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At least 145 records · Page 8

GRinding Automated Classification Engine

This work is an ML-driven framework for automated surface analysis of microscopy images. We create a training dataset by imaging stainless steel samples to benchmark four developed deep neural network architectures. These models, based on a YOLOv8n-cls backend, integrate image features and process metadata using various fusion methods to distinguish between acceptable and unacceptable surface finishes. This code is associated with publication "Classifying Alloy Surface Preparation Quality with Metadata-Infused Machine Learning for Rapid Alloy Discovery" for project APEX LDRD-ER (25-ERD-039)

Gongora, AldairE [Lawrence Livermore National Labo↗

Transition boiling heat transfer and the film transition regime

The Berenson (1960) flat-plate transition-boiling experiment has been recreated with a reduced thermal resistance in the heater, and an improved access to those portions of the transition boiling regime that have a steep negative slope. Tests have been made in Freon-113, acetone, benzene, and n-pentane boiling on horizontal flat copper heaters that have been mirror-polished, 'roughened', or teflon-coated. The resulting data reproduce and clarify certain features observed by Berenson: the modest surface finish dependence of boiling burnout, and the influence of surface chemistry on both the minimum heat flux and the mode of transition boiling, for example. A rational scheme of correlation yields a prediction of the heat flux in what Witte and Lienhard (1982) previously identified as the 'film-transition boiling' region. It is also shown how to calculate the heat flux at the boundary between the pure-film, and the film-transition, boiling regimes, as a function of the advancing contact angle.

Ramilison, J. M.↗

Some aerodynamic considerations related to wind tunnel model surface definition

The aerodynamic considerations related to model surface definition are examined with particular emphasis in areas of fabrication tolerances, model surface finish, and orifice induced pressure errors. The effect of model surface roughness texture on skin friction is also discussed. It is shown that at a given Reynolds number, any roughness will produce no skin friction penalty.

Gloss, B. B.↗

Effect of Coaxial Electrode Geometry on the Electric Field Enhancement Factor for a High Voltage Vacuum Gap

We present an experimental analysis of the change in the electric field enhancement factor with varying gap size and penetration depth (P.D) of cathode into anode for a coaxial vacuum gap, diagnosed using Fowler–Nordheim analysis and optical imaging via scanning electron microscope (SEM) and time integrated Digital single lens reflex camera (DSLR). Data were collected on the Coaxial Gap Breakdown Machine (240 A, 25 kV, 150 ns, 0.1 Hz). Experiments using five different gap sizes at nine different P.Ds are compared over runs comprising 50 shots for each case. The results show a strong link between enhancement factor and gap size, with P.D and surface topology. For large gap sizes, 150, 330, and 700 μm, the average enhancement factor value increases with increasing P.D. For smaller gap sizes, 50 and 100 μm, the average enhancement factor decreases with P.D. SEM imaging before and after plasma formation for each gap size allows for quantifying surface finish, microprotrusion growth, average blast diameter, and an estimation of the surface area breakdowns occupy. Time integrated DSLR imaging analysis of the gap at each shot allows for a determination of the distribution of breakdowns about the circumference of the gap for each case tested. Here, the Fowler–Nordheim analysis allows for a quantitative analysis of the surface roughness of all gap sizes tested. Results show that for large gap sizes, the gap geometry and increasing area of breakdown is the main cause for increasing average enhancement factor. For small gap sizes, the dominant driving factor for small average enhancement factors—that subsequently decrease with P.D—is significant changes in surface topology due to an increased number of breakdowns.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Detection of tightly closed flaws by nondestructive testing (NDT) methods in steel and titanium

