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NASA NTRS2002

Particle Size Effects on Flow Properties of PS304 Plasma Spray Feedstock Powder Blend

The effects of BaF2-CaF2 particle size and size distribution on PS304 feedstock powder flowability have been investigated. Angular BaF2-CaF2 eutectic powders were produced by comminution and classified by screening to obtain 38 to 45 microns 45 to 106 microns, 63 to 106 microns, 45 to 53 microns, 63 to 75 microns, and 90 to 106 microns particle size distributions. The fluorides were added incrementally from 0 to 10 wt% to the other powder constituents of the PS304 feedstock: nichrome, chromia, and silver powders. The flow rate of the powder blends decreased linearly with increasing concentration of the fluorides. Flow was degraded with decreasing BaF2-CaF2 particle size and with increasing BaF2-CaF2 particle size distribution. A semiempirical relationship is offered to describe the PS304 powder blend flow behavior. The Hausner Ratio confirmed the funnel flow test results, but was slightly less sensitive to differences in BaF2-CaF2 particle size and size distribution. These findings may have applicability to other powders that do not flow easily, such as ceramic powders.

Stanford, Malcolm K.↗

NASA NTRS2003

Deposition of Nanostructured Thin Film from Size-Classified Nanoparticles

Materials comprising nanometer-sized grains (approximately 1_50 nm) exhibit properties dramatically different from those of their homogeneous and uniform counterparts. These properties vary with size, shape, and composition of nanoscale grains. Thus, nanoparticles may be used as building blocks to engineer tailor-made artificial materials with desired properties, such as non-linear optical absorption, tunable light emission, charge-storage behavior, selective catalytic activity, and countless other characteristics. This bottom-up engineering approach requires exquisite control over nanoparticle size, shape, and composition. We describe the design and characterization of an aerosol system conceived for the deposition of size classified nanoparticles whose performance is consistent with these strict demands. A nanoparticle aerosol is generated by laser ablation and sorted according to size using a differential mobility analyzer. Nanoparticles within a chosen window of sizes (e.g., (8.0 plus or minus 0.6) nm) are deposited electrostatically on a surface forming a film of the desired material. The system allows the assembly and engineering of thin films using size-classified nanoparticles as building blocks.

Camata, Renato P.↗

NASA NTRS2004

Can Effective Synthetic Vision System Displays be Implemented on Limited Size Display Spaces?

The Synthetic Vision Systems (SVS) element of the NASA Aviation Safety Program is striving to eliminate poor visibility as a causal factor in aircraft accidents, and to enhance operational capabilities of all types or aircraft. To accomplish these safety and situation awareness improvements, the SVS concepts are designed to provide a clear view of the world ahead through the display of computer generated imagery derived from an onboard database of terrain, obstacle and airport information. An important issue for the SVS concept is whether useful and effective Synthetic Vision System (SVS) displays can be implemented on limited size display spaces as would be required to implement this technology on older aircraft with physically smaller instrument spaces. In this study, prototype SVS displays were put on the following display sizes: (a) size "A' (e.g. 757 EADI), (b) form factor "D" (e.g. 777 PFD), and (c) new size "X" (Rectangular flat-panel, approximately 20 x 25 cm). Testing was conducted in a high-resolution graphics simulation facility at NASA Langley Research Center. Specific issues under test included the display size as noted above, the field-of-view (FOV) to be shown on the display and directly related to FOV is the degree of minification of the displayed image or picture. Using simulated approaches with display size and FOV conditions held constant no significant differences by these factors were found. Preferred FOV based on performance was determined by using approaches during which pilots could select FOV. Mean preference ratings for FOV were in the following order: (1) 30 deg., (2) Unity, (3) 60 deg., and (4) 90 deg., and held true for all display sizes tested. Limitations of the present study and future research directions are discussed.

