Search NASA⌕ Search

SEARCH · Search NASA

Results for “manufacturing visualization”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

PTT System Performance Evaluation in 3-D Imaging of Calibrated Defects: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Research activity in this project is aimed at developing pulsed thermal tomography (PTT) architecture and algorithms for in-service non-destructive examination (NDE) of additively manufactured (AM) reactor components and materials. Recent advances in AM technology could allow cost-efficient fabrication of parts for operating reactors. However, because of stringent safety requirements, long-term performance of AM reactor components needs to be investigated before AM is widely accepted. Because of the complex shapes and significant surface roughness of components due to layer-by-layer welding process in AM, conventional methods might not be useful for in-service NDE of AM components. PTT is ideally suited for in-service NDE of AM metallic components because the method is non-contact, and offers high resolution #-D imaging of material flaws. The objective of this report is to provide initial evaluate of PTT performance sin detecting calibrated flaws in reactor structural materials. Preliminary COMSOL models were developed to conduct super computing simulations of PTT. In the experimental studies, high strength Stainless Steel 316 and Inconel 718 alloys were considered, as well as lower grade Stainless Steel 304, Nickel 200, and Hastelloy C276. Specimens investigated in this report consisted of approximately 1/4in-thick plates made out of these alloys using conventional manufacturing methods. The calibrated defects were created in the form of flat bottom holes (FBH) drilled in metallic plates. The diameters of FBH's varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. The size of the smallest FBH was limited to 1mm because conventional mechanic drills were used for creating the holes. PTT imaging results have shown that 1mm-diameter FBH located 1mm and 2mm below the surface were detectable. Larger size FBH were detectable at greater depth. For example, 6mm-diameter FBH could be detected at 8mm depth. Image contrast varied slightly between the specimens, with the best reconstructions obtained in SS316 and C276 plates. In addition, a 2/3in-thick Inconel 718 nozzle plate produced with additive manufacturing method was imaged with PTT. It was shown that PTT can scan through the plate in approximately 20s. Several modes of 3-D data visualization were explored, including using ImageJ and MATLAB software packages.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Closing the Loop

Like all research, the concepts of exactly what a slicer should accomplish, and how, continue to evolve. The development of next-generation slicing is already underway, and this chapter introduces several related topics. This includes a new slicing paradigm driven by network connectivity, called “slice on demand.” This paradigm enables additional capabilities such as closing the loop with sensor feedback, experimental system support, and connectivity to simulation and visualization software, all of which are also discussed. Each of these concepts represents future opportunities for slicing software and supports the growing expectations of additive manufacturing technology.

Borish, Michael↗
DOE OSTI2016

Evaporation-driven clustering of microscale pillars and lamellae

As a liquid film covering an array of micro- or nanoscale pillars or lamellae evaporates, its meniscus pulls the elastic patterns together because of capillary effects, leading to clustering of the slender microstructures. While this elastocapillary coalescence may imply various useful applications, it is detrimental to a semiconductor manufacturing process called the spin drying, where a liquid film rinses patterned wafers until drying. To understand the transient mechanism underlying such self-organization during and after liquid evaporation, we visualize the clustering dynamics of polymer micropatterns. Our visualization experiments reveal that the patterns clumped during liquid evaporation can be re-separated when completely dried in some cases. This restoration behavior is explained by considering adhesion energy of the patterns as well as capillary forces, which leads to a regime map to predict whether permanent stiction would occur. This work does not only extend our understanding of micropattern stiction, but also suggests a novel path to control and prevent pattern clustering.

