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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Spatially resolved phase transformation mapping in 410 stainless steel during additive manufacturing visualized via real-time infrared data

Here, in this study, we demonstrate that spatially resolved cooling curves derived from real-time infrared (IR) thermography during additive manufacturing (AM) can capture spatial variations in phase transformation temperatures through cooling curve analysis (CCA). Using this approach, we show that during laser hot-wire deposition of 410 stainless steel (410SS), the martensite start temperature (M s ) evolves dynamically throughout the build. The M s temperature is spatially nonuniform, ranging from 185 °C to 348 °C, with the lowest values toward the build center and higher values toward the upper region of the deposit. In the lower portion of the build, no M s inflection is detected via CCA, consistent with transformation occurring earlier during thermal cycling followed by tempering during subsequent thermal cycles. These trends in M s are corroborated by characterizing the microstructure by electron backscatter diffraction (EBSD). Traditionally, M s is assumed to be constant, and a single interpass temperature is applied during both deposition and residual stress modeling. Our results demonstrate that IR-derived cooling curves provide a route to spatially and temporally resolved transformation temperature tracking for dynamic interpass control and improved residual-stress modeling.

Additive manufacturing↗
DOE OSTI2021

IoT Devices and Applications for Wire-Based Hybrid Manufacturing Machine Tools

Hybrid manufacturing machine tools have the potential to be a disruptive technology as they can leverage the benefits of both additive and subtractive manufacturing by incorporating both processes on the same machine while limiting the downsides of the individual processes. Since these machines use two very disparate manufacturing processes and hybrid manufacturing is an emerging technology, it will be useful to monitor data coming from the machine and apply it to improve the manufacturing process, the operation of the machine, and to integrate the machine into the larger digital framework of Industrial Internet of Things (IoT). The present work discusses IoT devices that would be beneficial to add to a hybrid machine tool as well as applications for those devices. The proposed methods discussed in this work have not been experimentally implemented on a hybrid machine tool and so there are no performance data available yet. The hybrid machine tool used as a basis to generate these IoT applications is the Mazak VC-500A/5x AM Hot Wire Deposition, which is a 5-axis machine tool incorporated with a wire feedstock 4kW laser deposition system. Methodologies and applications will be outlined for machine health and process monitoring. Other areas covered include process benchmarking, secure networking options for the proposed IoT framework, and hybrid process improvement. Limitations of these methods and future work for new sensor devices and application areas is also discussed.

Thien, Austen↗
DOE OSTI2026

AMVOS: Additive Manufacturing Video Object Segmentation Dataset

This dataset provides labeled video frames from four additive manufacturing (AM) processes for video object segmentation (VOS) tasks. It contains 90 video segments comprising 900 individually annotated frames across five AM datasets: laser hot-wire directed energy deposition (LHW-DED), tungsten inert gas wire arc additive manufacturing (TIG-WAAM), plasma arc welding (PAW), visible-light polymer extrusion (visPolymer), and near-infrared polymer extrusion (irPolymer). Each video segment consists of 10 contiguous frames with corresponding pixel-level object instance annotations. Depending on the process, two of four object classes are labeled per frame: Melt Pool, Feed Wire, Nozzle, or Material. Raw frames are provided as .jpg files and annotations as palettized .png files. The dataset follows the directory structure of established VOS benchmarks (DAVIS, YouTube-VOS, MOSE), enabling direct integration into VOS model training and evaluation pipelines for foundation model fine-tuning, domain adaptation, or zero-shot performance benchmarking. Data was collected at Oak Ridge National Laboratory's Manufacturing Demonstration Facility.

Wetzel, Jon [ORNL]↗
NASA NTRS1974

Calculation of turbulent shear stress in supersonic boundary layer flows

Turbulent shear stress distributions for supersonic boundary layer flows have been computed from experimental mean boundary layer data. The computations have been made by numerically integrating the time averaged continuity and streamwise momentum equations. Distributions have been obtained for flows upstream and downstream of shock-wave-boundary layer interactions and for both two-dimensional and axisymmetric flows. The computed results are compared with recently reported shear stress measurements which were obtained by hot wire anemometer and laser velocimeter techniques.

