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DOE OSTI2022

Improving fatigue performance of additively manufactured Ti-6Al-4V using sulfur-based self-terminating etching processes

The adoption of Additively Manufactured (AM) Ti-6Al-4V (Ti64) is continually increasing in the industry due to its benefits over the conventional manufacturing techniques. However, AM Ti64 parts are prone to poor surface finish, which significantly affects their fatigue performance. Therefore, AM Ti64 parts need post-processing to enhance surface finish and fatigue performance. Prior work with a sulfur-based self-terminating etching process for AM Ti64 demonstrated support removal and surface roughness reduction. To further this work, this manuscript details the impact of this sulfur-based post-processing technique on the mechanical properties and the fatigue life of AM Ti64 by characterizing the surface roughness, microstructural evolution, and fracture surfaces. Finally, this post-processing technique decreased the surface roughness parameter - S v by 55 % from 84 ± 11 µm to 38 ± 19 µm and increased the average fatigue life by 340 % from about 7000 cycles to 30,000 cycles.

36 MATERIALS SCIENCE↗

DOE OSTI2015

ParaView Catalyst: Enabling In Situ Data Analysis and Visualization

Computer simulations are growing in sophistication and producing results of ever greater fidelity. This trend has been enabled by advances in numerical methods and increasing computing power. However these advances come with several costs including massive increases in data size, difficulties examining output data, challenges in configuring simulation runs, and difficulty debugging running codes. Interactive visualization tools, like ParaView, have been used for post-processing of simulation results. However, the increasing data sizes, and limited storage and bandwidth make high fidelity post-processing impractical. In situ analysis is recognized as one of the ways to address these challenges. In situ analysis moves some of the post-processing tasks in line with the simulation code thus short circuiting the need to communicate the data between the simulation and analysis via storage. ParaView Catalyst is a data processing and visualization library that enables in situ analysis and visualization. Built on and designed to interoperate with the standard visualization toolkit VTK and the ParaView application, Catalyst enables simulations to intelligently perform analysis, generate relevant output data, and visualize results concurrent with a running simulation. Here, we provide an overview of the Catalyst framework and some of the success stories.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Investigation of interlayer adhesion of 3D printable cementitious material from the aspect of printing process

The safety of structure printed by extrusion-based 3D concrete printing (3DCP) is significantly influenced by interlayer bonding, which is governed by fresh material properties and processes, including mixing, printing, and post-processing phases. Much literature focused on improving interlayer bond strength via material tailoring/bonding agent addition but gave insufficient attention to other phases' impacts. This study investigates the effects of parameters on interlayer bond strength from different phases in 3DCP, including superplasticizer dosage, printing speed, and curing condition. In the mixing phase, the superplasticizer dosage was increased to reduce I{sub thix} and increase surface moisture content (SMC), consequently improving interface microstructure and interlayer bond strength. In the printing phase, similar results were observed by increasing pumping speed to increase material shear rate. In the post-processing phase, proper curing also improved interlayer bond strength. While SMC has a critical impact on interlayer bond strength, material thixotropic index (I{sub thix}) probably has a stronger influence.

36 MATERIALS SCIENCE↗

DOE OSTI2025

LiDAR Point Cloud Data from the 2018 NGEE Arctic UAS Campaign at the Teller 47 Field Site, Seward Peninsula, Alaska

Airborne remote sensing data collected from Los Alamos National Laboratory’s (LANL) heavy-lift unoccupied aerial system (UAS) hexacopter platform operated by NGEE Arctic scientists from the EES-14 group at Los Alamos National Laboratory. These data were collected in July 2018 at a field site near mile marker 47 along the Teller Road between Nome, Alaska and Teller, Alaska. A DJI Matrice 600 Pro Airframe and Routescene UAV LiDAR System was used to collect LiDAR data. The LiDAR data has undergone basic post-processing using Routescene LidarViewer Pro software to create point cloud data (.laz files). This data package contains point clouds (.laz), processing metadata files (json.lvp), and post-processed kinematic files (.csv). Ancillary aircraft data, flight mission parameters, weather conditions, and lidar data and imagery can be found in NGA281 (https://doi.org/10.5440/1671794).The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research. The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska. Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

