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NASA NTRS2021

ICESat-2 Constraint Analysis and Monitoring System (CAMS)

The Ice, Cloud and land Elevation Satellite-2 was launched on 15 September 2018 with mission goals of collecting surface elevation data that can precisely measure ice sheet topography, cloud and aerosol heights, land topography, as well as vegetation height for ecosystems studies. The Constraint Analysis and Monitoring System (CAMS) was implemented as an ICESat-2 ground system element to perform Mission Planning and Spacecraft Safety Monitoring. Mission Planning requires CAMS to serve as an interface between the Project Science Office, the Instrument Support Facility and the Mission Operation Control Center. By ingesting inputs received from all three groups, the CAMS builds an optimized and deconflicted timeline of science and instrument activities. Based upon the timeline of activities, the CAMS utilizes a sophisticated set of algorithms to model and predict the location and pointing of the spacecraft instrument relative to the Earth and Sun. From the predicted position and pointing, the CAMS provides precise monitoring of instrument health, and performs space asset laser conjunction detection. Furthermore, the CAMS determines alternative plans to prevent detected health constraint violations or mitigate potential laser conjunctions. This paper provides an overview of the CAMS and presents the operational performance of planning science and instrument activities, the monitoring of instrument constraints for health and safety, and the space asset laser conjunction screening and mitigation process.

ICESat-2↗

NASA NTRS2002

Computing the Envelope for Stepwise-Constant Resource Allocations

Computing tight resource-level bounds is a fundamental problem in the construction of flexible plans with resource utilization. In this paper we describe an efficient algorithm that builds a resource envelope, the tightest possible such bound. The algorithm is based on transforming the temporal network of resource consuming and producing events into a flow network with nodes equal to the events and edges equal to the necessary predecessor links between events. A staged maximum flow problem on the network is then used to compute the time of occurrence and the height of each step of the resource envelope profile. Each stage has the same computational complexity of solving a maximum flow problem on the entire flow network. This makes this method computationally feasible and promising for use in the inner loop of flexible-time scheduling algorithms.

Muscettola, Nicola↗

NASA NTRS1995

Thermal Conductivity Measurements of Helium 4 Near the Lambda-Transition Using a Magnetostrictive Low Gravity Simulator

There has been a recent increase in interest both experimentally and theoretically in the study of liquid helium very near the lambda-transition in the presence of a heat current. In traditional ground based experiments there are gravitationally induced pressure variations in any macroscopic helium sample that limit how closely the transition can be approached. We have taken advantage of the finite magnetic susceptibility of He 4 to build a magnetostrictive low gravity simulator. The simulator consists of a superconducting magnet with field profile shaped to counteract the force of gravity in a helium sample. When the magnet is operated with B x dB/dz = 21T(exp 2)/cm at the location of the cell, the gravitationally induced pressure variations will be canceled to within 1% over a volume of 0.5 cm in height and 0.5 cm in diameter. This technique for canceling the pressure variations in a long sample cell allows the lambda-transition to be studied much closer in reduced temperature and under a wider range of applied heat currents than is possible using other ground based techniques. Preliminary results using this low gravity simulator and the limitations of the magnetostrictive technique in comparison to doing space based experiments will be presented.

