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DOE OSTI2026

Identifying the Accuracy of Surface Roughness for Metal Additive Manufacturing Parts Captured with Computed Tomography Scanning

Conventional surface roughness measurement techniques require direct access to internal surfaces, often necessitating destructive sectioning of test articles. Computed tomography (CT) offers a non-destructive alternative for internal surface characterization, but its application in metrology remains unstandardized and sensitive to machine resolution and operator technique. This study investigates the feasibility of using CT scanning to quantify areal surface roughness in metal AM heat exchanger tubes with three distinct internal geometries: ribbed, discrete W, and featureless. CT-derived surface parameters were extracted using custom Python scripts and compared to measurements obtained from a focus variation microscope calibrated against a known standard. Results show that CT-based roughness measurements closely matched microscope values for the discrete W specimen, deviations between CT and microscope measurements were minimal—less than 1 µm—indicating reliable reconstruction. In contrast, the ribbed and featureless specimens, with lower roughness values showed greater discrepancies. The findings suggest that CT scanning can be a viable non-destructive metrology tool for AM parts with surface roughness above approximately 8 µm. For smoother surfaces, current CT capabilities may not provide sufficient accuracy, highlighting the need for resolution-aware workflows and further standardization in CT-based surface metrology.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Stable Rate of Slip Along the Karakax Section of the Altyn Tagh Fault from Observation of Interglacial and Postglacial Offset Morphology and Surface Dating

Digital elevation maps obtained using TanDEM-X and Pleiades data combined with newly obtained surface age estimates using cosmogenic radionuclide (CRN) and optically simulated luminescence (OSL) methods are used to quantify the slip rate along the western section of the Altyn Tagh Fault in southern Xinjiang. The reconstruction of the conical shape of massive alluvial fans inferred to be from the Eemian (115±7 ka) from CRN dating shows consistent left-lateral offsets of 300±20 m, yielding a slip rate of 2.6±0.3 mm/year. Successive episodes of incision have left cut terraces inset in wide canyons, 10–25 m below the fans' surface. The incision was followed by the deposition of a broad terrace of early Holocene age, which is reincised by modern stream channels. Near the village of Shanxili, a 200 m wide valley is partially dammed by a shutter ridge displaced by the fault. A fill terrace deposited upstream from the ridge has an OSL age of 8.8±0.6 ka. The 23±2 m offset of the riser incising the terrace indicates a minimum postdepositional movement on the fault, yielding a Holocene rate of 2.6±0.5 mm/year, consistent with the 115-ka average slip rate. Furthermore, scarp degradation analysis using mass diffusion reveals a nonlinear relationship between fault displacement and degradation coefficient along the progressively exposed fault scarp, a pattern suggesting either seismic clustering or variable diffusion rate since the Eemian. Together with the Gozha Co-Longmu Co fault to the south, the Karakax section of the Altyn Tagh Fault contributes to the eastward movement of the western corner of Tibet.

58 GEOSCIENCES↗

DOE OSTI2013

The relationship between local liquid density and force applied on a tip of atomic force microscope: A theoretical analysis for simple liquids

The density of a liquid is not uniform when placed on a solid. The structured liquid pushes or pulls a probe employed in atomic force microscopy, as demonstrated in a number of experimental studies. In the present study, the relation between the force on a probe and the local density of a liquid is derived based on the statistical mechanics of simple liquids. When the probe is identical to a solvent molecule, the strength of the force is shown to be proportional to the vertical gradient of ln(ρ{sub DS}) with the local liquid's density on a solid surface being ρ{sub DS}. The intrinsic liquid's density on a solid is numerically calculated and compared with the density reconstructed from the force on a probe that is identical or not identical to the solvent molecule.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2015

EVIDENCE OF CROSS-CORRELATION BETWEEN THE CMB LENSING AND THE γ-RAY SKY

We report the measurement of the angular power spectrum of cross-correlation between the unresolved component of the Fermi-LAT γ-ray sky maps and the cosmic microwave background lensing potential map reconstructed by the Planck satellite. The matter distribution in the universe determines the bending of light coming from the last scattering surface. At the same time, the matter density drives the growth history of astrophysical objects, including their capability at generating non-thermal phenomena, which in turn give rise to γ-ray emissions. The Planck lensing map provides information on the integrated distribution of matter, while the integrated history of γ-ray emitters is imprinted in the Fermi-LAT sky maps. We report here the first evidence of their correlation. We find that the multipole dependence of the cross-correlation measurement is in agreement with current models of the γ-ray luminosity function for active galactic nuclei and star-forming galaxies, with a statistical evidence of 3.0σ. Moreover, its amplitude can in general be matched only assuming that these extragalactic emitters are also the bulk contribution of the measured isotopic γ-ray background (IGRB) intensity. This leaves little room for a big contribution from galactic sources to the IGRB measured by Fermi-LAT, pointing toward direct evidence of the extragalactic origin of the IGRB.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Reconstructing the Wave Function of Magnetic Topological Insulators MnBi 2 ⁢Te 4 and MnBi 4 ⁢Te 7 Using Spin-Resolved Photoemission

