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Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.

Laser Powder Bed Fusion↗

NASA NTRS2018

The Mars Reconnaissance Orbiter Mission: 2018 Status

The Mars Reconnaissance Orbiter (MRO) continues its dual-mode mission of scientific exploration and programmatic support. Now in its 13th year of flight (and its 12th year in its low-altitude, sun-synchronous orbit around Mars), the spacecraft continues in its normal flight mode and its science instruments continue to acquire a treasure trove of data which is being used to study the Martian environment (surface, sub-surface, and atmosphere). To date (July 2018), more than 333 TB of scientific data have been returned to Earth. Building onto the 2017 IAC paper: “The Mars Reconnaissance Orbiter Mission: Continuing a Record of Exploration from Mars Orbit,” [1] this paper provides a 2018 status update on the MRO Mission. A signature event since the 2017 writing is the onset and evolution of a planet-encircling dust event (PEDE), the first such event since 2007. Additional recent science highlights for MRO include the discovery of mid-latitude ice cliffs, polar cap characterization, daily global mapping of the 2018 PEDE dust activity and the atmospheric thermal response, further characterization of the tantalizing recurring slope lineae (RSL), and continued detection of surface changes. Programmatically, UHF relay support for the Mars Science Laboratory (MSL) rover Curiosity and the Mars Exploration Rover (MER) rover Opportunity continues at a pace that provides the engineers and scientists operating those surface vehicles timely information to support their mission planning and science analysis. Most of the landing site characterization requests for the NASA Mars 2020 rover and the ESA ExoMars Rover/Surface Platform (RSP) missions have been completed, with final acquisitions delayed due to the obscuring dust haze from the current PEDE. In parallel, the flight team has faced new engineering challenges as the spacecraft has aged. The team has developed and is implementing actions that are aimed at stretching spacecraft battery life. A new all-stellar capability using the spacecraft’s star trackers now allows for normal spacecraft operations without IMUs. In addition to its current relay duties, MRO will be synchronized to provide critical communications support for the InSight Entry, Descent, and Landing (EDL) event on November 26, 2018, and will be readied to support InSight’s critical commissioning phase with UHF relay support and environmental characterization. A new split-pass relay capability has been developed which will allow MRO to relay with two surface vehicles in “close proximity” on the same overflight, i.e. the InSight lander and the Curiosity rover. Extended for another year of operations by NASA, this paper will highlight recent scientific progress and describe actions that will extend MRO’s life well into the 2020’s as a key element of the Mars Exploration Program.

Zurek, Richard W.↗

DOE OSTI2022

Dynamics of particle network in composite battery cathodes

We report that improving composite battery electrodes requires a delicate control of active materials and electrode formulation. The electrochemically active particles fulfill their role as energy exchange reservoirs through interacting with the surrounding conductive network. We formulate a network evolution model to interpret the regulation and equilibration between electrochemical activity and mechanical damage of these particles. Through statistical analysis of thousands of particles using x-ray phase contrast holotomography in a LiNi 0.8 Mn 0.1 Co 0.1 O 2 -based cathode, we found that the local network heterogeneity results in asynchronous activities in the early cycles, and subsequently the particle assemblies move toward a synchronous behavior. Our study pinpoints the chemomechanical behavior of individual particles and enables better designs of the conductive network to optimize the utility of all the particles during operation.

25 ENERGY STORAGE↗

NASA NTRS1987

Evolution of magnetic cataclysmic binaries

The physics of magnetic cataclysmic binary evolution is considered, and it is suggested that DQ Her stars will not evolve into AM Her stars (assuming that mu1 remains constant throughout their evolution), in contradiction to previous assertions. Four regimes that depend on mu1 values are identified, and it is suggested that the mu1 values of the known DQ Her stars are significantly less than those of the known AM Her stars (unless all known stars of both groups have M1 greater than 1 solar mass). A new way of producing ultrashort period binaries is proposed in which synchronization of the magnetic degenerate dwarfs injects angular momentum into the binary, driving the system apart and producing a synchronization-induced period gap. The secondaries in these binaries are shown to be hydrogen-rich rather than hydrogen depleted or pure helium.

Lamb, D. Q.↗

NASA NTRS1972

Dynamical characteristics of Phobos and Deimos.