LiDAR Point Cloud Data from the 2018 NGEE Arctic UAS Campaign at the Kougarok 64 Field Site, Seward Peninsula, Alaska

Airborne remote sensing data collected from Los Alamos National Laboratory's (LANL) heavy-lift unoccupied aerial system (UAS) hexacopter platform operated by NGEE Arctic scientists from the EES-14 group at Los Alamos National Laboratory. These data were collected in July 2018 at a field site near mile marker 64 along the Kougarok road (Nome-Taylor Highway) between Nome, Alaska and Taylor, Alaska. A DJI Matrice 600 Pro Airframe and Routescene UAV LiDARSystem was used to collect LiDAR data. The LiDAR data has undergone basic post-processing using Routescene LidarViewer Pro software to create point cloud data (.laz files). This data package contains point clouds (.laz), processing metadata files (json.lvp), and post-processed kinematic files (.csv). Ancillary aircraft data, flight mission parameters, weather conditions, raw LiDAR data, and RGB imagery can be found in NGA298.The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research. The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska. Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Enabling On-Demand Aerospace Component Manufacturing: Topology Optimization of GE Engine Bracket and Fabrication Using Metal FFF

Additive Manufacturing (AM) offers advantages over conventional manufacturing processes, particularly by reducing the number of parts produced through multistage combined technologies, but these often result in low manufacturing yields or require post-processing. AM facilitates the production of complex geometries with fine features, overhangs, and lattice structures. For instance, Laser Powder Bed Fusion (LPBF) technology enables the fabrication of intricate parts that can be easily post-processed by removing residual powder. Laser powder bed AM technologies are widely discussed in the literature due to their design freedom in creating complex geometries, with and without the need for support generation. However, rapid solidification due to a thermal gradient in the build direction, which leads to the formation of columnar grains and warpage, is one of the challenges. To address this challenge, we propose layer-by-layer metal FFF technology, followed by the debinding and sintering process, as an alternative to powder- and laser-based approaches. Furthermore, design for additive manufacturing (DfAM) principles are discussed to minimize the need for support generation and enable easy post-processing, thereby improving surface finish to meet high tolerances in fabricating components for aerospace and healthcare applications.

Singh, Abhishek [University of Michigan, Ann Arbor↗

DOE OSTI2025

Power and Limitations of Linear Programming Decoder for Quantum LDPC Codes

Decoding quantum error-correcting codes is a key challenge in enabling fault-tolerant quantum computation. In the classical setting, linear programming (LP) decoders offer provable performance guarantees and can leverage fast practical optimization algorithms. Although LP decoders have been proposed for quantum codes, their performance and limitations remain relatively underexplored. In this work, we uncover a key limitation of LP decoding for quantum low-density parity-check (LDPC) codes: certain constant-weight error patterns lead to ambiguous fractional solutions that cannot be resolved through independent rounding. To address this issue, we incorporate a post-processing technique known as ordered statistics decoding (OSD), which significantly enhances LP decoding performance in practice. Our results show that LP decoding, when augmented with OSD, can outperform belief propagation with the same post-processing for intermediate code sizes of up to hundreds of qubits. These findings suggest that LP-based decoders, equipped with effective post-processing, offer a promising approach for decoding near-term quantum LDPC codes.