superconductive magnet heat current↗

NASA NTRS2005

Automated Rapid Prototyping of 3D Ceramic Parts

An automated system of manufacturing equipment produces three-dimensional (3D) ceramic parts specified by computational models of the parts. The system implements an advanced, automated version of a generic rapid-prototyping process in which the fabrication of an object having a possibly complex 3D shape includes stacking of thin sheets, the outlines of which closely approximate the horizontal cross sections of the object at their respective heights. In this process, the thin sheets are made of a ceramic precursor material, and the stack is subsequently heated to transform it into a unitary ceramic object. In addition to the computer used to generate the computational model of the part to be fabricated, the equipment used in this process includes: 1) A commercially available laminated-object-manufacturing machine that was originally designed for building woodlike 3D objects from paper and was modified to accept sheets of ceramic precursor material, and 2) A machine designed specifically to feed single sheets of ceramic precursor material to the laminated-object-manufacturing machine. Like other rapid-prototyping processes that utilize stacking of thin sheets, this process begins with generation of the computational model of the part to be fabricated, followed by computational sectioning of the part into layers of predetermined thickness that collectively define the shape of the part. Information about each layer is transmitted to rapid-prototyping equipment, where the part is built layer by layer. What distinguishes this process from other rapid-prototyping processes that utilize stacking of thin sheets are the details of the machines and the actions that they perform. In this process, flexible sheets of ceramic precursor material (called "green" ceramic sheets) suitable for lamination are produced by tape casting. The binder used in the tape casting is specially formulated to enable lamination of layers with little or no applied heat or pressure. The tape is cut into individual sheets, which are stacked in the sheet-feeding machine until used. The sheet-feeding machine can hold enough sheets for about 8 hours of continuous operation.

McMillin, Scott G.↗

NASA NTRS2001

Computing the Envelope for Stepwise Constant Resource Allocations

Estimating tight resource level is a fundamental problem in the construction of flexible plans with resource utilization. In this paper we describe an efficient algorithm that builds a resource envelope, the tightest possible such bound. The algorithm is based on transforming the temporal network of resource consuming and producing events into a flow network with noises equal to the events and edges equal to the necessary predecessor links between events. The incremental solution of a staged maximum flow problem on the network is then used to compute the time of occurrence and the height of each step of the resource envelope profile. The staged algorithm has the same computational complexity of solving a maximum flow problem on the entire flow network. This makes this method computationally feasible for use in the inner loop of search-based scheduling algorithms.

Muscettola, Nicola↗

NASA NTRS1998

Issues in the reconstruction of environmental doses on the basis of thermoluminescence measurements in the Techa riverside

The potential of thermoluminescence measurements of bricks from the contaminated area of the Techa river valley, Southern Urals, Russia, for reconstructing external exposures of affected population groups has been studied. Thermoluminescence dating of background samples was used to evaluate the age of old buildings available on the river banks. The anthropogenic gamma dose accrued in exposed samples is determined by subtracting the natural radiation background dose for the corresponding age from the accumulated dose measured by thermoluminescence. For a site in the upper Techa river region, where the levels of external exposures were extremely high, the depth-dose distribution in bricks and the dependence of accidental dose on the height of the sampling position were determined. For the same site, Monte Carlo simulations of radiation transport were performed for different source configurations corresponding to the situation before and after the construction of a reservoir on the river and evacuation of the population in 1956. A comparison of the results provides an understanding of the features of the measured depth-dose distributions and height dependencies in terms of the source configurations and shows that bricks from the higher sampling positions are likely to have accrued a larger fraction of anthropogenic dose from the time before the construction of the reservoir. The applicability of the thermoluminescent dosimetry method to environmental dose reconstruction in the middle Techa region, where the external exposure was relatively low, was also investigated.

NASA Discipline Radiation Health↗

NASA NTRS2010

The ICESat-2 Laser Altimetry Mission

Satellite and aircraft observations have revealed that remarkable changes in the Earth s polar ice cover have occurred in the last decade. The impacts of these changes, which include dramatic ice loss from ice sheets and rapid declines in Arctic sea ice, could be quite large in terms of sea level rise and global climate. NASA's Ice, Cloud and Land Elevation Satellite-2 (ICESat-2), currently planned for launch in 2015, is specifically intended to quantify the amount of change in ice sheets and sea ice and provide key insights into their behavior. It will achieve these objectives through the use of precise laser measurements of surface elevation, building on the groundbreaking capabilities of its predecessor, the Ice Cloud and Land Elevation Satellite (ICESat). In particular, ICESat-2 will measure the temporal and spatial character of ice sheet elevation change to enable assessment of ice sheet mass balance and examination of the underlying mechanisms that control it. The precision of ICESat-2's elevation measurement will also allow for accurate measurements of sea ice freeboard height, from which sea ice thickness and its temporal changes can be estimated. ICESat-2 will provide important information on other components of the Earth System as well, most notably large-scale vegetation biomass estimates through the measurement of vegetation canopy height. When combined with the original ICESat observations, ICESat-2 will provide ice change measurements across more than a 15-year time span. Its significantly improved laser system will also provide observations with much greater spatial resolution, temporal resolution, and accuracy than has ever been possible before.

