Results for “shaping” — Page 6

DOE OSTI2023

Shape memory polymers

New shape memory polymer compositions, methods for synthesizing new shape memory polymers, and apparatus comprising an actuator and a shape memory polymer wherein the shape memory polymer comprises at least a portion of the actuator. A shape memory polymer comprising a polymer composition which physically forms a network structure wherein the polymer composition has shape-memory behavior and can be formed into a permanent primary shape, re-formed into a stable secondary shape, and controllably actuated to recover the permanent primary shape. Polymers have optimal aliphatic network structures due to minimization of dangling chains by using monomers that are symmetrical and that have matching amine and hydroxl groups providing polymers and polymer foams with clarity, tight (narrow temperature range) single transitions, and high shape recovery and recovery force that are especially useful for implanting in the human body.

Wilson, Thomas S.↗

DOE OSTI2021

Definition of a new (Doniach-Sunjic-Shirley) peak shape for fitting asymmetric signals applied to reduced graphene oxide/graphene oxide XPS spectra

The existence of asymmetry in X-ray photoelectron spectroscopy (XPS) photoemission lines is widely accepted, but line shapes designed to accommodate asymmetry are generally lacking in theoretical justification. Here in this work, we present a new line shape for describing asymmetry in XPS signals that is based on two facts. First, the most widely known line shape for fitting asymmetric XPS signals that has a theoretical basis, referred to as the Doniach-Sunjic (DS) line shape, suffers from a mathematical inconvenience, which is that for asymmetric shapes the area beneath the curve (above the x-axis) is infinite. Second, it is common practice in XPS to remove the inelastically scattered background response of a peak in question with the Shirley algorithm. The new line shape described herein attempts to retain the theoretical virtues of the DS line shape, while allowing the use of a Shirley background, with the consequence that the resulting line shape has a finite area. To illustrate the use of this Doniach-Sunjic-Shirley (DSS) line shape, a set of spectra obtained from varying amounts of graphene oxide (GO) and reduced GO on a patterned, heterogeneous surface are fit and discussed.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Effect of post-extrusion heat treatment on mechanical property of aluminum alloy 2024 tube produced using Shear Assisted Processing and Extrusion (ShAPE)

The present work deals with the Shear Assisted Processing and Extrusion (ShAPE) of aluminum alloy 2024 tubes and mechanical property optimization via post extrusion heat treatments (T3510 and T8510). The ShAPE process enables extruding AA2024 at an extrusion speed of 7.4 m/min and extrusion temperature of 480 °C, which is otherwise beyond the extrudability limit of this alloy using conventional extrusion techniques. The ultimate tensile strength reaches 466 MPa for ShAPE+T3510 condition and 503 MPa for ShAPE+T8510 condition, both of which exceed the corresponding ASTM/ASM (minimum/typical) values for the studied tube geometry. The yield strength reaches 382 MPa for ShAPE+T3510 condition and 481 MPa for ShAPE+T8510 condition, both of which surpass any reported values in the literature or the highest industrial values. In addition, the ductility of AA2024 tube fabricated from ShAPE+T3510 or ShAPE+T8510 are evidently improved by the grain size refinement, second phase refinement, and enhanced uniformity in second phase distribution due to the severe plastic deformation of ShAPE process.

Shear Assisted Processing and Extrusions (ShAPE), ↗

DOE OSTI2020

Elastic depths for detecting shape anomalies in functional data

This this paper, we propose a new family of depth measures called the elastic depths that can be used to greatly improve shape anomaly detection in functional data. Shape anomalies are functions that have considerably different geometric forms or features from the rest of the data. Identifying them is generally more difficult than identifying magnitude anomalies because shape anomalies are often not distinguishable from the bulk of the data with visualization methods. The proposed elastic depths use the recently developed elastic distances to directly measure the centrality of functions in the amplitude and phase spaces. Measuring shape outlyingness in these spaces provides a rigorous quantification of shape which, in turn, gives the elastic depths a strong theoretical and practical advantage over other methods in detecting shape anomalies. A simple boxplot and thresholding method are introduced to identify shape anomalies using the elastic depths. We assess the elastic depth's detection skill on simulated shape outlier scenarios and compare them against popular shape anomaly detectors. Finally, bond yields, image outlines, and hurricane trajectories are used to demonstrate our method's applicability to functional data observed on three different manifolds.