Comstock, J. Raymond, Jr.↗

NASA NTRS2002

Preliminary Sizing Completed for Single- Stage-To-Orbit Launch Vehicles Powered By Rocket-Based Combined Cycle Technology

Single-stage-to-orbit (SSTO) propulsion remains an elusive goal for launch vehicles. The physics of the problem is leading developers to a search for higher propulsion performance than is available with all-rocket power. Rocket-based combined cycle (RBCC) technology provides additional propulsion performance that may enable SSTO flight. Structural efficiency is also a major driving force in enabling SSTO flight. Increases in performance with RBCC propulsion are offset with the added size of the propulsion system. Geometrical considerations must be exploited to minimize the weight. Integration of the propulsion system with the vehicle must be carefully planned such that aeroperformance is not degraded and the air-breathing performance is enhanced. Consequently, the vehicle's structural architecture becomes one with the propulsion system architecture. Geometrical considerations applied to the integrated vehicle lead to low drag and high structural and volumetric efficiency. Sizing of the SSTO launch vehicle (GTX) is itself an elusive task. The weight of the vehicle depends strongly on the propellant required to meet the mission requirements. Changes in propellant requirements result in changes in the size of the vehicle, which in turn, affect the weight of the vehicle and change the propellant requirements. An iterative approach is necessary to size the vehicle to meet the flight requirements. GTX Sizer was developed to do exactly this. The governing geometry was built into a spreadsheet model along with scaling relationships. The scaling laws attempt to maintain structural integrity as the vehicle size is changed. Key aerodynamic relationships are maintained as the vehicle size is changed. The closed weight and center of gravity are displayed graphically on a plot of the synthesized vehicle. In addition, comprehensive tabular data of the subsystem weights and centers of gravity are generated. The model has been verified for accuracy with finite element analysis. The final trajectory was rerun using OTIS (Boeing Corporation's trajectory optimization software package), and the sizing output was incorporated into a solid model of the vehicle using PRO/Engineer computer-aided design software (Parametric Technology Corporation, Waltham, MA).

Roche, Joseph M.↗

NASA NTRS2008

Raindrop Size Distribution Measurements in Tropical Cyclones

Characteristics of the raindrop size distribution in seven tropical cyclones have been studied through impact-type disdrometer measurements at three different sites during the 2004-06 Atlantic hurricane seasons. One of the cyclones has been observed at two different sites. High concentrations of small and/or midsize drops were observed in the presence or absence of large drops. Even in the presence of large drops, the maximum drop diameter rarely exceeded 4 mm. These characteristics of raindrop size distribution were observed in all stages of tropical cyclones, unless the storm was in the extratropical stage where the tropical cyclone and a midlatitude frontal system had merged. The presence of relatively high concentrations of large drops in extratropical cyclones resembled the size distribution in continental thunderstorms. The integral rain parameters of drop concentration, liquid water content, and rain rate at fixed reflectivity were therefore lower in extratropical cyclones than in tropical cyclones. In tropical cyclones, at a disdrometercalculated reflectivity of 40 dBZ, the number concentration was 700 plus or minus 100 drops m(sup -3), while the liquid water content and rain rate were 0.90 plus or minus 0.05 g m(sup -3) and 18.5 plus or minus 0.5 mm h(sup -1), respectively. The mean mass diameter, on the other hand, was 1.67 plus or minus 0.3 mm. The comparison of raindrop size distributions between Atlantic tropical cyclones and storms that occurred in the central tropical Pacific island of Roi-Namur revealed that the number density is slightly shifted toward smaller drops, resulting in higher-integral rain parameters and lower mean mass and maximum drop diameters at the latter site. Considering parameterization of the raindrop size distribution in tropical cyclones, characteristics of the normalized gamma distribution parameters were examined with respect to reflectivity. The mean mass diameter increased rapidly with reflectivity, while the normalized intercept parameter had an increasing trend with reflectivity. The shape parameter, on the other hand, decreased in a reflectivity range from 10 to 20 dBZ and remained steady at higher reflectivities. Considering the repeatability of the characteristics of the raindrop size distribution, a second impact disdrometer that was located 5.3 km away from the primary site in Wallops Island, Virginia, had similar size spectra in selected tropical cyclones.

