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NASA NTRS2010

Modeling of LEO Orbital Debris Populations in Centimeter and Millimeter Size Regimes

The building of the NASA Orbital Debris Engineering Model, whether ORDEM2000 or its recently updated version ORDEM2010, uses as its foundation a number of model debris populations, each truncated at a minimum object-size ranging from 10 micron to 1 m. This paper discusses the development of the ORDEM2010 model debris populations in LEO (low Earth orbit), focusing on centimeter (smaller than 10 cm) and millimeter size regimes. Primary data sets used in the statistical derivation of the cm- and mm-size model populations are from the Haystack radar operated in a staring mode. Unlike cataloged objects of sizes greater than approximately 10 cm, ground-based radars monitor smaller-size debris only in a statistical manner instead of tracking every piece. The mono-static Haystack radar can detect debris as small as approximately 5 mm at moderate LEO altitudes. Estimation of millimeter debris populations (for objects smaller than approximately 6 mm) rests largely on Goldstone radar measurements. The bi-static Goldstone radar can detect 2- to 3-mm objects. The modeling of the cm- and mm-debris populations follows the general approach to developing other ORDEM2010-required model populations for various components and types of debris. It relies on appropriate reference populations to provide necessary prior information on the orbital structures and other important characteristics of the debris objects. NASA's LEO-to-GEO Environment Debris (LEGEND) model is capable of furnishing such reference populations in the desired size range. A Bayesian statistical inference process, commonly adopted in ORDEM2010 model-population derivations, changes a priori distribution into a posteriori distribution and thus refines the reference populations in terms of data. This paper describes key elements and major steps in the statistical derivations of the cm- and mm-size debris populations and presents results. Due to lack of data for near 1-mm sizes, the model populations of 1- to 3.16-mm objects are an empirical extension from larger debris. The extension takes into account the results of micro-debris (from 10 micron to 1 mm) population modeling that is based on shuttle impact data, in the hope of making a smooth transition between micron and millimeter size regimes. This paper also includes a brief discussion on issues and potential future work concerning the analysis and interpretation of Goldstone radar data.

Xu, Y.-L.↗

NASA NTRS2004

Nanofluidic Size-Exclusion Chromatograph

Efforts are under way to develop a nanofluidic size-exclusion chromatograph (SEC), which would be a compact, robust, lightweight instrument for separating molecules of interest according to their sizes and measuring their relative abundances in small samples. About as large as a deck of playing cards, the nanofluidic SEC would serve, in effect, as a laboratory on a chip that would perform the functions of a much larger, conventional, bench-top SEC and ancillary equipment, while consuming much less power and much smaller quantities of reagent and sample materials. Its compactness and low power demand would render it attractive for field applications in which, typically, it would be used to identify and quantitate a broad range of polar and nonpolar organic compounds in soil, ice, and water samples. Size-exclusion chromatography is a special case of high-performance liquid chromatography. In a conventional SEC, a sample plug is driven by pressure along a column packed with silica or polymer beads that contain uniform nanopores. The interstices between, and the pores in, the beads collectively constitute a size-exclusion network. Molecules follow different paths through the size-exclusion network, such that characteristic elution times can be related to sizes of molecules: basically, smaller molecules reach the downstream end of the column after the larger ones do because the smaller ones enter minor pores and stay there for a while, whereas the larger ones do not enter the pores. The volume accessible to molecules gradually diminishes as their size increases. All molecules bigger than a pore size elute together. For most substances, the elution times and sizes of molecules can be correlated directly with molecular weights. Hence, by measuring the flux of molecules arriving at the downstream end as a function of time, one can obtain a liquid mass spectrum for the molecules present in a sample over a broad range of molecular weights.

Feldman, Sabrina↗

NASA NTRS2014

Turbulent Concentration of MM-Size Particles in the Protoplanetary Nebula: Scaled-Dependent Multiplier Functions

