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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1989

Experimental investigation into passive damping enhancement for space structures

This work presents experiments which were conducted to verify kinetic and strain energy damping enhancement schemes for large/precision space structures. Two types of damping mechanisms were applied to a 5 meter long, 10 bay aluminum box truss with a quasi free-free three-dimensional suspension. Tuneable proof mass dampers (PMDs) were implemented with space realizable linear electromechanical drivers. Tuneable piezoelectric truss members were designed and constructed for the demonstration of resonant shunted piezoelectric damping concepts. The truss damping was measured and compared to analytical predictions obtained from a frequency domain system modeling technique. The proof mass damper implementation was found to increase first mode damping from 0.6 percent of critical to 6.4 percent of critical with a system mass increase of 2.7 percent. The resonant shunted piezoelectrics increased first mode damping to 6.0 percent with a similar mass penalty.

Hagood, Nesbitt W.↗
NASA NTRS1990

COS-B gamma ray sources beyond the predicted diffuse emission

COS-B data were reanalyzed using for background subtraction the modeled galactic diffuse gamma-ray emission based on HI- and CO-line surveys and the gamma-ray data itself. A methodology was developed for this purpose with the following three features: automatic generation of source catalogs using correlation analysis, simulation of trials to derive significance thresholds for source detection, and bootstrap sampling to drive error boxes and confidence intervals for source parameters. The analysis shows that about half of the 2CG sources are explained by concentrations in the distribution of molecular hydrogen. Indication for a few weak new sources is also obtained.

Mayer-Hasselwander, H. A.↗
DOE OSTI2026

A wide-range thermodynamically consistent constitutive model for dynamic loading of partially saturated porous media

SUMMARY This paper presents a novel thermodynamically consistent constitutive model for partially saturated porous rocks across a wide range of conditions. The material states generated behind the shock wave from an explosive source can vary significantly, ranging from crushed and melted rock near the source to a poroelastic medium in the far field. In the model, rock strength is determined by the effective pressure, which is calculated using two independent equations of state: one for the solid rock and another for the pore fluid. The model accounts for shock-induced liquefaction resulting from fluid pressure buildup in the pore spaces near the explosive source. Simultaneously, it describes the increase in wave propagation speed due to elastic pore contraction in both dry and partially saturated rocks. This model is applied to investigate how fluid saturation affects the amplitude and shape of the generated waves, as well as the residual stress surrounding the cavity formed by spherical explosions.

Vorobiev, Oleg [Lawrence Livermore National Labora↗
DOE OSTI2024

Reduction of Methane Leaks through Corrosion Mitigation Pre-treatments for Pipelines with Field Applied Coatings

Corrosion of buried, coated steel pipelines transporting natural gas is a significant source of methane emissions, from pipeline venting required for maintenance and repairs and from pipeline leaks and incidents. Corrosion of steel under field applied coatings is an important safety concern for the pipeline industry. This project investigates the application of a field applied alloy over girth welds to mitigate external corrosion of buried coated steel pipelines. Various metallic coating options were considered, which were required to meet several criteria: (1) it must resist corrosion under open-circuit or mild cathodic protection conditions, (2) it must protect the substrate steel, and (3) it must not negatively affect the adhesion of the field coating. Finite element models and lab testing were performed of alloy coating compositions to identify promising alloy types underneath disbonded coatings. Polarization curves of coating alloys were generated to provide the boundary conditions for the COMSOL model to compute potential and current distributions around coated areas. Sacrificial and corrosion-resistant metal alloy coatings were evaluated and optimized using corrosion modeling and laboratory electrochemical testing, where aluminum alloy 5356 (5% Mg) and steel alloy B9 (9% Cr) were selected. Corrosion test coupons were designed and fabricated using thermal spray aluminum 5356 and welded B9 steel overlays on API 5L grade X42 line pipe steel. The corrosion test coupons, with simulated pipe coating damage, were tested in a laboratory soil box and a field pipeline site in Texas for 3-months. Corrosion test coupons were then tested for 6-months at field pipeline sites in Texas and Tennessee to quantify corrosion rates and performance of the aluminum and steel alloys under polyethylene tape and 2-part epoxy coatings, various coating holidays, and with and without cathodic protection.

