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At least 127 records · Page 7

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DOE OSTI2024

Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies

Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. Here, in the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.

36 MATERIALS SCIENCE↗

NASA NTRS2015

Optical Distortion Evaluation in Large Area Windows using Interferometry

It is important that imagery seen through large area windows, such as those used on space vehicles, not be substantially distorted. Many approaches are described in the literature for measuring the distortion of an optical window, but most suffer from either poor resolution or processing difficulties. In this paper a new definition of distortion is presented, allowing accurate measurement using an optical interferometer. This new definition is shown to be equivalent to the definitions provided by the military and the standards organizations. In order to determine the advantages and disadvantages of this new approach the distortion of an acrylic window is measured using three different methods; image comparison, Moiré interferometry, and phase-shifting interferometry.

Interferometer↗

NASA NTRS2015

A Comparison of Three Methods for Measuring Distortion in Optical Windows

It's important that imagery seen through large-area windows, such as those used on space vehicles, not be substantially distorted. Many approaches are described in the literature for measuring the distortion of an optical window, but most suffer from either poor resolution or processing difficulties. In this paper a new definition of distortion is presented, allowing accurate measurement using an optical interferometer. This new definition is shown to be equivalent to the definitions provided by the military and the standards organizations. In order to determine the advantages and disadvantages of this new approach, the distortion of an acrylic window is measured using three different methods: image comparison, moiré interferometry, and phase-shifting interferometry.

Interferometry↗

NASA NTRS2018

Cyclic Symmetry Finite Element Forced Response Analysis of a Distortion-Tolerant Fan with Boundary Layer Ingestion

Accurate prediction of the blade vibration stress is required to determine overall durability of fan blade design under Boundary Layer Ingestion (BLI) distorted flow environments. Traditional single blade modeling technique is incapable of representing accurate modeling for the entire rotor blade system subject to complex dynamic loading behaviors and vibrations in distorted flow conditions. A particular objective of our work was to develop a high-fidelity full-rotor aeromechanics analysis capability for a system subjected to a distorted inlet flow by applying cyclic symmetry finite element modeling methodology. This reduction modeling method allows computationally very efficient analysis using a small periodic section of the full rotor blade system. Experimental testing by the use of the 8-foot by 6-foot Supersonic Wind Tunnel Test facility at NASA Glenn Research Center was also carried out for the system designated as the Boundary Layer Ingesting Inlet/Distortion-Tolerant Fan (BLI2DTF) technology development. The results obtained from the present numerical modeling technique were evaluated with those of the wind tunnel experimental test, toward establishing a computationally efficient aeromechanics analysis modeling tool facilitating for analyses of the full rotor blade systems subjected to a distorted inlet flow conditions. Fairly good correlations were achieved hence our computational modeling techniques were fully demonstrated. The analysis result showed that the safety margin requirement set in the BLI2DTF fan blade design provided a sufficient margin with respect to the operating speed range.

forced response analysis↗

DOE OSTI2025

Shaping dark photon spectral distortions

The cosmic microwave background (CMB) spectrum is an extraordinary tool for exploring physics beyond the Standard Model. The exquisite precision of its measurement makes it particularly sensitive to small effects caused by hidden sector interactions. In particular, CMB spectral distortions can unveil the existence of dark photons which are kinetically coupled to the standard photon. In this work, we use the COBE-FIRAS dataset to derive accurate and robust limits on photon-to-dark-photon oscillations for a large range of dark photon masses, from 10$^{−10}$ to 10$^{−4}$ eV. We consider in detail the redshift dependence of the bounds, computing CMB distortions due to photon injection/removal using a Green’s function method. Our treatment improves on previous results, which had set limits studying energy injection/removal into baryons rather than photon injection/removal, or ignoring the redshift evolution of distortions. The difference between our treatment and previous ones is particularly noticeable in the predicted spectral shape of the distortions, a smoking gun signature for photon-to-dark-photon oscillations. The characterization of the spectral shape is crucial for future CMB missions, which could improve the present sensitivity by orders of magnitude, exploring regions of the dark photon parameter space that are otherwise difficult to access [inline-graphic not available: see fulltext].