Despite their importance for exotic quantum effects, the surface electronic structure of magnetic topological insulators MnBi 2 ⁢Te 4 and MnBi 4 ⁢Te 7 remains poorly understood. Using high-efficiency spin- and angle-resolved photoemission spectroscopy, we directly image the spin-polarization and orbital character of the surface states in both compounds and map our observations onto a model wave function to describe the complex spin-orbital texture, which solidifies our understanding of the surface band structure by establishing the single-band nature of the most prominent states. Most importantly, our analysis reveals a new mechanism for reducing the magnetic gap of the topological surface states based on the orbital composition of the wave function.

Han, Xue [SLAC National Accelerator Laboratory (SL↗

NASA NTRS2004

Three-Dimensional High-Order Spectral Volume Method for Solving Maxwell's Equations on Unstructured Grids

A three-dimensional, high-order, conservative, and efficient discontinuous spectral volume (SV) method for the solutions of Maxwell's equations on unstructured grids is presented. The concept of discontinuous 2nd high-order loca1 representations to achieve conservation and high accuracy is utilized in a manner similar to the Discontinuous Galerkin (DG) method, but instead of using a Galerkin finite-element formulation, the SV method is based on a finite-volume approach to attain a simpler formulation. Conventional unstructured finite-volume methods require data reconstruction based on the least-squares formulation using neighboring cell data. Since each unknown employs a different stencil, one must repeat the least-squares inversion for every cell at each time step, or to store the inversion coefficients. In a high-order, three-dimensional computation, the former would involve impractically large CPU time, while for the latter the memory requirement becomes prohibitive. In the SV method, one starts with a relatively coarse grid of triangles or tetrahedra, called spectral volumes (SVs), and partition each SV into a number of structured subcells, called control volumes (CVs), that support a polynomial expansion of a desired degree of precision. The unknowns are cell averages over CVs. If all the SVs are partitioned in a geometrically similar manner, the reconstruction becomes universal as a weighted sum of unknowns, and only a few universal coefficients need to be stored for the surface integrals over CV faces. Since the solution is discontinuous across the SV boundaries, a Riemann solver is thus necessary to maintain conservation. In the paper, multi-parameter and symmetric SV partitions, up to quartic for triangle and cubic for tetrahedron, are first presented. The corresponding weight coefficients for CV face integrals in terms of CV cell averages for each partition are analytically determined. These discretization formulas are then applied to the integral form of the Maxwell equations. All numerical procedures for outer boundary, material interface, zonal interface, and interior SV face are unified with a single characteristic formulation. The load balancing in a massive parallel computing environment is therefore easier to achieve. A parameter is introduced in the Riemann solver to control the strength of the smoothing term. Important aspects of the data structure and its effects to communication and the optimum use of cache memory are discussed. Results will be presented for plane TE and TM waves incident on a perfectly conducting cylinder for up to fifth order of accuracy, and a plane wave incident on a perfectly conducting sphere for up to fourth order of accuracy. Comparisons are made with exact solutions for these cases.

Liu, Yen↗

NASA NTRS2016

Mars 2020 Entry, Descent and Landing Instrumentation (MEDLI2)