97 MATHEMATICS AND COMPUTING↗

NASA NTRSDate not supplied

A Solar Sail Shape Modeling Approach for Attitude Control Design and Analysis

Solar sails operating in the space environment experience deformations in sail shape that result in relatively large disturbance torques which dictate the required performance of the spacecraft attitude control and momentum management systems. These deformations are driven by thermal loads on the booms (due to uneven solar heating), manufacturing and assembly tolerances, and variations in membrane tension. The Solar Cruiser spacecraft utilizes a four-quadrant sail design with four 30-meter length booms and four triangular sail membranes, creating a square sail structure of >1600 m2. Medium-fidelity mesh models were developed based on a characteristic deformed shape. A series of parametric studies were conducted using this shape paradigm to determine worst-case deformed sail shapes which produce bounding disturbance torques. A large database of shapes was produced, and the forces and moments induced by each individual shape were calculated using a Rios-Reyes reduced order generalized sail model. Two were selected as reference worst-case shapes for the Solar Cruiser mission: one which produced the highest pitch/yaw root-sum-squared (RSS) torque, and one which produced the highest roll torque. The results showed that the worst-case shapes at high solar incidence angles induce significantly higher (2-10x) disturbance torques than an ideal, flat-plate sail. Even with considerable safety margins, assuming an ideal sail is unlikely to sufficiently bound the disturbances, which is critical when designing the attitude control system and sizing actuators. Accurate sail shape modeling methodologies should therefore be employed on future solar sail missions.

Solar Sail↗

NASA NTRSDate not supplied

A Solar Sail Shape Modeling Approach for Attitude Control Design and Analysis

Solar sails operating in the space environment experience deformations in sail shape that result in relatively large disturbance torques which dictate the required performance of the spacecraft attitude control and momentum management systems. These deformations are driven by thermal loads on the booms (due to uneven solar heating), manufacturing and assembly tolerances, and variations in membrane tension. The Solar Cruiser spacecraft utilizes a four-quadrant sail design with four 30-meter length booms and four triangular sail membranes, creating a square sail structure of >1600 m2. Medium-fidelity mesh models were developed based on a characteristic deformed shape. A series of parametric studies were conducted using this shape paradigm to determine worst-case deformed sail shapes which produce bounding disturbance torques. A large database of shapes was produced, and the forces and moments induced by each individual shape were calculated using a Rios-Reyes reduced order generalized sail model [1]. Two were selected as reference worst-case shapes for the Solar Cruiser mission: one which produced the highest pitch/yaw root-sum-squared (RSS) torque, and one which produced the highest roll torque. The results showed that the worst-case shapes at high solar incidence angles induce significantly higher (2-10x) disturbance torques than an ideal, flat-plate sail. Even with considerable safety margins, assuming an ideal sail is unlikely to sufficiently bound the disturbances, which is critical when designing the attitude control system and sizing actuators. Accurate sail shape modeling methodologies should therefore be employed on future solar sail missions. References [1] L. Rios-Reyes and D. J. Scheeres, “Generalized Model for Solar Sails,” Journal of Spacecraft and Rockets, Vol. 42, Jan. 2005, pp. 182–185, 10.2514/1.9054.

Solar Sail↗

NASA NTRS1982

The room-temperature shapes of four-layer unsymmetric cross-ply laminates

A geometrically nonlinear extension of classical lamination theory developed by Hyer (1981) for predicting the room-temperature shapes of unsymmetric laminates is reformulated using relaxed restrictions regarding the inplane strains. The inplane residual strains of unsymmetric laminates which have cooled from curing into a cylindrical room-temperature shape are examined numerically. Results show that the residual strains are compressive and practically independent of spatial location on the laminate. In addition, the room temperature shapes of the four-layer unsymmetric cross-ply laminates are predicted, and it is shown that the temperature shapes are a strong function of their size and their stacking arrangement. It is demonstrated that, depending on the parameters selected, the room-temperature shape of a four-layer cross-ply unsymmetric laminate can be a unique saddle shape, a unique cylindrical shape, or a cylindrical shape that can be snapped through to another cylindrical shape.