Abdalati, Waleed↗

NASA NTRS1992

The FML compressor as a drive system for the LFSWT: A narrative

During 1988, a feasibility study was performed to decide how best to build a Laminar Flow Supersonic Wind Tunnel (LFSWT) at the NASA-Ames Fluid Mechanics Laboratory (FML) for boundary layer transition research. A full report was received in June 1988. The report was based on the following guidelines: continuous operation at Mach numbers within the range from 1.8-4.0 was required to impact the NASA 'HiStar' project; low disturbance flow is essential for transition research; minimum test section height is 8 inches; tunnel must fit in an FML test cell; tunnel design should be simple; and construction costs should be minimized. The study considered three drive system options: (1) use surplus JPL compressors and support equipment; (2) use of the FML compressor with ambient injectors; and (3) use of the FML compressor with injectors driven by the NASA-Ames 3000 psia air supply.

Laub, James↗

NASA NTRSDate not supplied

The geologic evolution of Imdr Regio: a possible active hot spot on Venus

Imdr Regio is a large igneous rise that extends approximately from 35ºS-50ºS and 195ºE-225ºE between the plains of Helen, Nsomeka and Wawalag Planitiae. Imdr Regio was classified as a volcano-dominated igneous rise with a minimum-maximum diameter of 1200-1400 km and a swell height of 1.6 km. The major volcanic feature in Imdr Regio is Idunn Mons (46.5ºS/214.5ºE), a large volcano. Studies using the 1 mm (derived) surface emissivity from the Venus Express mission of the volcanic flows surrounding Idunn Mons suggest that high emissivity values in the volcano flanks are related to relatively unweathered basaltic rock and therefore indicative of a recent or even ongoing volcanic activity in Idunn Mons. Building on this previous work, here we present the first preliminary geologic map of Imdr Regio, characterize the different types of volcanism besides Idunn Mons, and their relationship with the rift and other regional structures, and discuss its geologic evolution.

I. López↗

NASA NTRS2014

Ultrasonic Inspection to Quantify Failure Pathologies of Crimped Electrical Connections

Previous work has shown that ultrasonic inspection provides a means of assessing electrical crimp quality that ensures the electrical and mechanical integrity of an initial crimp before the installation process is completed. The amplitude change of a compressional ultrasonic wave propagating at right angles to the wire axis and through the junction of a crimp termination was shown to correlate with the results of destructive pull tests, which is a standard for assessing crimp wire junction quality. Of additional concern are crimps made at high speed assembly lines for wiring harnesses, which are used for critical applications, such as in aircraft. During high-speed assembly it is possible that many faulty crimps go undetected until long after assembly, and fail in service. The position and speed of the crimping jaw become factors as the high-speed crimp is formed. The work presented in this paper is designed to cover the more difficult and more subtle area of high-speed crimps by taking into account the rate change of the measurements. Building on the previous work, we present an analysis methodology, based on transmitted ultrasonic energy and timing of the first received pulse that is shown to correlate to the gauge of the crimp/ferrule combination and the position of the crimping jaw. Results demonstrating the detectability of a number of the crimp failure pathologies, such as missing strands, partially inserted wires and incomplete crimp compression, are presented. The ability of this technique to estimate crimp height, a mechanical measure of crimp quality, is discussed.