The orbital properties of the two small Martian satellites, Phobos and Deimos, are discussed, as well as those dynamical constants of Mars that can be determined from the satellite orbits. The secular acceleration of the mean motion of Phobos is shown to be very small. Of mechanisms that could cause any such acceleration, only tidal friction appears to be important. From the orbital evolution of the Martian satellites under tidal forces, Phobos and Deimos seem to have originated in nearly circular orbits of low inclination fairly close to the distance at which a satellite's orbital period is the planet's rotation period. It is proposed that the Martian satellites were born at the same time as Mars from equatorial dust clouds. The satellites are predicted to be locked in synchronous rotation, with their axes of minimum moment of inertia pointing on the average toward Mars, whereas their maximum axes are approximately normal to their orbit planes.

Burns, J. A.↗

NASA NTRS1977

The Space Shuttle Main Engine High-Pressure Fuel Turbopump rotordynamic instability problem

The SSME (Space Shuttle Main Engine) HPFTP (High-Pressure Fuel Turbopump) has been subject to a rotordynamic instability problem, characterized by large and damaging subsynchronous whirling motion. The original design of the HPFTP (from a rotordynamic viewpoint) and the evolution of the HPFTP subsynchronous whirl problem are reviewed. The models and analysis which have been developed and utilized to explain the HPFTP instability and improve its stability performance are also reviewed. Elements of the rotordynamic model which are discussed in detail include the following: (a) hydrodynamic forces due to seals, (b) internal rotor damping, (c) bearing and casing support stiffness asymmetry, and (d) casing dynamics. The stability and synchronous response characteristics of the following two design alternatives are compared: (a) a 'stiff' symmetric bearing support design and (b) a damped asymmetric stiffness design. With appropriate interstage seal designs, both designs are shown, in theory to provide substantially improved stability and synchronous response characteristics in comparison to the original design. The asymmetric design is shown to have better stability and synchronous response characteristics than the stiffly supported design.

Childs, D. W.↗

DOE OSTI2021

Proposed Longitudinal Profile Diagnostics for Optical Stochastic Cooling of Stored Electrons in the IOTA Ring

One of the predicted signatures of successful optical stochastic cooling (OSC) in the Fermilab Integrable Optics Test Accelerator (IOTA) ring is reduction of the bunch length. The IOTA OSC experiment is designed for a low nominal beam current (~0.1 microAmps of 100-MeV electrons) to reduce intrabeam scattering (IBS), and during cooling, OSC is expected to reduce the bunch length from ~200 ps to ~130 ps*. These equilibrium bunch lengths can be measured using a streak camera and the optical synchrotron radiation (OSR) generated in a ring dipole by the circulating beam. A similar measurement was previously performed at the Advanced Photon Source with a Hamamatsu C5680 synchroscan streak camera operating at 117.3 MHz**. In this case, synchronous summing of OSR resulted in a bunch length measurement of 276 ± 30 ps using only 57 electrons circulating at 425 MeV. At IOTA, an existing streak camera has been modified to operate at the 11th harmonic of the ring’s revolution frequency of 7.50 MHz and has been installed on an OSR port in support of the OSC experiments. The integrated system will have sufficient sensitivity and resolution for measuring the evolution and equilibrium values of the bunch length during OSC experiments.

Lumpkin, Alex H.↗

DOE OSTI2025

Probing Operando Electrochemical Strain Generation in α-NaFeO 2 Composite Cathodes during Cycling of Na-Ion Batteries

The transition metal oxide (TMO) cathodes in Na-ion batteries suffer from low-capacity retention. Chemo-mechanical instabilities lead to the deterioration of the electrochemical performance of TMO cathodes in Li-ion batteries. However, there is not much known about the chemo-mechanical instabilities in the TMO cathodes for Na-ion batteries. Understanding the governing forces behind the interplay between the electrochemical performance and mechanical stability in TMO cathodes is critical for the development of Na-ion batteries. Here, we synchronize the digital image correlation (DIC) technique with electrochemical analysis to capture the real-time deformation behavior of the α-NaFeO 2 cathodes during cycling. When the charge cutoff voltage is 3.6 V, the cathode experiences reversible deformations (except for the first cycle). There is negative strain (shrinkage) generation during Na extraction and positive strain (expansion) generation during the subsequent Na insertion. A detailed analysis of the potential-dependent strain rate evolution points out complicated phase transformations and nonequilibrium conditions in the α-NaFeO 2 cathodes during cycling. When the charge cutoff voltage was increased to 4.2 V, there was a rapid capacity loss and large plastic deformations in the α-NaFeO 2 cathodes. We provide an in-depth discussion about the possible mechanisms behind the chemo-mechanical instabilities in the α-NaFeO 2 . In conclusion, the correlation is critical to develop material-based strategies to mitigate instability mechanisms in TMO cathodes for Na-ion batteries.

