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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

SURFACE FINISHING AND ELECTROLESS NICKEL PLATING OF ADDITIVELY MANUFACTURED (AM) METAL COMPONENTS

This study investigates the application of electroless nickel deposition on additively manufactured stainless steel samples. Current additive manufacturing (AM) technologies produce metal components with a rough surface. Rough surfaces generally exhibit fatigue characteristics, increasing the probability of initiating a crack or fracture to the printed part. For this reason, the direct use of as-produced parts in a finished product cannot be actualized, which presents a challenge. Post-processing of the AM parts is therefore required to smoothen the surface. This study analyzes chempolish (CP) and electropolish (EP) surface finishing techniques for post-processing AM stainless steel components CP has a great advantage in creating uniform, smooth surfaces regardless of size or part geometry EP creates an extremely smooth surface, which reduces the surface roughness to the sub-micrometer level. In this study, we also investigate nickel deposition on EP, CP, and as-built AM components using electroless nickel solutions. Electroless nickel plating is a method of alloy treatment designed to increase manufactured component's hardness and surface resistance to the unrelenting environment. The electroless nickel plating process is more straightforward than its counterpart electroplating.. We use low-phosphorus (2-5% P), medium-phosphorus (6-9% P), and high-phosphorus (10-13% P). These Ni deposition experiments were optimized using the L9 Taguchi design of experiments (TDOE), which compromises the prosperous content in the solution, surface finish, plane of the geometry, and bath temperature. The pre-and post-processed surface of the AM parts was characterized by KEYENCE Digital MicroscopeVHX-7000 and Phenom XL Desktop SEM. The experimental results show that electroless nickel deposition produces uniform Ni coating on the additively manufactured components up to 20 μm per hour. Mechanical properties of as-built and Ni coated AM samples were analyzed by applying a standard 10 N scratch test. Nickel coated AM samples were up to two times scratch resistant compared to the as-built samples. This study suggests electroless nickel plating is a robust viable option for surface hardening and finishing AM components for various applications and operating conditions.

Keywords: additive manufacturing, fatigue, chempol↗
NASA NTRS1973

Analysis of internal flow characteristics of a smooth-disk water-brake dynamometer

The principal of absorbing power with an enclosed partially submerged rotating disk through the turbulent viscous shearing of water is discussed. Reference information is used to develop a flow model of the water brake. A method is then presented that uses vector diagrams to relate the effects of rotational flow, through flow, and secondary flow to power absorption. The method is used to describe the operating characteristics of an example 111-cm (43.7-in.) diameter water brake. Correlating performance parameters are developed in a dimensional analysis.

Evans, D. G.↗
DOE OSTI2024

Methods to Evaluate Subcolumn Profiles Based on Two-Point Diagnostics

In atmospheric models, stochastic generation of subgrid-scale profiles or “subcolumns” has been used for a variety of purposes. Such subcolumns can be generated from subgrid probability density functions (PDFs) at different vertical levels, when such PDFs are available. To do so, the generator needs to decide how strongly points should be correlated in the vertical, that is, how much the values should be overlapped. This is sometimes called “PDF overlap.” To assess vertical correlation in a simplified, observable setting, here the vertical correlation of vertical velocity in subcloud layers is examined. Doppler lidar is used to evaluate the vertical profiles of vertical velocity produced by a large-eddy simulation (LES) model and the Subgrid Importance Latin Hypercube Sampler (SILHS) subcolumn generator. In order to diagnose unrealistic features in subcolumn profiles, various statistical diagnostics are examined here, including the bivariate PDF of vertical velocity at two separated points (i.e., altitudes), the two-point velocity correlation, the integral correlation length, the PDF of two-point velocity differences, and the skewness and kurtosis of two-point velocity differences. The profiles produced by LES match lidar well, except that they are too smooth at small scales. The profiles produced by SILHS exhibit sharp jumps from updraft to downdraft that are not observed in the lidar data. To reduce the generation of these unrealistically sharp jumps, the SILHS sampling method is revised. The diagnostics confirm that the revised sampling method reduces the overprediction of sharp jumps.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1984