03 NATURAL GAS↗
NASA NTRS1991

A comparison of two closely-related approaches to aerodynamic design optimization

Two related methods for aerodynamic design optimization are compared. The methods, called the implicit gradient approach and the variational (or optimal control) approach, both attempt to obtain gradients necessary for numerical optimization at a cost significantly less than that of the usual black-box approach that employs finite difference gradients. While the two methods are seemingly quite different, they are shown to differ (essentially) in that the order of discretizing the continuous problem, and of applying calculus, is interchanged. Under certain circumstances, the two methods turn out to be identical. We explore the relationship between these methods by applying them to a model problem for duct flow that has many features in common with transonic flow over an airfoil. We find that the gradients computed by the variational method can sometimes be sufficiently inaccurate to cause the optimization to fail.

Shubin, G. R.↗
NASA NTRS2016

NDARC NASA Design and Analysis of Rotorcraft - Input, Appendix 4

The NDARC code performs design and analysis tasks. The design task involves sizing the rotorcraft to satisfy specified design conditions and missions. The analysis tasks can include off-design mission performance analysis, flight performance calculation for point operating conditions, and generation of subsystem or component performance maps. The principal tasks (sizing, mission analysis, flight performance analysis) are shown in the figure as boxes with heavy borders. Heavy arrows show control of subordinate tasks. The aircraft description consists of all the information, input and derived, that denes the aircraft. The aircraft consists of a set of components, including fuselage, rotors, wings, tails, and propulsion. This information can be the result of the sizing task; can come entirely from input, for a fixed model; or can come from the sizing task in a previous case or previous job. The aircraft description information is available to all tasks and all solutions. The sizing task determines the dimensions, power, and weight of a rotorcraft that can perform a specified set of design conditions and missions. The aircraft size is characterized by parameters such as design gross weight, weight empty, rotor radius, and engine power available. The relations between dimensions, power, and weight generally require an iterative solution. From the design flight conditions and missions, the task can determine the total engine power or the rotor radius (or both power and radius can be fixed), as well as the design gross weight, maximum takeoff weight, drive system torque limit, and fuel tank capacity. For each propulsion group, the engine power or the rotor radius can be sized. Missions are defined for the sizing task, and for the mission performance analysis. A mission consists of a number of mission segments, for which time, distance, and fuel burn are evaluated. For the sizing task, certain missions are designated to be used for design gross weight calculations; for transmission sizing; and for fuel tank sizing. The mission parameters include mission takeoff gross weight and useful load. For specified takeoff fuel weight with adjustable segments, the mission time or distance is adjusted so the fuel required for the mission equals the takeoff fuel weight. The mission iteration is on fuel weight or energy. Flight conditions are specified for the sizing task, and for the flight performance analysis. For the sizing task, certain flight conditions are designated to be used for design gross weight calculations; for transmission sizing; for maximum takeoff weight calculations; and for anti-torque or auxiliary thrust rotor sizing. The flight condition parameters include gross weight and useful load. For flight conditions and mission takeoff, the gross weight can be maximized, such that the power required equals the power available. A flight state is defined for each mission segment and each flight condition. The aircraft performance can be analyzed for the specified state, or a maximum effort performance can be identified. The maximum effort is specified in terms of a quantity such as best endurance or best range, and a variable such as speed, rate of climb, or altitude.

Rotorcraft Input↗
NASA NTRS2016

Maps Suggest Transport and Source Processes of PM2.5 at 1 km x 1 km for the Whole San Joaquin Valley, Winter 2011 (Generalizations from DISCOVER-AQ)