Wable, Minal [University of Maryland Baltimore Cou↗

NASA NTRS1973

The role of rotation in close binary systems of high mass.

A quantitative confrontation of theory and observation of massive close binary systems is presented in order to evaluate the role of axial rotation in the evolution of the individual stellar components as well as of the system as a whole. The detached systems are essentially unevolved, and possess components in approximately uniform rotation. The semidetached systems are definitely evolved, having suffered a heavy mass exchange before the stage of hydrogen exhaustion at the center of the original primary, and often possess mass-gaining components in fast nonuniform rotation. Except in the case of wide systems, tidal friction eventually reinduces synchronism of rotation in both components and both components evolve inhomogeneously. Spin-down times of the envelope and core, total rotational angular momenta, and effects of spin-orbit interaction are calculated.

Stothers, R.↗

DOE OSTI2024

Study of synchronous RF pulsing in dual frequency capacitively coupled plasma

Low-pressure multi-frequency capacitively coupled plasmas (CCPs) are used for numerous etch and deposition applications in the semiconductor industry. Pulsing of the radio-frequency (RF) sources enables control of neutral and charged species in the plasma on a millisecond timescale. The synchronous (i.e. simultaneous, in-phase) pulsing of both power sources in a dual frequency CCP is examined in this article. Due to the low gas pressure, modeling has been done using the electrostatic particle-in-cell/Monte Carlo collision method. Here, the objective of this work is to investigate the sensitivity of the plasma properties to small changes in timing during synchronous pulsing of the two RF sources. It is demonstrated that small deviations in the on and off times of the two RF sources can lead to major changes in the plasma characteristics. This high sensitivity is of concern for process repeatability but can be utilized to enable better control of the dynamics of plasma-surface interaction. In the simulations, the pulsing parameters (on and off times and ramp rates) are varied and the temporal evolution of plasma characteristics such as electron density (n e ), species current at the electrode, and electron temperature are examined. It is demonstrated that if the low-frequency (LF) source is turned off a few μs before (or after) the high-frequency source, n e during the off-state is significantly higher (or lower) due to the frequency coupling effect. Similarly, turning on the LF source with a small delay results in a sharp increase in the plasma density when the RF sources are turned on.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Coordinated Frequency Regulation in Grid-Forming Storage Network via Safety-Consensus

Inverter-based storages are poised to play a prominent role in future power grid with massive renewable generation. Grid-forming inverters (GFMs) are emerging as a dominant technology with synchronous generators (SG)-like characteristics through primary control loops. Advanced secondary-layer control schemes, e.g., consensus algorithms, allow GFM-interfaced storage units to participate in frequency regulations and restore nominal frequency following grid disturbances. However, it is imperative to ensure critical frequency safety limits are not violated while the grid transitions from pre- to post-disturbance operating point. This paper presents a novel safety-enforced consensus method, having three distinct objectives: safe transient frequency evolution, minimizing frequency deviation, and coordinated power sharing. The proposed technique is illustrated using a GFM-interfaced grid-wide storage network on the IEEE 68-bus system under multiple grid transient scenarios.

consensus control↗

DOE OSTI2024

A novel open-source cultivation system helps establish the first full cycle chemosynthetic symbiosis model system involving the giant ciliate Zoothamnium niveum

Symbiotic interactions drive species evolution, with nutritional symbioses playing vital roles across ecosystems. Chemosynthetic symbioses are globally distributed and ecologically significant, yet the lack of model systems has hindered research progress. The giant ciliate Zoothamnium niveum and its sulfur-oxidizing symbionts represent the only known chemosynthetic symbiosis with a short life span that has been transiently cultivated in the laboratory. While it is experimentally tractable and presents a promising model system, it currently lacks an open-source, simple, and standardized cultivation setup. Following the FABricated Ecosystems (EcoFABs) model, we leveraged 3D printing and polydimethylsiloxane (PDMS) casting to develop simple flow-through cultivation chambers that can be produced and adopted by any laboratory. The streamlined manufacturing process reduces production time by 86% and cuts cost by tenfold compared to the previous system. Benchmarking using previously established optimal growth conditions, the new open-source cultivation system proves stable, efficient, more autonomous, and promotes a more prolific growth of the symbiosis. For the first time, starting from single cells, we successfully cultivated the symbiosis in flow-through chambers for 20 days, spanning multiple generations of colonies that remained symbiotic. They were transferred from chamber to chamber enabling long-term cultivation and eliminating the need for continuous field sampling. The chambers, optimized for live imaging, allowed detailed observation of the synchronized growth between the host and symbiont. Highlighting the benefit of this new system, we here describe a new step in the first hours of development where the host pauses growth, expels a coat, before resuming growth, hinting at a putative symbiont selection mechanism early in the colony life cycle. With this simple, open-source, cultivation setup, Z. niveum holds promises for comparative studies, standardization of research and wide adoption by the symbiosis research community.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2008