Tokay, Ali↗

NASA NTRS2009

LDPC Codes with Minimum Distance Proportional to Block Size

Low-density parity-check (LDPC) codes characterized by minimum Hamming distances proportional to block sizes have been demonstrated. Like the codes mentioned in the immediately preceding article, the present codes are error-correcting codes suitable for use in a variety of wireless data-communication systems that include noisy channels. The previously mentioned codes have low decoding thresholds and reasonably low error floors. However, the minimum Hamming distances of those codes do not grow linearly with code-block sizes. Codes that have this minimum-distance property exhibit very low error floors. Examples of such codes include regular LDPC codes with variable degrees of at least 3. Unfortunately, the decoding thresholds of regular LDPC codes are high. Hence, there is a need for LDPC codes characterized by both low decoding thresholds and, in order to obtain acceptably low error floors, minimum Hamming distances that are proportional to code-block sizes. The present codes were developed to satisfy this need. The minimum Hamming distances of the present codes have been shown, through consideration of ensemble-average weight enumerators, to be proportional to code block sizes. As in the cases of irregular ensembles, the properties of these codes are sensitive to the proportion of degree-2 variable nodes. A code having too few such nodes tends to have an iterative decoding threshold that is far from the capacity threshold. A code having too many such nodes tends not to exhibit a minimum distance that is proportional to block size. Results of computational simulations have shown that the decoding thresholds of codes of the present type are lower than those of regular LDPC codes. Included in the simulations were a few examples from a family of codes characterized by rates ranging from low to high and by thresholds that adhere closely to their respective channel capacity thresholds; the simulation results from these examples showed that the codes in question have low error floors as well as low decoding thresholds. As an example, the illustration shows the protograph (which represents the blueprint for overall construction) of one proposed code family for code rates greater than or equal to 1.2. Any size LDPC code can be obtained by copying the protograph structure N times, then permuting the edges. The illustration also provides Field Programmable Gate Array (FPGA) hardware performance simulations for this code family. In addition, the illustration provides minimum signal-to-noise ratios (Eb/No) in decibels (decoding thresholds) to achieve zero error rates as the code block size goes to infinity for various code rates. In comparison with the codes mentioned in the preceding article, these codes have slightly higher decoding thresholds.

Divsalar, Dariush↗

NASA NTRS2009

Probabilistic Estimation of Critical Flaw Sizes in the Primary Structure Welds of the Ares I-X Launch Vehicle

The primary structure of the Ares I-X Upper Stage Simulator (USS) launch vehicle is constructed of welded mild steel plates. There is some concern over the possibility of structural failure due to welding flaws. It was considered critical to quantify the impact of uncertainties in residual stress, material porosity, applied loads, and material and crack growth properties on the reliability of the welds during its pre-flight and flight. A criterion--an existing maximum size crack at the weld toe must be smaller than the maximum allowable flaw size--was established to estimate the reliability of the welds. A spectrum of maximum allowable flaw sizes was developed for different possible combinations of all of the above listed variables by performing probabilistic crack growth analyses using the ANSYS finite element analysis code in conjunction with the NASGRO crack growth code. Two alternative methods were used to account for residual stresses: (1) The mean residual stress was assumed to be 41 ksi and a limit was set on the net section flow stress during crack propagation. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if this limit was exceeded during four complete flight cycles, and (2) The mean residual stress was assumed to be 49.6 ksi (the parent material s yield strength) and the net section flow stress limit was ignored. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if catastrophic crack growth occurred during four complete flight cycles. Both surface-crack models and through-crack models were utilized to characterize cracks in the weld toe.