Cramer, K. Elliott↗

NASA NTRS2015

Development of the Resource Prospector Planetary Rover

The Resource Prospector (RP) is an In-‐Situ Resource Utilization (ISRU) lunar rover mission under study by NASA. RP is planned to launch in 2020 to prospect for subsurface volatiles and to extract oxygen from lunar regolith. The mission will address several of NASA's "Strategic Knowledge Gaps" for lunar exploration. The mission will also address the Global Exploration Roadmap's strategic goal of using local resources for human exploration. The distribution of lunar subsurface volatiles drives the mission requirement for mobility. The spatial distribution is hypothesized to be governed by impact cratering with the top 0.5 m being patchy at scales of 100 m. The mixing time scale increases with depth (less frequent larger impacts). Consequently, increased mobility reduces the depth requirement for sampling. The target RP traverse will extend 1 km radially from the landing site to sample craters of varying sizes. Sampling craters with different ages will reveal possible volatile emplacement history. In 1 Ga, approximately 60-70 craters of 10 m diameter form per km2. Thus, the rover will need to sample at least ten of these craters, which may require a total traverse path length of 2-‐3 km. During 2014-2015, we developed an initial prototype rover for RP. The current design is a solar powered, four-wheeled vehicle, with hub motor drive, offset four wheel steering, and active suspension. Active suspension provides capabilities including changing vehicle ride height, traversing comparatively large obstacles, and controlling load on the wheels. All-wheel steering enables the vehicle to point arbitrarily while roving, e.g., to keep the solar array pointed at the sun while in motion. The offset steering combined with active suspension improves driving in soft soil. The rover's on-board software utilizes NASA's Core Flight Software, which is a reusable flight software environment. During 2015, we completed the initial rover software build, which provides low-level hardware interfaces, basic mobility control, waypoint driving, odometry, basic error checking, and camera services. Development of the prototype rover has enabled maturation of many of the subsystems to TRL 5. During the next year, we will conduct integrated testing of concepts of operation, navigation, and remote driving tools. In addition, we will perform environmental tests including radiation (avionics), thermal and thermal/vacuum (mechanisms), and gravity offload (mobility).

robotics↗

NASA NTRSDate not supplied

Development and Airborne Demonstration of the Concurrent Artificially-Intelligent Spectrometry and Adaptive Lidar System: Advancing Lidar Capabilities for the STV Observing System

We report on the design, build and planned airborne demonstration of a spaceflight-prototype Concurrent Artificially-intelligent Spectrometry and Adaptive Lidar System (CASALS). The CASALS lidar is an Adaptive Wavelength Scanning Lidar (AWSL) operating in push broom mode. The demonstration has three major goals: advance the Technical Readiness Level of the AWSL hardware, validate its measurement performance and mature algorithms and methods needed for the Surface Topography and Vegetation (STV) observing system. AWSL acquires parallel tracks of surface heights by rapidly steering a laser beam across a swath. A 1040nm-centered laser is tuned across 30nm and carved into 2-ns pulses, the pulse energy is fiber amplified and the pulses are dispersed cross-track using a non-mechanical wavelength-to-angle grating. For the spaceflight system the beam will be pointable to 1200 10m footprints across a 7km swath. For the airborne demonstration there will be 256 0.7m footprints across a 110m swath. In both cases the footprints overlap across- and along-track for uniform target illumination. For the airborne demonstration a steering mirror will increase the accessible swath width to 4km. At the receiver, solar radiation is filtered with a narrow-slit grating-spectrometer and the footprints are imaged onto a linear-mode, photon-sensitive HgCdTe APD-array. The received pulses are time-division-multiplexed to a few high-speed analog-to-digital converters to record waveforms. Spaceflight and airborne CASALS are designed to nominally detect 20 photons per pulse and, by averaging 27 overlapping footprints, achieve 2cm flat target range precision and high-quality vegetation structure waveforms The AWSL will be flown in the summer of 2024, along with a Headwall VNIR-SWIR hyperspectral sensor imaging a 4km wide swath, at NEON eddy covariance flux towers in the U.S. mid-Atlantic where high resolution hyperspectral and lidar data, acquired annually, are available for validation.

