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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
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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 NTRS1977

Exploration of an oculometer-based model of pilot workload

Potential relationships between eye behavior and pilot workload are discussed. A Honeywell Mark IIA oculometer was used to obtain the eye data in a fixed base transport aircraft simulation facility. The data were analyzed to determine those parameters of eye behavior which were related to changes in level of task difficulty of the simulated manual approach and landing on instruments. A number of trends and relationships between eye variables and pilot ratings were found. A preliminary equation was written based on the results of a stepwise linear regression. High variability in time spent on various instruments was related to differences in scanning strategy among pilots. A more detailed analysis of individual runs by individual pilots was performed to investigate the source of this variability more closely. Results indicated a high degree of intra-pilot variability in instrument scanning. No consistent workload related trends were found. Pupil diameter which had demonstrated a strong relationship to task difficulty was extensively re-exmained.

Krebs, M. J.↗
DOE OSTI2025

A Fast-Pass, Desorption Electrospray Ionization Mass Spectrometry Strategy for Untargeted Metabolic Phenotyping

Desorption electrospray ionization mass spectrometry imaging (DESI-MSI) provides direct analytical readouts of small molecules that can be used to characterize the metabolic phenotypes of genetically engineered bacteria. In an effort to accelerate the time frame associated with the screening of mutant libraries, we have developed a high-throughput DESI-MSI analytical workflow implementing a single raster line-scan strategy that facilitates the collection of location-resolved molecular information from engineered strains on a subminute time scale. Evaluation of this “Fast-Pass” DESI-MSI phenotyping workflow on analytical standards demonstrated the capability of acquiring full metabolic profiling information with a throughput of ~40 s per sample. This Fast-Pass strategy was implemented in the analysis of genetically edited Escherichia coli strains that have been engineered to produce various free-fatty acids (FFAs) for applications relevant to biofuels. Due to the untargeted nature of DESI-MSI, the investigation of these strains yielded molecular information for both global metabolites and targeted detection of accumulated bioproducts, allowing simultaneous readouts of strain-specific chemical profiles and comparative measurements of FFA production levels.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1986

The NASA SETI program at JPL

The NASA All Sky Survey strategy for detecting signals of extraterrestrial origin is examined. The All Sky Survey observes the entire celestial sphere, covers a frequency range of 1-10 Ghz, and has spatial direction and frequency coverage. The survey time is dependent on the area of the sky surveyed, the telescope diameter, scan rate, the angular separation of the scans, the bandwidth of the receiver, and the frequency coverage. The distance at which a transmitter can be detected for a given sensitivity is analyzed. The interaction between scan strategy and various accumulation strategies and its effect on the sensitivity of the survey are investigated using field tests. A diagram of the SETI Sky Survey observational system is provided.

Gulkis, Sam↗
DOE OSTI2023

CSAPR2 Optimized Convective Cell Tracking Data during TRACER

One of the challenges in analyzing convective cell properties is to observe the quick evolution of individual convective cells. While the operational radar data provide a volumetric data set to analyze radar observables of convective precipitation clouds, previous studies also suggested the quick evolution of cell life cycle that might not be captured by conventional radar volume scan strategies that take ~5-7 minutes. Aiming at enhancing our understanding of the links between convective cloud kinematic and microphysical processes as well as life cycles, the Tracking Aerosol Convection Interactions ExpeRiment (TRACER; Jensen et al. 2019) was conducted at Houston, Texas, in 2022. The TRACER campaign deployed the 2nd generation C-band Scanning ARM Precipitation Radar (CSAPR2), which performed frequent updates of range height indicator (RHI) and sector plan position indicator (PPI) scans to track individual convective cells every < 2 minutes, guided by a new cell tracking framework, Multisensor Agile Adaptive Sampling (MAAS; Kollias et al. 2020). This allows for capturing fast-evolving radar observables. We provide the processed CSAPR2 cell tracking data in CfRadial format collected during the TRACER field campaign from June to September 2022. The data files include processed radar variables: noise-masked reflectivity and differential reflectivity corrected for rain attenuation and systematic biases, noise-masked dealiased radial velocity, specific differential phase, locations of target cells (latitude, longitude, radar range), and radar-echo classification. Figure 1 provides an example of a 3D image of CSAPR2 reflectivity from the lowest PPI scan and an RHI scan after data processing.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Solidification and crystallographic texture modeling of laser powder bed fusion Ti-6Al-4V using finite difference-monte carlo method