This paper will introduce Mars Entry Descent and Landing Instrumentation (MEDLI2) on NASA's Mars2020 mission. Mars2020 is a flagship NASA mission with science and technology objectives to help answer questions about possibility of life on Mars as well as to demonstrate technologies for future human expedition. Mars2020 is scheduled for launch in 2020. MEDLI2 is a suite of instruments embedded in the heatshield and backshell thermal protection systems of Mars2020 entry vehicle. The objectives of MEDLI2 are to gather critical aerodynamics, aerothermodynamics and TPS performance data during EDL phase of the mission. MEDLI2 builds up the success of MEDLI flight instrumentation on Mars Science Laboratory mission in 2012. MEDLI instrumentation suite measured surface pressure and TPS temperature on the heatshield during MSL entry into Mars. MEDLI data has since been used for unprecedented reconstruction of aerodynamic drag, vehicle attitude, in-situ atmospheric density, aerothermal heating, transition to turbulence, in-depth TPS performance and TPS ablation. [1,2] In addition to validating predictive models, MEDLI data has highlighted extra margin available in the MSL forebody TPS, which can potentially be used to reduce vehicle parasitic mass. MEDLI2 expands the scope of instrumentation by focusing on quantities of interest not addressed in MEDLI suite. The type the sensors are expanded and their layout on the TPS modified to meet these new objectives. The paper will provide key motivation and governing requirements that drive the choice and the implementation of the new sensor suite. The implementation considerations of sensor selection, qualification, and demonstration of minimal risk to the host mission will be described. The additional challenges associated with mechanical accommodation, electrical impact, data storage and retrieval for MEDLI2 system, which extends sensors to backshell will also be described.

Thermal Protection System↗

NASA NTRS2014

MSL Entry, Descent, and Landing Instrumentation: Return on Investment

On Aug 5, 2012 the Mars Science Laboratory (MSL) Entry, Descent, and Landing Instrumentation (MEDLI) suite on MSL entry vehicle heatshield suc-cessfully returned surface pressure and in-depth temperature data.1,2 The MEDLI data has given scientists and engineers an unprecedented ability to reconstruct entry environment, atmospheric density, and flight trajectory, and flight validation of predic-tions vehicle aerodynamics and thermal protection system (TPS) performance. This presentation will dis-cuss key findings from MEDLI, some of which are being applied to improve definition of aerothermal environment and TPS sizing margins for existing NASA entry missions. The postflight analysis has shown that a significant thermal protection mass saving upon redesign is possible for an MSL-class vehicle. The success of MEDLI has also demonstrated and qualified robust flight instrumentation technologies at very low risk to the mission. The potential benefits of MEDLI to planetary exploration and sample return missions, as well as to exploration class missions to Mars will be presented.

MEDLI↗

DOE OSTI2024

Modeling Ni Coarsening under Humid Atmosphere in the Electrode of Solid Oxide Cells

Ni coarsening is an important degradation mechanism in solid oxide cells. It is reported that Ni coarsening is faster under a humid atmosphere experimentally, but the underline mechanism is not well understood. In this work, Ni coarsening through Ni(OH)x surface diffusion was investigated by a combination of density-functional theory (DFT) and phase-field modeling (PFM). DFT is used to evaluate the surface coverage and diffusivity of Ni(OH)x on Ni (111) surface and the results are used as an input to the PFM to simulate Ni coarsening under humid atmospheres on both reconstructed and synthetic microstructures. It is found that steam partial pressure and microstructure effect alone cannot explain the faster Ni coarsening under a humid atmosphere observed experimentally. Large local overpotential in fuel cell mode is needed to explain the fast Ni coarsening.

Lei, Yinkai↗

DOE OSTI2022

Li-ion Battery Material phase prediction through Hierarchical Curriculum Learning

Li-ion Batteries (LIB), one of the most efficient energy storage devices, are widely adopted in many industrial applications. Imaging data of these battery electrodes obtained from X-ray tomography can explain the distribution of material constituents and allow reconstructions to study electron transport pathways. Therefore, it can eventually help quantify various associated properties of electrodes (e.g., volume-specific surface area, porosity) which determine the performance of batteries. However, these images often suffer from low image contrast between multiple material constituents , making it difficult for humans to distinguish and characterize these constituents through visualization. A minor error in detecting distributions among the material constituents can lead to a high error in the calculated parameters of material properties.We present a novel hierarchical curriculum learning framework to address the complex task of estimating material constituent distribution in battery electrodes. To provide spatially smooth prediction, our framework comprises three modules: (i) an uncertainty-aware model trained to yield inferences conditioned upon global knowledge of material distribution, (ii) a technique to capture relatively more fine-grained (local) distributional signals, (iii) an aggregator to appropriately fuse the local and global effects towards obtaining the final distribution.

