EVALUATING THE MECHANICAL PROPERTIES WITHIN THE TRANSITION REGION OF MULTI-MATERIAL LARGE-FORMAT EXTRUSION ADDITIVE MANUFACTURING
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Brackett, James↗
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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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Designs and Modeling of Architect Multi-material Scintillator System
We present a new conceptual radiation detector, the Architected Multimaterial Scintillator System, that utilizes a scintillator composed of multiple materials arranged in architected structures to enable new capabilities. By structuring differently-dyed materials, the wavelength of the scintillation light encodes additional information in radiation measurements. These structures can be realized through additive manufacture (3D-printing). Two classes of this concept are described and modelled using Monte Carlo simulations to evaluate their performance. The first detector design uses dye microstructures to encode particle tracking information, allowing for directional neutron detection and gamma/neutron discrimination. The second design uses a dye gradient to indicate the position of radiation along the gradient. The simulation results indicate this new concept in radiation detection can achieve strong performance in a variety of capabilities including particle identification, directionality and spectroscopy measurements, and particle position reconstruction.
72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
RF cured nanocomposite adhesives for multi-material joining applications
A method for fabricating, and curing, nanocomposite adhesives including introducing nanoheater elements into a heat-curing adhesive to fabricate a nanocomposite adhesive, and providing a radio-frequency (RF) electromagnetic wave to the nanocomposite adhesive to heat, and cure the nanocomposite adhesive. The nanocomposite adhesive is physically applied to first and second materials to bond the first and second materials upon curing of the nanocomposite adhesive, and the RF electromagnetic wave has a frequency in the radio-frequency range, having energy that is transferred to the nanoheater elements by electromagnetic wave interactions with permanent and induced dipoles, intrinsic photon-phonon interaction, or interactions with nanoheater defects and grain structures.
Zhang, Yuepeng↗
Lithography-Based Additive Manufacturing of Ceramics and Metals for Structural Integrity, Joining, and Multi-Material Integration
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Cillessen, Dale [Sandia National Laboratories (SNL↗
Physics augmented machine learning discovery of composition-dependent constitutive laws for 3D printed digital materials
Multi-material 3D printing, particularly through polymer jetting, enables the fabrication of digital materials by mixing distinct photopolymers at the micron scale within a single build to create a composite with tunable mechanical properties. Here, this work presents an integrated experimental and computational investigation into the composition-dependent mechanical behavior of 3D printed digital materials. We experimentally characterize five formulations, combining soft and rigid UV-cured polymers under uniaxial tension and torsion across three strain and twist rates. The results reveal nonlinear and rate-dependent responses that strongly depend on composition. To model this behavior, we develop a physics-augmented neural network (PANN) that combines a partially input convex neural network (pICNN) for learning the composition-dependent hyperelastic strain energy function with a quasi-linear viscoelastic (QLV) formulation for time-dependent response. The pICNN ensures convexity with respect to strain invariants while allowing non-convex dependence on composition. To enhance interpretability, we apply $L_0$ sparsification. For the time-dependent response, we introduce a multilayer perceptron (MLP) to predict viscoelastic relaxation parameters from composition. The proposed model accurately captures the nonlinear, rate-dependent behavior of 3D printed digital materials in both uniaxial tension and torsion, achieving high predictive accuracy for interpolated material compositions. This approach provides a scalable framework for automated, composition-aware constitutive model discovery for multi-material 3D printing.
Constitutive modeling↗
NASA's Advanced TPS Materials and Technology Development: Multi-Functional Materials and Systems for Space Exploration
NASA's future missions will be more demanding. They require materials to be mass efficient, robust, multi-functional, scalable and able to be integrated with other subsystems to enable innovative missions to accomplish future science missions. Thermal protection systems and materials (TPSM) are critical for the robotic and human exploration of the solar system when it involves entry. TPSM is a single string system with no back-up. Mass efficiency and robustness are required. Integration of TPSM with the aeroshell is both a challenge and an opportunity. Since 2010, NASA's Space Technology Mission Directorate has invested in innovative new materials and systems across a spectrum of game changing technologies. In this keynote address, we plan to highlight and present our successful approaches utilized in developing four different materials and system technologies that use innovative new manufacturing techniques to meet mission needs. 3-D weaving and felt manufacturing allowed us to successfully propose new ways of addressing TPSM challenges. In the 3-D MAT project, we developed and delivered a multi-functional TPS materials solution, in under three years that is an enabler for Lunar Capable Orion Spacecraft. Under the HEEET project, we are developing a robust heat-shield that can withstand extreme entry conditions, both thermally and mechanically, for entry at Venus, Saturn or higher speed sample return missions. The improved efficiency of HEEET allows science missions entry at much reduced G'loads enabling delicate science instruments to be used. The ADEPT concept is a foldable and deployable entry system and the critical component is a multi-functional fabric that is foldable and deployable and also functions as a mechanical aeroshell and a TPS. The fourth technology we will highlight involves felt to address integration challenges of rigid ablative system such as PICA that was used on MSL. The felt technology allows us to develop a compliant TPS for easy integration. The above four technology developments have focused on mission infusion as the success criteria. These technologies are in different stages of mission infusion. These innovations have led to new mission concepts to be proposed in the future. In our keynote address we will present approaches we have employed throughout the project to create the bridge to transition from low TRL to mission infusion and to overcome the traditional TRL valley of death.