Laser powder bed fusion (LPBF) additive manufacturing makes near-net-shaped parts with reduced material cost and time, rising as a promising technology to fabricate Ti-6Al-4V, a widely used titanium alloy in aerospace and medical industries. However, LPBF Ti-6Al-4V parts produced with 67° rotation between layers, a scan strategy commonly used to reduce microstructure and property inhomogeneity, have varying grain morphologies and weak crystallographic textures that change depending on processing parameters. Here, this study predicts LPBF Ti-6Al-4V solidification at three energy levels using a finite difference-Monte Carlo method and validates the simulations with large-area electron backscatter diffraction (EBSD) scans. The developed model accurately shows that a <001> texture forms at low energy and a <111> texture occurs at higher energies parallel to the build direction but with a lower strength than the textures observed from EBSD. A validated and well-established method of combining spatial correlation and general spherical harmonics representation of texture is developed to calculate a difference score between simulations and experiments. The quantitative comparison enables effective fine-tuning of nucleation density (N 0 ) input, which shows a nonlinear relationship with increasing energy level. Future improvements in texture prediction code and a more comprehensive study of N 0 with different energy levels will further advance the optimization of LPBF Ti-6Al-4V components. These developments contribute a novel understanding of crystallographic texture formation in LPBF Ti-6Al-4V, the development of robust model validation and calibration pipeline methodologies, and provide a platform for mechanical property prediction and process parameter optimization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1992

Status of the NASA SETI Sky Survey microwave observing project

The Sky Survey observing program is one of two complementary strategies that NASA plans to use in its microwave Search for Extraterrestrial Intelligence (SETI). The primary objective of the Sky Survey is to search the entire sky over the frequency range 1000-10,000 MHz for evidence of narrow band signals of extraterrestrial, intelligent origin. Spectrum analyzers with upwards of 10 million channels and data rates in excess of 10 gigabits per second are required to complete the survey in less than 7 years. To lay the foundation for the operational SETI Sky Survey, a prototype system has been built to test and refine real time signal detection algorithms, to test scan strategies and observatory control functions, and to test algorithms designed to reject radio frequency interference. This paper presents a high level description of the prototype hardware and reports on the preparations to deploy the system to the 34-m antenna at the research and development station of NASA's Deep Space Communication Complex, Goldstone, California.

Klein, M. J.↗
DOE OSTI2020

Mapped Moments to a Cartesian Grid (MMCG) Value-Added Product Report

Objective analysis (OA) is a method of mapping unstructured data to a structured grid. In the context of scanning radar data, OA is used to interpolate data in antenna coordinates (range, azimuth, and elevation) onto a regularly spaced Cartesian grid (Trapp and Doswell 2000). The U.S. Department of Energy Atmospheric Radiation Measurement (ARM) user facility’s Mapped Moments to a Cartesian Grid (MMCG) Value-Added Product (VAP) uses the Python ARM Radar Toolkit (Py-ART), a data model-driven interactive architecture for working with weather radar data, to map the data to a Cartesian grid (Helmus and Collis 2016). MMCG, with Py-ART built in, has the ability to take radar data in antenna coordinates and map the gates to a Cartesian grid using inverse distance weight functions such as Cressman (square) and Barnes (exponential), but also can filter the data during the interpolation. MMCG also allows arbitrary formulations for the radius of influence, which are matched to particular radar scanning strategies. This creates a complex parameter space for optimizing the retention of storm structure detail while minimizing artifacts. MMCG takes data processed with ARM’s Corrected Precipitation Radar Moments in Antenna Coordinates (CMAC) VAP and maps it to a Cartesian grid as the output product. A variety of fields that have been mapped to the Cartesian grid are then saved to plots to complement each grid file.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1991