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2026

Reduction of baseplate distortion during directed energy deposition using compliant features

Distortion in additive manufacturing (AM) remains a barrier to its adoption in precision industries. Baseplate warpage is one such issue which compromises the feasibility of post-process precision machining. The restriction to thermal contraction of the deposited part, imposed by the baseplate, generates bending moments, that in turn causes warpage. A novel distortion mitigation strategy using baseplates with integrated compliant features, which enables thermal contraction of the build is presented. Six unique design concepts are evaluated, including a solid reference, using two deposition geometries. A laser, hot-wire, directed energy deposition (DED) process is used to deposit a symmetric cylindrical part (C-part) and a T-shaped asymmetric part (T-part). Flatness deviation of baseplates is measured using structured light 3D scanning. Measurements reveal a reduction in net flatness deviation of 58.8% for the C-part and 40.9% for the T-part, compared to the solid reference. While most designs yielded reductions exceeding 30% and 20% for the C- and T-parts, respectively, one configuration resulted in increased deviation. Finite element (FE) simulations are performed to elucidate the underlying mechanisms affecting distortion of compliant baseplates during DED. Despite variations between predictions and measurements, agreement in the general trend is observed. It also revealed that initial flatness errors in baseplates significantly affect its deviation during deposition. Predictions indicate that compliant features significantly affect the thermal distribution as well as the evolution of flatness deviation in the baseplate during deposition. Notably, one design exhibited a reduction in distortion during cooling, following its initial increase during deposition. FE predictions show a maximum reduction of 60.9% and 38.8% in net flatness deviation for the C- and T-parts, respectively. The performance of compliant baseplates is found to be governed by both its the thermal and mechanical characteristics, which are crucial factors to be considered during design.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗

DOE OSTI2026

Pseudo–Jahn–Teller Distortion in a One-Dimensional π-Conjugated Polymer

Structural distortions in low-dimensional π-conjugated systems profoundly influence their electronic properties, but the control of such behavior in laterally extended systems remains challenging. Here, in this study, we demonstrate that a one-dimensional conjugated polymer─ poly -(difluorenoheptalene-ethynylene) (PDFHE)─undergoes a pronounced out-of-plane backbone distortion, equivalent to a spontaneous symmetry breaking (SSB) of its mirror symmetry. We synthesized PDFHE on noble metal surfaces and characterized its structure and electronic states using low-temperature scanning tunneling microscopy (STM). Rather than adopting a planar, high-symmetry conformation, PDFHE relaxes into nonplanar isomers stabilized by a pseudo–Jahn–Teller (PJT) distortion having mirror-odd out-of-plane character. The distortion lowers the total energy and increases the band gap, providing a concise rationale for the observed symmetry breaking. Density functional theory calculations corroborate these findings, providing a microscopic explanation for the SSB. Our results show that even in mechanically robust extended π-systems, subtle electron–lattice coupling can spontaneously drive significant structural rearrangements, even in mechanically robust extended π-systems.

conformation↗

DOE OSTI2025

Local structural distortions drive magnetic molecular field in compositionally complex spinel oxide

Understanding how local distortions determine the functional properties of high entropy materials, containing five or more elements at the same crystallographic site, is an open challenge. We address this for a compositionally complex spinel oxide (Mn 0.2 Co 0.2 Ni 0.2 Cu 0.2 Zn 0.2 )Cr 2 O 4 (A 5 Cr 2 O 4 ). By comparatively examining extended X-ray absorption fine structure on A 5 Cr 2 O 4 and its parent counterparts, ACr 2 O 4 , along with density functional theory calculations for multiple configurations, we find that the element-specific distortions go beyond the first neighbor. Specifically, the strong Jahn-Teller distortion present in CuCr 2 O 4 is found to be completely suppressed in A 5 Cr 2 O 4 even locally. Instead, there is a broad distribution of Cu-O and Cu-Cr bond distances, while other A-O distances acquire certain specific values. This study demonstrates the additional flexibility of a cationic sublattice in maintaining a uniform long-range structure, in contrast to previous reports showing only the accommodative anionic sublattice. The mean-field magnetic interactions of A 5 Cr 2 O 4 exhibit a striking resemblance to those of NiCr 2 O 4 , despite the presence of multiple magnetic ions and variable bond lengths. This originates from the comparability of bond lengths around Cr in both materials. Our study paves the way for a deeper understanding of the impact of local structural distortions on the physical properties of compositionally complex quantum materials.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Interplay between element-specific distortions and electrocatalytic oxygen evolution for cobalt–iron hydroxides