Hyer, M. W.↗

NASA NTRS1987

Shape design sensitivity analysis and optimization of three dimensional elastic solids using geometric modeling and automatic regridding

An automatic regridding method and a three dimensional shape design parameterization technique were constructed and integrated into a unified theory of shape design sensitivity analysis. An algorithm was developed for general shape design sensitivity analysis of three dimensional eleastic solids. Numerical implementation of this shape design sensitivity analysis method was carried out using the finite element code ANSYS. The unified theory of shape design sensitivity analysis uses the material derivative of continuum mechanics with a design velocity field that represents shape change effects over the structural design. Automatic regridding methods were developed by generating a domain velocity field with boundary displacement method. Shape design parameterization for three dimensional surface design problems was illustrated using a Bezier surface with boundary perturbations that depend linearly on the perturbation of design parameters. A linearization method of optimization, LINRM, was used to obtain optimum shapes. Three examples from different engineering disciplines were investigated to demonstrate the accuracy and versatility of this shape design sensitivity analysis method.

Yao, Tse-Min↗

NASA NTRS2008

Interactive Inverse Design Optimization of Fuselage Shape for Low-Boom Supersonic Concepts

This paper introduces a tool called BOSS (Boom Optimization using Smoothest Shape modifications). BOSS utilizes interactive inverse design optimization to develop a fuselage shape that yields a low-boom aircraft configuration. A fundamental reason for developing BOSS is the need to generate feasible low-boom conceptual designs that are appropriate for further refinement using computational fluid dynamics (CFD) based preliminary design methods. BOSS was not developed to provide a numerical solution to the inverse design problem. Instead, BOSS was intended to help designers find the right configuration among an infinite number of possible configurations that are equally good using any numerical figure of merit. BOSS uses the smoothest shape modification strategy for modifying the fuselage radius distribution at 100 or more longitudinal locations to find a smooth fuselage shape that reduces the discrepancies between the design and target equivalent area distributions over any specified range of effective distance. For any given supersonic concept (with wing, fuselage, nacelles, tails, and/or canards), a designer can examine the differences between the design and target equivalent areas, decide which part of the design equivalent area curve needs to be modified, choose a desirable rate for the reduction of the discrepancies over the specified range, and select a parameter for smoothness control of the fuselage shape. BOSS will then generate a fuselage shape based on the designer's inputs in a matter of seconds. Using BOSS, within a few hours, a designer can either generate a realistic fuselage shape that yields a supersonic configuration with a low-boom ground signature or quickly eliminate any configuration that cannot achieve low-boom characteristics with fuselage shaping alone. A conceptual design case study is documented to demonstrate how BOSS can be used to develop a low-boom supersonic concept from a low-drag supersonic concept. The paper also contains a study on how perturbations in the equivalent area distribution affect the ground signature shape and how new target area distributions for low-boom signatures can be constructed using superposition of equivalent area distributions derived from the Seebass-George-Darden (SGD) theory.

Li, Wu↗

NASA NTRSDate not supplied

Comparison of Ice Shapes on Full-Chord and Truncated Swept Wing Models

A research program was conducted to evaluate the effectiveness of icing tunnel hybrid model design. A hybrid design is where the full-scale leading edge of a wing section is maintained only to a certain percentage of the local chord, while the aft section of the model is redesigned into a shortened or truncated planform. Ice shape geometries on a full-chord length and hybrid versions of the swept CRM65 wing model were obtained in NASA Icing Research Tunnel and compared. For most test conditions, the overall size and shape of the ice shapes compared well. On the main part of the ice shape, the hybrid model had larger chordwise extent, resulting in wider ice shape. For the scallop ice shapes, the ice shape heights at attachment line location were identical. For conditions that produced rime shape, hybrid model ice shapes were larger overall, even at the attachment line location. The only location where there was more ice on the full chord model was on the lower surface, downstream of where the hybrid model no longer had full-scale leading edge. For the test conditions where ice mass measurements were acquired for both models, the full-chord models had 11-22% less ice mass than on the hybrid wing. These differences were larger and opposite of those predicted from LEWICE 3D ice prediction calculations. Further investigation is needed in order determine the cause of the differences between the full-chord and hybrid models.