NASA SETI microwave observing project: Sky Survey element

The SETI Sky Survey Observing Program is one of two complimentary strategies that NASA plans to use in its microwave Search for Extraterrestrial Intelligence (SETI). The primary objective of the sky survey is to search the entire sky over the frequency range of 1.0 to 10.0 GHz for evidence of narrow band signals of extraterrestrial intelligent origin. Frequency resolutions of 30 Hz or narrower will be used across the entire band. Spectrum analyzers with upwards of ten million channels are required to keep the survey time approximately 6 years. Data rates in excess of 10 megabits per second will be generated in the data taking process. Sophisticated data processing techniques will be required to determine the ever changing receiver baselines, and to detect and archive potential SETI signals. Existing radio telescopes, including several of NASA's Deep Space Network (DSN) 34 meter antennas located at Goldstone, CA and Tidbinbilla, Australia will be used for the observations. The JPL has the primary responsibility to develop and carry out the sky survey. In order to lay the foundation for the full scale SETI Sky Survey, a prototype system is being developed at the JPL. The system will be installed at the new 34-m high efficiency antenna at the Deep Space Station (DSS) 13 research and development station, Goldstone, CA, where it will be used to initiate the observational phase of the NASA SETI Sky Survey. It is anticipated that the early observations will be useful to test signal detection algorithms, scan strategies, and radio frequency interference rejection schemes. The SETI specific elements of the prototype system are: (1) the Wide Band Spectrum Analyzer (WBSA); a 2-million channel fast Fourier transformation (FFT) spectrum analyzer which covers an instantaneous bandpass of 40 MHz; (2) the signal detection processor; and (3) the SETI Sky Survey Manager, a network-based C-language environment that provides observatory control, performs data acquisition and analysis algorithms. A high level description of the prototype hardware and software systems will be given and the current status of the system development will be reported.

Klein, M. J.↗
DOE OSTI2023

Frequency‐Scanning Considerations in Axionlike Dark Matter Spin‐Precession Experiments

Abstract Galactic dark matter may consist of axionlike particles (ALPs) that can be described as an “ultralight bosonic field” oscillating at the ALP Compton frequency. The ALP field can be searched for using nuclear magnetic resonance (NMR), where resonant precession of spins of a polarized sample can be sensitively detected. The ALP mass to which the experiment is sensitive is scanned by sweeping the bias magnetic field. The scanning either results in detection of ALP dark matter or rules out ALP dark matter with sufficiently strong couplings to nuclear spins over the range of ALP masses corresponding to the covered span of Larmor frequencies. In this work, scanning strategies are analyzed with the goal of optimizing the parameter‐space coverage via a proper choice of experimental parameters (e.g., the effective transverse relaxation time).

Zhang, Yuzhe (ORCID:0009000660829066)↗
DOE OSTI2025

Laser powder bed fusion parameter estimation with k-NN

Abstract Laser powder bed fusion (L-PBF) is a technique within additive manufacturing that uses a high power density laser to build parts from fused powdered metal alloy. This technology is well equipped to produce complex parts with otherwise impossible features, such as hidden voids or lattice structures. Alongside capability, reliability and quality are key characteristics considered when choosing a manufacturing method, and these are gaining attention as this method becomes more prevalent in industry. One main indicator of a stable L-PBF process is consistent melt pool geometry, and the properties of which are likely to determine the quality of the part produced. As computing power and sensing technologies become more advanced, this melt pool geometry could be studied in real time. This work addresses the challenge by leveraging a k-nearest neighbor (k-NN) model to identify key features within melt pool imagery and predict the energy density. The k-NN model was trained on data provided by the National Institute of Standards and Technology (NIST). Data preprocessing was performed on the images to extract features that were used in the k-NN model. This approach was used to accurately infer the energy density of unseen layers within the same part. The algorithm was subsequently tested with unique scan strategies and found to reasonably estimate the energy density of different parts. A fivefold cross validation found the algorithm to be consistently predicting the class of 91.4% of the in situ melt pool images.

Jung, Patrick (ORCID:0000000267890859)↗
DOE OSTI2022

Boundary characterization using 3D mapping of geometrically necessary dislocations in AM Ta microstructure

Additive manufacturing (AM) of high strength metallic materials produces microstructures and defects that deviate substantially from those created through conventional manufacturing methods. It has recently been demonstrated that with application of extreme energy densities, a high-temperature refractory metal, tantalum (Ta), can be printed to a fully dense state with exceptionally low porosity. Here we employ a combination of three-dimensional electron backscattered diffraction (EBSD) TriBeam technology and crystallographic geometrically necessary dislocation (GND) theory to characterize the microstructure and defect boundaries of this unusual AM product. Two-dimensional (2D) EBSD and these three-dimensional (3D) measurements indicate that the microstructure of AM Ta is highly oriented <111> along the build direction, yet at the same time contains large crystallographic orientation gradients that span mm’s across the build. Crystallographic GND density analysis of the 3D microstructure reveals that highly misoriented subboundaries exist within this strongly textured microstructure that have large dislocation densities of 1×10 16 m –2 , just as large as those comprising the high-angle grain boundaries (HAGBs) in the same material. The 3D crystallographic GND density mapping reveals these subboundaries are part of a complex, finely spaced network that extends throughout the entire microstructure. Here, the orientation of these boundaries can be related to the scan strategy used during printing. TEM measurements corroborate an extremely high dislocation density at the microscale and indicate a cell-like dislocation network structure existing in the AM Ta at the sub-μm scale.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A dynamic volumetric heat source model for laser additive manufacturing