A microscopic understanding of how Fe-doping of Co(OH) 2 improves electrocatalytic oxygen evolution remains elusive. We study two Co 1–x Fex(OH) 2 series that differ in fabrication protocol and find composition alone poorly correlates to catalyst performance. Structural descriptors extracted using X-ray diffraction, X-ray absorption spectroscopy, and Raman spectroscopy reveal element-specific distortions in Co 1–x Fe x (OH) 2 . These structural descriptors are composition-dependent within individual sample series but inconsistent across fabrication protocols, revealing fabrication-dependence in catalyst microstructure. Correlations between structural parameters from different techniques show that Fe–O resists bond length changes, forcing distortion of Co environments. We find the difference in O–M–O bond angles between Co and Fe sites to correlate with electrocatalytic behavior across both sample series, which we attribute to asymmetric distortion of potential energy surfaces for the Co(III) to Co(IV) oxidation. A Tafel slope consistent with a rate-limiting step without electron transfer emerges as the O–Co–O angle decreases, implying a distortion-induced transition in the rate-limiting step. The fabrication dependence of electronic and bonding structure in the catalysts should be considered in theoretical and high-throughput analyses of electrocatalyst materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Lattice distortions and metal-insulator transition in hexagonal FeS

Using total x-ray scattering and density functional theory calculations based on experimental data, we study the metal-insulator transition (MIT) in the strongly correlated system FeS with hexagonal symmetry. We find that it arises from the combined effect of static lattice distortions and antiferromagnetic ordering, while electron-electron correlations appear to play a minor role. The presence of local lattice distortions above the MIT explains well the evolution of transport and magnetic properties with changing temperature or pressure. Intrinsically, lattice distortions in hexagonal FeS act as lattice degrees of freedom that bridge competing electronic phases, thus facilitating transitions between them. The mechanism of MIT operating in h-FeS appears to be common to strongly correlated binary systems involving 3d transition metals, warranting further investigations on the lattice distortions-property relationship in this broad class of materials using the approach adopted here.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Close-up view of the interplay between lattice distortions and charge density waves: Case study on rare-earth nickel carbides

Using variable temperature total x-ray scattering and large-scale structure modeling, we study the temperature and composition evolution of lattice distortions and charge density waves (CDWs) in the archetypal strongly correlated system RENi⁢ C 2 (RE=Dy, Tb, Gd, and Sm). Joint analysis of reciprocal and real space data reveals the presence of strong lattice distortions that, depending on the RE species and temperature, appear periodic or remain local, forming a complex CDW phase diagram. Apparently, the CDWs in RENi⁢ C 2 materials arise from a common to the system lattice instability involving diverse distortion modes that persist when magnetic order also sets in at very low temperature. In conclusion, the results support the notion that intrinsic lattice distortions are important to the emergence of exotic electronic phases in strongly correlated systems and call for their further investigation using the advanced approach adopted here.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Effects of radial and circumferential inlet velocity profile distortions on performance of a short-length double-annular ram induction combustor

Inlet air velocity profile tests were conducted on a full-scale short-length 102-centimeter-diameter annual combustor designed for advanced gas turbine engine applications. The inlet profiles studied include radial distortions that were center peaked, and tip peaked, as well as a circumferential distortion which was center peaked for one-third of the circumference and flat for the other two-thirds. An increase in combustor pressure loss was the most significant effect of the radial air velocity distortions. With the circumferential distortion, exit temperature pattern factor doubled when compared to a flat velocity profile.

