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A comparative survey of current and proposed tropospheric refraction-delay models for DSN radio metric data calibration

The standard tropospheric calibration model implemented in the operational Orbit Determination Program is the seasonal model developed by C. C. Chao in the early 1970's. The seasonal model has seen only slight modification since its release, particularly in the format and content of the zenith delay calibrations. Chao's most recent standard mapping tables, which are used to project the zenith delay calibrations along the station-to-spacecraft line of sight, have not been modified since they were first published in late 1972. This report focuses principally on proposed upgrades to the zenith delay mapping process, although modeling improvements to the zenith delay calibration process are also discussed. A number of candidate approximation models for the tropospheric mapping are evaluated, including the semi-analytic mapping function of Lanyi, and the semi-empirical mapping functions of Davis, et. al.('CfA-2.2'), of Ifadis (global solution model), of Herring ('MTT'), and of Niell ('NMF'). All of the candidate mapping functions are superior to the Chao standard mapping tables and approximation formulas when evaluated against the current Deep Space Network Mark 3 intercontinental very long baselines interferometry database.

Estefan, J. A.↗

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↗

Managing Through Continuous Improvement: If it doesn’t challenge you, it won’t change you

The past 24 months has been one of non-stop continuous improvement – every month, every week, every day, and every hour. It has been filled with continuously re-examining and challenging business systems, work processes, and legacy culture. The journey was difficult, but well worth it. It began by examining the existing conditions in each organization and building the case for change. When we stepped back and looked at our processes, systems, tools, and performance objectively, we realized we were struggling with frequent organizational, resource, and schedule conflicts, work processes that were not well-defined or expert based, project delays were common, management methods were predominantly reactive, advanced planning was limited to the near-term, no integration in scheduling across organizations, limited to no performance metrics to measure and manage performance, and internal and external customers did not feel like we were meeting their quality and performance expectations. It was a wake-up call. Change began at the top with a change leadership with where a new vision, expectations, and commitment were established. Leaving no stone left unturned, every aspect of the business was challenged which opened up communication and exposed the gaps. This was done in a ‘safe’ environment allowing for honest and solution-oriented discussion and action. The leadership team committed to managing through continuous improvement. The organizational structure was realigned to better align scope, responsibilities, execution, and customer focus. Visibility and transparency became the norm as higher levels of leadership and supporting organizations were invited to be part of regular strategy meetings and partnership discussion, effectively opening up the dialogue. This required a tremendous amount of trust and faith in a short period of time. Health assessments were conducted on each organization with specific lines of inquiry. These self-assessments helped to identify better define the scope of the organization and where targeted improvements were needed. Frequent organizational reviews were implemented to answer three fundamental questions: 1) What is your organization paid to do (scope)?, 2) How does your organization, or you, demonstrate that you are doing the job effectively?, and 3) What are you doing to improve your performance? To answer the first question, leaders defined the scope of the organization. Leaders were required to provide a path forward, with specific actions, where performance was not at expected levels internally at first and then from the stakeholders. Where business processes were not clearly understood, process maps were developed to provide this clarity for both those performing the work and those utilizing the process – the customers. To help answer the second question, numerous automated or semi-automated real-time, dynamic performance metrics were developed and implement to help leaders gain the visibility and demonstrate performance in six areas of operational excellence: safety, security, quality, effectiveness, productivity, and sustainability. Analysis of the performance provided windows of transparency and trends of work performance, work delays, cycle times, utilization, and much more that revealed many areas of improvement that were either not visible or desired to be visible. At the same time, they provided real-time progress which generated initial performance improvements by just beginning to measure. To address the third question, where systems did not support effectiveness of an existing or new process, then systems and tools were developed and implemented to drive the right behaviors and reinforce the processes. Tools and metrics were one of the major catalysts for culture shift and change. Risk assessments were leveraged into continuous improvement strategies, plans, and schedules. Targeted initiatives were identified and performed. Change and improvement was not, and is not, without significant and common challenges including limited/fixed budgets, resource availability, data access, natural resistance to change, and numerous other reasons or excuses – we called them ‘off-ramps’ and began to close them one-by-one. The results and outputs were significant and impactful in each organization and across the business with increased productivity, efficiency, visibility, accountability, management, and performance. Stakeholder satisfaction also increased. Cost and time savings allowed to more continuous improvement efforts to be performed. The effort clearly provided clear and measurable return on investment and value. Efforts that once seemed impossible, not feasible, or not achievable were performed. Decades-long issues were solved. ‘Impossible things are simply those which so far have never been done’ said Elbert Hubbard. So what will the next year be for you and your organization? Are you satisfied with the ‘same ‘ol, same ‘ol?’ Will you fall into the complacency trap and believe that change is too difficult, too expensive, and not necessary (or any number of possible excuses) or will you make this year your year or continuous improvement (and every year thereafter…)? Remember – what you do today can improve all your tomorrows’ (Ralph Marston).