Re-Engineering the Tropical Rainfall Measuring Mission (TRMM) Satellite Utilizing Goddard Space Flight Center (GSFC) Mission Services Center (GMSEC) Middleware Based Technology to Enable Lights Out Operations and Autonomous Re-Dump of Lost Telemetry Data

The Tropical Rainfall Measuring Mission (TRMM) spacecraft was launched in November of 1996 in order to obtain unique three dimensional radar cross sectional observations of cloud structures with particular interest in hurricanes. The TRMM mission life was recently extended with current estimates that operations will continue through the 2012-2013 timeframe. Faced with this extended mission profile, the project has embarked on a technology refresh and re-engineering effort. TRMM has recently implemented a re-engineering effort to expand a middleware based messaging architecture to enable fully redundant lights-out of flight operations activities. The middleware approach is based on the Goddard Mission Services Evolution Center (GMSEC) architecture, tools and associated open-source Applications Programming Interface (API). Middleware based messaging systems are useful in spacecraft operations and automation systems because private node based knowledge (such as that within a telemetry and command system) can be broadcast on the middleware messaging bus and hence enable collaborative decisions to be made by multiple subsystems. In this fashion, private data is made public and distributed within the local area network and multiple nodes can remain synchronized with other nodes. This concept is useful in a fully redundant architecture whereby one node is monitoring the processing of the 'prime' node so that in the event of a failure the backup node can assume operations of the prime, without loss of state knowledge. This paper will review and present the experiences, architecture, approach and lessons learned of the TRMM re-engineering effort centered on the GMSEC middleware architecture and tool suite. Relevant information will be presented that relates to the dual redundant parallel nature of the Telemetry and Command (T and C) and Front-End systems and how these systems can interact over a middleware bus to achieve autonomous operations including autonomous commanding to recover missing science data during the same spacecraft contact.

Marius, Julio L.↗

NASA NTRS1999

Tholins: Can They Provide a Substrate, Carbon and Nitrogen for Plant Production?

Tholin is a word coined to describe the entire class of complex organic solids produced in laboratory experiments where pre-biotic gaseous chemicals are subject to bombardment by high energy. The atomic composition of Titan tholin produced from 10 percent CH4 and 90 percent N2 in a simulation of Titan atmosphere irradiated by charged particles trapped in the magnetosphere of Saturn gave 67 percent C and 33 percent N. Hydrolysis of Titan tholin with 6N HCl produced a racemic mixture of biological and non-biological amino acids that was confirmed by GC/MS. Other tholins, that revealed the presence of amino acids, were UV tholin produced under possible primitive Earth conditions by irradiation of a mixture of gases (CH4, C2H6, NH3, H2S and liquid H2O) with long-wavelength ultraviolet light, representing the most abundant useful energy source for prebiological organic synthesis; Spark tholin in a crude simulation of Jupiter atmosphere using electrical discharge through a mixture of CH4, NH3, and H2O vapor. Pyrolytic GC/MS of Titan tholin produced more than one hundred organic compounds including saturated and unsaturated aliphatic hydrocarbons, substituted polycyclic aromatics, nitriles, amines, pyrroles, pyrazines, pyridines, pyrimidines, and the purine, adenine. Similar rich pyrolytic products were obtained with UV as well as Spark tholins. A range of two to four ring PAHs (Polycyclic Aromatic Hydrocarbons) in Spark as well as Titan tholins, some with one to four alkylation sites, were identified by two-step laser desorption/multiphoton ionization mass spectrometry and also confirmed by the synchronous fluorescence technique. Previous studies have demonstrated the potential for use of tholins as a source of carbon and energy by microbes. This paper describes studies that evaluate the potential for using different types of tholins as (a) a substrate for growing plants and (b) a source of carbon and nitrogen for plants. The data are interpreted in terms of the potential for using such tholins to grow plants for food in extraterrestrial habitats and also to speculate on the possibilities of abiotic evolution of plants.