The initial accretion of primitive bodies (asteroids and TNOs) from freely-floating nebula particles remains problematic. Here we focus on the asteroids where constituent particle (read "chondrule") sizes are observationally known; similar arguments will hold for TNOs, but the constituent particles in those regions will be smaller, or will be fluffy aggregates, and are unobserved. Traditional growth-bysticking models encounter a formidable "meter-size barrier" [1] (or even a mm-cm-size barrier [2]) in turbulent nebulae, while nonturbulent nebulae form large asteroids too quickly to explain long spreads in formation times, or the dearth of melted asteroids [3]. Even if growth by sticking could somehow breach the meter size barrier, other obstacles are encountered through the 1-10km size range [4]. Another clue regarding planetesimal formation is an apparent 100km diameter peak in the pre-depletion, pre-erosion mass distribution of asteroids [5]; scenarios leading directly from independent nebula particulates to this size, which avoid the problematic m-km size range, could be called "leapfrog" scenarios [6-8]. The leapfrog scenario we have studied in detail involves formation of dense clumps of aerodynamically selected, typically mm-size particles in turbulence, which can under certain conditions shrink inexorably on 100-1000 orbit timescales and form 10-100km diameter sandpile planetesimals. The typical sizes of planetesimals and the rate of their formation [7,8] are determined by a statistical model with properties inferred from large numerical simulations of turbulence [9]. Nebula turbulence can be described by its Reynolds number Re = L/eta sup(4/3), where L = ETA alpha sup (1/2) the largest eddy scale, H is the nebula gas vertical scale height, and α the nebula turbulent viscosity parameter, and η is the Kolmogorov or smallest scale in turbulence (typically about 1km), with eddy turnover time tη. In the nebula, Re is far larger than any numerical simulation can handle, so some physical model is needed to extend the results of numerical simulations to nebula conditions.

protoplanetary nebula↗

NASA NTRSDate not supplied

Assessment of Sensor Footprint Size and Comparison of Commercial Smallsat Images

Science users of commercial satellite data build their studies on the properties of the satellite data they work with, pixel size being one of the determining factors. However, pixel size and nominal image footprint size can be different, impacting the scale of features discernable in the satellite images. Here, we assess geometric properties such as nominal image footprint size for Planet Labs' SuperDove series, MAXAR's WorldView series, and potentially BlackSky. Additionally, we assess temporal change in nominal footprint size for the SuperDove series. Nominal Image footprint size is assessed over the CalVal sites in Baotou, China; Shadnagar, India; and Big Spring, TX. Edge spread functions are constructed along the black/white transitions, from which the line spread functions are constructed and modulation transfer functions of the scene are estimated. Scene full width half maximum (FWHM), which represents sensor footprint size, is estimated from the line spread function. The average nominal footprint size is 3.3 pixels for SuperDove series, 1.5 pixels for WorldView-2, and 1.3 pixels for WorldView-3. The SuperDove series nominal footprint size improves with time in orbit, from an average of 3.4 pixels soon after launch to an average of 3.2 pixels one or more years after launch.

PlanetScope↗

DOE OSTI2026

The impact of optical measurement techniques on measured aerosol particle size distributions

Ambient aerosol particle size distributions measured by the Ultra-High Sensitivity Aerosol Spectrometer (UHSAS) at various sites around the world exhibit modes at optical diameters near 600 nm and 850 nm. These modes are not present in concurrent measurements with the Grimm 11-D Optical Particle Counter (OPC). Here, in this study, we argue that these modes result from the optical measurement technique itself, and we explain why they appear in measurements by the UHSAS but not in those by the Grimm OPC. We construct computer models of the UHSAS and Grimm (“digital UHSAS” and “digital Grimm”) and use these to investigate the size distribution that would result from measurements of artificial aerosol particle size distributions that do not contain modes. The appearance of modes for the structureless incoming size distributions sampled by the digital UHSAS is explained by the nonlinear behavior of partial scattering cross sections of uniform spherical particles as a function of their diameter. The absence of modes in the digital Grimm is explained by the coarser size resolution of that instrument. Detailed analysis of the relationship between optical and geometric diameters for uniform spherical particles reveals two important results. First, these diameters generally have different numerical values for the same particle, and second, the relationship is nonlinear; thus, widths of size bins in terms of optical diameter differ from those in geometric diameter. These results explain the modes observed in the ambient size distributions and highlight concerns with attempts to create a merged size distribution by combining measurements from different instruments.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

A combined experimental and crystal plasticity study of grain size effects in magnesium alloys