Gu, Shouzhen [Yale U.]↗

DOE OSTI2025

Power and Limitations of Linear Programming Decoder for Quantum LDPC Codes

Gu, Shouzhen [Yale U.]↗

DOE OSTI2025

Power and Limitations of Linear Programming Decoder for Quantum LDPC Codes

Gu, Shouzhen [Yale U.]↗

DOE OSTI2019

An ASIC With A Low Power Multichannel ADC For Energy and Timing Measurements

Densely packed gamma-ray imaging and spectroscopy instruments employing high performance multichannel electronics occupy large volume and dissipate excessive power. Therefore, the availability of a low power application specific integrated circuit (ASIC) incorporating multiple channels of ADCs and post processing electronics is of critical importance for nuclear physics (NP) instrumentation. Currently available 12-bit 0.2GSps ADC channel count is usually not exceeding 8. Coarse technologies at 130nm or 180nm node usually used for implementing ADCs do not permit achieving low power consumption and cannot be arrayed on a chip. Thus, a new ADC device is required to satisfy the need of electronics for NP and commercial systems. The research carried out during the Phase I project aimed to prove the feasibility of implementing a 28nm CMOS based 32 channel 12-bit ADC ASIC. Most importantly for NP instrumentation, in addition to including a 32-channel ADC array, our proposed ASIC aims to provide digitized signal post-processing function. In current systems digitized signal post-processing is implemented in FPGAs. Thus, the functionality our ASIC provides is equivalent to the functionality currently realized using 8 ADC parts (each containing 4 channels), an FPGA and a great number of wiring between the ADCs and the FPGA. By using a single part instead of 9, our solution offers a great reduction in volume, power consumption and cost.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Demonstration and analysis of volumetric additive manufacturing via sub-orbital spaceflight testing

Computed Axial Lithography (CAL) represents a significant advancement in the emerging field of Volumetric Additive Manufacturing (VAM). CAL addresses key limitations of traditional photopolymer additive manufacturing technologies, by eliminating the need for layering and support structures. Unlike conventional methods, CAL prints components by illuminating all points within a desired geometry simultaneously, using tomographic reconstruction to form the object in a single step. This unique approach eliminates the relative motion between the object and the precursor material, enabling faster printing speeds and reducing the waste associated with support structures. However, CAL parts require post-processing steps before they can be utilized. CAL's core attributes make it particularly suited for In-Space Manufacturing (ISM), due to its fast fabrication times, wide breadth of materials it can use, and minimized footprint. CAL has been successfully demonstrated in microgravity during parabolic flight experiments. However to fully validate and understand CAL's behaviour in microgravity, all manufacturing and post-processing steps must be integrated. In June 2024, we conducted SpaceCAL Mission 3, testing this entire workflow on a suborbital flight aboard Virgin Galactic's SpaceShipTwo. During ~140 s of microgravity, the system autonomously manufactured and post-processed four parts using PEGDA700 resin. Post-flight analysis showed that 2/4 parts were recognisable, while others were distorted due to bubble formation from residual water droplets, off-axis optical aberrations, and non-uniform solvent rinsing. Despite these limitations, this study represents the first integrated CAL workflow in space, providing an initial experimental demonstration and analysis for closed-loop in-space manufacturing.

Waddell, Taylor [Department of Mechanical Engineer↗

DOE OSTI2020

Data Services for Visualization and Analysis - ASC Level II Milestone (7186)

A new in transit Data Service is presented and compared to the traditional file-based workflow and the newly refactored in situ Catalyst workflow. Each workflow is enabled by the IOSS mesh interface equipped with data management layers for Exodus and CGNS (file-based), Catalyst (in situ), and FAODEL (in transit). FAODEL is a distributed object store that can transmit data across MPI allocations. Catalyst is a Para View-based visualization capability developed as part of the CSSE Data Services effort. The workflows considered here take SPARC data into Catalyst for visualization post-processing. Although still in unoptimized form, we show that the in transit approach is a viable alternative to file-based and in situ workflows and offers several advantages to both simulation and post-processing developers. Since IOSS is a mature interface with wide adoption across Sandia and externally, each workflow can be reconfigured to use different simulations that generate mesh data and post-processing tools that consume it.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Improving the Estimation of the Atmospheric Water Vapor Pressure Using Interpretable Long Short-Term Memory Networks: Dataset, Python code, and trained models