Icing↗

NASA NTRSDate not supplied

Comparison of Ice Shapes on Full-Chord and Truncated Swept Wing Models

A research program was conducted to evaluate the effectiveness of icing tunnel hybrid model design. A hybrid design is where the full-scale leading edge of a wing section is maintained only to a certain percentage of the local chord, while the aft section of the model is redesigned into a shortened or truncated planform. Ice shape geometries on a full-chord length and hybrid versions of the swept CRM65 wing model were obtained in NASA Icing Research Tunnel and compared. For most test conditions, the overall size and shape of the ice shapes compared well. On the main part of the ice shape, the hybrid model had larger chordwise extent, resulting in wider ice shape. For the scallop ice shapes, the ice shape heights at attachment line location were identical. For conditions that produced rime shape, hybrid model ice shapes were larger overall, even at the attachment line location. The only location where there was more ice on the full chord model was on the lower surface, downstream of where the hybrid model no longer had full-scale leading edge. For the test conditions where ice mass measurements were acquired for both models, the full-chord models had 11-22% less ice mass than on the hybrid wing. These differences were larger and opposite of those predicted from LEWICE 3D ice prediction calculations. Further investigation is needed in order determine the cause of the differences between the full-chord and hybrid models.

Icing↗

NASA NTRSDate not supplied

Characterizing Detailed Grain Shape and Size Distribution Properties of Lunar Regolith

Introduction: As the nation prepares to return to the Moon, there is an increasing need for testing tools, instruments, and equipment in simulated environments on Earth to ensure successful operations during lunar missions. Regolith will affect all aspects of future lunar missions, from plume interactions during landing to space suit and tool design [1]. Because of this, it is important to understand the grain shape and size properties of lunar regolith and how those influence regolith behavior in order to prepare for these missions. This knowledge is also vital to create more accurate lunar regolith simulants for testing equipment in a lunar environment. While particle size analyses have been performed on most Apollo soils using simple sieving, shape has only been crudely addressed [2]. This work analyzes 4 lunar regolith samples to provide a better understanding of these size and shape parameters and will provide a more accurate baseline of data to create high-fidelity lunar regolith simulants. Methods: New technologies exist today that are capable of measuring size and shape simultaneously for hundreds of thousands of particles in a single measurement. We conducted a rigorous analysis of the particle size distribution (PSD) as well as the size-dependent 2D and 3D shape parameters of lunar regolith samples of different compositions and maturity levels. This analysis was done using a Microtrac SYNC which provides a unique combination of tri-laser diffraction and Dynamic Image Analysis (DIA). Sample Selection. Four regolith samples were selected for analysis based on maturity level and lunar terrain type: • 10084 – Mature high-Ti mare regolith • 15601 – Immature low-Ti mare regolith • 64501 – Mature highland regolith • 67461 – Immature highland regolith Sample Analysis. After receiving the samples, each sample was imaged with an optical microscope (Figure 1). To obtain 2D and 3D particle size and shape, 0.1 g of each sample was then added to the SYNC for analysis, which outputs more than 30 size and shape parameters for each individual grain as well as the complete size distribution from 0.01-2000 μm by blending laser diffraction and DIA together. For the 0.1 g sample masses requested, ~100,000 grains per sample were captured by DIA. Results: From the PSD analysis, it can be seen that the average particle size of 10084 is ~24.5 µm which is much smaller than the average particle size of the Apollo sample collection (~72 µm) [3], while the average particle size of samples 15601, 64501, and 67461 are larger than the Apollo sample average at ~106 µm, ~103 µm, and ~118.5 µm respectively. The size and shape measurements for the samples output ~30 parameters, four of which were focused on for this study: sphericity, aspect ratio, roundness, and concavity (Figure 3). However, after analyzing the plots it was found that only sphericity and aspect ratio showed differences between the samples. These two parameters are measured on a scale from 0 to 1, with 1 being a perfect sphere with equal dimensions. The results show that the sphericity values are slightly high-er for the mature samples 10084 and 64501 (~0.96) than they are for samples 15601 and 67461 (~0.95) (Figure 4). The aspect ratio values are slightly lower for samples 64501 (~0.7) and 67461 (~0.74) than they are for samples 10084 (~0.76) and 15601 (~0.8) (Figure 5). Discussion: Mature regoliths are those that have been exposed to micrometeorite and solar wind bombardment for long periods of time, breaking up particles and causing them to become more rounded [4]. Therefore, the smaller particle sizes and higher sphericity values for samples 10084 and 64501 are expected due to their higher maturity level compared to 15601 and 67461. However, the aspect ratio values are not dependent on maturity and are instead dependent on terrain type. The lower aspect ratio values for the high-land samples is potentially due to the higher plagioclase content, which occurs in elongated particles and does not break down as easily as the pyroxenes or olivines that are present in the mare. Conclusion and Future Work: The results of this work provide a baseline of high-quality data that will contribute to the creation of high-fidelity lunar simulants and will greatly benefit NASA’s efforts of establishing a human presence on the Moon. Future work includes performing unsupervised image classification on the ~105 particle images per sample in order to identify different classes of grains. These grain classes can then be linked to detailed shape properties, and the relative abundance of each class in the samples can be compared. Acknowledgments: We would like to thank the Extraterrestrial Materials Analysis Group (ExMAG) and the Astromaterials Allocation Review Board (AARB) for allocating lunar regolith samples 10084,9010, 15601,365, 64501,249, and 67461,171 for this work. References: [1] Taylor, L. A. et al. (2005) AIAA #2510. [2] Katagiri et al. (2015) ASCE. [3] Carrier III, W. D. (2005) Lunar Geotech Institute Tech Report. [4] McKay, D. S. et al. (1991) The Lunar Sourcebook, Chapter 7.