We present interpreted data analysis using MAIAC (Multiangle implementation of Atmospheric Correction) retrievals and appropriate RAPid Update Cycle (RAP) meteorology to map respirable aerosol (PM2.5) for the period January and February, 2011. The San Joaquin Valley is one of the unhealthiest regions in the USA for PM2.5 and related morbidity. The methodology evaluated can be used for the entire moderate-resolution imaging spectrometer (MODIS, VIIRS) data record. Other difficult areas of the West: Riverside, CA, Salt Lake City, UT, and Doa Ana County, NM share similar difficulties and solutions. The maps of boundary layer depth for 1116 hr local time from RAP allows us to interpret aerosol optical thickness as a concentration of particles in a nearly well-mixed box capped by clean air. That mixing is demonstrated by DISCOVER-AQ data and afternoon samples from the airborne measurements, P3B (on-board) and B200 (HSRL2 lidar). This data and the PM2.5 gathered at the deployment sites allowed us to estimate and then evaluate consistency and daily variation of the AOT to PM2.5 relationship. Mixed-effects modeling allowed a refinement of that relation from day to day; RAP mixed layers explained the success of previous mixed-effects modeling. Compositional, size-distribution, and MODIS angle-of-regard effects seem to describe the need for residual daily correction beyond ML depth.We report on an extension method to the entire San Joaquin Valley for all days with MODIS imagery using the permanent PM2.5 stations, evaluated for representativeness. Resulting map movies show distinct sources, particularly Interstate-5 (at approx. 1km x 1km resolution) and the broader Bakersfield area. Accompanying winds suggest transport effects and variable pathways of pollution cleanout. Such estimates should allow morbiditymortality studies. They should be also useful for actual model assimilations, where composition and sources are uncertain. We conclude with a description of new work to extend these insights to similar regions, e.g. interior valleys of California, the Po Valley, the Mediterranean litoral, and the Ganges Plain.This work show generalizable use of remote sensing, a major goal of DISCOVER-AQ, Deriving Information on Surface Conditions from COlumn and VERtically Resolved Observations Relevant to Air Quality.

Chatfield, R.↗
NASA NTRSDate not supplied

NASA/GEWEX SRB Surface Radiation Budget Fluxes Through the Prism of Weather States

The NASA/GEWEX Surface Radiation Budget Version 4 (SRB Rel4) product is now publicly available, covering the period from July 1983 through June 2017. This supersedes the SRB Rel3 (Stackhouse et al., 2011) product which has been used in the community for a wide variety of applications, including climate model validation, agriculture, solar energy, and architecture. SRB Rel4 uses the newly recalibrated and processed ISCCP HXS product as its primary input for cloud and radiance data, replacing ISCCP DX with a ninefold increase in pixel count (10km instead of 30km). This version retains a 1°x1° resolution but benefits from a much larger number of samples per grid box than the SRB Rel3. ISCCP also provides an atmospheric temperature and moisture dataset known as nnHIRS which we use here, along with Seaflux and Landflux surface and near-surface meteorological parameters. Rel4 incorporates several important algorithm improvements. These include recalculated shortwave (SW) atmospheric transmissivities and reflectivities yielding a somewhat less transmissive atmosphere. Both shortwave and longwave (LW) now also include variable aerosol composition and radiative properties, allowing for the use of a detailed aerosol history from the Max Planck Institute Aerosol Climatology (MACv1). LW and SW algorithms now produce pristine sky fluxes, allowing the aerosol flux effects to be quantified. For SW, ocean albedo and snow/ice albedo are improved from Release 3. Total solar irradiance is now variable, and reduced to an average of 1361 Wm-2. The radiative treatment of ice cloud is improved. For the LW, a climatological monthly varying spectral surface emissivity is added. Here we evaluate the SRB Rel4 top of atmosphere (TOA) and surface fluxes in the context of weather states and oceanic regions. Weather states (Tselioudis et al., 2013, Tselioudis et al., 2021) are defined by K-means clustering 2-D histograms of satellite-retrieved cloud optical depths and cloud top pressures. The most recent (Tselioudis et al., 2021) weather states derived from the International Satellite Cloud Climatology Project (ISCCP) H-series data results in eight cloud weather states and one clear sky weather state, for a total of nine weather states. We examine the statistics of SRB Rel4 fluxes for each weather state and a variety of relevant land and ocean regions. We compare to similar analyses performed on CERES EBAF and SYN1Deg flux products, and validate against Baseline Surface Radiometer Network (BSRN) land stations and Pacific Marine Environmental Laboratory (PMEL) ocean buoy data. It is demonstrated that the weather state concept is valuable when examining the comparative strengths and weaknesses of satellite radiative flux algorithms.