Melt pool scale models of laser powder bed fusion (LPBF) offer insights into the process-structure-property relationships in additive manufacturing (AM). These models often neglect physical phenomena such as vapor cavity formation and fluid mechanics to reduce computational demands. Instead, volumetric heat source models are used to represent the effects that these phenomena have on the predicted melt pool dimensions. Generally, the dimensions and effective absorption of the volumetric heat source are calibrated to reproduce melt pool dimensions observed in metallographic cross sections taken from single-track experiments on bare plate. However, the transient nature of LPBF often deviates the melt pool dimensions from the assumed steady-state conditions of single-track experiments, motivating the need for a volumetric heat source model that more generally considers the dynamic relationship between melt pool shape and laser-material interactions. Here, we introduce a two-parameter volumetric heat source model that integrates several existing models into a generalized mathematical expression, providing independent control over the radial heat distribution via the parameter k and the volumetric shape of the heat source via the parameter m. This parameterization enables the calibration of melt pool shape predictions through simultaneous adjustment of these parameters, while keeping the radial heat source dimensions consistent with the experimental spot size (D4σ) and constraining the heat source depth and absorption to physically derived expressions for cavities. Consequently, the proposed volumetric heat source model adapts to changes in the local melt pool conditions due to scanning strategy and part geometry by dynamically adjusting the heat source depth and absorption. We demonstrate the capabilities of the proposed model through comparisons with a collection of experiments from the Additive Manufacturing Benchmark (AMBench).

36 MATERIALS SCIENCE↗
DOE OSTI2020

The microstructure of a selective laser melting (SLM)-fabricated NiTi shape memory alloy with superior tensile property and shape memory recoverability

A selective laser melting (SLM)-fabricated NiTi with superior tensile property and shape memory recoverability was obtained by using a unique stripe rotation scanning strategy. Here, the alloy characteristics, formation mechanisms and evolution in terms of twins, dislocations and precipitations of the alloy were systematically studied. Compared to the conventional smelting-followed-by-machining, the SLM fabrication process involves rapid solidification and repeated heating, which confer distinctive characteristics to the microstructures of SLM-fabricated NiTi alloys. Rapid solidification promotes the formation of a supersaturation solid solution matrix containing a high concentration vacancies, which in turn aggregate to generate a high density of dislocations. During subsequent repeated heating stages, these dislocations occur thermal motion along three directions of <001 > , <111> and <110 >, leading to the formation of thermal kinks, helical dislocations and wave morphology. Simultaneously, precipitated particles Ti 3 Ni 4 repeatedly nucleate and heterogeneous grow with the movement of dislocation. Such precipitation behavior, termed repeated precipitation, has not been previously reported in the conventional NiTi alloys, suggesting that it could be a unique characteristic of such alloy. After martensitic transformation, only two twins, {1 1¯ 1} type I twin and compound twin, are detected. The twinning lamellae of these two twins, where precipitation and dislocation pile-ups exist, often have uneven thickness and chaotic arrangement. Besides, the unique self-accommodated microstructures, such as secondary {1 1¯ 1} type I twin and compound twin with “herring-bone’’ lamellae, which often appear in the deformed or nanocrystalline NiTi, can also be observed. These unique microstructures may confer the distinctive properties to the SLM-fabricated NiTi.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Directed energy deposition of radially functionally graded nickel based superalloys IN625 and IN738: Microstructure and mechanical properties

This study investigates the microstructure and mechanical properties of radially functionally graded (RFG) materials fabricated from nickel-based superalloys IN625 and IN738 using directed energy deposition (DED). RFG cylindrical deposits with radial gradients of IN625-IN738 and IN738-IN625 were successfully fabricated and confirmed to be crack-free through tailored composition grading, scan strategy and process parameters that minimized thermal gradients and solidification velocities. Microstructural analysis revealed distinct variations across the gradient, characterized by differences in dendrite arm spacing, microsegregation, and the formation of distinct γ' precipitates and carbide/boride phases (MC, M 6 C, M 2 C, and MB 2 ) in as-deposited (AD) conditions, which evolved into M 23 C 6 and M 2 B upon subsequent heat treatment (HT). EBSD showed predominant columnar grains with a [100] texture, while microhardness profiles demonstrated consistent variation across the gradients. Mechanical testing highlighted the synergy of the graded structure, combining IN738's strength with IN625's ductility, resulting in enhanced properties such as a yield strength of 1131 MPa, ultimate tensile strength of 1382 MPa, and elongation of 12 % for HT IN625-IN738 grading. Numerical simulations employing CALPHAD thermodynamic calculations and finite element thermal modeling are used to establish phase evolution and microstructural feature correlation with thermal profiles, aiding in the optimization of process-structure-property relationship.