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

FORTRAN programs to process Magsat data for lithospheric, external field, and residual core components

The FORTRAN programs supplied in this document provide a complete processing package for statistically extracting residual core, external field and lithospheric components in Magsat observations. To process the individual passes: (1) orbits are separated into dawn and dusk local times and by altitude, (2) passes are selected based on the variance of the magnetic field observations after a least-squares fit of the core field is removed from each pass over the study area, and (3) spatially adjacent passes are processed with a Fourier correlation coefficient filter to separate coherent and non-coherent features between neighboring tracks. In the second state of map processing: (1) data from the passes are normalized to a common altitude and gridded into dawn and dusk maps with least squares collocation, (2) dawn and dusk maps are correlated with a Fourier correlation efficient filter to separate coherent and non-coherent features; the coherent features are averaged to produce a total field grid, (3) total field grids from all altitudes are continued to a common altitude, correlation filtered for coherent anomaly features, and subsequently averaged to produce the final total field grid for the study region, and (4) the total field map is differentially reduced to the pole.

Alsdorf, Douglas E.↗

Design for Manufacturing of Structures with Automated Fiber Placement via Integration of Analysis and Process Planning

Under the Design for Manufacturing (DFM) task in the NASA HiCAM program, significant process has been made towards establishing a fully automated optimization process that spans the structural analysis, design, and manufacturing process planning for Automated Fiber Placement (AFP) structures. Previous efforts in this area established the data formats and mapping processes needed to exchange data between disciplines. The software tools used in the framework are HyperX (structural optimization), CAPP (process planning), and VCP (AFP path generation). The work has culminated with automation of data exchanges and an optimization process that drives the three software toward convergence. Within this framework, HyperX is used to generate mass-optimum composite designs which are iterated with VCP and CAPP to improve manufacturability of the designs. As the ply manufacturing process is adjusted by CAPP and VCP, HyperX continually re-assesses the structural integrity of the part and makes adjustments to the laminate as needed. For example, the position of fiber steering and tow overlaps/gaps can necessitate changes to the laminate design. Once the design converges, the end result is a stack of plies that meets both structural and manufacturing requirements. This paper presents the details of the framework and demonstrations the automated process on several parts with significant double-curvature.

HiCAM↗

Towards a Comparative Assessment of Data-Driven Process Models in Health Information Technology

Process mining for conformance analysis focuses on comparing a reference process model against a data-driven process model that is generated via log files from information technology systems. While this approach is helpful when there is an existing process model in an organization, it leaves the question of what to do in the absence of a complete reference process model unanswered. In this paper, we present a comparative assessment approach that combines process mining, process mapping for dimensionality reduction, and statistical analysis. Our goal is to find similarities and dissimilarities in data-driven process models among U.S. Veterans Health Administration (VHA) facilities to assess process conformance among different healthcare facilities, which can help assess the standardization of care. We illustrate our approach by applying it to two clinical radiology order process models generated by two similar facilities. Our results demonstrate statistical similarities in the standardization of care among those two facilities.

Klasky, Hilda↗

Comparative Assessment of Data-driven Process Models in Health Information Technology

Process mining for conformance analysis consists of comparing a reference process model against a data-driven process model generated via log files from information technology systems. However, in the absence of a complete reference process model, we found no suggested approaches in the literature to address the need for evaluating process conformance among different healthcare facilities to assess standardization of care. Our goal is to find similarities and dissimilarities in data-driven process models among US Veterans Health Administration (VHA) facilities that can be indicative of patient safety issues. Our hypothesis was that the analysis would not produce statistically significant differences in outcome. We present a unique implementation of conformance analysis in process mining that consists of combining process mining, process mapping and statistical metrics. We illustrate our approach by applying it to the analysis of two clinical radiology order process models generated from healthcare data provided by two similar facilities in the VHA. The comparative assessment showed that about 70% of the orders completed successfully and 30% were not completed due to policy and duplications. Our analysis found a good statistical correlation between both facilities, as the Spearman’s correlation coefficient between facilities for the frequency of cases per total hours was 0.87879, for the frequency of cases by state transition was 0.79702 and for the throughput time per state transition was 0.63582. Additional statistical analyses using the Mann-Whitney U test and the root mean square error both produced values that were not significant. The foregoing approach validated our hypothesis by demonstrating a good statistical correlation of data describing the flow of clinical radiology orders absent a credible reference model. Finding good agreement between both facilities was important in confirming that the clinical orders flow in a similar manner, suggesting standardization of care.