Atmospheric Radiation↗
DOE OSTI2014

New approach for precise computation of Lyman-α forest power spectrum with hydrodynamical simulations

Current experiments are providing measurements of the flux power spectrum from the Lyman-α forests observed in quasar spectra with unprecedented accuracy. Their interpretation in terms of cosmological constraints requires specific simulations of at least equivalent precision. In this paper, we present a suite of cosmological N-body simulations with cold dark matter and baryons, specifically aiming at modeling the low-density regions of the inter-galactic medium as probed by the Lyman-α forests at high redshift. The simulations were run using the GADGET-3 code and were designed to match the requirements imposed by the quality of the current SDSS-III/BOSS or forthcoming SDSS-IV/eBOSS data. They are made using either 2 × 768{sup 3} ≅ 1 billion or 2 × 192{sup 3} ≅ 14 million particles, spanning volumes ranging from (25 Mpc h{sup −1}){sup 3} for high-resolution simulations to (100 Mpc h{sup −1}){sup 3} for large-volume ones. Using a splicing technique, the resolution is further enhanced to reach the equivalent of simulations with 2 × 3072{sup 3} ≅ 58 billion particles in a (100 Mpc h{sup −1}){sup 3} box size, i.e. a mean mass per gas particle of 1.2 × 10{sup 5}M{sub ⊙} h{sup −1}. We show that the resulting power spectrum is accurate at the 2% level over the full range from a few Mpc to several tens of Mpc. We explore the effect on the one-dimensional transmitted-flux power spectrum of four cosmological parameters (n{sub s}, σ{sub 8}, Ω{sub m} and H{sub 0}) and two astrophysical parameters (T{sub 0} and γ) that are related to the heating rate of the intergalactic medium. By varying the input parameters around a central model chosen to be in agreement with the latest Planck results, we built a grid of simulations that allows the study of the impact on the flux power spectrum of these six relevant parameters. We improve upon previous studies by not only measuring the effect of each parameter individually, but also probing the impact of the simultaneous variation of each pair of parameters. We thus provide a full second-order expansion, including cross-terms, around our central model. We check the validity of the second-order expansion with independent simulations obtained either with different cosmological parameters or different seeds. Finally, a comparison to the one-dimensional Lyman-α forest power spectrum obtained with BOSS by [1] shows an excellent agreement.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Analytical and numerical treatment of resistive drift instability in a plasma slab

An analytic approach combining the effect of equilibrium diamagnetic flows and the finite ionsound gyroradius associated with electron−ion decoupling and kinetic Alfvén wave dispersion is derived to study resistive drift instabilities in a plasma slab. Linear numerical computations using the NIMROD code are performed with cold ions and hot electrons in a plasma slab with a doubly periodic box bounded by two perfectly conducting walls. A linearly unstable resistive drift mode is observed in computations with a growth rate that is consistent with the analytic dispersion relation. The resistive drift mode is expected to be suppressed by magnetic shear in unbounded domains, but the mode is observed in numerical computations with and without magnetic shear. In the slab model, the finite slab thickness and the perfectly conducting boundary conditions are likely to account for the lack of suppression.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

QUOTAS: A New Research Platform for the Data-driven Discovery of Black Holes

We present QUOTAS, a novel research platform for the data-driven investigation of supermassive black hole (SMBH) populations. While SMBH data—observations and simulations—have grown in complexity and abundance, our computational environments and tools have not matured commensurately to exhaust opportunities for discovery. To explore the BH, host galaxy, and parent dark matter halo connection—in this pilot version—we assemble and colocate the high-redshift, z > 3 quasar population alongside simulated data at the same cosmic epochs. As a first demonstration of the utility of QUOTAS, we investigate correlations between observed Sloan Digital Sky Survey (SDSS) quasars and their hosts with those derived from simulations. Leveraging machine-learning algorithms (ML), to expand simulation volumes, we show that halo properties extracted from smaller dark-matter-only simulation boxes successfully replicate halo populations in larger boxes. Next, using the Illustris-TNG300 simulation that includes baryonic physics as the training set, we populate the larger LEGACY Expanse dark-matter-only box with quasars, and show that observed SDSS quasar occupation statistics are accurately replicated. First science results from QUOTAS comparing colocated observational and ML-trained simulated data at z3 are presented. QUOTAS demonstrates the power of ML, in analyzing and exploring large data sets, while also offering a unique opportunity to interrogate theoretical assumptions that underpin accretion and feedback models. QUOTAS and all related materials are publicly available at the Google Kaggle platform. (The full data set—observational data and simulation data—are available at: https://www.kaggle.com/ and the codes are available at:https://www.kaggle.com/datasets/quotasplatform/quotas)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS1998