X-radiographic, liquid penetrant, ultrasonic, eddy current and magnetic particle testing techniques were optimized and applied to the evaluation of 4340 steel (180 KSI-UTS) and 6Al-4V titanium (STA) alloy specimens. Sixty steel specimens containing a total of 176 fatigue cracks and 60 titanium specimens containing a total of 135 fatigue cracks were evaluated. The cracks ranged in length from .043 cm (0.017 inch) to 1.02 cm (.400 inch) and in depth from .005 cm (.002 inch) to .239 cm (.094 inch) for steel specimens. Lengths ranged from .048 cm (0.019 inch) to 1.03 cm (.407 inch) and depths from 0.010 cm (.004 inch) to .261 cm (0.103 inch) for titanium specimens. Specimen thicknesses were nominally .152 cm (0.060 inch) and 0.635 cm (0.250 inch) and surface finishes were nominally 125 rms. Specimens were evaluated in the "as machined" surface condition, after etch surface and after proof loading in a randomized inspection sequence.

Rummel, W. D.↗

NTF: Soldering Technology Development for Cryogenics

The advent of the National Transonic Facility (NTF) brought about a new application for an old joining method, soldering. Soldering for use at cryogenic temperatures requires that solders remain ductile and free from tin-pest (grey tin), have toughness to withstand aerodynamic loads associated with flight research, and maintain their surface finishes. Solders are used to attach 347 Stainless-Steel tubing in surface grooves of models. The solder must fill up the gap and metallurgically bound to the tubing and model. Cryogenic temperatures require that only specific materials for models can be used, including: Vasco Max 200 CVM, lescalloy A-286 Vac Arc, pH 13-8 Mo. Solders identified for testing at this time are: 50% Sn - 49.5% Pb - 0.5% Sb, 95% Sn - 5% Sb, 50% In 50% Pb, and 37.5% Sn - 37.5% Pb - 25% In. With these materials and solders, it is necessary to determine their solderability. After solderability is determined, tube/groove specimens are fabricated and stressed under cryogenic temperatures. Compatible solders are then used for acutual models.

Hall, E. T., Jr.↗

High-Temperature Solid Lubricant Coating

NASA PS400 is a solid lubricant coating invented for high-temperature tribological applications. This plasma-sprayed coating is a variant of the previously patented PS304 coating, and has been formulated to provide higher density, smoother surface finish, and better dimensional stability. This innovation is a new composite material that provides a means to reduce friction and wear in mechanical components. PS400 is a blend of a nickel-molybdenum binder, chrome oxide hardener, silver lubricant, and barium fluoride/calcium fluoride eutectic lubricant that can either be sprayed or deposited by other means, such as powder metallurgy. The resulting composite material is then finished by grinding and polishing to produce a smooth, self-lubricating surface.

DellaCorte, Christopher↗

Non-Richtmyer–Meshkov instability ejecta production based on shallow bubble collapse

The study of shock-driven ejecta production has focused on Richtmyer–Meshkov instability (RMI) growth from geometric features of the material surface. Extensive study of this mechanism under both single- and multiple-shock conditions has found that the ejected mass tends to be closely associated with the shocked surface phase, and its temperature is not dramatically greater than the hydrodynamic shock temperature of the bulk. In this work, we propose and demonstrate a new ejecta production mechanism that can occur under multiple-shock conditions based on the collapse of bubbles near the free surface of the material. This mechanism produces ejected mass that is much greater in quantity than observed in the RMI case. The particles are much hotter than predicted by the shock Hugoniot state, and the ejected mass does not appear to be strongly dependent upon initial surface finish. The ejecta source extends into the material with no clear remaining free surface. We name this mechanism Shallow Bubble Collapse (SBC) and discuss the conditions under which it activates. We demonstrate resolved modeling methods that enable the calculation, design, and study of SBC as a mechanism and perform a series of experiments to compare with the models. Under some multiple-shock conditions, SBC ejection produces ten times more ejected mass than RMI growth.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Effects of various consolidation techniques on microstructure, strength, and reliability of alpha-SiC

The effects of slurry pressing, HIP, and sinter-HIP on the strength, microstructure, and critical processing flaws in alpha-SiC are examined. Also, the feasibility of glass encapsulation is determined. Baseline strength was improved by about 25 percent by using slurry pressing instead of dry pressing. HIP further improved average strength to as high as 655 MPa. Sinter-HIP did not noticeably improve average strength. Although process-related flaws such as shrinkage cracks and large voids were not seen in HIPed alpha-SiC, surface-related flaws were observed. It is suggested that surface finishing by lapping, polishing, and heat treating might reduce the effect of surface-related flaws, improving the Weibull modulus in HIPed alpha-SiC.