Additive manufacturing↗
DOE OSTI2022

Mapping 3D grain and precipitate structure during in situ mechanical testing of open-cell metal foam using micro-computed tomography and high-energy X-ray diffraction microscopy

Open-cell metal foams are ultra-low-density cellular metals with complex hierarchical structures that span bulk, cell, ligament, and sub-ligament scales and give rise to desirable properties such as high strength-to-weight ratio and excellent energy absorption. Although literature suggests that intrinsic material structures at sub-ligament length scales (e.g., grains and precipitates) play an important role in mechanical behavior of open-cell metal foams, there are very few experimental measurements of such structures in three dimensions and for meaningful volumes of foam. This study seeks to map and track the three-dimensional (3D) grain and precipitate structures of an intact volume of open-cell aluminum foam by advancing microstructural characterization techniques that leverage X-ray micro-computed tomography (μCT) and far-field high-energy X-ray diffraction microscopy (FF-HEDM). A 6%-relative-density aluminum foam sample was mechanically tested in compression while μCT and FF-HEDM measurements were collected at interrupted loading states at beamline 1-ID of the Advanced Photon Source. Further, a new scanning strategy and reconstruction algorithm were established to enable characterization of a foam volume with diameter approximately four times wider than the nominal width of the X-ray beam. The result is a set of maps that detail both the 3D grain and precipitate structures throughout the foam volume at successive strain steps. A novel grain tracking procedure was developed to track individual grains within the foam volume by accounting for the large rigid-body motions that individual ligaments can undergo during mechanical loading. The ability to track grains and precipitate structures in three dimensions throughout large bulk deformation of ultra-low-density polycrystalline materials enables new possibilities for validating numerical models and investigating local failure mechanisms. Furthermore, the methods and procedures developed in this study could be applied to other ultra-low-density structures, such as additively manufactured lattices.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Dynamic phase transformations in additively manufactured Ti-6Al-4V during thermo-mechanical gyrations

A complex interaction of process parameters, geometry and scan strategies in Additive Manufacturing (AM), can bring about spatial and temporal transients, i.e., Σ T ( x, y, z, time ), within a part. Published literature focusses on fluctuating thermal cycles on the microstructure evolution. However, the microstructural variations have not been correlated to dynamic flow behavior due to the macro- and micro-scale phenomena, i.e., accumulated plastic strains brought about by large thermal gradients, transformational strains and crystallographic misfit strains. Therefore, here we studied the mechanical response of Ti6Al4V alloys produced by AM under externally imposed controlled thermo-mechanical reversals in a Gleeble® thermo-mechanical simulator. The stress-strain behaviors were correlated to phase fractions, lattice strains, and also limited information on crystallographic texture using neutron diffraction techniques at the VULCAN Beamline at SNS, ORNL and also metallographic studies. The results are discussed and rationalized based on theories of static and dynamic phase transformations.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Stress localization investigation of additively manufactured GRCop-42 thin-wall structure

A full-field crystal plasticity (CP) framework is presented for the GRCop-42 alloy to study microscopic mechanical behavior and local stress heterogeneities. The microstructures of additively manufactured (AM) materials are often unique relative to conventionally processed materials, and the local thermal histories drive these differences during the build process. These thermal histories depend on the process parameters (laser power, scan speed, and scan strategy) and the part geometry. Prior research has shown that the mechanical properties of thin-walled structures can vary significantly with wall thickness due to changes in the thermal boundary conditions during manufacturing. It is, therefore, desirable to perform CP simulations based on the phenomenological constitutive model to predict the local mechanical responses induced by microstructural heterogeneities. This work generates representative microstructures based on experimentally collected grain information (i.e., texture) for grain scale stress analysis, and the material constitutive parameters are calibrated using the experimental mechanical testing data. Here, we specifically investigated the effect of crystallographic texture and grain morphologies on the size-dependent mechanical properties of AM GRCop-42. The selection of appropriate material properties for implementing an effective free surface boundary condition and the influence of adjacent buffer layers are also discussed. Analysis of local field results reveals a strong correlation between stress localization and the initial grain orientation. However, no significant relationship between the misorientation of the individual adjacent grains and the average misorientation is observed.

36 MATERIALS SCIENCE↗