Guangning Yang↗

NASA NTRS2006

Solar CIV Vacuum-Ultraviolet Fabry-Perot Interferometers

Aims: A tunable, high spectral resolution, high effective finesse, vacuum ultraviolet (VUV) Fabry-Perot interferometer (PPI) is designed for obtaining narrow-passband images, magnetograms, and Dopplergrams of the transition region emission line of CIV (155 nm). Methods: The integral part of the CIV narrow passband filter package (with a 2-10 pm FWHM) consists of a multiple etalon system composed of a tunable interferometer that provides high-spectral resolution and a static low-spectral resolution interferometer that allows a large effective free spectral range. The prefilter for the interferometers is provided by a set of four mirrors with dielectric high-reflective coatings. A tunable interferometer, a VUV piezoelectric-control etalon, has undergone testing using the surrogate F2 eximer laser line at 157 nm for the CIV line. We present the results of the tests with a description of the overall concept for a complete narrow-band CIV spectral filter. The static interferometer of the filter is envisioned as being hudt using a set of fixed MgF2 plates. The four-mirror prefilter is designed to have dielectric multilayer n-stacks employing the design concept used in the Ultraviolet Imager of NASA's Polar Spacecraft. A dual etalon system allows the effective free spectral range to be commensurate with the prefilter profile. With an additional etalon, a triple etalon system would allow a spectrographic resolution of 2 pm. The basic strategy has been to combine the expertise of spaceflight etalon manufacturing with VUV coating technology to build a VUV FPI which combines the best attributes of imagers and spectrographs into a single compact instrument. Results. Spectro-polarimetry observations of the transition region CIV emission can be performed to increase the understanding of the magnetic forces, mass motion, evolution, and energy release within the solar atmosphere at the base of the corona where most of the magnetic field is approximately force-free. The 2D imaging of the full vector magnetic field at the height of maximum magnetic influence (minimum plasma beta) can be accomplished, albeit difficult, by measuring the Zeeman splitting of the CIV resonance pair. Designs of multiple VUV FPIs can be developed for integration into future orbiting solar observatories to obtain rapid cadence, spectral imaging of the transition region.

Gary, G. Allen↗

NASA NTRS2011

Teleoperated Marsupial Mobile Sensor Platform Pair for Telepresence Insertion Into Challenging Structures

A platform has been developed for two or more vehicles with one or more residing within the other (a marsupial pair). This configuration consists of a large, versatile robot that is carrying a smaller, more specialized autonomous operating robot(s) and/or mobile repeaters for extended transmission. The larger vehicle, which is equipped with a ramp and/or a robotic arm, is used to operate over a more challenging topography than the smaller one(s) that may have a more limited inspection area to traverse. The intended use of this concept is to facilitate the insertion of a small video camera and sensor platform into a difficult entry area. In a terrestrial application, this may be a bus or a subway car with narrow aisles or steep stairs. The first field-tested configuration is a tracked vehicle bearing a rigid ramp of fixed length and width. A smaller six-wheeled vehicle approximately 10 in. (25 cm) wide by 12 in. (30 cm) long resides at the end of the ramp within the larger vehicle. The ramp extends from the larger vehicle and is tipped up into the air. Using video feedback from a camera atop the larger robot, the operator at a remote location can steer the larger vehicle to the bus door. Once positioned at the door, the operator can switch video feedback to a camera at the end of the ramp to facilitate the mating of the end of the ramp to the top landing at the upper terminus of the steps. The ramp can be lowered by remote control until its end is in contact with the top landing. At the same time, the end of the ramp bearing the smaller vehicle is raised to minimize the angle of the slope the smaller vehicle has to climb, and further gives the operator a better view of the entry to the bus from the smaller vehicle. Control is passed over to the smaller vehicle and, using video feedback from the camera, it is driven up the ramp, turned oblique into the bus, and then sent down the aisle for surveillance. The demonstrated vehicle was used to scale the steps leading to the interior of a bus whose landing is 44 in. (.1.1 m) from the road surface. This vehicle can position the end of its ramp to a surface over 50 in. (.1.3 m) above ground level and can drive over rail heights exceeding 6 in. (.15 cm). Thus configured, this vehicle can conceivably deliver the smaller robot to the end platform of New York City subway cars from between the rails. This innovation is scalable to other formulations for size, mobility, and surveillance functions. Conceivably the larger vehicle can be configured to traverse unstable rubble and debris to transport a smaller search and rescue vehicle as close as possible to the scene of a disaster such as a collapsed building. The smaller vehicle, tethered or otherwise, and capable of penetrating and traversing within the confined spaces in the collapsed structure, can transport imaging and other sensors to look for victims or other targets.