Pai, Shantaram S.↗

NASA NTRS2010

Effects of Ice Particle Size Vertical Inhomogeneity on the Passive Remote Sensing of Ice Clouds

The solar reflectance bi-spectral (SRBS) and infrared split-window (IRSpW) methods are two of the most popular techniques for passive ice cloud property retrievals from multispectral imagers. Ice clouds are usually assumed to be vertically homogeneous in global operational algorithms based on these methods, although significant vertical variations of ice particle size are typically observed in ice clouds. In this Study we investigate uncertainties in retrieved optical thickness, effective particle size, and ice water path introduced by a homogeneous cloud assumption in both the SRBS and IRSpW methods, and focus on whether the assumption can lead to significant discrepancies between the two methods. The study simulates the upwelling spectral radiance associated with vertically structured clouds and passes the results through representative SRBS and IRSpW retrieval algorithms. Cloud optical thickness is limited to values for which IRSpW retrievals are possible (optical thickness less than about 7). When the ice cloud is optically thin and yet has a significant ice particle size vertical variation, it is found that both methods tend to underestimate the effective radius and ice water path. The reason for the underestimation is the nonlinear dependence of ice particle scattering properties (extinction and single scattering albedo) on the effective radius. Because the nonlinearity effect is stronger in the IRSpW than the SRBS method, the IRSpW-based IWP tends to be smaller than the SRBS counterpart. When the ice cloud is moderately optically thick, the IRSpW method is relatively insensitive to cloud vertical structure and effective radius retrieval is weighted toward smaller ice particle size, while the weighting function makes the SRBS method more sensitive to the ice particle size in the upper portion of the cloud. As a result, when ice particle size increases monotonically toward cloud base, the two methods are in qualitative agreement; in the event that ice particle size decreases toward cloud base, the effective radius and ice water path retrievals based on the SRBS method are substantially larger than those from the IRSpW. The main findings of this Study Suggest that the homogenous cloud assumption can affect the SRBS and IRSpW methods to different extents and, consequently, can lead to significantly different retrievals. Therefore caution should be taken when comparing and combining the ice cloud property retrievals from these two methods.

Zhang, Zhibo↗

NASA NTRS2012

Influence of Finite Element Size in Residual Strength Prediction of Composite Structures

The sensitivity of failure load to the element size used in a progressive failure analysis (PFA) of carbon composite center notched laminates is evaluated. The sensitivity study employs a PFA methodology previously developed by the authors consisting of Hashin-Rotem intra-laminar fiber and matrix failure criteria and a complete stress degradation scheme for damage simulation. The approach is implemented with a user defined subroutine in the ABAQUS/Explicit finite element package. The effect of element size near the notch tips on residual strength predictions was assessed for a brittle failure mode with a parametric study that included three laminates of varying material system, thickness and stacking sequence. The study resulted in the selection of an element size of 0.09 in. X 0.09 in., which was later used for predicting crack paths and failure loads in sandwich panels and monolithic laminated panels. Comparison of predicted crack paths and failure loads for these panels agreed well with experimental observations. Additionally, the element size vs. normalized failure load relationship, determined in the parametric study, was used to evaluate strength-scaling factors for three different element sizes. The failure loads predicted with all three element sizes provided converged failure loads with respect to that corresponding with the 0.09 in. X 0.09 in. element size. Though preliminary in nature, the strength-scaling concept has the potential to greatly reduce the computational time required for PFA and can enable the analysis of large scale structural components where failure is dominated by fiber failure in tension.

Satyanarayana, Arunkumar↗

NASA NTRS2013

Centrifugal Sieve for Gravity-Level-Independent Size Segregation of Granular Materials