This work presents a method to incorporate the micro Hall-Petch equation into the crystal plasticity finite element (CPFE) framework accounting for the microstructural features to understand the coupling between grain size, texture, and loading direction in magnesium alloys. The effect of grain size and texture is accounted for by modifying the slip resistances of individual basal and prismatic systems based on the micro Hall-Petch equation. The modification based on the micro Hall-Petch equation endows every slip system at each microstructural point with a slip system-level grain size and maximum compatibility factor, which are in turn used to modify the slip resistance. While the slip-system level grain size is a measure of the grain size, the maximum compatibility factor encodes the effect of the grain boundary on the slip system resistance modification and is computed based on the Luster-Morris factor. The model is calibrated using experimental stress-strain curves of Mg-4Al samples with three different grain sizes from which the Hall-Petch coefficients are extracted and compared with Hall-Petch coefficients predicted using original parameters from previous work. The predictability of the model is then evaluated for a Mg-4Al sample with different texture and three grain sizes subjected to loading in different directions. The calibrated parameters are then used for some parametric studies to investigate the variation of Hall-Petch slope for different degrees of simulated spread in basal texture, variation of Hall-Petch slope with loading direction relative to basal poles for a microstructure with strong basal texture, and variation of yield strength with change in grain morphology. The proposed approach to incorporate the micro Hall-Petch equation into the CPFE framework provides a foundation to quantitatively model more complicated scenarios of coupling between grain size, texture and loading direction in the plasticity of Mg alloys.

Crystal plasticity↗

DOE OSTI2023

Sample Size Effects on Petrophysical Characterization and Fluid-to-Pore Accessibility of Natural Rocks

Laboratory-scale analysis of natural rocks provides petrophysical properties such as density, porosity, pore diameter/pore-throat diameter distribution, and fluid accessibility, in addition to the size and shape of framework grains and their contact relationship with the rock matrix. Different types of laboratory approaches for petrophysical characterization involve the use of a range of sample sizes. While the sample sizes selected should aim to be representative of the rock body, there are inherent limitations imposed by the analytical principles and holding capacities of the different experimental apparatuses, with many instruments only able to accept samples at the μm–mm scale. Therefore, a total of nine (three limestones, three shales, two sandstones, and one dolomite) samples were collected from Texas to fill the knowledge gap of the sample size effect on the resultant petrophysical characteristics. The sample sizes ranged from 3 cm cubes to <75 μm particles. Using a combination of petrographic microscopy, helium expansion pycnometry, water immersion porosimetry, mercury intrusion porosimetry, and (ultra-) small-angle X-ray scattering, the impact of sample size on the petrophysical properties of these samples was systematically investigated here. The results suggest that the sample size effect is influenced by both pore structure changes during crushing and sample size-dependent fluid-to-pore connectivity.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Phase-field simulation of domain size effect on dielectric and piezoelectric responses in K 0.5 Na 0.5 NbO 3 epitaxial thin films with superdomain structures

Size effects of mesoscale ferroelectric domains on the macroscopic dielectric and piezoelectric responses in domain-engineered bulk piezocrystals have been extensively studied for more than two decades. However, less is known about the domain size effects in ferroelectric epitaxial thin films, especially for films consisting of low-symmetry ferroelectric phases and exhibits hierarchical superdomain structures. Herein, using phase-field simulations, we systemically evaluate the effective out-of-plane dielectric and piezoelectric coefficients, κ$^{*}_{33}$ and d$^{*}_{33}$, as a function of the domain periods for two types of superdomain structures in ferroelectric K 0.5 Na 0.5 NbO 3 epitaxial thin films. In one type of the superdomain structures, we find that more than 70% increase of κ$^{*}_{33}$ and nearly 20% increase of d$^{*}_{33}$ can be achieved by tuning the domain period by a few tens of nanometers. Dissimilar behaviors are found when the domain period varies along different lateral directions, suggesting anisotropic domain size effects in thin films. By analyzing the local dielectric and piezoelectric responses from each domain variants and domain walls, we reveal that the domain size effect is governed by the variation of out-of-plane polarization inside the domains. Moreover, we also demonstrate enhanced domain size effects by modulating the misfit strains and temperature to approach the polymorphic phase boundaries, suggesting tunability of the size effect by doping and strain engineering. Furthermore, our results reveal multimodal domain size dependence of dielectric and piezoelectric responses in low-symmetry ferroelectric epitaxial thin films, implying that domain size engineering can be used to tune macroscopic properties of thin-film ferroelectrics, similar to their bulk counterparts.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Effect of sample size on the maximum value distribution of fatigue driving forces in metals and alloys