TPS↗
NestedAE: interpretable nested autoencoders for multi-scale materials characterization
The multi-scale features and latent space are connected by a nested autoencoder.
Chemistry↗
Corrosion Protection and Dissimilar Material Joining for Next Generation Lightweight Vehicles
The Arconic Technology Center working with Honda R&D Americas, LLC and the Ohio State University evaluated the corrosion performance of several multi-material conditions and demonstrated the production worthiness of the Resistance Spot Riveting (RSR™) process. RSR is a new technology being developed by Howmet Fastening Systems (formerly Arconic, Inc.) that employs a fastener that is installed using conventional resistance spot welding equipment to produce multi-material joints. The goal of the 3-year project was to demonstrate the use of RSR to join aluminum to steel and aluminum to carbon fiber composites on a prototype scale. Deployment of this technology would help the automotive industry achieve an additional 10 to 20% weight reduction over high strength steels. These weight-savings to the body in white generally translates to 2.5-5.0% of overall vehicle curb weight. The resulting total weight-savings could provide a 1.5% to 3.0% total improvement in fuel efficiency for vehicles that incorporate RSR for multi-material joining. The RSR technology addresses several production barriers to achieving DOE’s fuel efficiency targets including eliminating the need of additional capital for new joining technologies and the flexibility to process conventional steel and multi-material structures with the same equipment. Additionally, the trend towards ultra-high strength steels limits the availability of conventional joining technologies that can effectively process these multi-material combinations. In order to accomplish these goals, the following program milestones were completed by the team: 1) Developed RSR process parameters, producing multi-material joints for mechanical testing and corrosion assessments. 2) Conducted corrosion evaluation of RSR and baseline joints assembled between automotive type aluminum alloys, steels, and carbon fiber using several corrosion mitigation strategies. 3) Developed a production ready feed system and integrate into a robotic resistance spot welding station to simulate automotive production conditions. 4) Produced demonstration assemblies for testing and evaluation.
36 MATERIALS SCIENCE↗
Production and identification of highly photoconductive CdSe-based hybrid organic-inorganic multi-layer materials
Highly photoconductive thin multi-layers of new hybrid organic-inorganic semiconductors have been developed. They result by the combination of an inorganic semiconductor with ferrocene, a commercially available compound, applying the electrodeposition and spin coating techniques, introducing sodium oxalate as an additive in the electrolytic bath. The organic layer of the hybrid system is enveloped between two inorganic layers in a sandwich-like structure. The full characterization of the final products by XRD, SEM-EDAX, band gap and photo electro chemical cell (PEC) measurements confirmed the development of the hybrid semiconducting system. The outer electrodeposited CdSe layer of the sandwich-like materials exhibits a definite hexagonal structure, whereas, as derived from the XRD and band gap data, the development of a new semiconducting compound has been confirmed. Thus, due to a synergic action, the three-layer materials present a remarkably improved photoresponse compared to that of the pure cubic CdSe electrodeposited in the presence of the oxalate additive as well as the three-layer hybrid CdSe-based products developed in our previous work in additive-free electrolytic baths.
36 MATERIALS SCIENCE↗
OLED with multi-emissive material layer
The present invention relates to organic light emitting devices with a multi-emissive material layer (EML), where a multi-EML generally refers to an emissive layer having at least two layers of emissive material, each layer having a different emitter concentration (e.g. a first EML in direct contact with a second EML, and the emitter concentration of the first EML (hole favorable) exceeds that of the second EML (electron favorable)).
