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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
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↗
DOE OSTI2025

Rapid Solidification Effects in Additively Manufactured Si and SiGe Compositions

SiGe alloys have a proven track record as robust high-temperature thermoelectric materials, powering NASA missions like SNAP-10A, LES-9, and Voyager 1 and 2. Enhancing thermoelectric efficiency hinges on minimizing thermal conductivity while preserving electrical conductivity. Rapid solidification via LPBF can generate microstructural features such as subgrain cellular boundaries and twinning, which may help reduce thermal conductivity while preserving semiconducting behavior. Here, this study investigates the potential of laser powder bed fusion (LPBF) additive manufacturing to fabricate nanostructured Si and SiGe thermoelectric materials. High cooling rates (10 5 to 10 7 K/s) rates inherent to the LPBF process are conducive to forming such nanostructures. Moreover, this fabrication technique could also be suitable for fabricating complex geometries needed to achieve improved device level performance. Process mapping of commercial Si powder with irregular morphology was first performed to understand the LPBF processing behavior of this semiconductor material. Subsequent studies included in-house synthesized B-doped (p-type) Si7 8 Ge 22 spherical powder that was produced via ultrasonic atomization. Scan strategies involved multiple laser exposures to mitigate solidification cracking: a high density of >98% was achieved, but solidification cracking could not be fully eliminated. Subsequently, a high electrical resistivity (i.e., low conductivity) was observed, but the measured Seebeck coefficient, ∼230 μV/K @ 500 °C, proved that good semiconductor material was being fabricated. A subgrain cellular structure (5–10 μm) was observed as defined by Ge segregation to the intercellular boundaries. The remelting strategies helped lower the cooling rates in processing SiGe, but this still resulted in high residual stresses, which induced a remarkably high density of twins (78–95%) to accommodate the deformation. This unique grain structure offers an avenue for phonon scattering and potential improvements in thermoelectric performance.

figure of merit↗
DOE OSTI2022

CO 2 Laser Sintering of Garnet-Type Solid-State Electrolytes

We report the processing of garnet-type solid-state electrolytes remains challenging as densification conventionally requires high sintering temperatures and long processing times, which can result in severe Li loss, the formation of secondary phases, and thus high porosity and low ionic conductivity. Here, we report an ultrafast sintering method based on CO 2 laser scanning with the assistance of a heating stage. We demonstrate the rapid densification of low-packing-density Li 6.4 La 3 Zr 1.4 Ta 0.6 O 12 (LLZTO) films, which are difficult to densify by conventional furnace sintering methods. This unique approach has three fingerprint characteristics: (1) mitigation of Li loss through ultrafast sintering (dwelling time $\ll$1 s); (2) a unique anisotropic shrinkage behavior that greatly reduces film thickness; (3) wave-like surface topology from point scanning strategy that enables 3D interfacial contacts with electrode materials. Herein, highly dense (95.68%) and highly conductive (0.26 mS·cm –1 at 25 °C) LLZTO films are obtained through CO2 laser sintering. This work provides a unique, scalable, and widely applicable ultrarapid laser sintering technique to overcome the difficulties associated with classic methods for the integration of SSEs for practical all-solid-state Li-metal battery applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

From BEYONDPLANCK to COSMOGLOBE: Preliminary WMAP Q -band analysis

We present the first application of the COSMOGLOBE analysis framework by analyzing nine-year WMAP time-ordered observations that uses similar machinery to that of BEYONDPLANCK for the Planck Low Frequency Instrument (LFI). We analyzed only the Q-band (41 GHz) data and report on the low-level analysis process based on uncalibrated time-ordered data to calibrated maps. Most of the existing BEYONDPLANCK pipeline may be reused for WMAP analysis with minimal changes to the existing codebase. The main modification is the implementation of the same preconditioned biconjugate gradient mapmaker used by the WMAP team. Producing a single WMAP Q1-band sample requires 22 CPU-hrs, which is slightly more than the cost of a Planck 44 GHz sample of 17 CPU-hrs; this demonstrates that a full end-to-end Bayesian processing of the WMAP data is computationally feasible. In general, our recovered maps are very similar to the maps released by the WMAP team, although with two notable differences. In terms of temperature, we find a ~2 μK quadrupole difference that most likely is caused by different gain modeling, while in polarization we find a distinct 2.5 μK signal that has been previously referred to as poorly measured modes by the WMAP team. In the COSMOGLOBE processing, this pattern arises from temperature-to-polarization leakage from the coupling between the CMB Solar dipole, transmission imbalance, and sidelobes. No traces of this pattern are found in either the frequency map or TOD residual map, suggesting that the current processing has succeeded in modeling these poorly measured modes within the assumed parametric model by using Planck information to break the sky-synchronous degeneracies inherent in the WMAP scanning strategy.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