A Method for Measuring the Effective Throughput Time Delay in Simulated Displays Involving Manual Control

The advent and widespread use of the computer-generated image (CGI) device to simulate visual cues has a mixed impact on the realism and fidelity of flight simulators. On the plus side, CGIs provide greater flexibility in scene content than terrain boards and closed circuit television based visual systems, and they have the potential for a greater field of view. However, on the minus side, CGIs introduce into the visual simulation relatively long time delays. In many CGIs, this delay is as much as 200 ms, which is comparable to the inherent delay time of the pilot. Because most GCIs use multiloop processing and smoothing algorithms and are linked to a multiloop host computer, it is seldom possible to identify a unique throughput time delay, and it is therefore difficult to quantify the performance of the closed loop pilot simulator system relative to the real world task. A method to address these issues using the critical task tester is described. Some empirical results from applying the method are presented, and a novel technique for improving the performance of GCIs is discussed.

Jewell, W. F.↗
DOE OSTI2017

Luminescence properties in relation to controllable morphologies of the InBO{sub 3}:Eu{sup 3+} phosphor

Graphical abstract: Four kinds of morphologies of Eu{sup 3+} doped indium borate of InBO{sub 3} phosphors have been prepared via a facile flux method only by adjusting the kinds of reaction boron source materials[(a)B{sub 2}O{sub 3}, (b)NH{sub 4}B{sub 5}O{sub 8}·4H{sub 2}O, (c)Li{sub 2}B{sub 4}O{sub 7}, (d)K{sub 2}B{sub 4}O{sub 7}·4H{sub 2}O], in which the monodisperse octahedral sample prepared with K{sub 2}B{sub 4}O{sub 7}·4H{sub 2}O as the boron source and Eu{sup 3+} doping concentration being 5% possesses the higher PL intensity and color purity, which can be used as a potential orange luminescent material. - Highlights: • InBO{sub 3}:Eu{sup 3+} phosphor with four morphologies were prepared by adjusting the boron source. • The doping concentration also has a great influence on the morphology. • The fluorescence performance is strongly correlated with morphology. • The smooth octahedral sample possesses the higher PL intensity and color purity. • InBO{sub 3}:Eu{sup 3+} smooth octahedra can be used as a potential orange luminescent material. - Abstract: Four kinds of morphologies of Eu{sup 3+} doped indium borate of the InBO{sub 3} phosphors have been prepared via a facile flux method only by adjusting the kinds of reaction boron source materials, which have been characterized by XRD, EDS and SEM. In addition, the doping concentration also has a great influence on the morphology of samples. Furthermore, the luminescence properties of the prepared InBO{sub 3}:Eu{sup 3+} samples have been investigated by photoluminescence (PL) spectra. The results show that the fluorescence performance is strongly correlated with morphologies. The prepared InBO{sub 3}:Eu{sup 3+} phosphors show strong orange emissions under ultraviolet excitation at 237 nm, in which the monodisperse octahedra sample prepared with K{sub 2}B{sub 4}O{sub 7}·4H{sub 2}O as the boron source and Eu{sup 3+} doping concentration being 5% possesses the higher PL intensity and color purity, which can be used as a potential orange luminescent material.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Estimating surface carbon fluxes based on a local ensemble transform Kalman filter with a short assimilation window and a long observation window: an observing system simulation experiment test in GEOS-Chem 10.1