Li, Jian↗
UNR ETI Computational Investigation (Year 2)
The LANL ASC Arbitrary Lagrange/Eulerian (ALE) code, FLAG, is being used to model experiments conducted under this grant in order to understand the physics limiting high-current conduction and thermal plasma production. This includes the effects of nonlinear magnetic diffusion (NLMD), the magnetic Rayleigh-Taylor (MRT) instability, and the electro-thermal instability (ETI). FLAG is a multi-dimensional, unstructured-grid, multi-material, multi-temperature, shockphysics code with a single-fluid, resistive magnetohydrodynamics (MHD) package. Equations-ofstate (EOS), conductivity, material-strength, and melt can be treated with a variety of analytic or tabular models.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Role of mechanical stress localizations on the radiation hardness of AlGaN/GaN high electron mobility transistors
Multi-material, multi-layered systems such as AlGaN/GaN high electron mobility transistors (HEMTs) contain residual mechanical stresses that arise from sharp contrasts in device geometry and materials parameters. These stresses, which can be either tensile or compressive, are difficult to detect and eliminate because of their highly localized nature. We propose that their high-stored internal energy makes potential sites for defect nucleation sites under radiation, particularly if their locations coincide with the electrically sensitive regions of a transistor. In this study, we validate this hypothesis with molecular dynamic simulation and experiments exposing both pristine and annealed HEMTS to 2.8 MeV Au +3 irradiation. Our unique annealing process uses mechanical momentum of electrons, also known as the electron wind force (EWF) to mitigate the residual stress at room temperature. High-resolution transmission electron microscopy and cathodoluminescence spectra reveal the reduction of point defects and dislocations near the two-dimensional electron gas region of EWF-treated devices compared to pristine devices. The EWF-treated HEMTs showed relatively higher resilience with approximately 10% less degradation of drain saturation current and ON-resistance and 5% less degradation of peak transconductance. Both mobility and carrier concentration of the EWF-treated devices were less impacted compared to the pristine devices. Our results suggest that the lower density of nanoscale stress localization contributed to the improved radiation tolerance of the EWF-treated devices. Intriguingly, the EWF is found to modulate the defect distribution by moving the defects to electrically less sensitive regions in the form of dislocation networks, which act as sinks for the radiation induced defects and this assisted faster dynamic annealing.
AlGaN/GaN HEMTs↗
Dark Field Proton Radiography (Los Alamos LDRD Report)
Proton radiography at LANL (pRad) takes advantage of the high flux, high proton energy, and flexible timing structure of LANSCE's 800-MeV proton beam to visualize dense, dynamic systems under extreme strain. With recent needs identified for the development of the W93, the pRad team has been actively searching for ways to increase the facility's radiographic capabilities. Recently, we discovered that utilizing two magnetic lenses (one upstream and one downstream of the object), and specific combinations of collimator choices within the two lenses, that the signal-to-noise ratio was improved by more than a factor of two. However, we did not fully understand the mechanism, and found that results did not match forward modeling predictions. This work specifically sought to implement an engineering solution to solve this problem, through the development of an actuated collimator that reduced the time required to swap collimator settings from a typical 4-8 hours, to less than 30 seconds. This allowed, in combination with a unique multi-material, multi-resolution stepwedge, to acquire an unprecedently enormous dataset, with in total 24 collimation combinations, and multiple diffuser settings and pulse patterns, equivalent to almost a full run cycle's worth of data in a few days. This massive dataset is currently being harnessed to make a fully-predictive, ultra-fast Python-based model of the system, to dial in specific settings for any future experiments that fully optimize that radiographic sensitivity to the material of interest.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Versatile tape-drive target for high-repetition-rate laser-driven proton acceleration
We present the development and characterization of a high-stability, multi-material, multi-thickness tape-drive target for laser-driven acceleration at repetition rates of up to 100 Hz. The tape surface position was measured to be stable on the sub-micrometre scale, compatible with the high-numerical aperture focusing geometries required to achieve relativistic intensity interactions with the pulse energy available in current multi-Hz and near-future higher repetition-rate lasers ( > kHz). Long-term drift was characterized at 100 Hz demonstrating suitability for operation over extended periods. The target was continuously operated at up to 5 Hz in a recent experiment for 70,000 shots without intervention by the experimental team, with the exception of tape replacement, producing the largest data-set of relativistically intense laser–solid foil measurements to date. This tape drive provides robust targetry for the generation and study of high-repetition-rate ion beams using next-generation high-power laser systems, also enabling wider applications of laser-driven proton sources.