Sun, C. C.↗
NASA NTRS1974

Calculation of turbulent shear stress in supersonic boundary layer flows

An analysis of turbulent boundary layer flow characteristics and the computational procedure used are discussed. The integrated mass and momentum flux profiles and differentials of the integral quantities are used in the computations so that local evaluation of the streamwise velocity gradient is not necessary. The computed results are compared with measured shear stress data obtained by using hot wire anemometer and laser velocimeter techniques. The flow measurements were made upstream and downstream of an adiabatic unseparated interaction of an oblique shock wave with the turbulent boundary layer on the flat wall of a two dimensional wind tunnel. A comparison of the numerical analysis and actual measurements is made and the effects of small differences in mean flow profiles on the computed shear stress distributions are discussed.

Sun, C. C.↗
NASA NTRS1980

Manufacturing process applications team (MATeam)

The objectives and activities of an aerospace technology transfer group are outlined and programs in various stages of progress are described including the orbital tube flaring device, infrared proximity sensor for robot positioning, laser stripping magnet wire, infrared imaging as welding process tracking system, carbide coating of cutting tools, nondestructive fracture toughness testing of titanium welds, portable solar system for agricultural applications, and an anerobic methane gas generator.

Bangs, E. R.↗
NASA NTRS1980

Applications of advanced electric/electronic technology to conventional aircraft

The desirability of seven advanced technologies as applied to three commercial aircraft of 1985 to 1995 was investigated. Digital fly by wire, multiplexing, ring laser gyro, integrated avionics, all electric airplane, electric load management, and fiber optics were considered for 500 passenger, 50 passenger, and 30 passenger aircraft. The major figure of merit used was Net Value of Technology based on procurement and operating cost over the life of the aircraft. An existing computer program, ASSET, was used to resize the aircraft and evalute fuel usage and maintenance costs for each candidate configuration. Conclusions were that, for the 500 passenger aircraft, all candidates had a worthwhile payoff with the all electric airplane having a large payoff.

Heimbold, R. L.↗
NASA NTRS1981

Highly separated transonic flows

Attention is given to the wind tunnel, to photographic visualization of the flow, and to measurements by pressure probes, hot wire anemometry and laser anemometry. The simultaneous use of different means of measurement provided a good description of the phenomenon, and indicated the existence of shocks and their stability, as well as the existence of the bubble, its dimensions, and in particular, the reattachment of its front. The results show that the bursting (or transition) of the bubble front is produced at an unstable position and creates a point of turbulent intensity which diffuses over the entire height of the flow.

Farcy, A.↗
NASA NTRS1982

Experimental measurements of unsteady turbulent boundary layers near separation

Investigations conducted to document the behavior of turbulent boundary layers on flat surfaces that separate due to adverse pressure gradients are reported. Laser and hot wire anemometers measured turbulence and flow structure of a steady free stream separating turbulent boundary layer produced on the flow of a wind tunnel section. The effects of sinusoidal and unsteadiness of the free stream velocity on this separating turbulent boundary layer at a reduced frequency were determined. A friction gage and a thermal tuft were developed and used to measure the surface skin friction and the near wall fraction of time the flow moves downstream for several cases. Abstracts are provided of several articles which discuss the effects of the periodic free stream unsteadiness on the structure or separating turbulent boundary layers.

Simpson, R. L.↗
NASA NTRS1988

The pros and cons of code validation

Computational and wind tunnel error sources are examined and quantified using specific calculations or experimental data, and a substantial comparison of theoretical and experimental results, or a code validation, is discussed. Wind tunnel error sources considered include wall interference, sting effects, Reynolds number effects, flow quality and transition, and instrumentation such as strain gage balances, electronically scanned pressure systems, hot film gages, hot wire anemometers, and laser velocimeters. Computational error sources include math model equation sets, the solution algorithm, artificial viscosity/dissipation, boundary conditions, the uniqueness of solutions, grid resolution, turbulence modeling, and Reynolds number effects. It is concluded that although improvements in theory are being made more quickly than in experiments, wind tunnel research has the advantage of the more realistic transition process of a right turbulence model in a free-transition test.