An analytical framework is presented to predict the effects of sample size on the maximum value distribution (MVD) of the driving forces for fatigue crack formation in metals and alloys. The distribution of the maximum driving force for fatigue crack formation over the domain follows the generalized extreme value theory in the limit as the domain size increases to infinity. Here, a simulation-based analysis of microstructure influences on fatigue resistance for polycrystalline metals and alloys is very costly, and reaching those limits is intractable. This work models the MVD of Fatigue Indicator Parameters (FIPs), which serve as surrogate measures for the driving force for fatigue crack formation, at finite sample sizes prior to their convergence to a limiting extreme value distribution. Large-scale crystal plasticity finite element (CPFE) simulations of FCC Al 7075-T6 with microstructure realizations of various sizes are incorporated to calibrate and evaluate the developed framework, and a total of ∼6.5 million grains of Al 7075-T6 are examined. The calibrated analytical solution agrees well with the brute force Monte Carlo simulation results extracted from the CPFE simulations. Furthermore, the developed formulation can predict the MVD of FIPs for different sample sizes using a size-dependent parameter, and it is capable of accurately extrapolating the MVD of FIPs for much larger microstructure sample sizes than the size used for its calibration.

Crystal plasticity↗

DOE OSTI2025

Crystallographic Evidence of Size-Dependent Bond Flexibility in Metal–Organic Framework Nanocrystals

Size-dependent electronic, magnetic, and optical behavior suggests that metal–organic frameworks become softer materials as their particle sizes decrease, but direct evidence is lacking. Here, we report variable-temperature powder X-ray diffraction data of Fe(1,2,3-triazolate)2 particles that offer crystallographic insight into size-dependent bond flexibility. Rietveld refinement reveals size-dependent positive thermal expansion upon downsizing the crystalline domains from 178 to 9 nm, with a 6-fold increase from 16 MK –1 to 96 MK –1 . Here, this behavior occurs in tandem with size-dependent elongation of metal–ligand bonds and increasing thermal displacement parameters, consistent with pronounced metal-linker bond lability. We propose that these effects, as well as size-dependent annealing of crystallite sizes, originate from the high charge density and surface stress of smaller particles. Taken together, these results provide structural evidence that size reduction serves as a synthetic route to controlling the dynamic response of materials to external stimuli.

Crystals↗

NASA NTRS1991

Reduction in bearing size due to superconductors in magnetic bearings

A design concept that reduces the size of magnetic bearings is assessed. The small size will enable magnetic bearings to fit into limited available bearing volume of cryogenic machinery. The design concept, called SUPERC, uses (high Tc) superconductors or high-purity aluminum conductors in windings instead of copper. The relatively high-current density of these conductors reduces the slot radial thickness for windings, which reduces the size of the bearings. MTI developed a sizing program called SUPERC that translates the high-current density of these conductors into smaller sized bearings. This program was used to size a superconducting bearing to carry a 500 lb. load. The sizes of magnetic bearings needed by various design concepts are as follows: SUPERC design concept = 3.75 in.; magnet-bias design concept = 5.25 in.; and all electromagnet design concept = 7.0 in. These results indicate that the SUPERC design concept can significantly reduce the size of the bearing. This reduction, in turn, reduces the weight and yields a lighter bearing. Since the superconductors have inherently near-zero resistance, they are also expected to save power needed for operation considerably.

Rao, Dantam K.↗

NASA NTRS1994

Estimation of grain sizes and mixing ratios of fine powder mixtures of common geologic minerals

Two different approaches for modeling reflectance spectra of intimate mixtures, Hapke's model and the isograin model, are used to estimate grain sizes and mixing ratios of powder mixtures of three geologic minerals: olivine, orthopyroxene, and plagioclase. In Hapke's model, scattering and extinction effiencies are mixed separately, and both models employ semiempirical refractive index spectra for component minerals. Mixing ratios of mixtures of grain size 45-75 micrometers are well estimated by both models assuming a common grain size of 60 micrometers and optimizing the constants for the single-particle scattering. For each model, effective grain size ratios for mineral constituents in mixtures of grain size less than 25 micrometers, are derived successfully that allows mineral abundances to be accurately predicted within approximately 4 wt percent. On the other hand, neither model can accurately predict mineral reflectance spectra for its smaller grain sizes less than 25 and 25-45 micrometers using an absorption coefficient spectrum derived from a larger grain size (45-75 micrometers). The errors in both models are significantly reduced if surface roughness effects of the smaller grain-size fractions are modeled.

