The experimental results indicate that an in-situ processing pressure change will result in either a transient change in pore diameter or a complete termination of pore growth, indicating that pressure changes can be used as a control parameter to terminate bubble growth. A simple analytical model has been introduced to explain the experimental observations.

Cox, Matthew C.↗
NASA NTRS2005

Advanced Metal Foam Structures for Outer Space

A document discusses a proposal to use advanced materials especially bulk metallic glass (BMG) foams in structural components of spacecraft, lunar habitats, and the like. BMG foams, which are already used on Earth in some consumer products, are superior to conventional metal foams: BMG foams have exceptionally low mass densities and high strength-to-weight ratios and are more readily processable into strong, lightweight objects of various sizes and shapes. These and other attractive properties of BMG foams would be exploited, according to the proposal, to enable in situ processing of BMG foams for erecting and repairing panels, shells, containers, and other objects. The in situ processing could include (1) generation of BMG foams inside prefabricated deployable skins that would define the sizes and shapes of the objects thus formed and (2) thermoplastic deformation of BMG foams. Typically, the generation of BMG foams would involve mixtures of precursor chemicals that would be subjected to suitable pressure and temperature schedules. In addition to serving as structural components, objects containing or consisting of BMG foams could perform such functions as thermal management, shielding against radiation, and shielding against hypervelocity impacts of micrometeors and small debris particles.

Hanan, Jay↗
NASA NTRS1991

Mining and beneficiation: A review of possible lunar applications

Successful exploration of Mars and outer space may require base stations strategically located on the Moon. Such bases must develop a certain self-sufficiency, particularly in the critical life support materials, fuel components, and construction materials. Technology is reviewed for the first steps in lunar resource recovery-mining and beneficiation. The topic is covered in three main categories: site selection; mining; and beneficiation. It will also include (in less detail) in-situ processes. The text described mining technology ranging from simple diggings and hauling vehicles (the strawman) to more specialized technology including underground excavation methods. The section of beneficiation emphasizes dry separation techniques and methods of sorting the ore by particle size. In-situ processes, chemical and thermal, are identified to stimulate further thinking by future researchers.

Chamberlain, Peter G.↗
DOE OSTI2025

Techno-economic analysis and life cycle analysis of renewable natural gas production from brewery wastewater via ex-situ methanation processes

As sustainability becomes increasingly critical, the brewing industry encounters challenges in managing high-organic-content wastewater, a promising renewable energy source. This study evaluates the economic feasibility and environmental impacts of converting brewery wastewater into renewable natural gas (RNG) through anaerobic digestion and biogas upgrading, with an emphasis on different hydrogen sources for biomethanation. Four scenarios were analyzed: Scenario 1 uses purchased hydrogen, while Scenarios 2–4 use renewable hydrogen from microbial electrolysis cells and water electrolyzers. Results show that capital investments for processing 139 MT/h of wastewater, yielding 208 m 3 /h of RNG, range from 10.6 M to 31.9M USD, with estimated minimum selling prices of RNG between 2.25 and 4.37 USD/m 3 . Life cycle greenhouse gas (GHG) emissions span from -21 to 32g CO 2 -equivalent per MJ of RNG. Further, this study presents key economic and environmental metrics for RNG production from brewery wastewater, offering insights to enhance sustainability in brewery wastewater management.

03 NATURAL GAS↗
DOE OSTI2021

Mechanisms and heterogeneity of in situ mineral processing by the marine nitrogen fixer Trichodesmium revealed by single-colony metaproteomics

The keystone marine nitrogen fixer Trichodesmium thrives in high-dust environments. While laboratory investigations have observed that Trichodesmium colonies can access the essential nutrient iron from dust particles, less clear are the biochemical strategies underlying particle–colony interactions in nature. Here we demonstrate that Trichodesmium colonies engage with mineral particles in the wild with distinct molecular responses. We encountered particle-laden Trichodesmium colonies at a sampling location in the Southern Caribbean Sea; microscopy and synchrotron-based imaging then demonstrated heterogeneous associations with iron oxide and iron-silicate minerals. Metaproteomic analysis of individual colonies by a new low-biomass approach revealed responses in biogeochemically relevant proteins including photosynthesis proteins and metalloproteins containing iron, nickel, copper, and zinc. The iron-storage protein ferritin was particularly enriched implying accumulation of mineral-derived iron, and multiple iron acquisition pathways including Fe(II), Fe(III), and Fe-siderophore transporters were engaged. While the particles provided key trace metals such as iron and nickel, there was also evidence that Trichodesmium was altering its strategy to confront increased superoxide production and metal exposure. Chemotaxis regulators also responded to mineral presence suggesting involvement in particle entrainment. These molecular responses are fundamental to Trichodesmium’s ecological success and global biogeochemical impact, and may contribute to the leaching of particulate trace metals with implications for global iron and carbon cycling.