47 OTHER INSTRUMENTATION↗
Low temperature recovery of OFF-state stress induced degradation of AlGaN/GaN high electron mobility transistors
Thermal annealing is a widely used strategy to enhance semiconductor device performance. However, the process is complex for multi-material multi-layered semiconductor devices, where thermoelastic stresses from lattice constant and thermal expansion coefficient mismatch may create more defects than those annealed. We propose an alternate low temperature annealing technique, which utilizes the electron wind force (EWF) induced by small duty cycle high density pulsed current. To demonstrate its effectiveness, we intentionally degrade AlGaN/GaN high electron mobility transistors (HEMTs) with accelerated OFF-state stressing to increase ON-resistance ∼182.08% and reduce drain saturation current ∼85.82% of pristine condition at a gate voltage of 0 V. We then performed the EWF annealing to recover the corresponding values back to ∼122.21% and ∼93.10%, respectively. The peak transconductance, degraded to ∼76.58% of pristine at the drain voltage of 3 V, was also recovered back to ∼92.38%. This recovery of previously degraded transport properties is attributed to approximately 80% recovery of carrier mobility, which occurs during EWF annealing. We performed synchrotron differential aperture x-ray microscopy measurements to correlate these annealing effects with the lattice structural changes. We found a reduction of lattice plane spacing of (001) planes and stress within the GaN layer under the gate region after EWF annealing, suggesting a corresponding decrease in defect density. Application of this low-temperature annealing technique for in-operando recovery of degraded electronic devices is discussed.
Physics↗
ARC+(Registered Trademark) and ARC PC Welding Simulators: Teach Welders with Virtual Interactive 3D Technologies
123 Certification Inc., a Montreal based company, has developed an innovative hands-on welding simulator solution to help build the welding workforce in the most simple way. The solution lies in virtual reality technology, which has been fully tested since the early 90's. President and founder of 123 Certification Inc., Mr. Claude Choquet Ing. Msc. IWE. acts as a bridge between the welding and the programming world. Working in these fields for more than 20 years. he has filed 12 patents world-wide for a gesture control platform with leading edge hardware related to simulation. In the summer of 2006. Mr Choquet was proud to be invited to the annual IIW International Weld ing Congress in Quebec City to launch the ARC+ welding simulator. A 100% virtual reality system and web based training center was developed to simulate multi process. multi-materiaL multi-position and multi pass welding. The simulator is intended to train welding students and apprentices in schools or industries. The welding simulator is composed of a real welding e[eetrode holder (SMAW-GTAW) and gun (GMAW-FCAW). a head mounted display (HMD), a 6 degrees of freedom tracking system for interaction between the user's hands and head. as well as external audio speakers. Both guns and HMD are interacting online and simultaneously. The welding simulation is based on the law of physics and empirical results from detailed analysis of a series of welding tests based on industrial applications tested over the last 20 years. The simulation runs in real-time, using a local logic network to determine the quality and shape of the created weld. These results are based on the orientation distance. and speed of the welding torch and depth of penetration. The welding process and resulting weld bc.1d are displayed in a virtual environment with screenplay interactive training modules. For review. weld quality and recorded process values can be displayed and diagnosed after welding. To help in the le.tming process, a learning curve for each student and each Virtual Welding Class'" can be plotted, for an instructor's review or a required third party evaluation.
Choquet, Claude↗
Ablative Laser Propulsion Using Multi-Layered Material Systems
Experimental investigations are ongoing to study the force imparted to materials when subjected to laser ablation. When a laser pulse of sufficient energy density impacts a material, a small amount of the material is ablated. A torsion balance is used to measure the momentum produced by the ablation process. The balance consists of a thin metal wire with a rotating pendulum suspended in the middle. The wire is fixed at both ends. Recently, multi-layered material systems were investigated. These multi-layered materials were composed of a transparent front surface and opaque sub surface. The laser pulse penetrates the transparent outer surface with minimum photon loss and vaporizes the underlying opaque layer.
Nehls, Mary↗
Multi-objective materials bayesian optimization with active learning of design constraints: Design of ductile refractory multi-principal-element alloys
We report Bayesian Optimization (BO) has emerged as a powerful framework to efficiently explore and exploit materials design spaces. To date, most BO approaches to materials design have focused on the materials discovery problem as if it were a single expensive-to-query ‘black box’ in which the target is to optimize a single objective (i.e., material property or performance metric). Also, such approaches tend to be constraint agnostic. Here, we present a novel multi-information BO framework capable of actively learning materials design as a multiple objectives and constraints problem. We demonstrate this framework by optimally exploring a Refractory Multi-Principal-Element Alloy (MPEA) space, here specifically, the system Mo-Nb-Ti-V-W. The MPEAs are explored to optimize two density-functional theory (DFT) derived ductility indicators (Pugh’s Ratio and Cauchy pressure) while learning design constraints relevant to the manufacturing of high-temperature gas-turbine components. Alloys in the BO Pareto-front are analyzed using DFT to gain an insight into fundamental atomic and electronic underpinning for their superior performance, as evaluated within this framework.
36 MATERIALS SCIENCE↗