Hiroi, Takahiro↗

NASA NTRS1998

The Effect of Set Size on the Relation Between Saccadic and Perceptual Decisions During Search

We have shown that when searching for a disk in noise at one of 10 locations, the accuracy of the I st saccade is similar to that of the perceptual decision at the time of saccadic programming. The present study has two goals: 1) to test whether this linden - extends to a contrast-discrimination task without noise, and 2) to measure the effect of set size on the relation between saccadic and perceptual decisions. Methods: Three observers searched over a grey background (34.5 cd/sq m) for a bright disk (63.2 cd/sq m) among dim disks (54.1 cd/sq m) along the circumference of a circle (r = 5.9 deg.) centered on a fixation cress. Four set sizes (2, 4, 6, 12) were used. In the 1st condition, stimuli were presented for 1 sec. and observers used natural eye movements. We then measured the accuracy of the first saccade (% correct using a shortest-distance criterion). In the 2nd condition, observers fixated a central cross at all times and the stimulus duration was approx. 70 as less than the median latency of the first saccade in the 1st condition (saccadic programming time). We then recorded perceptual performance and discarded trials in which observers broke fixation. Results: For set sizes of 2, 4, 8, and 12, the mean d' across observers for the perceptual decision was 2.03, 1.96, 1.94, 1.71, respectively, while the mean d' of the first saccade was only 0.73, 1.40, 1.23, 1.17. Conclusions: Unlike detection of a disk in noise, for all observers and set-sizes, the perceptual accuracy at the time of saccadic programming is better than that of the lst saccade. For set-sizes of 4, 6, and 12, the amount of information available to the perceptual system relative to that available to the saccadic system is approximately constant (fixed do ratio). For these higher set sizes, the constancy in do across set size for both perception and saccadic decisions is consistent with a simple signal detection theory (SDT) model that processes noisy signals in parallel. However, for 2 observers, at a set-size of 2, saccadic targeting appears to be worse than the SDT model prediction, perhaps due to speed-accuracy trade-off.

Eckstein, M. P.↗

NASA NTRS2014

3D-HST + CANDELS: the Evolution of the Galaxy Size-mass Distribution Since Z=3

Spectroscopic and photometric redshifts, stellar mass estimates, and rest-frame colors from the 3D-HST survey are combined with structural parameter measurements from CANDELS imaging to determine the galaxy size-mass distribution over the redshift (z) range 0 < z < 3. Separating early- and late-type galaxies on the basis of star-formation activity, we confirm that early-type galaxies are on average smaller than late-type galaxies at all redshifts, and find a significantly different rate of average size evolution at fixed galaxy mass, with fast evolution for the early-type population, effective radius is in proportion to (1 + z) (sup −1.48), and moderate evolution for the late-type population, effective radius is in proportion to (1 + z) (sup −0.75). The large sample size and dynamic range in both galaxy mass and redshift, in combination with the high fidelity of our measurements due to the extensive use of spectroscopic data, not only fortify previous results, but also enable us to probe beyond simple average galaxy size measurements. At all redshifts the slope of the size-mass relation is shallow, effective radius in proportion to mass of a black hole (sup 0.22), for late-type galaxies with stellar mass > 3 x 10 (sup 9) solar masses, and steep, effective radius in proportion to mass of a black hole (sup 0.75), for early-type galaxies with stellar mass > 2 x 10 (sup 10) solar masses. The intrinsic scatter is approximately or less than 0.2 decimal exponents for all galaxy types and redshifts. For late-type galaxies, the logarithmic size distribution is not symmetric, but skewed toward small sizes: at all redshifts and masses a tail of small late-type galaxies exists that overlaps in size with the early-type galaxy population. The number density of massive (approximately 10 (sup 11) solar masses), compact (effective radius less than 2 kiloparsecs) early-type galaxies increases from z = 3 to z = 1.5 − 2 and then strongly decreases at later cosmic times.

EVOLUTION↗

NASA NTRSDate not supplied

Spacesuit Sizing by Multivariate Simulation: Case Study for Liquid Cooling and Ventilation Garment

A technique was developed to assess the fit of spacesuit garment liquid cooling and ventilation garment (LCVG). A fit scoring scheme was built from the spacesuit sizing requirements and guidelines, and the accommodated proportion of the wearer population was estimated from statistically synthesized pseudo population data. The method evaluated different scenarios of LCVG sizing systems including 1) baseline 7-size system, 2) 7-sizes with target body dimensions iteratively adjusted for maximum fit, and 3) 9-sizes with iterative adjustments. Overall, the baseline sizing system showed 81% accommodation rate, while the hypothetical new systems in-tegrating iterative adjustments for 7- and 9-sizes predictively indicated that accommodation could improve up to 92 and 97%. The proposed method provided a structured metric to quantify fit performance of a garment sizing system, which can be further applied to different spacesuit component, PPE and garment designs.

