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Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗

Electromagnetic and Mechanical Analysis of the Coil Structure for the CLAS12 Torus for 12 GeV Upgrade

The torus magnet for the CLAS12 spectrometer is a 3.6 T superconducting magnet being designed and built as part of the Jefferson Lab 12 GeV Upgrade. The magnet consists of six coil case assemblies mounted to a cold central hub. The coil case assembly consists of an aluminum case and cover enclosing an epoxy vacuum impregnated coil pack. The coil pack consists of a 117 turn double-pancake winding wrapped with 2 layers of 0.635 mm thick copper cooling sheets. The coil case assembly is cooled by supercritical helium at 4.6 K. This report details the structural analysis of the coil case assembly and the assessment of the coil pack stresses. For the normal operation of the torus magnet, the coil case assembly was analyzed for cool down to 4.6 K and the Lorentz forces at normal operating current. In addition to the normal operating configuration, the coil case assembly was analyzed for Lorentz forces arising from coil misalignment and current imbalances. The allowable stress criteria for the magnet followed the approach of the ASME codes. Primary stresses were limited to the lesser of 2/3 times the yield strength or 1/3 times the ultimate tensile strength. Primary plus secondary stresses were limited to 3 times the primary stress allowable. The analysis was performed using ANSYS Maxwell to calculate the magneto-static loads and ANSYS Mechanical to calculate the stresses.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Beyond union of subspaces: Subspace pursuit on Grassmann manifold for data representation

Discovering the underlying structure of a high-dimensional signal or big data has always been a challenging topic, and has become harder to tackle especially when the observations are exposed to arbitrary sparse perturbations. Here in this paper, built on the model of a union of subspaces (UoS) with sparse outliers and inspired by a basis pursuit strategy, we exploit the fundamental structure of a Grassmann manifold, and propose a new technique of pursuing the subspaces systematically by solving a non-convex optimization problem using the alternating direction method of multipliers. This problem as noted is further complicated by non-convex constraints on the Grassmann manifold, as well as the bilinearity in the penalty caused by the subspace bases and coefficients. Nevertheless, numerical experiments verify that the proposed algorithm, which provides elegant solutions to the sub-problems in each step, is able to de-couple the subspaces and pursue each of them under time-efficient parallel computation.

97 MATHEMATICS AND COMPUTING↗

Studies of BONuS12 Radial GEM Detector and TCS Beam Spin Asymmetry in CLAS12

The Barely Offshell Nucleon Structure (BONuS12) experiment adopted the concept of spectator tagging technique to study the nearly-free neutron structure function Fn2 in the CLAS12 of Jefferson Lab. A novel Radial Time Projection Chamber (RTPC) detector was built, tested and integrated into the CLAS12 system to detect a back-moving low momentum tagged proton in d(e,ep)X deep-inelastic scattering. It was a 40 cm long gaseous detector consisting of 3 layers of cylindrical GEM foils for the charge amplification, with the data readout directly from the surrounding padboard. The RTPC detected the recoiling spectator proton, in coincidence with the scattered electron in the CLAS12. Nucleon structure functions are directly related to the partonic functions, quarks momentum distribution in one dimension. A Generalized Parton Distribution (GPD) came to the lime-light as it encodes the information of both longitudinal momentum and transverse position of partons inside the nucleons. Factorization of hard process such as DVCS allows to access GPDs. Timelike Compton Scattering (TCS), ?p ? ??p, is another process that allows to access the GPDs. TCS is studied experimentally in the CLAS12 of Jefferson lab using the quasi-real photoproduction of time-like photon which eventually decays to lepton pair. This dissertation presents the concept of spectator tagging in BONuS12, and the research and development efforts during the BONuS12 preparation leading up to the successful data-taking during spring and summer 2020. In addition, analysis framework to extract the beam spin asymmetry of TCS events through the CLAS12 Run group A data is presented.

Poudel, Jiwan↗

A multi-microprocessor system for finite element structural analysis

During the last few years, advances in microprocessor technology have spurred a renewed interest in special-purpose computers. The microprocessor has become small, inexpensive, and powerful enough to be considered as a building block for special-purpose hardware. A description is presented of the architecture of a prototype 'finite element machine' currently being built. Attention is given to details regarding the finite element analysis problem, the arrangement of the processors as finite element nodes in the structural model, the influence of the architecture on the solution algorithm, interprocessor communication primitives, and the performance of the finite element machine.