Dutta, Sunil↗

ADDITIVELY MANUFACTURED SURFACE HEAT TRANSFER ENHANCEMENTS FOR THE TRANSFORMATIONAL CHALLENGE REACTOR

The Transformational Challenge Reactor (TCR) is a high-temperature gas-cooled reactor design that uses additively manufactured fuel elements. TCR fuel elements have walls made of silicon carbide and are filled with tristructural-isotropic fuel particles. These fuel elements can have radically different shapes and integrated features than existing designs due to the reduced cost for complex structures in binder jet additive manufacturing. As such, binder jet additive manufacturing enables wall surface features to be embedded that can deliver superior heat transfer performance than smooth wall designs. In this work, the authors conducted a computational fluid dynamics study to evaluate selected wall features integrated into TCR fuel elements. Results show that surface features can outperform smooth wall designs; however, there are unique challenges for gas-cooled reactor core designs that have not been fully explored by previous research. For example, the rough surface finish and process variability of ceramics additive manufacturing make it challenging to predict surface roughness effects before fabrication. Additionally, the small hydraulic diameters of coolant channels in reactor cores make it difficult to engineer surface features that do not significantly increase the pressure drop. Engineers must carefully size surface features for heat transfer enhancement in additive fuel elements to operate above the base material's surface roughness effects and below the coolant channel size.

Weinmeister, Justin↗

Topographic Evolution of Heat-Treated Nb Upon Electropolishing for SRF Applications

Surface finish plays an essential role in the performance of superconducting radio frequency cavities. Several surface treatments have been developed to reduce surface resistance at a moderate accelerating gradient. We investigated the effects of sequential electropolishing on samples vacuum heat-treated at 300 and 600 °C and N-doped Nb samples using atomic force microscopy. The N-doping process precipitates niobium nitrides within grains and, most notably, continuously and deeply along some grain boundaries. Upon electropolishing, the nitrides are preferentially removed leaving behind a topographically imperfect surface marked by relatively deep holes and grooves with low radius of curvature edges. The progression of magnetic field enhancement and superheating field suppression factors upon electropolishing were investigated using atomic force micrographs. While minor changes in magnetic field enhancement and superheating field suppression factors are observed for the 300 and 600 °C heat-treated Nb, substantial improvements are observed for N-doped Nb. In this system, the most severe topographic defects are the grain boundary grooves which substantially suppress the superheating field. We find that the severity of topographic defects is related to the N-doping process.

Lechner, Eric↗

Electro-Chemically Enhanced Mechanical Polishing of Nickel Mandrels

Grinding and mechanical polishing techniques used for x-ray optics mandrel figuring lead to mid-frequency surface ripple. These small figure variations have to be addressed in order to improve the performance of the resulting x-ray mirrors. If the electrochemical etching is combined with mechanical polishing, the figuring and the surface finishing cm be done simultaneously and be used to correct the mid-frequency surface ripple. It is shown that the electrochemical mechanical polishing method allows selective removal of nickel alloy without mandrel surface microroughness degradation.

Gubarev, Mikhail↗

Growth defects in thick ion-plated coatings

Industrial ion plating conditions were selected to deposit metallic coatings such as copper, gold, and chromium 2 micrometer thick on metal and glass substrates. The surface finishes of 304 stainless steel, copper, and brass were utilized with mechanically and electrolytically polished surfaces. Nodular growth occurred in these coatings during ion plating as revealed by scanning electron microscopy. Surface irregularities such as scratches, steps, ledges, and so forth are responsible for outward growth, the typical cone type, whereas surface contaminants and loosely settled foreign particles are responsible for lateral growth; namely, the extreme localized surface outgrowths. These defect crystallographic features create porosity in the coatings when subjected to stresses and strains.