Conventional size segregation or screening in batch mode, using stacked vibrated screens, is often a time-consuming process. Utilization of centrifugal force instead of gravity as the primary body force can significantly shorten the time to segregate feedstock into a set of different-sized fractions. Likewise, under reduced gravity or microgravity, a centrifugal sieve system would function as well as it does terrestrially. When vibratory and mechanical blade sieving screens designed for terrestrial conditions were tested under lunar gravity conditions, they did not function well. The centrifugal sieving design of this technology overcomes the issues that prevented sieves designed for terrestrial conditions from functioning under reduced gravity. These sieves feature a rotating outer (cylindrical or conical) screen wall, rotating fast enough for the centrifugal forces near the wall to hold granular material against the rotating screen. Conventional centrifugal sieves have a stationary screen and rapidly rotating blades that shear the granular solid near the stationary screen, and effect the sieving process assisted by the airflow inside the unit. The centrifugal sieves of this new design may (or may not) have an inner blade or blades, moving relative to the rotating wall screen. Some continuous flow embodiments would have no inner auger or blades, but achieve axial motion through vibration. In all cases, the shearing action is gentler than conventional centrifugal sieves, which have very high velocity differences between the stationary outer screen and the rapidly rotating blades. The new design does not depend on airflow in the sieving unit, so it will function just as well in vacuum as in air. One advantage of the innovation for batch sieving is that a batch-mode centrifugal sieve may accomplish the same sieving operation in much less time than a conventional stacked set of vibrated screens (which utilize gravity as the primary driving force for size separation). In continuous mode, the centrifugal sieves can provide steady streams of fine and coarse material separated from a mixed feedstock flow stream. The centrifugal sieves can be scaled to any desired size and/or mass flow rate. Thus, they could be made in sizes suitable for small robotic exploratory missions, or for semi-permanent processing of regolith for extraction of volatiles of minerals. An advantage of the continuous-mode system is that it can be made with absolutely no gravity flow components for feeding material into, or for extracting the separated size streams from, the centrifugal sieve. Thus, the system is capable of functioning in a true microgravity environment. Another advantage of the continuous-mode system is that some embodiments of the innovation have no internal blades or vanes, and thus, can be designed to handle a very wide range of feedstock sizes, including occasional very large oversized pieces, without jamming or seizing up.

Walton, Otis R.↗

NASA NTRSDate not supplied

The Relationship Of Size Distributions To Spectral (300 - 700 Nm) Extinction Parameterization Of Ambient In Situ Aerosols Measured During FIREX-AQ And The Influence Of Aerosol Composition

Hyperspectral (300 - 700 nm, 0.7 nm resolution) aerosol extinction spectra were measured at seven fires in six states in the western United States during the Fire Influence on Regional to Global Environments and Air Quality (FIREX-AQ) field campaign in July and August 2019. Obtained using an in situ aerosol sampling method, these spectra are directly comparable to other in situ aerosol measurements such as size distribution and composition. A previous deployment of the in situ Spectral Aerosol Extinction (SpEx) instrument that measured fine mode aerosols (50% size cut of 1.3 µm particle diameter) around the Korean peninsula showed that over this spectral range 2nd order polynomials provided a better fit to the logarithmically transformed spectra than linear fits (representative of Ångström exponents). The two fit parameters (a1, a2) of the polynomials are related to the classic Ångström exponent but provide additional information via their two-dimensional parameter space. The previous work was limited by the lack of commensurate size distribution information. Here, using the FIREX-AQ spectra set it is possible to expand on the previous analysis in three specific ways: 1) size distribution information is available to further elucidate how size distribution maps into (a1, a2) space, 2) the sampled size distributions include larger particles than the Korean study, and 3) the FIREX-AQ data set exhibits smoke-related spectral features in the UV part of the spectrum that are not present in background air nor were they observed previously in the Korean study. The UV spectral features are particularly intriguing as they likely arise from the absorption component of the extinction measurement and therefore may be related to composition. The relationships between the ambient in situ aerosol size distributions, the extinction spectra, and composition will be presented.