97 MATHEMATICS AND COMPUTING↗

Experimental Study on the Hot Deformation Characterization of Low-Carbon Nb-V-Ti Microalloyed Steel

X80 steel, as typical low-carbon Nb-V-Ti microalloyed steel, is getting more and more attention in oil and gas transmission pipeline manufacturing. In this paper, the hot deformation behavior of X80 steel has been investigated. Hot compression tests of the steel were conducted under different temperatures and strain rates. Based on the experimental data, the flow stress constitutive equations were established. It is found that the hot deformation activation energy of this steel is higher than C-Mn and low-carbon steel. Then, the kinetics model and grain size model of dynamic recrystallization were developed according to the flow curves and the optical microstructures. In addition, the processing maps were developed to analyze the workability of X80 steel at elevated temperature. The analysis results show that the optimum processing window is at the temperature of 1300-1473 K and the strain rate of 0.01-10 s{sup −1}. The microstructure observation indicates that the optimum processing parameters are applicable to the tested steel.

36 MATERIALS SCIENCE↗

Systematic analysis of melt pool dynamics in laser processing of mixed powder feedstocks

Functionally graded materials (FGMs) fabricated via additive manufacturing of blended powders offer the potential to spatially tailor properties for new technologies, such as fusion first-wall systems, turbine blades, and spacecraft. However, processing these materials is difficult due to the multiplicity of processing parameters to optimize, all of which must be changed as substrate material, powder feedstock compositions, and melt pool dynamics evolve. Here, this work systematically evaluates the qualitative and quantitative effects of these variables on the melt pool size, shape, composition, and particle distribution in an exemplar Ti-Ta system, and connects the experimental results to Marangoni flow behavior and phenomena observed in other systems. Increasing laser power linearly increases melt pool size and layer thickness, driving engineering considerations such as part/geometrical tolerances. Decreasing laser velocity changes the melt pool shape from lenticular to convex and reduces chemical homogeneity due to extreme thermal and compositional gradients between the melt pool center and boundaries. Thermophysical property differences between the powder feedstock and substrate material, as well as the directionality of the gradient, affect dilution and melt pool dynamics, which in turn affect the melt pool boundary characteristics, shape, and uniformity. Mixed powder feedstocks of intermediate compositions do not behave according to linear interpolations between single-material endpoints, instead building taller and wider melt pools. As such, it is recommended to quantify process maps for at least one intermediate composition in the FGM or multi-material system of interest to ensure optimized processing parameters, predictable melt pool sizes and shapes, and compositional and spatial precision.

Dissimilar↗

Approach to qualification using E-PBF in-situ process monitoring in Ti-6Al-4V

Traditional design and qualification methodologies for parts manufactured by traditional methods are being applied to Additive Manufacturing (AM) without understanding the nuances of the machines. While mapping process variables and tracking build data is helpful, some variables such as build geometry, support structure, and part melt order have not been researched in depth. Changing these variables can result in significant variations in material properties and defect structure such that the process appears to be unreliable compared to traditional manufacturing. Hence, this research focuses on the need to understand the effects of overlooked variables such as melt order and nested geometry on the distribution of defects and bulk material properties in Ti-6Al-4 V alloy builds manufactured using the Arcam AB ® electron beam powder bed fusion process 1 . This work collected and analyzed process log data and near infrared (NIR) images for every layer to correlate trends in porosity formation and mechanical performance. The location of pores, while naturally stochastic, is greatly influenced by the cross-sectional area as detected by NIR images and correlates with the failure sites from uniaxial testing.