Jordan, H. F.↗

A Summary of Structural Test and Simulation Results for Hawker 4000 Composite Fuselage Hardware

NASA Langley Research Center (LaRC) was able to obtain a partially fabricated Hawker Beechcraft Model 4000 (Hawker 4000) aft aircraft section to use for study. The Hawker 4000 is a medium sized business jet (14 Code of Federal Regulations Part 25 – Transport Category Aircraft) with seating for 8 to 14 people and fabricated out of carbon composite. The Hawker 4000 was designed in the early 2000s to compete with Gulfstream and Bombardier business jet units. The Hawker Beechcraft business unit declared bankruptcy in 2012, and abruptly halted production of the 4000 series aircraft. As a result, only 73 full production aircraft were built. This all-composite aft fuselage section was an ideal candidate to utilize for investigations of composite structures undergoing dynamic loading in order to satisfy NASA Revolutionary Vertical Lift Technology (RVLT) project objectives. Thus, a team at NASA LaRC embarked on a test and simulation program in late 2021 in order to generate test data of composite structures undergoing dynamic loading conditions. As a part of these investigations, methods including reverse engineering the geometry, conducting as-fabricated materials testing and using non-destructive evaluation (NDE) techniques such as ultrasonic through transmission were utilized in order to develop digital twin finite element models for use in computational simulations.

dynamic composite testing↗

Contribution of individual interfaces in the MgO/Co/Pd trilayer to perpendicular magnetic anisotropy upon annealing

The contribution of each interface of the MgO/Co/Pd trilayer to the perpendicular magnetic anisotropy (PMA) was studied by changing chemical and crystalline structures through annealing. We found that volumetric anisotropy in the MgO/Co/Pd trilayer was significantly increased due to enhanced magnetoelastic anisotropy caused by stress built up most likely at the MgO/Co interface during annealing. When the trilayer was annealed at 400 °C, the alloy formation at the Co/Pd interface additionally increased the volumetric anisotropy. Our x-ray magnetic circular dichroism study supported that those structural modifications led to an increase in the orbital moment through spin-orbit coupling (SOC) along the film normal two times larger than that of the as-deposited trilayer, thereby enhancing PMA greatly. Our experimental results prove that the Co/Pd interface, rather than the MgO/Co interface, plays an essential role in inducing strong PMA in the trilayer. The precise investigation of annealing effect on both volumetric and interfacial anisotropies can provide a methodological solution to improve the SOC of the trilayer that can serve as the core unit of spintronic devices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Barless flocculent galaxies: a dynamic puzzle

We draw attention to the bright galaxies that do not show a bar in their structure but have a flocculent spiral structure. Using the THINGS and HERACLES kinematic data for four barless galaxies (NGC 2841, NGC 3512, NGC 5055, NGC 7331), we built their mass models including dark haloes. We concluded that the fraction of the dark matter does not exceed 50 per cent within the optical radii of the galaxies. This is too little to explain the lack of a bar in these galaxies. In an attempt to understand the featureless structure of these galaxies, we constructed several N-body models with an initially reduced content of dark matter. We concluded that, in addition to the low mass of the dark halo, the decisive factor that leads to a barless disc is the start from an initially unstable state. An isolated dynamically cold disc (with the Toomre parameter Q < 0.5) settled into rotational equilibrium passes through the short stage of violent instability with fragmentation and formation of stellar clumps. After that, it evolves passively and ends up with a featureless structure. We assume that the barless flocculent galaxies studied in this work may be descendants of galaxies at high redshifts with rotation curves that are consistent with the high mass fraction of baryons relative to the total dark matter halo.

79 ASTRONOMY AND ASTROPHYSICS↗

The Role of Guidance, Navigation, and Control in Hypersonic Vehicle Multidisciplinary Design and Optimization