Carolyn Jordan↗

NASA NTRS2024

Effect of Varying HUT Sizing on Human-Spacesuit Contact Patterns

Fit, comfort, and mobility of the spacesuit rely on the location, magnitude, and type of contact between the suit and wearer. Typically, spacesuits include the Hard Upper Torso (HUT) comprising the upper torso of the spacesuit. Potential injuries from hard contact between the wearer’s shoulders and the HUT are a concern; therefore, to investigate spacesuit-wearer contact patterns, data from a retrospective study was analyzed. This study had eight subjects wearing the Shuttle Extravehicular Mobility Unit (EMU) spacesuit in two configurations, one with a nominally sized HUT and another with an oversized HUT. The subjects were sized per the NASA standard suit fit procedure. The suit’s arms and lower body were also resized to provide nominal arm and lower body fit, accounting for the larger HUT. Subjects held various shoulder postures (neutral posture, and various maximum shoulder rotations) with the suit pressurized to 4.3 PSI. For each posture, subjects reported the intensity of their perceived contact with the suit on a Borg CR10 scale, 0 indicating a non-existent contact intensity, and 10 representing a maximal contact intensity. Ratings were recorded for 11 regions covering the upper body and these ratings were used to determine the impact of body shape and size on suit contact. Our preliminary findings suggest that oversized HUTs had less contact regions than compared to the nominal HUT; and the region of contact, contact patterns, and contact intensities varied from person to person with the oversized HUT. This variance could be linked to subjects’ body shape and size. The next goal is to establish a causal factor between body shape and size, pose, contact region, and the HUT size. The outcome is expected to help understand the overall contact trends and insights into the influence of HUT sizing on suit fit.

Will Green↗

NASA NTRSDate not supplied

Laboratory Radar Measurements in Support of the NASA Orbital Debris Program Office’s Size Estimation Model

The NASA Orbital Debris Program Office (ODPO) relies on ground-based radar measurements from both the Haystack Ultrawideband Satellite Imaging Radar (HUSIR) and the Goldstone Solar System Radar (Goldstone) to characterize mm to cm debris population in low Earth orbit (LEO). Radar measurements help characterize the size of orbital debris objects, particularly fragmentation debris. However, debris size is not directly measured by radar but inferred from the measured radar cross section (RCS) which depends on several parameters in addition to physical size including electrical conductivity and polarization. To interpret the observed RCS of orbital debris objects detected by radar measurements as physical sizes, NASA uses an empirical size estimation model (SEM) based on laboratory RCS measurements of breakup fragments generated during hypervelocity impact tests as well as some pieces of non-impact-generated “artificial” debris-like objects expected to be representative of the debris population. Since the development of the ODPO SEM, many new materials have been introduced to spacecraft construction. Consequently, ODPO plans to update the radar SEM based on planned laboratory RCS measurements of debris fragments from DebriSat, a ground-based hypervelocity impact experiment conducted in 2014 that consisted of a high-fidelity spacecraft model characteristic of a modern LEO spacecraft. Prior to measuring DebriSat fragments, a set of calibration targets with well-defined geometries and material compositions were measured at The Ohio State University’s ElectroScience Laboratory (OSU-ESL) compact radar range. These calibration measurements help to validate, and understand any limitations of, laboratory measurements of RCS. Calibration targets include idealizations of typical shape categories seen in DebriSat fragments such as nuggets, flat plates, and cylinders. As with DebriSat, calibration target materials were chosen to represent typical modern-day spacecraft components and include stainless steel, aluminum, printed circuit board (PCB) substrate, and carbon fiber-reinforced polymer (CFRP). These materials also represent a wide range of electrical conductivities, which strongly influences measured RCS and inferred target size. The RCS calibration measurements were collected over a frequency sweep from 2 to 18 GHz and stepping through different azimuth angles from 0 to 360 degrees at an elevation of 0 degrees. A second set of calibration measurements is in work consisting of more complex shapes such as bent rods and plates as well as different mounting options including epoxy and a 3D printed holder. These further measurements along with our initial calibration set will inform selection of representative DebriSat fragments for laboratory RCS measurements that will contribute to the planned update to the ODPO radar SEM. An appropriate subset of both the radar calibration and DebriSat samples will also be measured in the ODPO Optical Measurements Center to cross-calibrate size estimates over these different wavelength regimes.