Wignarajah, Kanapathipillai↗

DOE OSTI2025

Adaptive modification of antiviral defense systems in microbial community under Cr-induced stress

Background The prokaryotic antiviral defense systems are crucial for mediating prokaryote-virus interactions that influence microbiome functioning and evolutionary dynamics. Despite the prevalence and significance of prokaryotic antiviral defense systems, their responses to abiotic stress and ecological consequences remain poorly understood in soil ecosystems. We established microcosm systems with varying concentrations of hexavalent chromium (Cr(VI)) to investigate the adaptive modifications of prokaryotic antiviral defense systems under abiotic stress. Results Utilizing hybrid metagenomic assembly with long-read and short-read sequencing, we discovered that anti- viral defense systems were more diverse and prevalent in heavily polluted soils, which was corroborated by meta-analyses of public datasets from various heavy metal-contaminated sites. As the Cr(VI) concentration increased, prokaryotes with defense systems favoring prokaryote-virus mutualism gradually supplanted those with defense systems incurring high adaptive costs. Additionally, as Cr(VI) concentrations increased, enriched antiviral defense systems exhibited synchronization with microbial heavy metal resistance genes. Furthermore, the proportion of antiviral defense systems carried by mobile genetic elements (MGEs), including plasmids and viruses, increased by approximately 43% and 39%, respectively, with rising Cr concentrations. This trend is conducive to strengthening the dissemination and sharing of defense resources within microbial communities. Conclusions Overall, our study reveals the adaptive modification of prokaryotic antiviral defense systems in soil ecosystems under abiotic stress, as well as their positive contributions to establishing prokaryote-virus mutualism and the evolution of microbial heavy metal resistance. These findings advance our understanding of microbial adaptation in stressful environments and may inspire novel approaches for microbiome manipulation and bioremediation.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1986

Europa

Europa, the second major satellite outward from Jupiter, is a lunar-sized object in synchronous rotation about that planet. Its high albedo and spectral characteristics indicate the presence of surface water ice and/or frost. Its density suggests a substantial silicate component of at least 85 percent by volume. A limited variety of landforms is seen in Voyager images, most likely because of poor spatial resolution of these data. The absence of numerous impact craters is interpreted as indicating a youthful surface and /or surface regenerating processes. A planet-wide lineament system has been interpreted to result from tectonic stresses induced by evolution of Europa's orbit and interior. Present data do not permit unambiguous tests of such interpretations. Greater insight may come from analytical or numerical models and future spacecraft observations.

Malin, Michael C.↗

NASA NTRS1983

The Ponta Grossa Arch: A proposal for ts configuration and evolution from the interpretation of remote sensing data

Visual analysis of MSS imagery was used to construct a map of dikes in a wide area of the Ponta Grossa Arch both in the Parana Basin and its basement. Analysis of the map by photographic methods defined the zone of highest density of the dikes, and some aspects of the longitudinal and transverse heterogeneities, as well as localized the apex of the Arch. Borders of the Arch were also suggested. Field investigations confirmed the position of the apex of the flexure on Palezoic sediments and pre-lava Mesozoic sediments. Controversial aspects of the relative absence of dikes in certain units or lithologies and the composition of intrusions surrounding the city of Castro were observed. The apparent synchronism between the activity of the Parana Basin and the Arch is discussed as well as the frequent inverse characteristics of vertical movements. The similarity of rocks in Brazil and Africa is also considered.

Parada, N. D. J.↗

DOE OSTI2023

Synchronizing the consistency relation

We study the N-point function of the density contrast to quadratic order in the squeezed limit during the matter-dominated (MD) and radiation-dominated (RD) eras in synchronous gauge. Since synchronous gauge follows the free-fall frame of observers, the equivalence principle dictates that in the gradient approximation for the long-wavelength mode there is only a single, manifestly time-independent consistency relation for the N-point function. This simple form is dictated by the initial mapping between synchronous and local coordinates, unlike Newtonian gauge and its correspondingly separate dilation and Newtonian consistency relations. Dynamical effects only appear at quadratic order in the squeezed limit and are again characterized by a change in the local background, also known as the separate universe approach. We show that for the 3-point function the compatibility between these squeezed-limit relations and second-order perturbation theory requires both the initial and dynamical contributions to match, as they do in single-field inflation. This clarifies the role of evolution or late-time projection effects in establishing the consistency relation for observable bispectra, which is especially important for radiation acoustic oscillations and for establishing consistency below the matter-radiation equality scale in the MD era. Defining an appropriate angle and time average of these oscillations is also important for making separate universe predictions of spatially varying local observables during the RD era, which can be useful for a wider range of cosmological predictions beyond N-point functions.

79 ASTRONOMY AND ASTROPHYSICS↗