36 MATERIALS SCIENCE↗
DOE OSTI2024

ResStock™ Data Visualization Tools - How to Use Them: A Demonstration [Slides]

This training from the National Renewable Energy Laboratory introduces Energy Efficiency Conservation Block Grant Program participants to ResStock, a modeling tool that can help states, municipalities, utilities, and manufacturers identify which residential building improvements save the most money and energy.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS2018

In Situ Thermal Inspection of Automated Fiber Placement Operations for Tow and Ply Defect Detection

The advent of Automated Fiber Placement (AFP) systems have aided the rapid manufacturing of composite aerospace structures. One of the challenges that AFP systems pose is the uniformity of the deposited prepreg tape layers, which complicates detection of laps, gaps, overlaps and twists. The current detection method used in industry involves halting fabrication and performing a time consuming, visual inspection of each tape layer. Typical AFP systems use a quartz lamp to heat the base layer to make the surface tacky as it deposits another tape layer. The innovation proposed in this paper is to use the preheated base layer as a through-transmission heat source for inspecting the newly added tape layer in situ using a thermographic camera mounted on to the AFP hardware. Such a system would not only increase manufacturing throughput by reducing inspection times, but it would also aid in process development for new structural designs or material systems by providing data on as-built parts. To this end, a small thermal camera was mounted onto an AFP robotic research platform at NASA, and thermal data was collected during typical and experimental layup operations. The data was post processed to reveal defects such as tow overlap/gap, wrinkling, and peel-up. Defects that would have been impossible to detect visually were also discovered in the data, such as poor/loss of adhesion between plies and the effects of vacuum debulking. This paper will cover the results of our experiments, and the plans for future versions of this inspection system.

Juarez, Peter D.↗
NASA NTRS1994

Implementing bright light treatment for MSFC payload operations shiftworkers

Intense light can phase-shift circadian rhythms and improve performance, sleep, and wellbeing during shiftwork simulations, but to date there have been very few attempts to administer light treatment to real shiftworkers. We have developed procedures for implementing light treatment and have conducted controlled trials of light treatment for MSFC Payload Operations staff during the USML-1 mission. We found that treatment had beneficial effects on fatigue, alertness, self-rated job performance, sleep, mood, and work attendance. Although there are portable bright light boxes commercially available, there is no testing protocol and little performance information available. We measure the illuminance of two candidate boxes for use in this study and found that levels were consistently lower than those advertised by manufacturers. A device was developed to enhance the illuminance output of such units. This device increased the illuminance by at least 60 % and provided additional improvements in visual comfort and overall exposure. Both the design of this device and some suggested procedures for evaluating light devices are presented.

Hayes, Benita C.↗
DOE OSTI2026

Background-Oriented Schlieren Velocimetry of Helium Coolant Flow in Additively Manufactured Channels

High-pressure helium gas cooling is an attractive solution for thermal management of the fusion blanket first wall, as this coolant is chemically and neutronically inert and separable from hydrogenic species. However, due to the low thermal mass of helium, geometric optimization of these channels is required to provide sufficient cooling at manageable flow rates and pumping burdens. Increasingly, analysis and optimization of these coolant channels rely on computational fluid dynamics (CFD) simulations, and these require relevant experimental data for turbulence model validation. Toward this end, a high-pressure helium gas flow visualization system has been employed to image the flow of helium in flow channels with one-sided heating, mimicking the blanket first wall environment. Flow of helium at 4 MPa pressure and flow rates up to 68 g/s (Reynolds number 57 000) is supplied to rectangular channel test sections, with uniform heating applied to the bottom wall of the channel at heat fluxes varied between roughly 50 and 130 kW/m2. A high-speed camera is used to image index of refraction (IOR) gradients in the fluid via background-oriented schlieren (BOS), and temperature and pressure instrumentation are used to characterize thermal-hydraulic performance of each channel. Cross correlation of time-resolved BOS images is then used to calculate time-averaged 2-D helium velocity fields. Flow in additively manufactured (AM) channels is examined in this manner, including both featureless channels and those containing baffling as a heat transfer enhancement. The flow distribution seen in the featureless case differs significantly from that seen in prior simulations, whereas the flow in the baffled case shows the predicted behavior of flow forced along the heated wall. This augmented flow distribution is seen to increase the heat transfer coefficient in the baffled test section. Here, strategies are discussed for ongoing and future validation of these simulations, with the aim of model deployment for blanket cooling design and optimization.