Bobbitt, Percy J.↗
NASA NTRS1988

The pros and cons of code validation

Computational and wind tunnel error sources are examined and quantified using specific calculations of experimental data, and a substantial comparison of theoretical and experimental results, or a code validation, is discussed. Wind tunnel error sources considered include wall interference, sting effects, Reynolds number effects, flow quality and transition, and instrumentation such as strain gage balances, electronically scanned pressure systems, hot film gages, hot wire anemometers, and laser velocimeters. Computational error sources include math model equation sets, the solution algorithm, artificial viscosity/dissipation, boundary conditions, the uniqueness of solutions, grid resolution, turbulence modeling, and Reynolds number effects. It is concluded that, although improvements in theory are being made more quickly than in experiments, wind tunnel research has the advantage of the more realistic transition process of a right turbulence model in a free-transition test.

Bobbitt, Percy J.↗
NASA NTRS1989

Instrumentation advances for transonic testing

New and improved instrumentation, like new and improved wind tunnels, provide capabilities which stimulate innovative research and discovery. During the past few years there have been a number of instrumentation developments which have aided and abetted the acquisition of more accurate aerodynamic data and have led to new physical insights as well. Some of these advances are reviewed, particularly in the area of thin film gages, hot wire anemometry, and laser instrumentation. A description is given of the instruments and/or techniques and some sample results are shown.

Bobbitt, Percy J.↗
NASA NTRS1992

Some aspects of unsteady separation

Unsteady separation can be forced in a variety of ways and in this presentation two fundamental means will be considered: (1) the introduction of convected vorticular disturbances into the flow; and (2) the influence of a specific type of three-dimensional geometry. In both situations a response of the viscous flow near the wall is provoked wherein the fluid near the surface abruptly focuses into a narrow region that erupts from the surface into the mainstream. In two-dimensional flows, the eruption takes the form of a narrow, explosively-growing spike, while in three-dimensional situations, examples are presented which indicate that the eruption is along a narrow zone in the shape of a crescent-shaped plume. The nature of the three-dimensional flow near a circular cylinder, which is mounted normal to a flat plate, is also examined in this study. Here the three-dimensional geometry induces complex three-dimensional separations periodically. The dynamics of the generation process is studied experimentally in a water channel using hydrogen bubble wires and a laser sheet, and the main features of the laminar regime through to transition are documented.

Smith, C. R.↗
NASA NTRS1997

Health Monitoring of Composite Material Structures using a Vibrometry Technique

Large composite material structures such as aircraft and Reusable Launch Vehicles (RLVS) operate in severe environments comprised of vehicle dynamic loads, aerodynamic loads, engine vibration, foreign object impact, lightning strikes, corrosion, and moisture absorption. These structures are susceptible to damage such as delamination, fiber breaking/pullout, matrix cracking, and hygrothermal strain. To ensure human safety and load-bearing integrity, these structures must be inspected to detect and locate often invisible damage and faults before becoming catastrophic. Moreover, nearly all future structures will need some type of in-service inspection technique to increase their useful life and reduce maintenance and overall costs. Possible techniques for monitoring the health and indicating damage on composite structures include: c-scan, thermography, acoustic emissions using piezoceramic actuators or fiber-optic wires with gratings, laser ultrasound, shearography, holography, x-ray, and others. These techniques have limitations in detecting damage that is beneath the surface of the structure, far away from a sensor location, or during operation of the vehicle. The objective of this project is to develop a more global method for damage detection that is based on structural dynamics principles, and can inspect for damage when the structure is subjected to vibratory loads to expose faults that may not be evident by static inspection. A Transmittance Function Monitoring (TFM) method is being developed in this project for ground-based inspection and operational health monitoring of large composite structures as a RLV. A comparison of the features of existing health monitoring approaches and the proposed TFM method is given.