Krasowski, Michael J.↗

NASA NTRS1981

Satellite services - An added benefit of the space transportation system

It is argued that the greatest economic benefit can be achieved by the Space Shuttle Orbiter's use as a satellite servicing platform if the following conditions are fulfilled: (1) the international user community must build serviceability features into its satellite and orbital platform designs, based on a common set of guidelines; (2) the various tools required for satellite servicing must be developed in a timely manner; and (3) servicing costs must be kept as low as possible, in order to appeal to the greatest number and variety of satellite operators. A three-part program development schedule is proposed, beginning with near-Orbiter servicing in low earth orbit, continuing with servicing at orbital heights between the low and geosynchronous at greater distances from the Orbiter, and culminating in the early 1990's with the use of the Space Operations Center (SOC) platform for servicing at all orbital heights.

Herardian, M. M.↗

NASA NTRS1977

Neutrally stable atmospheric flow over a two-dimensional rectangular block

The phenomena of atmospheric flow over a two dimensional surface obstruction such as a building modeled as a rectangular block are analyzed by an approach using the Navier-Stokes equations with a two equation model of turbulence. The partial differential equations for the vorticity, stream function, turbulence kinetic energy, and turbulence length scale are solved by a finite difference technique. The predicted results are in agreement with the limited experimental data available. Current computed results show that the separation bubble originates from the upper front corner of the block and extends approximately 11.5 block heights behind the block. The decay of the mean velocity along the wake center line coincides almost perfectly with the experimental data. The vertical profiles of the mean velocity defect are also in reasonable agreement with wind tunnel results. Velocity profiles in the mixing region are shown to agree with the error function profile typically found in the shear layer. Details of the behavior of the turbulence kinetic energy and the turbulence length scale are also discussed.

Shieh, C. F.↗

NASA NTRS1994

Consequences of impacts of small asteroids and comets with Earth

The fragmentation of a small asteroid in the atmosphere greatly increases its cross sections for aerodynamic braking and energy dissipation. At a typical impact velocity of 22 km/s, the atmosphere absorbs more than half the kinetic energy of stony meteoroids with diameters, D(sub m), less than 220 m and iron meteoroids with D(sub m) less than 80 m. The corresponding diameter for comets with impact velocity 50 km/s is D(sub m) less than 1600 m. Most of the atmospheric energy dissipation occurs in a fraction of a scale height, so large meteors appear to 'explode' or 'flare' at the end of their visible paths. This dissipation of energy in the atmosphere protects the earth from direct impact damage (e.g., craters), but it produces a blast wave that can do considerable damage. The area of destruction around the impact point in which the over-pressure in the blast wave exceeds 4 lb/sq in = 2.8 x 10(exp 5) dynes/cu cm, which is enough to knock over trees and destroy buildings, increases rapidly from zero for chondritic meteoroids less than 56 m in diameter (15 megatons) to about 200 sq km for those 80 m in diameter (48 megatons); the probable diameter of the tunguska impactor of 1908 is about 80 m. Crater formation and earthquakes are not significant in land impacts by stony asteroids less than about 200 m in diameter because of the air protection. A tsunami is probably the most devastating type of damage for asteroids 200 m to 1 km in diameter. An impact by an asteroid this size anywhere in the Atlantic would devastate coastal areas on both sides of the ocean. An asteroid a few kilometers across would produce a tsunami that would reach the foothills of the Appalachian Mountains in the upper half of the East Coast of the United States. Most of Florida is protected from a tsunami by the gradual slope of the ocean off its coast, which causes most of the tsunami energy to be reflected back into the Atlantic. The atmosphere plume produced by asteroids with diameters exceeding about 120 m cannot be contained by the atmosphere, so this bubble of high-temperature gas forms a new layer on top of the atmosphere. The dust entrapped in this hot gas is likely to have optical depths exceeding tau = 10 for asteroids with diameters exceeding about 0.5 to 1 km. The optical flux from asteroids 60 m or more in diameter is enough to ignite pine forests. However, the blast wave from an impacting asteroid goes beyond the radius in which the fire starts. The blast wave tends to blow out the fire, so it is likely that the impact will char the forest, as at Tunguska, but the impact will not produce a sustained fire. Because comets dissipate their energy much higher in the atmosphere than asteroids, they illuminate a much larger region and their blast wave is weaker. So they are much more effective in producing large fires. This suggests that the KT impactor was a comet rather than an asteroid.