S R Deitrick↗

NASA NTRS2020

Prediction and Evaluation of the Image of the WFIRST Coronagraph Pupil at the Shaped-Pupil Mask

To create a high contrast field of view with a shaped pupil coronagraph (SPC), the telescope pupil is imaged onto the shaped pupil mask, the shaped pupil mask is designed and fabricated through a design optimization based on a given pupil wavefront, and deformable mirrors (DM) in the coronagraph are modulated according to a nonlinear optimization procedure. Both the mask design optimization and the DM optimization require accurate knowledge of the image of the pupil at the shaped pupil plane for the calculation of Jacobians, and the evaluation of alignment tolerances. The shaped pupil coronagraphs demonstrated in the high contrast imaging testbed (HCIT) at JPL has heretofore assumed perfect imaging of the pupil onto the shaped pupil mask. Similarly, the design and performance modeling of the WFIRST CGI instrument makes the same assumption. In this paper we estimate and compare the image of the pupil mask at the shaped pupil plane in the case of the coronagraph testbed, and the image of the telescope pupil at the shaped pupil plane for the WFIRST CGI instrument. The estimated pupil images include field curvature and aberrations resulting from the layout of the parabolic mirror imaging system, which is optimized for the source image, not the image of the pupil. We also show the results of direct measurement of the image of the pupil mask at the shaped pupil plane in the coronagraph testbed.

Crowther, Blake↗

NASA NTRS2022

Linear and Geometrically Nonlinear Structural Shape Sensing from Strain Data

An aircraft’s shape must be measured during flight to implement active shape controls such as active trim shape, divergence, and sonic boom controls. A basis function method for linear as well as geometrically nonlinear structural shape sensing is proposed in this study. Basis functions can be mode shapes, linear static deformation shapes, and/or geometrically nonlinear static deformation shapes. The proposed basis function method is validated using a high-aspect-ratio wing, a swept test plate, and the National Aeronautics and Space Administration X-59 aircraft. A large structural deformation of a high-aspect-ratio wing is successfully captured using the proposed basis function method with less than 0.3%prediction error at the wing-tip section. The basis function method gives excellent deformation prediction, even with stress concentration. Performance of the basis functions is compared using the X-59 stabilator sample case. In most of the sample load cases, static deformations give a better correlation with the target deformation than do mode shapes. Wing shape sensing with sparse strain data are also demonstrated in this study using the X-59 aircraft. Predicted structural deformations match reasonably with the target deformations, even without strain gauges on some structural components. The predicted deformations have a good match with the target deformations.