Spalvins, T.↗

Scanning Laser Infrared Molecular Spectrometer (SLIMS)

This prototype innovation is a novel design that achieves very long, effective laser path lengths that are able to yield ppb (parts per billion) and sub-ppb measurements of trace gases. SLIMS can also accommodate multiple laser channels covering a wide range of wavelengths, resulting in detection of more chemicals of interest. The mechanical design of the mirror cell allows for the large effective path length within a small footprint. The same design provides a robust structure that lends itself to being immune to some of the alignment challenges that similar cells face. By taking a hollow cylinder and by cutting an elliptically or spherically curved surface into its inner wall, the basic geometry of a reflecting ring is created. If the curved, inner surface is diamond-turned and highly polished, a surface that is very highly reflective can be formed. The surface finish can be further improved by adding a thin chrome or gold film over the surface. This creates a high-quality, curved, mirrored surface. A laser beam, which can be injected from a small bore hole in the wall of the cylinder, will be able to make many low-loss bounces around the ring, creating a large optical path length. The reflecting ring operates on the same principle as the Herriott cell. The difference exists in the mirror that doesn't have to be optically aligned, and which has a relatively large, internal surface area that lends itself to either open air or evacuated spectroscopic measurements. This solid, spherical ring mirror removes the possibility of mirror misalignment caused by thermal expansion or vibrations, because there is only a single, solid reflecting surface. Benefits of the reflecting ring come into play when size constraints reduce the size of the system, especially for space missions in which mass is at a premium.

Scott, David C.↗

Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls

Thin-walled features can be difficult to produce with traditional machining methods which often rely on excess stock material for stiffness. This challenge is increased in hybrid manufacturing where the feature is already near net shape before machining. Significant workpiece deflection can result in poor geometric and surface finish tolerances on the finished part. A potential solution to this problem is to implement sacrificial support structures to the as-printed geometry. The supports are then machined away during the finishing portion of the hybrid process. In the present work, several different design parameters for these sacrificial supports were evaluated to determine their impact on the quality of representative thin wall geometry samples. The angle, height, and spacing of triangular support structures were varied for each sample and then machined and examined. The addition of these supports relative to an unsupported configuration provided a deflection reduction of around 0.2 mm. Surface roughness was improved by approximately 1.5 µm. Increasing values of support height were found to correspond to reduced wall deflection. Similarly, decreasing values of support angle and support spacing improved geometric accuracy. Efficiency comparisons showed that increases in print time corresponded to rapidly diminishing gains in geometric accuracy but continued to improve surface roughness. Implications for hybrid finishing of additively manufactured thin-walled structures is briefly discussed.

36 MATERIALS SCIENCE↗

Technical Use Guidance for Engraving with a FiberMark Epilog Laser Engraver

The FiberMark Epilog Laser Engraver is useful tool having the ability to etch and mark a wide variety of metals and plastics. This laser engraver is capable of creating different marks including annealing metal, etching metal, metal polishing, and plastic marking. Annealing metal is a process in which the metal is heated to a high temperature creating a permanent oxide layer on the surface resulting in a high contrast mark. The benefit of annealing is this type of mark is created without changing the surface finish of the metal. Annealing is the best choice for marking targets used in the Pu238 program due to the high contrast mark it is easily visible throughout the production process. Metal engraving is a process in which the metal is removed from the surface by vaporization. To make a deep metal engraving multiple passes may be required particularly if the metal has a high hardness level (such as stainless steel). Metal polishing is a process in which the surface of the metal is heated quickly causing the color to change and take on a mirror-like finish. This process is best for metals that are darker or have a matte finish. Plastic marking occurs with engineered plastics which undergo a color change in the surface without the surface being damaged. The plastics that are most compatible with the laser engraver’s 1065 nm wavelength of light are PET, ABS, polycarbonate and colored Delrin.

36 MATERIALS SCIENCE↗