Schulz, Mark J.↗
NASA NTRSDate not supplied

A Comparison of Microstructure and Mechanical Performance of Inconel 718 Manufactured via L-PBF, LP-DED, and WAAM Technologies

The microstructure and mechanical properties of additively manufactured (AM) alloys can be significantly affected by variations in cooling rates, resulting from different process conditions across different additive manufacturing (AM) platforms. Therefore, it is crucial to understand the effect of manufacturing process on the microstructure and mechanical properties of AM Inconel 718. This study examines three AM processes: laser powder bed fusion, laser powder directed energy deposition, and wire arc additive manufacturing. Results show that fully heat treated laser powder bed fused (L-PBF) and wire arc additively manufactured (WAAM) Inconel 718 specimens exhibit higher strength compared to laser powder directed energy deposited (LP-DED) ones due to finer grain structure in L-PBF and retained dendritic microstructure in WAAM. The ductility in LP-DED Inconel 718 was slightly higher compared to WAAM and L-PBF due to relatively small carbide size, which causes stress concentration in a small material volume, leading to delayed fracture.

Additive manufacturing (AM)↗
DOE OSTI2021

Measuring magnetic fields in laser-driven coils with dual-axis proton deflectometry

Abstract By driving hot electrons between two metal plates connected by a wire loop, high power lasers can generate multi-tesla, quasi-static magnetic fields in miniature coil targets. Many experiments involving laser-coil targets rely on proton deflectometry directed perpendicular to the coil axis to extract a measurement of the magnetic field. In this paper, we show that quantitative measurements using perpendicular probing are complicated by the presence of GV m −1 electric fields in the target that develop on sub-ns timescales. Probing parallel to the coil axis with fiducial grids is shown to reliably separate the electric and magnetic field measurements, giving current estimates of I ≈ 5 kA in 1 mm- and 2 mm-diameter wire loops. An analytic model of proton deflection in electric and magnetic fields is used to benchmark results from the particle-in-cell code and help deconvolve the magnetic and electric field deflections. Results are used to motivate a new experimental scheme that combines a single-plate target with axial proton probing and direct current measurements. This scheme has several important advantages over the traditional target and diagnostic set-up, enabling the robust measurement of coil magnetic fields and plasma properties, as well as making it easier to validate different theoretical models at a range of laser intensities.

Bradford, P. (ORCID:0000000296186342)↗
NASA NTRS1989

Accuracy Of Hot-Wire Anemometry In Supersonic Turbulence

Sensitivity of hot-wire probe compared to laser-induced-florescence measurements. Report discusses factors affecting readings of hot-wire anemometer in turbulent supersonic boundary layer. Presents theoretical analysis of responses of hot-wire probe to changes in flow; also compares measurements by hot-wire probe with measurements of same flows by laser-induced fluorescence (LIF). Because LIF provides spatially and temporally resolved data on temperature, density, and pressure, provides independent means to determine responses of hot-wire anemometers to these quantities.

Logan, Pamela↗
NASA NTRS1985

Fast laser-induced aerosol formation for visualization of gas flows

A technique for aerosol seeding of gas flows by laser-induced particle formation is demonstrated using a pulsed Nd:YAG laser (1.06 microns) for optical breakdown of a mixture of SF6 and H2 in an inert carrier gas. It is noted that, contrary to the smoke-wire approach, the laser-induced particles form first in zones of high turbulence, since mixing enhances coagulation. The method also allows seeding to be performed in locations hardly accessible otherwise and is mechanically nonintrusive. Finally, a study of the mixture and the breakdown effects indicates that for H2:SF6 ratios between 3:1 and 15:1 the particle formation is only limited by the physics of the gas/particle conversion.

Hassa, C.↗