The large scale polarization explorer (LSPE) for CMB measurements: performance forecast

The measurement of the polarization of the Cosmic Microwave Background (CMB) radiation is one of the current frontiers in cosmology. In particular, the detection of the divergence-free component of the polarization field, the B-mode component, reveals the presence of gravitational waves in the early Universe. The detection of such component is at the moment the most promising technique to probe the inflationary theory describing the very early evolution of the Universe. The measurement of the polarization of the Cosmic Microwave Background (CMB) radiation is one of the current frontiers in cosmology. In particular, the detection of the primordial divergence-free component of the polarization field, the B-mode, could reveal the presence of gravitational waves in the early Universe. The detection of such a component is at the moment the most promising technique to probe the inflationary theory describing the very early evolution of the Universe. We present the updated performance forecast of the Large Scale Polarization Explorer (LSPE), a program dedicated to the measurement of the CMB polarization. LSPE is composed of two instruments: LSPE-Strip, a radiometer-based telescope on the ground in Tenerife-Teide observatory, and LSPE-SWIPE (Short-Wavelength Instrument for the Polarization Explorer) a bolometer-based instrument designed to fly on a winter arctic stratospheric long-duration balloon. The program is among the few dedicated to observation of the Northern Hemisphere, while most of the international effort is focused into ground-based observation in the Southern Hemisphere. Measurements are currently scheduled in Winter 2022/23 for LSPE-SWIPE, with a flight duration up to 15 days, and in Summer 2022 with two years observations for LSPE-Strip. In this work, we describe the main features of the two instruments, identifying the most critical aspects of the design, in terms of impact on the performance forecast. We estimate the expected sensitivity of each instrument and propagate their combined observing power to the sensitivity to cosmological parameters, including the effect of scanning strategy, component separation, residual foregrounds and partial sky coverage. We also set requirements on the control of the most critical systematic effects and describe techniques to mitigate their impact. LSPE will reach a sensitivity in tensor-to-scalar ratio of σr < 0.01, set an upper limit r < 0.015 at 95% confidence level, and improve constraints on other cosmological parameters.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Probing anisotropies of the Stochastic Gravitational Wave Background with LISA

Here, we investigate the sensitivity of the Laser Interferometer Space Antenna (LISA) to the anisotropies of the Stochastic Gravitational Wave Background (SGWB). We first discuss the main astrophysical and cosmological sources of SGWB which are characterized by anisotropies in the GW energy density, and we build a Signal-to-Noise estimator to quantify the sensitivity of LISA to different multipoles. We then perform a Fisher matrix analysis of the prospects of detectability of anisotropic features with LISA for individual multipoles, focusing on a SGWB with a power-law frequency profile. We compute the noise angular spectrum taking into account the specific scan strategy of the LISA detector. We analyze the case of the kinematic dipole and quadrupole generated by Doppler boosting an isotropic SGWB. We find that β Ω GW ~ 2 × 10 -11 is required to observe a dipolar signal with LISA. The detector response to the quadrupole has a factor ~ 10 3 β relative to that of the dipole. The characterization of the anisotropies, both from a theoretical perspective and from a map-making point of view, allows us to extract information that can be used to understand the origin of the SGWB, and to discriminate among distinct superimposed SGWB sources.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

The Atacama Cosmology Telescope: map-based noise simulations for DR6

Abstract The increasing statistical power of cosmic microwave background (CMB) datasets requires a commensurate effort in understanding their noise properties. The noise in maps from ground-based instruments is dominated by large-scale correlations, which poses a modeling challenge. This paper develops novel models of the complex noise covariance structure in the Atacama Cosmology Telescope Data Release 6 (ACT DR6) maps. We first enumerate the noise properties that arise from the combination of the atmosphere and the ACT scan strategy. We then prescribe a class of Gaussian, map-based noise models, including a new wavelet-based approach that uses directional wavelet kernels for modeling correlated instrumental noise. The models are empirical, whose only inputs are a small number of independent realizations of the same region of sky. We evaluate the performance of these models against the ACT DR6 data by drawing ensembles of noise realizations. Applying these simulations to the ACT DR6 power spectrum pipeline reveals a ∼ 20% excess in the covariance matrix diagonal when compared to an analytic expression that assumes noise properties are uniquely described by their power spectrum. Along with our public code,mnms, this work establishes a necessary element in the science pipelines of both ACT DR6 and future ground-based CMB experiments such as the Simons Observatory (SO).