Radar↗

NASA NTRS2019

Nasa Glenn Icing Research Tunnel: 2018 Change in Drop-Sizing Equations Due to Change in Cloud Droplet Probe Sample Area

Although there has been no physical change to the cloud drop diameters in the NASA Glenn Icing Research Tunnel (IRT), the IRT cloud calibration team now has an improved understanding of the facility’s drop-sizing instrumentation, which has resulted in a recent change to the drop-sizing equations. Only the calculated values given in the previous calibration report have changed. In 2017, IRT staff found reason to believe that since at least 2014, the sample area for its Cloud Droplet Probe (CDP) (Droplet Measurement Technologies, Inc.) has been closer to 0.289 mm2, rather than the user manual’s suggested value of 0.24 mm2. In September 2017, the probe’s sample area was measured both before and after the probe was realigned, and the end sample area was measured to be 0.248 mm2. Following the probe’s realignment, drop size measurements were made in the IRT using the CDP as well as optical array probes OAP–230X and OAP–230Y (Particle Measurement Systems, Inc.). These measurements suggested that 0.289 mm2 was the more accurate value for historical measurements. When the CDP sample area used for calculations was changed from 0.24 to 0.289 mm2, distributions previously reported to have a median volumetric diameter (MVD) between 30 and 100 μm were instead calculated to have MVD values 10 to 18 percent higher. The analyses that led to these conclusions are reported in this paper, as well as the new drop-sizing equations that have been developed for the corrected measurement values. This report contains updates to drop-sizing data for the IRT’s “normal” operating conditions (MVD < 50 μm) and discusses the effects on the IRT’s “large-drop” conditions (Mod1 nozzles, Pair < 10 psig), but it does not include updates to the drop-sizing equations for those large-drop conditions.

Particle sizing↗

DOE OSTI2025

A statistical and simulation-informed model for estimating permeability from pore size distribution in saturated geomaterials

Accurate permeability estimation is essential across subsurface engineering applications but remains challenging due to the complex pore structures of natural geomaterials. Traditional empirical methods and simplified theoretical models often inadequately capture the role of pore size distribution and connectivity. Here, this study develops a statistical and simulation-informed permeability model that collapses pore-scale complexity into a compact scaling of the form k = αϕμ d 2 , where ϕ is porosity, μ d is mean pore size, and α is a weakly varying coefficient. By combining pore network simulations with statistical analysis of unimodal and bimodal pore size distributions, we identify three key findings: (i) permeability is much more sensitive to mean pore size than to porosity; (ii) across extensive datasets, the ratio σ d /μ d (standard deviation to mean) clusters around a characteristic value ∼0.4, allowing the effects of the full pore size distribution to be represented by μ d and a narrowly varying α ≈ 0.05; and (iii) for bimodal systems, there exists a critical fraction of small pores ∼0.78 above which flow becomes small-pore dominated, enabling the definition of an effective flow-controlling pore population and facilitating simplified permeability estimation for such systems. The resulting model, which requires only porosity and a representative mean pore size as inputs, is validated against comprehensive experimental datasets (>1700 samples) spanning diverse soils and rocks and achieves good predictive accuracy. Overall, this work provides a physically grounded yet practically simple permeability estimator suitable for subsurface engineering, environmental protection, and resource management applications.

Permeability↗

DOE OSTI2025

The role of specimen size and grain boundary characteristics in the yield strength of tungsten in microtensile tests

To effectively use the measured properties from small-scale tensile tests for bulk material performance predictions, it is essential to understand the threshold of specimen size-effect strengthening and the interaction between dislocations and microstructures within miniaturized specimens. This study uses pure tungsten to investigate the size effect in terms of specimen size, grain size, and grain boundary characteristics relative to the yield strength of tungsten at room temperature. We evaluate the transition from miniaturized specimen properties to bulk properties and the deformation behavior through small-scale tensile tests of three specimen sizes (large: 80 × 100 × 233 µm³; medium: 7 × 7 × 18 µm³; and small: 2 × 2 × 5 µm³). The testing results reveal that the small and medium specimens exhibit high yield strength with ductile behavior, while the large specimens exhibit brittle failure, consistent with the room temperature strength of tungsten, indicating bulk behavior. We further explore the specimen size-effect sensitivity to yield stress and the scaling relationship between yield strength and the number of grains involved in the deformation. A power-law relationship with the exponent value of approximately -0.5 was found in the yield strength–grain number scaling, implying the Hall-Petch like behavior. A minimum of 7–17 effective grain boundaries across the tensile gauge dimension is required to accurately measure bulk properties.