Atmospheric water vapor pressure is an essential meteorological control on land surface and hydrologic processes. It is not as frequently observed as other meteorologic conditions, but often inferred through the August–Roche–Magnus formula by simply assuming dew point and daily minimum temperatures are equivalent or by empirically correlating the two temperatures using an aridity correction. The performance of both methods varies considerably across different regions and during different time periods; obtaining consistently accurate estimates across space and time remains a great challenge. We applied an interpretable Long Short-Term Memory (iLSTM) network conditioned on static, location specific attributes to estimate daily vapor pressure for 83 FLUXNET sites in the United States and Canada. This data package includes all raw data of the 83 FLUXNET sites, input data for model training/validation/test, trained models and results, and python codes for the manuscript "Improving the Estimation of the Atmospheric Water Vapor Pressure Using an Interpretable Long Short-term Memory Network". Specifically, it consists of five parts. - First, "1_Daymet_data_83sites.zip" includes raw data downloaded from Daymet for the 83 sites used in the paper according to their longitude and latitude, in which vapor pressure is used. It also includes a pre-processed CSV data file combining all data from the 83 sites which is specifically used for the paper. - Second, "2_Fluxnet2015_data_83sites.zip" includes raw half hourly data of the 83 sites downloaded from FLUXNET2015 data portal, pre-processed daily data of the 83 sites, a CSV file including combined pre-processed daily data of the 83 sites, and a CSV file including the information (site ID, site name, latitude, longitude, data available period) of the 83 sites. - Third, "3_MODIS_LAI_data_83sites_raw.zip" includes raw leaf area index (LAI) data downloaded from the AppEEARs data portal. - Fourth, "4_Scripts.zip" includes all scripts related to model training and post-processing of a trained model, and a jupyter notebook showing an example for model post-processing. Two typo errors in files titled "run2get_args.py" and "postprocess.py" were corrected on March 27, 2024 to avoid confusions. - Finally, "Trained_models_and_results.zip" includes three folders and three files with suffix ".npy", and each folder corresponds to one file with suffix ".npy" with the same title. Each of the three folders include all trained models associated with one iLSTM model configuration (35 models for each configuration, details are described in the paper). Each file with suffix ".npy" includes the post-processed results of the corresponding 35 models under one iLSTM model configuration.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

The Exploitation of Data Reduction for Visualization

The disparity between the computational speed and storage bandwidth, as demonstrated in Figure 1, is a well known problem that grows with each successive generation. The visualization community is principally responding to this issue by using in situ to reduce which data must be written to storage. However, other communities are taking different, possibly complementary approaches. In particular, data compression is a common general approach to reduce storage demands. Data compression technologies are typically not designed with post processing in mind. The principal metrics measured are compression ratio, the improved bandwidth to storage, and the error introduced. It is assumed that data is inflated to its full size before any post processing can happen. Although when talking about bandwidth disparities, HPC’s dirty little secret is that no part of the memory nor interconnect hardware is increasing at the rate of computation. For example, the Summit supercomputer has a peak computation rate almost 10 times its predecessor, Titan, but only about 4 times the memory, less than twice the aggregate memory bandwidth, and almost no improvement in the interconnect bisection bandwidth. Naively inflating data for post processing does not help with limitations in the memory and interconnect systems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Hydrogen-Aided Microstructural Engineering of Additively Manufactured Ti–6Al–4V

Electron beam melting (EBM) additive manufacturing of Ti–6Al–4V subjects the material to complex thermal cycles, resulting in a columnar morphology of the prior β grains (PBGs). While the columnar PBGs of EBM-processed Ti–6Al–4V can be transformed to an equiaxed morphology through a super-transus (i.e., above the β -transus temperature) heat treatment, this also leads to the formation of a coarse lamellar two-phase microstructure. Such a microstructure is prone to strain localization and premature fracture. In this study, we present a thermohydrogen post-process treatment that achieves equiaxed PBG morphology in EBM-processed Ti–6Al–4V without sacrificing mechanical properties. Our results show that a three-step thermohydrogen post-process treatment can transform the columnar PBG morphology to an equiaxed morphology with fine microstructure, and strength and ductility levels comparable to those of the most optimum as-fabricated samples. This three-step thermohydrogen post-process treatment involves hydrogenation and phase transformation treatment in a hydrogen atmosphere, and subsequent dehydrogenation treatment in vacuum. Notably, all these treatments are carried out at temperatures well below the β -transus temperature of hydrogen-free Ti–6Al–4V.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Rapid doubling of the critical current of YBa{sub 2}Cu{sub 3}O{sub 7−δ} coated conductors for viable high-speed industrial processing