We developed a carbon data assimilation system to estimate surface carbon fluxes using the local ensemble transform Kalman filter (LETKF) and atmospheric transport model GEOS-Chem driven by the MERRA-1 reanalysis of the meteorological field based on the Goddard Earth Observing System model,version 5 (GEOS-5). This assimilation system is inspired by the method of Kang et al. (2011, 2012), who estimated the surface carbon fluxes in an observing system simulation experiment (OSSE) as evolving parameters in the assimilation of the atmospheric CO 2 , using a short assimilation window of 6 h. They included the assimilation of the standard meteorological variables, so that the ensemble provided a measure of the uncertainty in the CO 2 transport. After proposing new techniques such as “variablelocalization”, and increased observation weights near the surface, they obtained accurate surface carbon fluxes at grid-point resolution. We developed a new version of the local ensemble transform Kalman filter related to the “running-in-place”(RIP) method used to accelerate the spin-up of ensemble Kalman filter (EnKF) data assimilation(Kalnay and Yang, 2010; Wang et al., 2013; Yang et al., 2012). Like RIP, the new assimilation system uses the “no cost smoothing” algorithm for the LETKF (Kalnay et al., 2007b), which allows shifting the Kalman filter solution forward or backward within an assimilation window at no cost. In the new scheme a long “observation window” (e.g., 7 d or longer) is used to design a LETKF ensemble at 7 d. Then, the RIP smoother is used to obtain an accurate final analysis at 1 d. This new approach has the advantage of being based on a short assimilation window, which makes it more accurate,and of having been exposed to the future 7 d observations, which improves the analysis and accelerates the spin-up. The assimilation and observation windows are then shifted forward by 1 d, and the process is repeated.This reduces significantly the analysis error, suggesting that the newly developed assimilation method can be used with other Earth system models,especially in order to make greater use of observations in conjunction with models.

58 GEOSCIENCES↗
DOE OSTI2018

Influence of Thickness on the Structural, Optical and Magnetic Properties of Bismuth Ferrite Thin Films

In this paper, the effect of thickness on the structural, optical, and magnetic properties of the BiFeO{sub 3} (BFO) thin films formed on a glass substrate by the chemical solution deposition has been studied. The sol-gel method combined by the spin-coating technique is used to fabricate BFO thin films. The XRD analysis indicated that BFO thin films had a rhombohedral perovskite structure. Polycrystallinity, smooth and compact surface morphology, and uniform size distribution, as well as average thickness of layers, were observed in FESEM images. UV-vis spectra showed that the absorption coefficient and energy bandgap increased by increasing the thickness of films. VSM measurements indicated that the thin films showed a behavior between weak ferromagnetic and anti-ferromagnetism for all samples.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Magnetic self-assembly for the synthesis of magnetically exchange coupled MnBi/Fe–Co composites

Exchange coupled hard/soft MnBi/Fe–Co core/shell structured composites were synthesized using a magnetic self-assembly process. MnBi particles were prepared by arc-melting, and Fe–Co nanoparticles were synthesized by an oleic acid assisted chemical reduction method. Grinding a mixture of micron-sized MnBi and Fe–Co nanoparticles in hexane resulted in MnBi/Fe–Co core/shell structured composites. The MnBi/Fe–Co (95/5 wt%) composites showed smooth magnetic hysteresis loops, enhanced remanent magnetization, and positive values in the ΔM curve, indicating exchange coupling between MnBi and Fe–Co particles. - Graphical abstract: Both MnBi and Fe–Co particles were dispersed in hexane for grinding. Because of the oleic acid used during the Fe–Co nanoparticle synthesis, they could be well dispersed in hexane. During the grinding, the size of MnBi particles was decreased, hexane was evaporated, and the Fe–Co nanoparticles were concentrated in the solvent and magnetically attracted by MnBi particles, forming a core/shell structure. - Highlights: • Exchange coupled MnBi/Fe–Co composites are synthesized through magnetic selfassembly. • Magnetic exchange coupling is demonstrated by smooth magnetic hysteresis loops, enhanced remanent magnetization, and dominant positive peak in the ΔM curve. • The experimental results in magnetic properties are close to the theoretical calculation results.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Controlling Thin-Film Stress and Wrinkling during Perovskite Film Formation