Tabassum, Anika↗

NASA NTRSDate not supplied

Variance Decomposition of MEDLI2 Reconstructed Heating Using Neural Networks

The Mars Entry, Descent, and Landing Instrumentation (MEDLI2) sensor suite collected data during entry of the Mars 2020 Perseverance rover into Mars’ atmosphere. An inverse estimation of the backshell and heatshield surface aeroheating was performed, using the data from the MEDLI2 Instrumented Sensor Plugs, a network of thermocouples embedded within the thermal protection system across the aeroshell. Monte Carlo analysis was conducted to assess the sensitivity of the surface heat rate, temperature, and heat load to uncertainties in thermocouple depth and material properties. In this paper, a variance decomposition method using Sobol indices was employed to understand the relative contributions of each uncertainty parameter. Performing this analysis using results from the inverse analysis tool FIAT_Opt was found to require incredibly high computation time, and thus machine learning models were trained and evaluated as a surrogate model for FIAT_Opt. This paper demonstrates that machine learning models can be an efficient, accurate alternative to state-of-the-art inverse analysis tools like FIAT_Opt, especially for computationally-expensive processes. Using these models, the sensitivity analysis showed that uncertainties in heat capacity and thermal conductivity were the main drivers for the overall uncertainty in peak reconstructed heating and heat load.

H S Alpert↗

DOE OSTI2025

Designing Antifouling and Antimicrobial Interfaces: Structural Characterization using CryoEM, Automated Microscopy, and AI Image Segmentation

The design of functionalized surfaces for interactions with biological systems is critical across sectors such as healthcare, energy, and agriculture. Tailoring materials for specific applications, such as antifouling and antimicrobial surfaces, demands a comprehensive understanding of topology and chemistry across multiple length and time scales on both biological and materials systems. This work presents the development and characterization of nanostructured surfaces with controlled topographies and chemistries that enhance bacterial membrane disruption, reduce biofilm formation, and improve antimicrobial and antifouling capabilities. Two specific use cases will be presented - the use of cellulose nanocrystals (CNCs) for bacterial growth inhibition and the development of antifouling surfaces to prevent protein and bacterial adsorption [1-4]. By leveraging large language models (LLMs) for image segmentation and training [5], we enable automated analysis of terabyte-scale cryogenic electron microscopy (cryoEM) datasets. This analysis provides statistical insights into the biotic/abiotic interface and facilitates automated electron microscopy experiments to mitigate time and dose. The integration of cryogenic electron tomography (cryoET) and cryogenic focused ion beam (cryoFIB) milling enables high-resolution, near-native-state imaging and 3D reconstructions of bio/material interfaces [6]. Orthogonal characterization techniques and computational modeling further enhances our understanding, offering a robust platform for the design and optimization of next-generation functional surfaces [7].

Williams, Alexis [ORNL] (ORCID:0000000252835822)↗

DOE OSTI2025

Calibration and Performance of the ICARUS Detector at Fermilab

ICARUS is the largest Liquid Argon Time Projection Chamber (LArTPC) in operation and serves as the Far Detector of the Short Baseline Neutrino (SBN) program at Fermilab. Precise detector calibration is essential for reliable energy reconstruction and for maximizing the physics reach of the experiment. In this talk, I will describe the energy and timing calibration procedures developed at ICARUS. Thanks to the abundant flux of cosmic ray muons at the surface, the TPC response to ionization charge has been equalized across the detector, removing non-uniformities and in-transparency effects. A novel data-driven procedure has been used to tune the simulation of ionization signals and electronics noise yielding close agreement between Monte Carlo and data with minimal residual bias in reconstructed charge. In addition, the light detection system has been calibrated to sub-nanosecond timing resolution. This precision enables efficient cosmic background rejection and accurate synchronization of neutrino interactions with the time structure of both the Booster Neutrino Beam (BNB) and Neutrinos at the Main Injector (NuMI) beam. Together, these efforts demonstrate the robust performance of the detector and provide critical experience for future large LArTPCs, such as DUNE.

Vicenzi, Matteo [Brookhaven]↗

NASA NTRSDate not supplied

Lessons Learned from Aerothermal Flight Data on NASA Mars Entry Vehicles

The NASA Mars Science Laboratory (MSL) and Mars 2020 entry vehicles included temperature measurements inside and direct heat flux on the surface of the thermal protection system (TPS) material. The instrumentation was included to begin addressing predictive capabilities for aerodynamic heating and ablative TPS material response. The MSL aeroshell included temperature measurements at seven heatshield locations, from which total aerodynamic heating was reconstructed. The Mars 2020 instrumentation suite included eleven heatshield measurement locations and new backshell measurements at nine locations: six with temperature sensors, two with sensors to directly measure total heat flux, and one to measure radiative heat flux. Both instrumentation suites returned full sets of data, with all temperature sensors nearest to the surface surviving entry, indicating minimal material recession. Heatshield boundary layer transition (BLT) was observed for both vehicles prior to the time of peak heating, with transition starting near the shoulder and progressing towards the stagnation area. MSL’s higher speed on approach to Mars resulted in higher total heating compared to Mars 2020, with the maximum occurring near the heatshield’s leeside shoulder. The Mars 2020 backshell heating data indicate significant contributions from shock layer radiation. Heating from Navier-Stokes flowfield calculations are in family with reconstructed heating. The paper covers the instrumentation, BLT and reconstructed heating on both heatshields, backshell heating for Mars 2020, TPS performance, and predicted versus reconstructed heat fluxes. Opportunities for improved design approaches for future Mars missions are discussed, especially for the upcoming Mars Sample Return mission.