Hills, J. G.↗

NASA NTRS2018

Plasticity and Damage Modeling of Stress Asymmetry and Dynamic Behavior of AFS Additive Manufactured Aluminum Alloy 2219

The Solid State Additive Manufacturing (AM) process referred as MELD that fabricated the samples in this study, provides a new path for repairing, coating, joining and additive manufacturing metals and metal matrix composites. This research will be the first application of a physics-based microstructure dependent internal state variable (ISV) plasticity and damage material model to capture the mechanical response of an AM Aluminum Alloy (AA) 2219 via the MELD process. In this research, a microstructure-based internal state variable (ISV) plasticity-damage model was used to capture the mechanical behavior of AFS 2219 aluminum alloy. Aeroprobe Corporation, creator and patent holder for the MELD process, fabricated the material by pushing a solid filler rod of AA2219-T861 material through a hollow rotating tool onto an AA2219 T851 plate substrate. As feedstock, solid or powder precursor metals are pushed through a nonconsumable rotating cylindrical tool. Herein, added layers are deposited and metallurgically bonded to substrate material or previously deposited layers by the heat generated from the rotating tool through plastic deformation of the filler material. Once a layer has been added, the tool height increases, and starts the deposition of the next layer. This process results in beneficial properties such as grain refinement, homogenization and reduced porosity (fully dense). This process will experience temperatures similar to those in the weld nugget zone (WNZ) in friction stir welding (FSW), ranging from 0.6-0.9 Tm, with Tm being the melting point of the material. MELD is highly scalable with AA deposition rates reaching over 1000 cm3/hr, which allows for MELD being used for repairs, coatings, and building components. A motivating factor driving the research for physics-based history dependent material modeling of MELD components is the ability to accurately capture the stress-state and strain rate dependence in the material caused by variations in material microstructure from the MELD processing of new or repaired components. The ISV model incorporates microstructural content and is consistent with continuum level kinematics, kinetics, and thermodynamics. These features allow the ISV model to capture large deformations at the structural scale using the kinematic and isotropic hardening, while microscale damage is obtained from the microstructural features. The benefits of the ISV model arise from the inclusion of structure-property relationships identified from microstructural characterization and experimentation. The Bauschinger effect (BE) is an important concept, vital in the accurate prediction of cyclic stress-strain response of ductile materials such as metals. The ISV model has been successfully used to capture the behavior and damage, and the BE of different aluminum alloys and steels. The ISV model uses kinematic and isotropic hardening to help capture deformations of the material at the macro scale. To understand this hardening relationship, calculating the kinematic and isotropic hardening relationship in the material is warranted for a high-fidelity model. Electron Backscattered Diffraction (EBSD) was used to characterize the as-fabricated microstructure, where a fully-dense equiaxed grain morphology with average grain size of 2.5 μm was observed. Microhardness mapping of the as-built structures, monotonic tension and compression experiments at both quasi-static (0.001/s) strain rates, tension-followed-by-compression and compression-followed-by-tension experiments were performed to obtain the set of plasticity and damage constants necessary to capture strain rate and stress state behavior of this additive material. To calibrate the plasticity-damage model, a single set of constants were determined to capture the different stress states the MELD AA2219. One set of the constants was determined from experimental true stress-strain curves for the tension and compression data. Additionally, microstructural information and data from the open literature were used as the other model constants. This research is a first of its kind for AFS AA2219, includes correlating the ISV model to the monotonic experimental results that capture the isotropic and kinematic plasticity mechanical response.

Rivera, O. G.↗