Significant effort has focused on controlling the deposition of perovskite films to enable uniform films, enabling efficiencies to climb dramatically. However, little attention has been paid to the evolution of thin-film stresses during deposition and the consequent effect on film morphology. While a textured surface topology has potential benefits for light scattering, a smooth surface is desirable to enable the pinhole-free deposition of contact layers. In this paper, we show that the highly textured morphology made by popular antisolvent conversion methods arises because of in-plane compressive stress experienced during the intermediate phase of film formation where the substrate constrains the film from expanding—leading to energy release in the form of wrinkling, resulting in trenches that can be hundreds of nanometers deep with periods of several micrometers. Finally, we demonstrate that the extent of wrinkling is correlated with the rate of film conversion and that ultrasmooth films are obtained by slowing the rate of film formation.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Assessing XMT-Measurement Variability of Air-Water Interfacial Areas in Natural Porous Media

This study investigates the accuracy and reproducibility of air-water interfacial areas measured with high-resolution synchrotron X-ray microtomography (XMT). Columns packed with one of two relatively coarse-grained monodisperse granular media, glass beads or a well-sorted quartz sand, were imaged over several years, encompassing changes in acquisition equipment, improved image quality, and enhancements to image acquisition and to processing software. For the glass beads, the specific solid surface area (SSSA-XMT) of 31.6 ± 1 cm -1 determined from direct analysis of the segmented solid-phase image data is statistically identical to the independently calculated geometric smooth-sphere specific solid surface area (GSSA, 32 ± 1 cm -1 ) and to the measured SSSA (28 ± 3 cm -1 ) obtained with the N2-Brunauer, Emmett, and Teller method. The maximum specific air-water interfacial area (Amax) is 27.4 (±2) cm -1 , which compares very well to the SSSA-XMT, GSSA, and SSSA-N2-Brunauer, Emmett, and Teller values. For the sand, the SSSA-XMT (111 ± 2 cm -1 ) and GSSA (113 ± 1 cm -1 ) are similar. The mean Amax is 96 ± 5 cm -1 , which compares well to both the SSSA and the GSSA values. The XMT-SSSA values deviated from the GSSA values by 7–16% for the first four experiments but were essentially identical for the later experiments. This indicates that enhancements in image acquisition and processing improved data accuracy. The Amax values ranged from 74 cm -1 to 101 cm -1 , with a coefficient of variation (COV) of 9%. The maximum capillary interfacial area ranged from 12 cm-1 to 19 cm -1 , for a COV of 10%. The COVs for both decreased to 5–6% for the latter five experiments. These results demonstrate that XMT imaging provides accurate and reproducible measurements of total and capillary interfacial areas.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2012

SOME CONSTRAINTS ON THE LOWER MASS LIMIT FOR DOUBLE-DEGENERATE PROGENITORS OF TYPE Ia SUPERNOVAE

Recent theoretical and observational studies both argue that the merging of double carbon-oxygen white dwarfs (WDs) is responsible for at least some Type Ia supernovae (SNe Ia). Previous (standard) studies of the anticipated SN birthrate from this channel have assumed that the merger process is conservative and that the primary criterion for explosion is that the merged mass exceeds the Chandrasekhar mass. Han and Webbink demonstrated that mass transfer and merger in close double WDs will in many cases be non-conservative. Pakmor et al. further suggested that the merger process should be violent in order to initiate an explosion. We have therefore investigated how the SN Ia birthrate from the double-degenerate (DD) channel is affected by these constraints. Using the binary-star population-synthesis method, we have calculated the DD SN Ia birthrate under conservative and non-conservative approximations, and including lower mass and mass-ratio limits indicated by recent smoothed-particle-hydrodynamic calculations. The predicted DD SN Ia rate is significantly reduced by all of these constraints. With dynamical mass loss alone (violent merger) the birthrate is reduced to 56% of the conservative rate. Requiring the mass ratio q > 2/3 further reduces the birthrate to 18% that of the standard assumption. An upper limit of 0.0061 SNuM, or a Galactic rate of 4.6 Multiplication-Sign 10{sup -4} yr{sup -1}, might be realistic.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Parameterization of photon beam dosimetry for a linear accelerator