Static Deformation↗

NASA NTRSDate not supplied

An Approach to Shape Parameterization Using Laboratory Hypervelocity Impact Experiments

NASA’s Orbital Debris Program Office relies on laboratory-based impact tests to supplement the measurement data of on-orbit events that defines the orbital debris environment. These experiments provide information that is essential to interpreting the radar and optical measurements of orbital fragmentation events into useful metrics, such as characteristic size of the debris, and to providing a better understanding of the distributions of fragment populations in terms of their masses, material constituents, fragment densities, cross-sectional areas, area-to-mass ratios, shapes, etc. The Satellite Orbital Debris Characterization Impact Test (SOCIT) was a notable laboratory impact experiment conducted in 1992 using a surplus U.S. Navy Transit navigation satellite of the 1960s. The data from this ground-based experiment were combined with on-orbit measurements to develop the NASA Standard Satellite Breakup Model (SSBM). To account for advancements in satellite design and construction since, a new impact test series – DebriSat – was conducted in 2014. This test utilized a high-fidelity mock-up spacecraft that better represents the materials and construction techniques used to design and manufacture modern spacecraft. Together, these tests offer valuable data to model an orbital debris environment composed of legacy and modern spacecraft. This paper presents an overview of the two laboratory impact tests, comparing their fragment parameter distributions with each other and with relevant distributions from the NASA SSBM. The categorization and descriptions of fragment shapes are of significant interest for future work, yet there are marked differences in the definitions of shape categories between each dataset. The categorizations of constituent materials, and the measurement techniques employed to populate these two datasets, are also different. New rubrics simplify and equate the categorizations between datasets to aid comparative analyses and to facilitate the potential use of both datasets in tandem with future environmental debris models. A preferred approach to classifying shape across disparate datasets uses the characteristic-length dimensions, and a simplified shape classification based on physical, solid-body dimensions, to mathematically construct an encapsulating right-circular cylinder that represents the fragment. The ratio of cylinder length-to-diameter (L:D) then provides a single continuum value for shape that is strongly correlated with its designated shape and size. This metric can then be used to further assess the distribution of shape with populations of other fragment characteristics within these datasets. The shape parameterization using the L:D ratios of right-circular cylinders is discussed.

John H. Seago↗

NASA NTRSDate not supplied

An Approach to Shape Parameterization Using Laboratory Hypervelocity Impact Experiments

NASA’s Orbital Debris Program Office relies on laboratory-based impact tests to supplement the measurement data of on-orbit events that defines the orbital debris environment. These experiments provide information that is essential to interpreting the radar and optical measurements of orbital fragmentation events into useful metrics, such as characteristic size of the debris, and to providing a better understanding of the distributions of fragment populations in terms of their masses, material constituents, fragment densities, cross-sectional areas, area-to-mass ratios, shapes, etc. The Satellite Orbital Debris Characterization Impact Test (SOCIT) was a notable laboratory impact experiment conducted in 1992 using a surplus U.S. Navy Transit navigation satellite of the 1960s. The data from this ground-based experiment were combined with on-orbit measurements to develop the NASA Standard Satellite Breakup Model (SSBM). To account for advancements in satellite design and construction since, a new impact test series – DebriSat – was conducted in 2014. This test utilized a high-fidelity mock-up spacecraft that better represents the materials and construction techniques used to design and manufacture modern spacecraft. Together, these tests offer valuable data to model an orbital debris environment composed of legacy and modern spacecraft. This paper presents an overview of the two laboratory impact tests, comparing their fragment parameter distributions with each other and with relevant distributions from the NASA SSBM. The categorization and descriptions of fragment shapes are of significant interest for future work, yet there are marked differences in the definitions of shape categories between each dataset. The categorizations of constituent materials, and the measurement techniques employed to populate these two datasets, are also different. New rubrics simplify and equate the categorizations between datasets to aid comparative analyses and to facilitate the potential use of both datasets in tandem with future environmental debris models. A preferred approach to classifying shape across disparate datasets uses the characteristic-length dimensions, and a simplified shape classification based on physical, solid-body dimensions, to mathematically construct an encapsulating right-circular cylinder that represents the fragment. The ratio of cylinder length-to-diameter (L:D) then provides a single continuum value for shape that is strongly correlated with its designated shape and size. This metric can then be used to further assess the distribution of shape with populations of other fragment characteristics within these datasets. The shape parameterization using the L:D ratios of right-circular cylinders is discussed.