I/O Parallelization for the Goddard Earth Observing System Data Assimilation System (GEOS DAS)

The National Aeronautics and Space Administration (NASA) Data Assimilation Office (DAO) at the Goddard Space Flight Center (GSFC) has developed the GEOS DAS, a data assimilation system that provides production support for NASA missions and will support NASA's Earth Observing System (EOS) in the coming years. The GEOS DAS will be used to provide background fields of meteorological quantities to EOS satellite instrument teams for use in their data algorithms as well as providing assimilated data sets for climate studies on decadal time scales. The DAO has been involved in prototyping parallel implementations of the GEOS DAS for a number of years and is now embarking on an effort to convert the production version from shared-memory parallelism to distributed-memory parallelism using the portable Message-Passing Interface (MPI). The GEOS DAS consists of two main components, an atmospheric General Circulation Model (GCM) and a Physical-space Statistical Analysis System (PSAS). The GCM operates on data that are stored on a regular grid while PSAS works with observational data that are scattered irregularly throughout the atmosphere. As a result, the two components have different data decompositions. The GCM is decomposed horizontally as a checkerboard with all vertical levels of each box existing on the same processing element(PE). The dynamical core of the GCM can also operate on a rotated grid, which requires communication-intensive grid transformations during GCM integration. PSAS groups observations on PEs in a more irregular and dynamic fashion.

Lucchesi, Rob↗
NASA NTRS2013

On the Origin of Multidecadal to Centennial Greenland Temperature Anomalies Over the Past 800 yr

The surface temperature of the Greenland ice sheet is among the most important climate variables for assessing how climate change may impact human societies due to its association with sea level rise. However, the causes of multidecadal-to-centennial temperature changes in Greenland temperatures are not well understood, largely owing to short observational records. To examine these, we calculated the Greenland temperature anomalies (GTA[G−NH]) over the past 800 yr by subtracting the standardized northern hemispheric (NH) temperature from the standardized Greenland temperature. This decomposes the Greenland temperature variation into background climate (NH); polar amplification; and regional variability (GTA[G−NH]). The central Greenland polar amplification factor as expressed by the variance ratio Greenland/NH is 2.6 over the past 161 yr, and 3.3-4.2 over the past 800 yr. The GTA[G−NH] explains 31-35%of the variation of Greenland temperature in the multidecadal-to-centennial time scale over the past 800 yr. We found that the GTA[G−NH] has been influenced by solar-induced changes in atmospheric circulation patterns such as those produced by the North Atlantic Oscillation/Arctic Oscillation (NAO/AO). Climate modeling and proxy temperature records indicate that the anomaly is also likely linked to solar-paced changes in the Atlantic meridional overturning circulation (AMOC) and associated changes in northward oceanic heat transport.

Kobashi, T.↗
DOE OSTI2017

Evaluation of Embedded VIPs for Use in the Building Envelope

An objective for expanded use of vacuum insulation panel (VIP) products in buildings will be assisted by an understanding of the relationship between small-scale laboratory thermal measurements and large-scale tests of building components. Thermal resistances of a typical element of VIP embedded in closed-cell cellular plastic (foam) insulation obtained with a heat flow meter (HFM) apparatus are compared with results obtained with a hot-box facility for a building component. Small-scale samples of the foam-VIP composites were measured in single- and multi-transducer HFMs. The multi-transducer HFM was used to determine the heat flow distribution across the different sections of the VIP, i.e. center-of-panel vs. edges and joints. These measurements enable validation of numerical models, which can be utilized to model and evaluate large-scale building components containing VIPs.