Purpose: In radiation therapy, accurate data acquisition of photon beam dosimetric quantities is important for (1) beam modeling data input into a treatment planning system (TPS), (2) comparing measured and TPS modeled data, (3) the quality assurance process of a linear accelerator’s (Linac) beam characteristics, (4) the establishment of a standard data set for comparison with other data, etcetera. Parameterization of the photon beam dosimetry creates a data set that is portable and easy to implement for different applications such as those previously mentioned. The aim of this study is to develop methods to parameterize photon beam dosimetric quantities, including percentage depth doses (PDDs), profiles, and total scatter output factors (S{sub cp}). Methods: S{sub cp}, PDDs, and profiles for different field sizes, depths, and energies were measured for a Linac using a cylindrical 3D water scanning system. All data were smoothed for the analysis and profile data were also centered, symmetrized, and geometrically scaled. The S{sub cp} data were analyzed using an exponential function. The inverse square factor was removed from the PDD data before modeling and the data were subsequently analyzed using exponential functions. For profile modeling, one halfside of the profile was divided into three regions described by exponential, sigmoid, and Gaussian equations. All of the analytical functions are field size, energy, depth, and, in the case of profiles, scan direction specific. The model’s parameters were determined using the minimal amount of measured data necessary. The model’s accuracy was evaluated via the calculation of absolute differences between the measured (processed) and calculated data in low gradient regions and distance-to-agreement analysis in high gradient regions. Finally, the results of dosimetric quantities obtained by the fitted models for a different machine were also assessed. Results: All of the differences in the PDDs’ buildup and the profiles’ penumbra regions were less than 2 and 0.5 mm, respectively. The differences in the low gradient regions were 0.20% ± 0.20% (<1% for all) and 0.50% ± 0.35% (<1% for all) for PDDs and profiles, respectively. For S{sub cp} data, all of the absolute differences were less than 0.5%. Conclusions: This novel analytical model with minimum measurement requirements was proved to accurately calculate PDDs, profiles, and S{sub cp} for different field sizes, depths, and energies.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2019

Globalized Modeling and Signal Timing Control for Large-scale Networked Intersections

Traffic intersections are often the bottlenecks of traffic systems. Given a traffic network, an optimal traffic signal control strategy can result in smooth traffic flow and thus reduce energy consumption and environmental impact at intersections. This study aims to develop a new multi input and multi output (MIMO) traffic signal control method that can improve network wide traffic operations in terms of delay and energy consumption. In this context, a 35 intersection network of Bellevue, WA is used as the basis for the development of the algorithm, where modeling and intersection controls in a globalized setting are established using MIMO linear control theory and high matrix formulation. The proposed control method is evaluated in a microscopic traffic simulation environment, VISSIM. Simulation results show that the proposed method has much shorter average travel delays in the network when compared with the delays of conventional pretimed and actuated controls.

Wang, Hong↗
DOE OSTI2025

An Innovative High Throughput Genome Releaser for Rapid and Efficient PCR Screening

High-throughput PCR screening is vital in synthetic biology and metabolic engineering as it allows researchers to rapidly analyze and detect numerous targeted genetic mutation in the genome. Current challenges for high-throughput PCR screening in synthetic biology include efficiently preparing genomic DNA, optimizing protocols for diverse sample types, managing contamination risks, and effectively analyzing the large volumes of data generated while ensuring consistent and accurate results. In this study, we present the development of a High Throughput Genome Releaser (HTGR), an innovative device addressing common challenges in screening PCR. This genome DNA releaser is designed based on a squash method for rapid, cost-effective, and efficient DNA release, optimized for subsequent PCR reactions. After experimenting with various synthetic materials, we selected a plastic that closely replicates the smooth surface and compression properties of microscope slides, ensuring reliable performance. We engineered a device featuring a 96-Well Plate and a shear applicator, operable both manually and automatically, and compatible with standard liquid-handling robot platform. This compatibility enhances ease of use in high-throughput PCR workflows. Additionally, we developed software to support its automatic functions. Our results demonstrated that the specially engineered 96-Well Plate and HTGR can effectively squash fungal spores , which release enough genome DNA for PCR screening. The genome releaser facilitates the preparation of PCR-amplifiable genomic DNA substrate from 96 samples within minutes, eliminates the need for extraction buffers, and is adaptable to a wide range of microorganisms and cells, which could significantly advance biomanufacturing processes.