We demonstrate that 3.5-MeV oxygen irradiation can markedly enhance the in-field critical current of commercial second generation superconducting tapes with an exposure time of just 1 s per 0.8 cm{sup 2}. The speed demonstrated here is now at the level required for an industrial reel-to-reel post-processing. The irradiation is made on production line samples through the protective silver coating and does not require any modification of the growth process. From TEM imaging, we identify small clusters as the main source of increased vortex pinning.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

code for "Improving the QBO forcing by resolved waves with vertical grid refinement in E3SMv2"

This is all code that used in the journal article "Improving the QBO forcing by resolved waves with vertical grid refinement in E3SMv2", including: Running and post processing E3SM: Run E3SM: run_E3SM.2023.scidac.MMF.amip.py Regrid: regrid.E3SM.py post processing, diagnostics, archive: run_post.2023.scidac.MMF.py TEM calculation, including filter TEM, E3SM: calculate.TEM.v2.py calculate.TEM.monthly_mean.v1.py TEM, ERA5: ERA5_calculate_TEM_90.py merge TEM data: merge_TEM_E3SM_ERA5.py TEM, filter, E3SM: filter_TEM_E3SM.py TEM, filter, ERA5: filter_TEM_ERA5.py WK wave analysis code from (https://github.com/brianpm/wavenumber_frequency): wavenumber_frequency_functions.py calculate the wave spectra so easy to plot: wk_calculation.py Make figures some functions for plot: plot.py code for drawing paper plots: figures_for_paper.ipynb

Hannah, WalterM↗

DOE OSTI2014

TH-E-17A-07: Improved Cine Four-Dimensional Computed Tomography (4D CT) Acquisition and Processing Method

Purpose: Artifacts arising from the 4D CT acquisition and post-processing methods add systematic uncertainty to the treatment planning process. We propose an alternate cine 4D CT acquisition and post-processing method to consistently reduce artifacts, and explore patient parameters indicative of image quality. Methods: In an IRB-approved protocol, 18 patients with primary thoracic malignancies received a standard cine 4D CT acquisition followed by an oversampling 4D CT that doubled the number of images acquired. A second cohort of 10 patients received the clinical 4D CT plus 3 oversampling scans for intra-fraction reproducibility. The clinical acquisitions were processed by the standard phase sorting method. The oversampling acquisitions were processed using Dijkstras algorithm to optimize an artifact metric over available image data. Image quality was evaluated with a one-way mixed ANOVA model using a correlation-based artifact metric calculated from the final 4D CT image sets. Spearman correlations and a linear mixed model tested the association between breathing parameters, patient characteristics, and image quality. Results: The oversampling 4D CT scans reduced artifact presence significantly by 27% and 28%, for the first cohort and second cohort respectively. From cohort 2, the inter-replicate deviation for the oversampling method was within approximately 13% of the cross scan average at the 0.05 significance level. Artifact presence for both clinical and oversampling methods was significantly correlated with breathing period (ρ=0.407, p-value<0.032 clinical, ρ=0.296, p-value<0.041 oversampling). Artifact presence in the oversampling method was significantly correlated with amount of data acquired, (ρ=-0.335, p-value<0.02) indicating decreased artifact presence with increased breathing cycles per scan location. Conclusion: The 4D CT oversampling acquisition with optimized sorting reduced artifact presence significantly and reproducibly compared to the phase-sorted clinical acquisition.

60 APPLIED LIFE SCIENCES↗