Airbreathing hypersonic systems offer distinct performance advantages over rocket-based systems for space access vehicles. However, these performance advantages are dependent upon advances in current state-of-the-art technologies in many areas such as ram/scramjet propulsion integration, high temperature materials, aero-elastic structures, thermal protection systems, transition to hypersonics and hypersonic control elements within the framework of complex physics and new design methods. The complex interactions between elements of an airbreathing hypersonic vehicle represent a new paradigm in vehicle design to achieve the optimal performance necessary to meet space access mission objectives. In the past, guidance, navigation, and control (GNC) analysis often follows completion of the vehicle conceptual design process. Individual component groups design subsystems which are then integrated into a vehicle configuration. GNC is presented the task of developing control approaches to meet vehicle performance objectives given that configuration. This approach may be sufficient for vehicles where significant performance margins exist. However, for higher performance vehicles engaging the GNC discipline too late in the design cycle has been costly. For example, the X-29 experimental flight vehicle was built as a technology demonstrator. One of the many technologies to be demonstrated was the use of light-weight material composites for structural components. The use of light-weight materials increased the flexibility of the X- 29 beyond that of conventional metal alloy constructed aircraft. This effect was not considered when the vehicle control system was designed and built. The impact of this is that the control system did not have enough control authority to compensate for the effects of the first fundamental structural mode of the vehicle. As a result, the resulting pitch rate response of the vehicle was below specification and no post-design changes could recover the desired capability.

Ouzts, Peter J.↗

Rotationally Adaptive Flight Test Surface

Research on a new design of flutter exciter vane using adaptive materials was conducted. This novel design is based on all-moving aerodynamic surface technology and consists of a structurally stiff main spar, a series of piezoelectric actuator elements and an aerodynamic shell which is pivoted around the main spar. The work was built upon the current missile-type all-moving surface designs and change them so they are better suited for flutter excitation through the transonic flight regime. The first portion of research will be centered on aerodynamic and structural modeling of the system. USAF DatCom and vortex lattice codes was used to capture the fundamental aerodynamics of the vane. Finite element codes and laminated plate theory and virtual work analyses will be used to structurally model the aerodynamic vane and wing tip. Following the basic modeling, a flutter test vane was designed. Each component within the structure was designed to meet the design loads. After the design loads are met, then the deflections will be maximized and the internal structure will be laid out. In addition to the structure, a basic electrical control network will be designed which will be capable of driving a scaled exciter vane. The third and final stage of main investigation involved the fabrication of a 1/4 scale vane. This scaled vane was used to verify kinematics and structural mechanics theories on all-moving actuation. Following assembly, a series of bench tests was conducted to determine frequency response, electrical characteristics, mechanical and kinematic properties. Test results indicate peak-to-peak deflections of 1.1 deg with a corner frequency of just over 130 Hz.

Barrett, Ron↗

Microstructure and mechanical behavior of hot-work tool steels processed by Selective Laser Melting

Highlights: • H11 and a modified H11 hot work tool steels have been produced by SLM. • As-built alloys are characterized by α-Fe cells surrounded by C-rich γ-Fe regions. • Rapidly solidified structures revealed able to respond to precipitation hardening. • Mechanical behavior of AM H11 is similar to that obtained by conventional processes. - Abstract: The present study is aimed at identifying and testing high-strength alloys for tooling applications featuring suitable processability for laser-based additive manufacturing technologies. The microstructure and mechanical properties of the H11 hot-work tool steel and a leaner version of the same alloy (L-H11) processed by Selective Laser Melting were assessed as a function of specific microstructural conditions obtained by performing different heat treatments. Tempering was performed on quenched alloys or simply from as built material. The rapidly solidified microstructures revealed able to respond directly to precipitation hardening treatment without performing any prior solution annealing. The microstructure of the as-built alloys revealed characterized by α-Fe dendritic cells decorated at boundaries by C-rich γ-Fe regions. Air quenching was responsible for the transformation of the solidification cells into lath martensitic structures and for the formation of the M{sub 3}C phase, which transformed into more complex carbide species on tempering. The hardness of quenched and tempered H11 steel is similar to that obtained by processing the alloy with conventional routes, and the final hardness gap between the two SLM processed H11 and L-H11 alloys treated according to optimal tempered condition was limited to 62 HV.

36 MATERIALS SCIENCE↗

Implementing a neural network interatomic model with performance portability for emerging exascale architectures

The two main thrusts of computational science are increasingly accurate predictions and faster calculations; to this end, the zeitgeist in molecular dynamics (MD) simulations is pursuing machine learned and data driven interatomic models, e.g. neural network potentials, and novel hardware architectures, e.g. GPUs. Current implementations of neural network potentials are orders of magnitude slower than traditional interatomic models and while looming exascale computing offers the ability to run large, accurate simulations with these models, achieving portable performance for MD with new and varied exascale hardware requires rethinking traditional algorithms, using novel data structures, and library solutions. We re-implement a neural network interatomic model in CabanaMD, an MD proxy application, built on libraries developed for performance portability. Our implementation shows significantly improved thread scaling in this complex kernel as compared to a current LAMMPS implementation, across both strong and weak scaling. Our single-source solution enables simulations up to 20 million atoms on a single CPU node and 4 million atoms with improved performance on a single GPU. Furthermore, we also explore parallelism and data layout choices (using flexible data structures called AoSoAs) and their effect on performance, seeing up to ~50% and ~5% improvements in performance on a GPU by choosing the right level of parallelism and data layout respectively.