Han Kim↗

DOE OSTI2023

Waffle Homes: Utilizing Aerial Imagery of Unfinished Buildings to Determine Average Room Size

A primary function of the Population Density Tables Project (PDT) at Oak Ridge National Laboratory is to produce residential population densities per 1000 sq. ft. for each country and their associated first-level administrative units. This is accomplished by utilizing the average size of different types of dwelling areas (urban, rural, single-family, multi-family, etc.) and the average household size provided by a country’s Census or statistical bureau records. This data is available for the majority of Europe, North America, and large swathes of Asia, but is less easily found in Africa and South America. In these regions, Censuses generally report dwelling area by number of rooms, which poses the challenging question of how we can translate number of rooms to dwelling size when no dwelling size areas are available with which to compare. Using sub-meter resolution satellite imagery of Accra, Ghana, this challenge can be tackled using imagery of roofless buildings currently under construction that show the interior floor plan of the dwelling. A sample of buildings from the different neighborhoods of Accra can be digitized to provide an estimate and range of average room sizes of dwellings. This average room size can then be translated to a total dwelling area using the "number of rooms occupied by a household" variable from the Ghanaian Census. This intermediate step between average dwelling size and number of rooms occupied, fills the missing link that prevents PDT from continually producing new population densities for countries where dwelling size is unavailable through any official means.

Woody, Carson↗

DOE OSTI2020

Fracture toughness of zirconia with a nanometer size notch fabricated using focused ion beam milling

Zirconia with 3 mol% yttria (3Y-TZP) has been used for dental crowns and bridges due to its excellent mechanical behavior. Performing fracture toughness testing on this nanograin material, however, can be a challenge. For reliable results, fracture toughness testing requires an extremely sharp notch in the test specimen that closely approximates a very sharp crack. This study was to investigate an alternative method to produce nanometer-sized notches, which are less than the average grain size of 3Y-TZP, during the preparation of single-edge V-notched beam specimens and report the resulting fracture toughness value. We present a method using focused ion beam (FIB) milling to fabricate nanometer-sized notches in 3Y-TZP. The notch tip is <100 nm wide, which is smaller than the grain size, and is consistent throughout the thickness of the specimen. The FIB-notched specimens show a much reduced average fracture toughness of 5.64 ± 1.14 MPa√m compared to 8.90 ± 0.23 MPa√m for the specimens without FIB-notches. The FIB-milling did not appear to create any monoclinic phase prior to fracture toughness testing. Fractures originated at the FIB-notches, and the notch size can be readily identified post-mortem using a microscope. A considerable amount of tetragonal-to-monoclinic phase transformation was observed throughout the fracture surfaces. FIB milling provides an alternative method to fabricate nanometer-sized notches that are smaller than the grain size of tetragonal zirconia polycrystal. The fracture toughness determined using FIB-notches was ~5.64 MPa√m, smaller than the specimens with V-notches fabricated using saw blades.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Size-dependent stochastic tensile properties in additively manufactured 316L stainless steel

Recent work in metal additive manufacturing (AM) suggests that mechanical properties may vary with feature size; however, these studies do not provide a statistically robust description of this phenomenon, nor do they provide a clear causal mechanism. Because of the huge design freedom afforded by 3D printing, AM parts typically contain a range of feature sizes, with particular interest in smaller features, so the size effect must be well understood in order to make informed design decisions. This work investigates the effect of feature size on the stochastic mechanical performance of laser powder bed fusion tensile specimens. A high-throughput tensile testing method was used to characterize the effect of specimen size on strength, elastic modulus and elongation in a statistically meaningful way. The effective yield strength, ultimate tensile strength and modulus decreased strongly with decreasing specimen size: all three properties were reduced by nearly a factor of two as feature dimensions were scaled down from 6.25 mm to 0.4 mm. Hardness and microstructural observations indicate that this size dependence was not due to an intrinsic change in material properties, but instead the effects of surface roughness on the geometry of the specimens. Finite element analysis using explicit representations of surface topography shows the critical role surface features play in creating stress concentrations that trigger deformation and subsequent fracture. The experimental and finite element results provide the tools needed to make corrections in the design process to more accurately predict the performance of AM components.

316L stainless steel↗