Mars Science Laboratory↗

NASA NTRSDate not supplied

Lessons Learned from Aerothermal Flight Data on NASA Mars Entry Vehicles

Mars Science Laboratory↗

DOE OSTI2014

SU-E-T-20: A Novel Hybrid CBCT, Bioluminescence and Fluorescence Tomography System for Preclinical Radiation Research

Purpose: A novel standalone bioluminescence and fluorescence tomography (BLT and FT) system equipped with high resolution CBCT has been built in our group. In this work, we present the system calibration method and validate our system in both phantom and in vivo environment. Methods: The CBCT is acquired by rotating the animal stage while keeping the x-ray source and detector panel static. The optical signal is reflected by the 3-mirror system to a multispectral filter set and then delivered to the CCD camera with f/1.4 lens mounted. Nine fibers passing through the stage and in contact with the mouse skin serve as the light sources for diffuse optical tomography (DOT) and FT. The anatomical information and optical properties acquired from the CBCT and DOT, respectively, are used as the priori information to improve the BLT/FT reconstruction accuracy. Flat field correction for the optical system was acquired at multiple wavelengths. A home-built phantom is used to register the optical and CBCT coordinates. An absolute calibration relating the CCD photon counts rate to the light fluence rate emitted at animal surface was developed to quantify the bioluminescence power or fluorophore concentration. Results: An optical inhomogeneous phantom with 2 light sources (3mm separation) imbedded is used to test the system. The optical signal is mapped onto the mesh generated from CBCT for optical reconstruction. Our preliminary results show that the center of mass can be reconstructed within 2.8mm accuracy. A live mouse with the light source imbedded is also used to validate our system. Liver or lung metastatic luminescence tumor model will be used for further testing. Conclusion: This hybrid system transforms preclinical research to a level that even sub-palpable volume of cells can be imaged rapidly and non-invasively, which largely extends the scope of radiobiological research. The research is supported by the NCI grant R01CA158100-01.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2014

Intermodulation electrostatic force microscopy for imaging surface photo-voltage

We demonstrate an alternative to Kelvin Probe Force Microscopy for imaging surface potential. The open-loop, single-pass technique applies a low-frequency AC voltage to the atomic force microscopy tip while driving the cantilever near its resonance frequency. Frequency mixing due to the nonlinear capacitance gives intermodulation products of the two drive frequencies near the cantilever resonance, where they are measured with high signal to noise ratio. Analysis of this intermodulation response allows for quantitative reconstruction of the contact potential difference. We derive the theory of the method, validate it with numerical simulation and a control experiment, and we demonstrate its utility for fast imaging of the surface photo-voltage on an organic photo-voltaic material.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2018

Pore-scale study of effects of macroscopic pores and their distributions on reactive transport in hierarchical porous media

For applications of reactive transport in porous media, optimal porous structures should possess both high surface area for reactive sites loading and low mass transport resistance. Hierarchical porous media with a combination of pores at different scales are designed for this purpose. In this paper, using the lattice Boltzmann method, pore-scale numerical studies are conducted to investigate diffusion-reaction processes in 2D hierarchical porous media generated by self-developed reconstruction scheme. Complex interactions between porous structures and reactive transport are revealed under different conditions. Simulation results show that adding macropores can greatly enhance the mass transport, but at the same time reduce the reactive surface, leading to complex change trend of the total reaction rate. Effects of gradient distribution of macropores within the porous medium are also investigated. It is found that a front-loose, back-tight (FLBT) hierarchical structure is desirable for enhancing mass transport, increasing total reaction rate, and improving catalyst utilization. Finally, on the whole, from the viewpoint of reducing cost and improving material performance, hierarchical porous structures, especially gradient structures with the size of macropores gradually decreasing along the transport direction, are desirable for catalyst application.

42 ENGINEERING↗