97 MATHEMATICS AND COMPUTING↗

Characterizing Peatland Microtopography Using Gradient and Microform-Based Approaches

Abstract Peatlands represent an important component of the global carbon cycle, storing 180–621 Gt of carbon (C). Small-scale spatial variations in elevation, frequently referred to as microtopography, influence ecological processes associated with the peatland C cycle, including Sphagnum photosynthesis and methane flux. Microtopography can be characterized with measures of topographic variability and by using conceptual classes (microforms) linked to function: most commonly hummocks and hollows. However, the criteria used to define these conceptual classes are often poorly described, if at all, and vary between studies. Such inconsistencies compel development of explicit quantitative methods to classify microforms. Furthermore, gradient-based characterizations that describe spatial variability without the use of microforms are lacking in the literature. Therefore, the objectives of this study were to (1) calculate peatland microtopographical elevation gradients and measures of spatial variability, (2) develop three microform classification methods intended for specific purposes, and (3) evaluate and contrast classification methods. Our results suggest that at spatial scales much larger than microforms, elevation distributions are unimodal and are well approximated with parametric probability density functions. Results from classifications were variable between methods and years and exhibited significant differences in mean hollow areal coverages of a raised ombrotrophic bog. Our results suggest that the conceptualization and classification of microforms can significantly influence microtopographic structural metrics. The three explicit methods for microform classification described here may be used and built upon for future applications.

54 ENVIRONMENTAL SCIENCES↗

Bond Order Conservation Strategies in Catalysis Applied to the NH 3 Decomposition Reaction

On the basis of an extensive set of density functional theory calculations, it is shown that a simple scheme provides a fundamental understanding of variations in the transition state energies and structures of reaction intermediates on transition metal surfaces across the periodic table. The scheme is built on the bond order conservation principle and requires a limited set of input data, still achieving transition state energies as a function of simple descriptors with an error smaller than those of approaches based on linear fits to a set of calculated transition state energies. Here, we have applied this approach together with linear scaling of adsorption energies to obtain the energetics of the NH 3 decomposition reaction on a series of stepped fcc(211) transition metal surfaces. Moreover, this information is used to establish a microkinetic model for the formation of N 2 and H 2 , thus providing insight into the components of the reaction that determines the activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Process-dependent anisotropic thermal conductivity of laser powder bed fusion AlSi10Mg: impact of microstructure and aluminum-silicon interfaces

Purpose AlSi10Mg alloy is commonly used in laser powder bed fusion due to its printability, relatively high thermal conductivity, low density and good mechanical properties. However, the thermal conductivity of as-built materials as a function of processing (energy density, laser power, laser scanning speed, support structure) and build orientation, are not well explored in the literature. This study aims to elucidate the relationship between processing, microstructure, and thermal conductivity. Design/methodology/approach The thermal conductivity of laser powder bed fusion (L-PBF) AlSi10Mg samples are investigated by the flash diffusivity and frequency domain thermoreflectance (FDTR) techniques. Thermal conductivities are linked to the microstructure of L-PBF AlSi10Mg, which changes with processing conditions. The through-plane exceeded the in-plane thermal conductivity for all energy densities. A co-located thermal conductivity map by frequency domain thermoreflectance (FDTR) and crystallographic grain orientation map by electron backscattered diffraction (EBSD) was used to investigate the effect of microstructure on thermal conductivity. Findings The highest through-plane thermal conductivity (136 ± 2 W/m-K) was achieved at 59 J/mm 3 and exceeded the values reported previously. The in-plane thermal conductivity peaked at 117 ± 2 W/m-K at 50 J/mm 3 . The trend of thermal conductivity reducing with energy density at similar porosity was primarily due to the reduced grain size producing more Al-Si interfaces that pose thermal resistance. At these interfaces, thermal energy must convert from electrons in the aluminum to phonons in the silicon. The co-located thermal conductivity and crystallographic grain orientation maps confirmed that larger colonies of columnar grains have higher thermal conductivity compared to smaller columnar grains. Practical implications The thermal properties of AlSi10Mg are crucial to heat transfer applications including additively manufactured heatsinks, cold plates, vapor chambers, heat pipes, enclosures and heat exchangers. Additionally, thermal-based nondestructive testing methods require these properties for applications such as defect detection and simulation of L-PBF processes. Industrial standards for L-PBF processes and components can use the data for thermal applications. Originality/value To the best of the authors’ knowledge, this paper is the first to make coupled thermal conductivity maps that were matched to microstructure for L-PBF AlSi10Mg aluminum alloy. This was achieved by a unique in-house thermal conductivity mapping setup and relating the data to local SEM EBSD maps. This provides the first conclusive proof that larger grain sizes can achieve higher thermal conductivity for this processing method and material system. This study also shows that control of the solidification can result in higher thermal conductivity. It was also the first to find that the build substrate (with or without support) has a large effect on thermal conductivity.