Held, Noelle A.↗
DOE OSTI2022

In Situ Plasma Processing of Superconducting Cavities at Jefferson Lab

Jef­fer­son Lab began a plasma pro­cess­ing pro­gram start­ing in the spring of 2019. Plasma pro­cess­ing is a com­mon tech­nique for re­mov­ing hy­dro­car­bons from sur­faces, which in­creases the work func­tion and re­duces the sec­ondary emis­sion co­ef­fi­cient. Un­like he­lium pro­cess­ing which re­lies on ion bom­bard­ment of the field emit­ters, plasma pro­cess­ing uses free oxy­gen pro­duced in the plasma to break down the hy­dro­car­bons on the sur­face of the cav­ity. The resid­u­als of the hy­dro­car­bons in the form of water, car­bon monox­ide and car­bon diox­ide are re­moved from the cry­omod­ule as part of the process gas flow. The ini­tial focus of the ef­fort is pro­cess­ing C100 cav­i­ties by in­ject­ing RF power into the HOM cou­pler ports. We will then start in­ves­ti­gat­ing pro­cess­ing of C50 cav­i­ties by in­tro­duc­ing RF into the fun­da­men­tal power cou­pler. The plan is to start pro­cess­ing cry­omod­ules in the CEBAF tun­nel in the mid-term fu­ture, with a goal of im­prov­ing the op­er­a­tional gra­di­ents and the en­ergy mar­gin of the linacs. This work will de­scribe the sys­tems and meth­ods used at JLAB for pro­cess­ing cav­i­ties using an argon oxy­gen gas mix­ture. Be­fore and after plasma pro­cess­ing re­sults will also be pre­sented.

Powers, T.↗
DOE OSTI2026

Advancing In-Situ Plasma Processing for SRF Cavities at Fermilab

This talk presents Fermilab’s experience with plasma processing applied to both elliptical and low-beta superconducting RF cavities. The development and implementation of the technique are compared across different geometries, with particular emphasis on constraints imposed by cryomodule assembly configurations. The talk also reports on systematic studies aimed at optimizing the processing recipe, including the exploration of various inert gas mixtures and oxygen concentrations. These results aim at providing guidance for tailoring plasma processing conditions to different cavity types and advancing plasma processing applicability in operational cryomodules.

Giaccone, Bianca [Fermilab] (ORCID:000000027275846↗
DOE OSTI2026

Advancing In-Situ Plasma Processing for SRF Cavities at Fermilab

This talk presents Fermilab’s experience with plasma processing applied to both elliptical and low-beta superconducting RF cavities. The development and implementation of the technique are compared across different geometries, with particular emphasis on constraints imposed by cryomodule assembly configurations. The talk also reports on systematic studies aimed at optimizing the processing recipe, including the exploration of various inert gas mixtures and oxygen concentrations. These results aim at providing guidance for tailoring plasma processing conditions to different cavity types and advancing plasma processing applicability in operational cryomodules.

Giaccone, Bianca [Fermilab] (ORCID:000000027275846↗
NASA NTRS1990

In-situ integrated processing and characterization of thin films of high temperature superconductors, dielectrics and semiconductors by MOCVD

In this strategy of depositing the basic building blocks of superconductors, semiconductors, and dielectric having common elements, researchers deposited superconducting films of Y-Ba-Cu-O, semiconductor films of Cu2O, and dielectric films of BaF2 and Y2O3 by metal oxide chemical vapor deposition (MOCVD). By switching source materials entering the chamber, and by using direct writting capability, complex device structures like three-terminal hybrid semiconductors/superconductors transistors can be fabricated. The Y-Ba-Cu-O superconducting thin films on BaF2/YSZ substrates show a T(sub c) of 80 K and are textured with most of the grains having their c-axis or a-axis perpendicular to the substrate. Electrical characteristics as well as structural characteristics of superconductors and related materials obtained by x-ray defraction, electron microscopy, and energy dispersive x-ray analysis are discussed.

Singh, R.↗
NASA NTRS1991

In-situ integrated processing and characterization of thin films of high temperature superconductors, dielectrics and semiconductors by MOCVD

In this strategy of depositing the basic building blocks of superconductors, semiconductors, and dielectrics having common elements, researchers deposited superconducting films of Y-Ba-Cu-O, semiconductor films of Cu2O, and dielectric films of BaF2 and Y2O3 by metal oxide chemical vapor deposition (MOCVD). By switching source materials entering the chamber, and by using direct writing capability, complex device structures like three terminal hybrid semiconductor/superconductor transistors can be fabricated. The Y-Ba-Cu-O superconducting thin films on BaF2/YSZ substrates show a T(sub c) of 80 K and are textured with most of the grains having their c-axis or a-axis perpendicular to the substrate. Electrical characteristics as well as structural characteristics of superconductors and related materials obtained by x-ray deffraction, electron microscopy, and energy dispersive x-ray analysis are discussed.

Singh, R.↗
NASA NTRS1997

Processing of Superconductor-Normal-Superconductor Josephson Edge Junctions

The electrical behavior of epitaxial superconductor-normal-superconductor (SNS) Josephson edge junctions is strongly affected by processing conditions. Ex-situ processes, utilizing photoresist and polyimide/photoresist mask layers, are employed for ion milling edges for junctions with Yttrium-Barium-Copper-Oxide (YBCO) electrodes and primarily Co-doped YBCO interlayers.

photoresist polyimide process interlayer materials↗