Astronomy & Astrophysics↗
DOE OSTI2025

An iterative CMB lensing estimator minimizing instrumental noise bias

Noise maps from cosmic microwave background (CMB) experiments are generally statistically anisotropic, due to scanning strategies, atmospheric conditions, or instrumental effects. Any mismodeling of this complex noise can bias the reconstruction of the lensing potential and the measurement of the lensing power spectrum from the observed CMB maps. We introduce a new CMB lensing estimator based on the maximum (MAP) reconstruction that is minimally sensitive to these instrumental noise biases. By modifying the likelihood to rely exclusively on correlations between CMB map splits with independent noise realizations, we minimize autocorrelations that contribute to biases. In the regime of many independent splits, this maximum closely approximates the optimal MAP reconstruction of the lensing potential. In simulations, we demonstrate that this method is able to determine lensing observables that are immune to any noise mismodeling with a negligible cost in signal-to-noise ratio. Our estimator enables unbiased and nearly optimal lensing reconstruction for next-generation CMB surveys.

Legrand, Louis [University of Cambridge (United Ki↗
DOE OSTI2022

Towards directed energy deposition of metals using polymer-based supports: porosity of 316L stainless steel deposited on carbon-fiber-reinforced ABS

Directed energy deposition (DED) is increasingly valuable to many industries because of its high deposition rates relative to other metal additive manufacturing processes, but the design space of DED is limited. For instance, steep overhangs are difficult or impossible to manufacture. Polymer-based support structures could help address this challenge. The viability of DED on polymer composite substrates has begun to be explored, specifically with 316L stainless steel on carbon-fiber-reinforced ABS substrates. Monolithic metal components can be deposited on the polymer, but it was found that gas release during polymer degradation causes porosity due to gas entrapment in the metal. An interlayer cooling time was introduced to reduce polymer degradation and decrease the porosity due to gas entrapment, but this led to porosity from lack of fusion. The results of this work provide insight into process parameter selection and scan strategy development to enable the use of polymer support structures in blown-powder DED.

Kurfess, Rebecca↗
DOE OSTI2021

In-situ digital image correlation and thermal monitoring in directed energy deposition additive manufacturing

As in welding, directed energy deposition (DED) additive manufacturing (AM) generates complex residual stresses and distortions commensurate with the complexity of the scan pattern used for deposition. To date, measuring DED distortions on complex geometries has only been achieved post process, discarding the complex thermomechanical history that leads to that final material state. In this work, surround stereo digital image correlation (DIC) is used to 3D map surfaces and strain tensors in-situ in a powder-blown laser DED system. Infrared thermography is then projected onto these surfaces to record the full thermomechanical history of printed parts. DIC presents a unique challenge to DED AM, as no part exists at the beginning of deposition, which (a) prevents application of an appropriate speckle pattern and (b) denies the user a zero strain reference frame. Solutions to these problems are proposed and their limitations explored herein. In sum, this work presents a relatively low-cost solution to monitoring and optimizing the unique temporal artifacts induced by complex scan strategies that was previously unobtainable.

42 ENGINEERING↗
DOE OSTI2022

High-resolution ptychographic imaging enabled by high-speed multi-pass scanning

As a coherent diffraction imaging technique, ptychography provides high-spatial resolution beyond Rayleigh’s criterion of the focusing optics, but it is also sensitively affected by the decoherence coming from the spatial and temporal variations in the experiment. Here we show that high-speed ptychographic data acquisition with short exposure can effectively reduce the impact from experimental variations. To reach a cumulative dose required for a given resolution, we further demonstrate that a continuous multi-pass scan via high-speed ptychography can achieve high-resolution imaging. This low-dose scan strategy is shown to be more dose-efficient, and has potential for radiation-sensitive sample studies and time-resolved imaging.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2020