Engineering↗

Report on Properties and Microstructure of 3D Printed Inc-718

The report presents the microstructure and mechanical properties of 3D printed Inconel 718 to assess its potential use as a structural material for the Transformation Challenge Reactor (TCR). The structural components near the outlet of the core will experience significant neutron fluxes and outlet coolant temperatures from the hot standby temperature of 300°C to nearly 550°C at the center of the part. These components must support the core in appropriate loading conditions and require structural analysis at relevant temperatures. Strong spatial and chemical heterogeneity was found in as-built (ASB) Inconel 718. Three heat treatments were designed and conducted to simplify the microstructure and determine how each precipitating phase contributed to the overall strength. Baseline mechanical properties were measured from uniaxial tensile tests on subsize SS-J2 specimens at room temperature and at elevated temperatures of 300, 450, and 600°C. Microstructure electron microscopy was performed on ASB Inconel 718 and heat treated to correlate the observed mechanical properties with nanoscale features. Homogenization of the microstructure led to a highly ductile Inconel with lower strength compared with wrought Inconel 718. The tensile properties of additively manufactured 718 using a standard ASTMrecommended heat treatment were consistent with literature and with the ASTM for the properties of this alloy. A higher fraction of the δ phase led to shorter uniform elongation without altering other engineering properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Requirements Description of DASSH-F

This report reviews the modeling and simulation capabilities of Argonne National Laboratory’s DASSH code that is used in present reactor analysis activities. These capabilities will be used to establish the set of verification tasks necessary to verify DASSH for use on commercial projects. A similar approach was taken for the PERSENT, REBUS and DIF3D software packages. The DASSH program is a thermal analysis code designed to rapidly allow a reactor design engineer to obtain flow rates requirements that satisfy peak temperature constraints in the domain. DASSH is a follow-on development to the SE2-ANL software and SUPERENERGY-2 software that it is based upon. DASSH was designed to account for both neutron and gamma heating and is inherently connected to the GAMSOR part of the ARC suite of fast reactor analysis software. SE2-ANL is a developed piece of software from the 1980s while DASSH is a modern implementation with notable improvements in geometry handling. The most important upgrade of DASSH relative to SE2-ANL is that it can analyze multiple time points in a single run where SE2-ANL can only treat a single time point. This allows the user to understand the impact of and search the flow distribution for the entire operational period of a reactor design considering pressure drop, peak coolant and fuel temperatures, and thermal striping. DASSH has three input paths that have to be verified. The first input path builds the geometry and power distribution based upon the DIF3D model but ignores the gamma heating aspects of the problem. The second input path also builds the geometry from the DIF3D model but it takes the neutron and gamma heating distributions from GAMSOR. The third input path is to take the geometry and power distribution directly from user input (i.e. not coupled to DIF3D or GAMSOR). DASSH also has many built in correlations for material properties along with a user defined specification of the fuel, structure, and coolant properties. There are correlations for flow split, mixing, pressure drop, and heat transfer coefficients (subchannel rather than a direct methodology). In total, verification of DASSH will require an extensive testing to cover all possible user features of the software.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Servosystem with an undulatory reducing gear

The development of a potentiometric servosystem is described that has a dc microservomotor, which is the built in drive of an undulatory reducing gear. The operation of the system and the structural design of the undulatory reducing gear are elaborated. Results are presented from analyzing some tests of various types of undulatory reducing gear generators.

Romashchenko, A. I.↗