36 MATERIALS SCIENCE↗

Constitutive Behavior and Hot Workability of a Hot Isostatic Pressed Ti-22Al-25Nb Alloy during Hot Compression

A Ti-22Al-25Nb alloy was fabricated from prealloyed powders by hot isostatic pressing for 2 h at a temperature of 1050 °C and pressure of 100 MPa. The hot deformation behavior of the Ti-22Al-25Nb alloy was characterized by isothermal compression testing at deformation temperatures between 900 and 1060 °C and strain rates between 0.001 and 1 s{sup −1}. Based on the true stress–strain curves, a constitutive equation was constructed to describe the flow stress as a function of the strain rate and deformation temperature. Three-dimensional (3D) processing maps were developed based on dynamic material model theory using the stress flow data to identify the instability and optimization regions of the hot processing parameters. The results show that the flow stress decreases with increasing deformation temperature and decreasing strain rate, and the softening mechanisms are different under different deformation conditions. The apparent activation energies in the (α{sub 2} + β/B2 + O) and (α{sub 2} + B2) phase regions are calculated to be 865.177 and 590.661 kJ/mol, respectively, which suggests that the hot isostatic pressed (HIPed) Ti-22Al-25Nb alloy requires a high hot deformation activation energy. Combined with microstructural observations, the optimal processing domains are determined to be a temperature range of 1030-1060 °C and strain rate range of 0.01-0.1 s{sup −1} in the α{sub 2} + B2 phase region. Moreover, the results indicate that adiabatic shear bands and severe inhomogeneous deformation cause flow instability at lower temperatures (900-1005 °C) and higher strain rates (> 0.1 s{sup −1}).

36 MATERIALS SCIENCE↗

Mapping and distortions of auroral structures in the quiet magnetosphere

The closed quiet magnetosphere model of Beard (1979) and Beard et al. (1982) is used to identify those features of commonly observed dayside auroras that can be explained by either of two processes: mapping distortions or distortions caused by nearby Birkeland currents. It is shown that single and multiple linear and hooked auroral forms can be easily explained in terms of mapping distortions in a quiet magnetosphere. On the other hand, the shapes of bright twisted or folded auroral forms can be more easily explained as distortions produced by localized Birkeland currents.

Kaufmann, Richard L.↗

Technology Assessment of Laser-Assisted Materials Processing in Space

Lasers are useful for performing operations such as joining, machining, built-up freeform fabrication, shock processing, and surface treatments. These attributes are attractive for the supportability of longer-term missions in space due to the multi-functionality of a single tool and the variety of materials that can be processed. However, current laser technology also has drawbacks for space-based applications, specifically size, power efficiency, lack of robustness, and problems processing highly reflective materials. A review of recent laser developments will be used to show how these issues may be reduced and indicate where further improvement is necessary to realize a laser-based materials processing capability in space. The broad utility of laser beams in synthesizing various classes of engineering materials will be illustrated using state-of-the art processing maps for select lightweight alloys typically found on spacecraft. With the advent of recent breakthroughs in diode-pumped solid-state lasers and fiber optic technologies, the potential to perform multiple processing techniques is increasing significantly. Lasers with suitable wavelengths and beam properties have tremendous potential for supporting future space missions to the moon, Mars and beyond.

Nagarathnam, Karthik↗

Technology Assessment of Laser-Assisted Materials Processing in Space

Lasers are useful for performing operations such as joining, machining, built-up freeform fabrication, shock processing, and surface treatments. These attributes are attractive for the supportability of longer-term missions in space due to the multi-functionality of a single tool and the variety of materials that can be processed. However, current laser technology also has drawbacks for space-based applications, specifically size, power efficiency, lack of robustness, and problems processing highly reflective materials. A review of recent laser developments will be used to show how these issues may be reduced and indicate where further improvement is necessary to realize a laser-based materials processing capability in space. The broad utility of laser beams in synthesizing various classes of engineering materials will be illustrated using state-of-the art processing maps for select lightweight alloys typically found on spacecraft. With the advent of recent breakthroughs in diode-pumped solid-state lasers and fiber optic technologies, the potential to perform multiple processing techniques is increasing significantly. Lasers with suitable wavelengths and beam properties have tremendous potential for supporting future space missions to the moon, Mars and beyond.