Description of the LASSO Data Bundles Product

The U. S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facility began a pilot project in May 2015 to design a routine, high-resolution modeling capability to complement ARM’s extensive suite of measurements. This modeling capability has evolved into the Large-Eddy Simulation (LES) ARM Symbiotic Simulation and Observation (LASSO) datastream. The datastream, broadly termed data bundles, contains high-resolution model output, input files, observations for evaluation, and skill scores for the simulations. The initial focus of LASSO is on shallow convection at the ARM Southern Great Plains (SGP) atmospheric observatory. The availability of LES simulations with concurrent observations serves many purposes. LES helps bridge the scale gap between DOE ARM observations and models, and the use of routine LES adds value to observations. It provides a self-consistent representation of the atmosphere and a dynamical context for the observations. Further, it elucidates unobservable processes and properties. LASSO generates a simulation library for researchers that enables statistical approaches beyond a single-case mentality. It also provides tools necessary for modelers to reproduce the LES and conduct their own sensitivity experiments. The LASSO library of data bundles is designed to facilitate a wide range of research. For an observationalist, LASSO can help inform instrument remote-sensing retrievals, conduct observation system simulation experiments (OSSEs), and test implications of radar scan strategies or flight paths. For a theoretician, LASSO can help calculate estimates of fluxes and co-variability of values, and test relationships without having to run the model personally. For a modeler, LASSO can help one know ahead of time which days have good forcing, have co-registered observations at high-resolution scales, and have simulation inputs and corresponding outputs to test parameterizations. Further details on the overall LASSO project are available at https://www.arm.gov/capabilities/modeling/lasso.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Rapid SACR Observations of Convection at Bankhead National Forest (RAPID) Field Campaign Report

Improving our representation of convective cell processes requires better quantification of convective clouds throughout their entire life cycle. This includes gaining a clearer understanding of the controls on key convective cloud properties, such as updraft intensity, particle size distributions, rainfall rates, and hydrometeor species. Our inability to improve convective cloud process modeling stems, in part, from a limited understanding of convective cell properties, particularly given how rapidly these storms evolve. This lack of detailed observations in the most intense and organized convective storms is especially significant, as large errors remain in representing these clouds, which are critical for severe weather prediction and Earth system model performance. Cloud and precipitation radars are essential tools for studying cloud microphysics and dynamics, particularly in deeper convective clouds. The recent U.S. Department of Energy Atmospheric Radiation Measurement (ARM) User Facility’s third Mobile Facility (AMF3) Bankhead National Forest (BNF) deployment provides a unique opportunity to investigate important land–atmosphere interactions, as well as the environmental controls on deep convective cloud processes, in a location favorable for frequent convection. We operate the X/Ka-band Scanning ARM Cloud Radar (X/Ka SACR) using a scan strategy optimized to capture these rapidly evolving clouds and their properties, thereby improving studies of deep convective cloud processes. This effort is strengthened by a complementary and coordinated partnership with ongoing university and multi-agency radar activities collocated in north Alabama—a unique opportunity to examine clouds and precipitation from a lifetime-centric perspective.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

In-situ digital image correlation and thermal monitoring in directed energy deposition

A method and a system for digital image correlation and thermal monitoring during directed energy deposition are provided. The method and the system include global off-axis 3D mapping of surfaces features at high frame rates using the natural surface roughness of the additive build. Infrared thermography is projected onto these surface features to record the thermo-mechanical history of the finished component. As set forth herein, the method and the system provide a low-cost solution to monitoring and optimizing the unique temporal artifacts induced by complex scan strategies.

Haley, James↗
DOE OSTI2026

On the formation of swelling and related flaws in laser powder bed fusion

Process monitoring in laser powder bed fusion additive manufacturing can provide insights into stochastic anomalies, melt pool and plume dynamics, and part quality. Swelling, a build anomaly where overbuilt material protrudes through the powder layer after recoating, is readily detectable in post-recoat visible light images of the powder bed. Here, this work identifies several of the underlying mechanisms driving swelling formation by analyzing the influence of processing parameters, laser scan paths, and build plate locations on the presence of swelling detected in situ. Swelling near the edge of the part and swelling in the internal region of the part are shown to correlate with different process conditions. Edge and internal swelling may be driven by different phenomena, with edge swelling predominately occurring on the edge of a part facing the laser module and correlated to clusters of near-surface voids (detected with X-ray computed tomography). A larger spot size, higher laser power, and lower scan velocity also increased the presence of edge swelling. Laser spot size and scan path influenced internal swelling, which occurred preferentially with a larger spot size and in regions with large melt pools, caused by localized heat accumulation due to non-optimal processing parameters or scan path strategies. For coupons processed with a slicer-defined maximum scan vector length, swelling seldom occurred at internal vector-stripe boundaries. These results provide a mechanistic understanding of how swelling can be linked to material flaws, insight into how some instances of swelling can be avoided, and evidence supporting the use of swelling as an in situ indicator for quality assurance and part qualification.

Anomaly↗