John H Seago↗

DOE OSTI2023

Airfoil Computational Fluid Dynamics - 9k shapes, 2 AoA's

This dataset contains aerodynamic quantities - including flow field values (momentum, energy, and vorticity) and summary values (coefficients of lift, drag, and momentum) - for 8,996 airfoil shapes, computed using the HAM2D CFD (computational fluid dynamics) model. The airfoil shapes were designed using the separable shape tensor parameterization that encodes two-dimensional shapes as elements of the Grassmann manifold. This data-driven approach learns two independent spaces of parameter from a collection of sample airfoils. The first captures large-scale, linear perturbations, and the second defines small-scale, higher-order perturbations. For this data, we used the G2Aero database of over 19,000 airfoil shapes to learn a parameter space that captured a wide array of shape characteristics. We fixed the linear deformations to be the mean over the database and sampled new shapes over a four-dimensional parameter space of higher-order perturbation. This sampling approaches allows for isolated analysis of non-linear airfoil shape deformations while holding other aspects (e.g., airfoil thickness) approximately constant. The aerodynamic quantities for the generated airfoil were obtained using the HAM2D code, which is a finite-volume Reynolds-averaged Navier-Stokes (RANS) flow solver. We employ a fifth-order WENO scheme for spatial reconstruction with Roe's flux difference scheme for inviscid flux and second-order central differencing for viscous flux. A preconditioned GMRES method is applied for implicit integration. The Spalart-Allmaras 1-eq turbulence model is used for the turbulence closure, and the Medida-Baeder 2-eq transition model is applied to account for the effects of laminar turbulent transition. The airfoil grid is generated with a total of 400 points on the airfoil surface, the initial wall-normal spacing of y+ = 1, and an outer boundary located at 300 chord lengths away from the wall. The CFD simulations are performed at a freestream Mach number of 0.1, Reynolds number of 9M, and at two angles of attack, 4 deg. and 12 deg. The simulations were performed using the Bridges-2 system at the Pittsburgh Supercomputing Center in February 2023 as part of the INTEGRATE project funded by the Advanced Research Projects Agency - Energy in the U.S. Department of Energy. The data was collected, reformatted, and preprocessed for this OEDI submission in July 2023 under the Foundational AI for Wind Energy project funded by the U.S. Department of Energy Wind Energy Technologies Office. This dataset is intended to serve as a benchmark against which new artificial intelligence (AI) or machine learning (ML) tools may be tested. Baseline AI/ML methods for analyzing this dataset have been implemented, and a link to their repository containing those models has been provided. The .h5 data file structure can be found in the GitHub Repository resource under explore_airfoil_9k_data.ipynb.

9k↗

DOE OSTI2025

Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

The laser powder bed fusion (LPBF) process utilizing a focused Gaussian-shaped beam faces challenges, including pore formation, melt pool fluctuation and liquid spattering. While beam shaping technology has been explored as a potential approach for defect mitigation, the beam-matter interaction dynamics during melting with shaped beams remain unclear. Here, we report the direct observation of ring-shaped beam-matter interaction dynamics, including pore formation, melt pool fluctuation and liquid spattering, and unveil defect mitigation mechanisms in ring-shaped beam laser powder bed fusion process. Here, we find that, by spatially manipulating incident laser rays, the ring-shaped beam controls keyhole morphology, thereby managing the distribution of the reflected rays. This manipulation can effectively eliminate the formation of an unstable cavity at the keyhole tip, stabilizing the keyhole and mitigating keyhole pores. This enhanced keyhole stability effectively reduces the melt pool fluctuation, the formation of liquid breakup induced spatters and liquid droplet colliding induced large spatters in the laser powder bed fusion process. Additionally, the high-energy forefront of the ring-shaped beam effectively melts the powder bed, reducing agglomeration liquid spatter in the laser powder bed fusion process. The discovered defect mitigation mechanisms may guide the design of beam shaping strategies for simultaneously increasing the quality and productivity of metal additive manufacturing.

Beam shaping↗