Nagarathnam, Karthik↗

Laser Materials Processing for NASA's Aerospace Structural Materials

Lasers are useful for performing operations such as joining, machining, built-up freeform fabrication, and surface treatment. Due to the multifunctional nature of a single tool and the variety of materials that can be processed, these attributes are attractive in order to support long-term missions in space. However, current laser technology also has drawbacks for space-based applications. Specifically, size, power efficiency, lack of robustness, and problems processing highly reflective materials are all concerns. With the advent of recent breakthroughs in solidstate laser (e.g., diode-pumped lasers) and fiber optic technologies, the potential to perform multiple processing techniques in space has increased significantly. A review of the historical development of lasers from their infancy to the present will be used to show how these issues may be addressed. The review will also indicate where further development is necessary to realize a laser-based materials processing capability in space. The broad utility of laser beams in synthesizing various classes of engineering materials will be illustrated using state-of-the art processing maps for select lightweight alloys typically found on spacecraft. Both short- and long-term space missions will benefit from the development of a universal laser-based tool with low power consumption, improved process flexibility, compactness (e.g., miniaturization), robustness, and automation for maximum utility with a minimum of human interaction. The potential advantages of using lasers with suitable wavelength and beam properties for future space missions to the moon, Mars and beyond will be discussed. The laser processing experiments in the present report were performed using a diode pumped, pulsed/continuous wave Nd:YAG laser (50 W max average laser power), with a 1064 nm wavelength. The processed materials included Ti-6AI-4V, Al-2219 and Al-2090. For Phase I of this project, the laser process conditions were varied and optimized to see the effects on melt-quenching, cladding/alloying (using the pre-placed powder technique), and cutting. Key parameters such laser power, pulse repetition frequency, process speed, and shield gas flow and the observed process characteristics such as plasma formation during laser/material interaction, have been reported for all experimental runs. Preliminary materials characterization of select samples was carried out using various microscopy, diffraction, spectroscopy and microhardness test methods, and reported. Select nitridation results of Ti-6AI-4V using nitrogen assist gas indicated the successful formation of hard titanium nitrides with much higher hardness (2180 kg/sq mm). A cost-effective and simple powder delivery system has been successfully fabricated for the further experimentation in Phase H.

Nagarathnam, Karthik↗

Fundamental procedures of geographic information analysis

Analytical procedures common to most computer-oriented geographic information systems are composed of fundamental map processing operations. A conceptual framework for such procedures is developed and basic operations common to a broad range of applications are described. Among the major classes of primitive operations identified are those associated with: reclassifying map categories as a function of the initial classification, the shape, the position, or the size of the spatial configuration associated with each category; overlaying maps on a point-by-point, a category-wide, or a map-wide basis; measuring distance; establishing visual or optimal path connectivity; and characterizing cartographic neighborhoods based on the thematic or spatial attributes of the data values within each neighborhood. By organizing such operations in a coherent manner, the basis for a generalized cartographic modeling structure can be developed which accommodates a variety of needs in a common, flexible and intuitive manner. The use of each is limited only by the general thematic and spatial nature of the data to which it is applied.

Berry, J. K.↗

The Coming Paradigm-Shift in Maintenance: From Metals to Composites

The purpose of this study is to examine the current maintenance practices of airline operators in the detection and repair of damage to composite structures, with the aim of learning lessons that will be applicable to the maintenance of future advanced composite airplanes. A process map was created to capture the events and activities that occur from the moment a damage event occurs, through damage detection, assessment and repair. The study is identifying areas where operational risks may negatively impact the process, where personnel are required to make judgments in the absence of procedural guidance, and areas where future tools or techniques may be of assistance.

Hobbs, Alan↗

Study on Tensile Deformation Behavior of TC21 Titanium Alloy

To investigate the tensile deformation behavior of TC21 titanium alloy wires, the isothermal tensile deformation tests were conducted by a Geeble-1500D simulator in the temperature range of 720-880 °C and strain rates of 0.01-10 s{sup −1}. The in situ tensile deformation behavior has been studied by SEM SURPA40. The stress–strain curves indicate that the flow stress has shown an inverse relationship with temperature and a direct relationship with strain rate. The flow stress immediately reached the peak value and, then, gradually decreased due to the dynamic softening induced by dynamic recovery and dynamic recrystallization. According to the hot processing maps, the temperatures ranging from 720 to 760 °C (corresponding to the strain rates of 0.01-0.032 s{sup −1}) and 800-840 °C (corresponding to the strain rates of 0.01-0.056 s{sup −1}) are suitable for processing. The in situ tensile results reveal that the cracks initiated at the pre-fabricated defects with the concentrated stress and mainly propagated in the transgranular mode.

36 MATERIALS SCIENCE↗