Biswas, Kaushik↗
DOE OSTI2019

Comparative Assessment of Experimental Testing of Instrument with an Embedded Digital Device Using Model-Based and Conventional Methods

The use of digital equipment has not been widespread in U.S. nuclear facilities. A major contributing factor to this situation arises from regulatory concerns about common cause failures (CCFs) stemming from the use of identical software in redundant systems, questions as to how to quantify the reliability of software-based products, validity of tools that are used for software verification and validation (V&V), and the effectiveness of software QA procedures. Compounding the concerns are sporadic incidents of digital equipment malfunctions in nuclear power plants, including lockups resulting from software memory leaks, feedwater control malfunctions due to excessive traffic on Ethernet networks, software logic errors, and other problems leading to plant trips. Additionally, the limited amount of demonstrated research and a lack of industry consensus on quantitative software reliability methodologies has hindered the widespread adoption of digital I&C in the nuclear industry. In a recent Regulatory Issue Summary (RIS), the U.S. Nuclear Regulatory Commission (NRC) identified concerns about the impact of greater use of instrumentation and control (I&C) equipment with an embedded digital device (EDD) [1]. Specifically, the NRC staff states that increased use of such devices “may increase a facility’s vulnerability to a CCF” (i.e., common-cause failure). The prevailing NRC guidance regarding software CCF (SCCF) identifies two design attributes that are acceptable for eliminating CCF concerns: (1) diversity or (2) testability (specifically, 100% testability). Either solution can result in high costs and remaining licensing uncertainty (i.e., how much diversity is enough? how to ensure test coverage of every possible sequence of device states?). Consequently, many utilities and reactor designers have limited or avoided more extensive use of digital technology to minimize licensing, scheduling, and financial risk. Without development of cost effective qualification methods to satisfy regulatory requirements and address the potential for CCF vulnerability associated with EDDs, the nuclear power industry may not be able to realize the benefits of digital technology achieved by other industries. In order to address these challenges, the U.S. Department of Energy (DOE) is sponsoring this research to assess the prospect of CCF in digital I&C equipment. The purpose of the current research is to develop an effective approach employing science-based methods to resolve concerns about CCF vulnerability that serve to inhibit deployment of advanced instrumentation (e.g., sensors, actuators, microcontrollers) with EDDs in nuclear power applications. The research objectives address the challenge of establishing high levels of safety and reliability assurance needed for the qualification of EDDs (e.g., microprocessors, programmable logic devices) that are subject to software design faults, complex failure modes, and CCF vulnerability. Specific objectives are: (1) assess the regulatory context for treatment of CCF vulnerability a graded approach to their qualification, (3) develop and extend model-based testing methods to enable effective demonstration of whether devices are subject to CCF, which may arise from vulnerabilities introduced at any stage of the design lifecycle, (4) establish a cost-effective testing framework that incorporates automation and test scenario prioritization, and (5) demonstrate the qualification approach through selection and testing of candidate digital device(s). This report documents an assessment of the results from experimental testing of a representative instrument with an embedded digital device. The experiment serves as a proof-of-concept demonstration of a model-based testing (MBT) framework. The objective of MBT is to ensure that an EDD undergoes suitably comprehensive testing to establish that it is not subject to SCCF. The approach by which MBT accomplishes this objective is through development and application of an effective test suite that provides the appropriate coverage to detect the full range of postulated faults that may arise at the requirements, design, and code (implementation) level of the EDD software. The findings of the experiment involve the application of the MBT framework by Ohio State University (OSU) through testing of the selected demonstration instrument (i.e., the prototype smart pressure sensor developed by Virginia Commonwealth University, VCU). In addition, the experiment findings also involve application of a more conventional black-box testing approach that serves as a baseline against which the MBT methodology can be compared. The primary outcome documented in this report is the comparative analysis of the capabilities demonstrated for each method. The results of the analysis demonstrate clear benefits that arise from the MBT methodology. The comparison indicates greater effectiveness from the more comprehensive evidence available through MBT and enhanced efficiency achieved through automation within the MBT framework. The structure of the report addresses the approach and application of each test method as well as the comparative analysis of the experimental results. Chapter 2 gives a summary overview of the demonstration approach. Chapter 3 covers the baseline testing and Chapter 4 documents the model-based testing. Chapter 5 describes the findings of the comparative analysis and presents the conclusions that can be drawn about the effectiveness and efficiency of the MBT methodology.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Multi phenomena melt pool sensor data fusion for enhanced process monitoring of laser powder bed fusion additive manufacturing