Yuan, Guoliang [BATTELLE (PACIFIC NW LAB)]↗
NASA NTRS1980

Attitude control study for a large flexible spacecraft using a Solar Electric Propulsion System (SEPS)

The attitude control performance of the solar electric propulsion system (SEPS) was evaluated. A thrust vector control system for powered flight control was examined along with a gas jet reaction control system, and a reaction wheel system, both of which have been proposed for nonpowered flight control. Comprehensive computer simulations of each control system were made and evaluated using a 30 mode spacecraft model. Results obtained indicate that thrust vector control and reaction wheel systems offer acceptable smooth proportional control. The gas jet control system is shown to be risky for a flexible structure such as SEPS, and is therefore, not recommended as a primary control method.

Tolivar, A. F.↗
NASA NTRS1980

Calculation of skin-friction coefficients for low Reynolds number turbulent boundary layer flows

An analysis is presented of the reliability of various generally accepted empirical expressions for the prediction of the skin-friction coefficient C/sub f/ of turbulent boundary layers at low Reynolds numbers in zero-pressure-gradient flows on a smooth flat plate. The skin-friction coefficients predicted from these expressions were compared to the skin-friction coefficients of experimental profiles that were determined from a graphical method formulated from the law of the wall. These expressions are found to predict values that are consistently different than those obtained from the graphical method over the range 600 Re/sub theta 2000. A curve-fitted empirical relationship was developed from the present data and yields a better estimated value of C/sub f/ in this range. The data, covering the range 200 Re/sub theta 7000, provide insight into the nature of transitional flows. They show that fully developed turbulent boundary layers occur at Reynolds numbers Re/sub theta/ down to 425. Below this level there appears to be a well-ordered evolutionary process from the laminar to the turbulent profiles. These profiles clearly display the development of the turbulent core region and the shrinking of the laminar sublayer with increasing values of Re/sub theta/.

Barr, P. K.↗
NASA NTRS1982

Cross-validation for densities and regressions

Virtually all nonparametric (infinite dimensional) problems require the choice of a smoothing parameter. It is natural to attempt to use the data to guide the choice of this parameter. The most widely applicable data driven technique is cross validation. The method of cross validation is introduced and results are presented which establish consistency for certain cross validated density estimators and consistency as well as asymptotic normality for rigid regression.

Geman, S.↗
NASA NTRS1988

Creep life prediction based on stochastic model of microstructurally short crack growth

A nondimensional model of microstructurally short crack growth in creep is developed based on a detailed observation of the creep fracture process of 304 stainless steel. In order to deal with the scatter of small crack growth rate data caused by microstructural inhomogeneity, a random variable technique is used in the model. A cumulative probability of the crack length at an arbitary time, G(bar a, bar t), and that of the time when a crack reaches an arbitary length, F(bar t, bar a), are obtained numerically by means of a Monte Carlo method. G(bar a, bar t), and F(bar t, bar a) are the probabilities for a single crack. However, multiple cracks generally initiate on the surface of a smooth specimen from the early stage of creep life to the final stage. TAking into account the multiple crack initiations, the actual crack length distribution observed on the surface of a specimen is predicted by the combination of probabilities for a single crack. The prediction shows a fairly good agreement with the experimental result for creep of 304 stainless steel at 923 K. The probability of creep life is obtained from an assumption that creep fracture takes place when the longest crack reaches a critical length. The observed and predicted scatter of the life is fairly small for the specimens tested.

Kitamura, Takayuki↗