36 - MATERIALS SCIENCE↗

DOE OSTI2025

Meshfree simulation and prediction of recrystallized grain size in friction stir processed 316L stainless steel

Friction stir processing (FSP) is a promising solid-phase microstructural modification technique that can repair and enhance damaged stainless steel surfaces exposed to harsh environments. The quality of the repaired material is closely correlated to the recrystallized grain size in the stir zone (SZ), which is influenced by the thermomechanical conditions dictated by FSP process parameters. Thus, establishing a reliable relationship between these parameters and recrystallized grain size in the SZ is crucial for optimizing repair quality. However, existing experimental approaches often rely on indirect temperatures measured far from the SZ, along with rough strain rate estimations, which are imprecise and time-consuming. Meanwhile, existing mesh-based modeling methods usually face numerical challenges when dealing with the large material deformations inherent in FSP. Here, to address these issues, this study introduces a meshfree process model for FSP based on the smoothed particle hydrodynamics (SPH) method, aimed at predicting process conditions under different parameters. The model is validated using experimental data from 11 combinations of tool traverse and rotation speeds on 316 L stainless steel. Correlations between process parameters, material flow, temperature, strain, strain rate, and recrystallized grain size are revealed through SPH simulations and electron backscatter diffraction (EBSD) imaging. The results show that in situ SZ temperatures range from 1071 to 1322°C, which exceed the tool temperature by over 300°C. Furthermore, SZ temperature, strain rate, and grain size increase monotonically with higher tool temperature and faster traverse speed. A relationship is then established between the model-predicted Zener-Hollomon parameter and the recrystallized grain size based on EBSD data, expressed as ln(d) = -0.364 ln(Z) + 14.673. Finally, this relationship exhibits satisfactory accuracy with errors of less than 26.9% in predicting grain sizes at various SZ locations, which offers valuable insights for optimizing FSP repair processes for 316 L stainless steel.

316L stainless steel↗

DOE OSTI2026

Effect of fiber sizing and glass fiber laminate hybridization on vibration damping and mechanical properties of banana fiber reinforced polypropylene composites

Modern automotive applications demand lightweight, multifunctional materials to reach mileage goals and natural fiber reinforced composites (NFRCs) are one of the classes of materials proposed as a solution. NFRCs exhibit good vibration damping properties and have low density, but are often limited by processing challenges, poor-fiber matrix compatibility and variable performance. Herein, we investigate non-woven wet-lay of comingled banana fiber (BF), recycled glass fiber (rGF), and polypropylene (PP) fibers to in situ sizing and preparation of composite feedstocks for compression molding. BF and rGF hybrids were prepared by stacking rGF layers during compression molding to produce composites with various fiber ratios. The effect of fiber content, in-situ sizing and ratio of BF to rGF on tensile, flexural and vibration damping performance are investigated. Key results are the significant increase in tensile strength by in situ sizing (40 % sized at 60 wt% BF) and in flexural modulus (+58 % sized at 60 wt% BF) and flexural strength (+41 % sized 60 wt% BF) compared to the unsized equivalent. For BF-rGF hybrid composites with40 wt% total fiber content, flexural strength and modulus were improved by 51 % and 231 % respectively for a 1:1 ratio BF:rGF compared to BF reinforced system. Lastly, identifying the cross-over point where damping and stiffness are optimized for a hybrid composite. These findings demonstrate that these composites can be used as alternative to synthetic fiber or mineral filled composites in automotive applications, particularly where weight reduction, vibration damping and stiffness are desired.

Banana fiber↗