Finding actionable trends in laser-based metal additive manufacturing process monitoring data is challenging owing to the diversity and complexity of the underlying physical interactions. A single monitoring solution that captures a particular process phenomenon, such as a photodiode that tracks melt pool intensity, is not alone capable of evaluating process stability or detecting flaw formation with sufficient precision for routine application in industry. In this work, to improve flaw detection performance, we adopted a data fusion approach that captures multiple process phenomena. To demonstrate this, we acquired data from laser powder bed fusion (LPBF) builds of cylindrical specimens produced with different laser spot sizes, emulating defocusing due to process faults such as thermal lensing. The resulting specimens had porosity of varying types and severity, quantified by post-build non-destructive X-ray computed tomography, Archimedes density measurements, and destructive metallographic characterization. During the build, the melt pool state was monitored with two coaxial high-speed video cameras and a temperature field imaging system. Physically intuitive low-level melt pool signatures, such as melt pool temperature, shape and size, and spatter intensity were extracted from this high-dimensional, image-based sensor data. These process signatures were subsequently used as input features in relatively simple machine learning models, such as a support vector machine, which were trained to detect laser defocusing, and in addition, predict porosity type and severity. The results show that the data fusion approach significantly enhanced system performance by reducing the overall false positive rate from ~ 0.1 to ~ 0.001 without sacrificing the true positive rate (~0.90). These results were at par with a black-box, deep machine learning approach (convolutional neural network).

36 MATERIALS SCIENCE↗
DOE OSTI2012

Medium Truck Duty Cycle Data from Real-World Driving Environments (Project Final Report)

Since the early part of the 20th century, the US trucking industry has provided a safe and economical means of moving commodities across the country. At present, nearly 80% of US domestic freight movement involves the use of trucks. The US Department of Energy (DOE) is spearheading a number of research efforts to improve heavy vehicle fuel efficiencies. This includes research in engine technologies (including hybrid and fuel cell technologies), lightweight materials, advanced fuels, and parasitic loss reductions. In addition, DOE is developing advanced tools and models to support heavy vehicle research and is leading the 21st Century Truck Partnership and the SuperTruck development effort. Both of these efforts have the common goal of decreasing the fuel consumption of heavy vehicles. In the case of SuperTruck, a goal of improving the overall freight efficiency of a combination tractor-trailer has been established. This Medium Truck Duty Cycle (MTDC) project is a critical element in DOE’s vision for improved heavy vehicle energy efficiency; it is unique in that there is no other existing national database of characteristic duty cycles for medium trucks based on collecting data from Class 6 and 7 vehicles. It involves the collection of real-world data on medium trucks for various situational characteristics (e.g., rural/urban, freeway/arterial, congested/free-flowing, good/bad weather) and looks at the unique nature of medium trucks’ drive cycles (stop-and-go delivery, power takeoff, idle time, short-radius trips). This research provides a rich source of data that can contribute to the development of new tools for FE and modeling, provide DOE a sound basis upon which to make technology investment decisions, and provide a national archive of real-world-based medium-truck operational data to support energy efficiency research. The MTDC project involved a two-part field operational test (FOT). For the Part-1 FOT, three vehicles each from two vocations (urban transit and dry-box delivery) were instrumented for the collection of one year of operational data. The Part-2 FOT involved the towing and recovery and utility vocations for a second year of data collection.

CMV↗
NASA NTRS1994

Benchmark panels

Results are presented for an analytical and experimental study of curved, stiffened composite panels for a commercial transport aircraft. Five panels representative of fuselage crown design alternatives were fabricated for concept evaluation. These panels are scheduled to be tested in the Pressure Box Test Machine at NASA Langley Research Center. The panels are characterized by a 122 in. radius, tow-placed skins, hot-drape-formed hat-section stringers, and braided/RTM J-section frames. A geometrically nonlinear finite element analysis was conducted to support the development of test fixturing and to provide predictions of undamaged panel response. A strain softening model for damaged structures is described and used to predict the response of damaged panels. Results for a study of the stringer-frame intersection ('mousehole') design detail are also presented. Bonded frame pull-off tests and supporting analyses are described.

T H Walker↗