Schultz, D. F.↗

NASA NTRS1972

Installation caused flow distortion and its effect on noise from a fan designed for turbofan engines

A ground test stand was used to obtain acoustic data on a full scale prototype fan designed for quiet subsonic aircraft engines. The fan was installed in three different ways in the test stand. In two of the installations the fan was driven by a shaft in the inlet; in the third installation the fan was driven from the rear. These three installations, and the structures associated with them, resulted in various amounts of inlet flow distortion to the fan. The rear drive installation had less inlet flow distortion than the two front drive installations. Some measurements of inlet flow distortion were made and used in a blade passage noise generation theory to predict the effects of distortion on noise. Good agreement was obtained when the predicted and measured power level differences between the front drive and rear drive installations were compared.

Povinelli, F. P.↗

NASA NTRS1973

Analysis of inlet flow distortion and turbulence effects on compressor stability

The effect of steady state circumferential total pressure distortion on the loss in compressor stall pressure ratio has been established by analytical techniques. Full scale engine and compressor/fan component test data were used to provide direct evaluation of the analysis. Specifically, since a circumferential total pressure distortion in an inlet system will result in unsteady flow in the coordinate system of the rotor blades, analysis of this type distortion must be performed from an unsteady aerodynamic point of view. By application of the fundamental aerothermodynamic laws to the inlet/compressor system, parameters important in the design of such a system for compatible operation have been identified. A time constant, directly related to the compressor rotor chord, was found to be significant, indicating compressor sensitivity to circumferential distortion is directly dependent on the rotor chord.

Melick, H. C., Jr.↗

NASA NTRS1974

Steady-state inlet temperature distortion effects on the stall limits of a J85-Ge-13 turbojet engine

The effects of circumferential and radial temperature distortions and combined temperature and pressure distortion on the performance of a J85-GE-13 turbojet engine were investigated. In terms of loss of compressor pressure ratio at stall, the most severe pattern of temperature distortion was hub radial while a circumferential pattern of diametrically opposed sectors was least severe. The effect of combined temperature and pressure distortion was dependent on the location of the high temperature and low pressure regions. The most serious stall pressure ratio losses occurred when these regions coincided.

Mehalic, C. M.↗

NASA NTRS1974

An investigation of the open-loop amplification of a Reynolds number dependent process by wave distortion

The response of a constant-temperature hot-wire anemometer to sinusoidal and distorted sinusoidal acoustic oscillations is examined. The output of the anemometer is dependent upon the Reynolds number of the flow over the wire. The response is a measure of the interaction between the anemometer output and the acoustic pressure in the neighborhood of the wire. It is an open-loop prediction of the characteristics of actual closed-loop operation of a system. If the open-loop response is large enough, unstable closed-loop operation is predicted. The study was motivated by a need to investigate the stability limits of liquid-propellant rockets when perturbed by pressure oscillations. The sinusoidal and distorted sinusoidal acoustic oscillations used for this study are the same as those characteristic of unstable rocket combustion. Qualitatively, the results are similar--the response of the system to pure sinusoidal acoustic vibration of the fluid surrounding the wire is small, even when the magnitude of the acoustic pressure is quite large; but the response can be increased by as much as an order of magnitude with respect to the sinusoidal case by the addition of distortion. The amplitude and phase of the distortion component, relative to the fundamental component, are the dominant factors in the increase in the response.

Ventrice, M. B.↗

NASA NTRS1973

Distortion generated in angle-modulation systems by phased arrays

The magnitude and characteristics of distortion produced in demodulated signals by corporate-fed phased arrays are reviewed. Graphs depicting distortion, plotted as a function of signal characteristics and array geometry, display the effects of large arrays on broadband signals. These curves show that distortion in angle-modulation systems is more a function of modulation index than of bandwidth. The data presented provide a basis for predicting distortion levels in practical array systems and for extending analyses to other signal-array configurations.

Rogers, J. D.↗

NASA NTRS1974

Tree encoding for symmetric sources with a distortion measure

A simple algorithm is developed for mapping the outputs of a source into a set of code sequences generated by a tree code. The algorithm is analyzed for the case of a source producing discrete independent equiprobable letters when the distortion measure satisfies a certain symmetry condition. It is shown that the algorithm is capable of achieving an average distortion as close as desired to the minimum average distortion for the code rate given by Shannon's rate-distortion theorem.

Gallager, R. G.↗