Additive manufacturing↗
DOE OSTI2019

A Balanced Approach to Molded Case Circuit Breaker Maintenance

Abstract – NFPA 70E mandates that "overcurrent devices shall be maintained in accordance with the manufacturer's instructions or industry consensus standards". At our laboratory this mandate is law, because 10 CFR 851 requires adherence to NFPA 70 and 70E. This begs the question, exactly what are those manufacturer's instructions, and what do the industry consensus standards require? In particular with Molded Case Circuit Breakers (MCCB's), how does one meet these requirements and still apply a balanced approach in a maintenance program when the facilities range from brand new construction to over fifty years old, and where circuit breakers exist that have been made by virtually every major manufacturer? This paper examines the instructions given by the various manufacturers, and examines the standards that exist, along with major guides and white paper recommendations. Both the consistencies and the inconsistencies are examined, recommendations are compared, and a general consensus of recommendations emerges. The various maintenance particulars are examined, from cycling of breakers and thermography to inverse thermal and instantaneous primary injection trip testing. The results of an FMEA (Failure Modes and Effects Analysis) was conducted at our facility; the results of that FMEA and the recommendations of that FMEA for maintenance of MCCB’s are presented. In this paper, we have examined the recommendations of manufacturers, standards, and guides that provide the guidelines for maintenance of molded case circuit breakers. Although many conflicts exist, a consensus of nearly universal recommendations emerges. A balanced approach to maintenance that provides the maximum safety benefit within the bounds of economic feasibility can be developed. We provide a condensation of the existing literature with references, a visual summary of that literature and propose a recommended maintenance approach.

42 ENGINEERING↗
DOE OSTI2022

Testing Asoleyo Decorative Solar Cell and Modules: Cooperative Research and Development, CRADA Number CRD-20-16732 (Final Report)

Team Asoleyo is transforming the utilitarian rectangular grid that dominates the visual style of standard solar panels by re-designing solar cells’ silver contact grid using principles of symmetry, rhythm, and line. Our designs use well-established manufacturing equipment, techniques, and materials, achieving similar manufacturing costs but far superior aesthetic effect- without the need for additional layers or occlusion. This project will test new decorative PV Cell front contact designs, individually and interconnected within modules, for their performance characteristics.

14 SOLAR ENERGY↗
DOE OSTI2014

Contributing Data to the Fleet DNA Project (Brochure)

The Fleet DNA clearinghouse of commercial fleet transportation data helps vehicle manufacturers and developers optimize vehicle designs and helps fleet managers choose advanced technologies for their fleets. This online tool - available at www.nrel.gov/fleetdna - provides data summaries and visualizations similar to real-world 'genetics' for medium- and heavy-duty commercial fleet vehicles operating within a variety of vocations. To contribute your fleet data, please contact Adam Duran of the U.S. Department of Energy's National Renewable Energy Laboratory (NREL) at adam.duran@nrel.gov or 303-275-4586.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Automated phase segmentation and quantification of high-resolution TEM image for alloy design

In the alloy design and development process, a wealth of atomically resolved structural high-resolution transmission electron microscopy (HRTEM) images are produced. Identifying the different nano-precipitate phases and tracking their evolution under various compositions and during manufacturing or post-processing requires hundreds of HRTEM images and thousands of precipitates. The nanoscopic phase information labeling and analysis purely relies on humans are prohibitively costly and time-consuming, sometimes not reliable because of the lack of authoritative knowledge. Here, in this work, we develop a novel unsupervised machine learning approach coupled with adaptive computer vision techniques with features in the Fourier space to automatically determine the number of phases and segment/quantify the phases with nanoscale resolution, allowing for quantitative correlation between nanostructure formation, processing and functional properties. To automate the phase extraction/quantification and ascertain its applicability, we have applied the developed framework to the HRTEM images from several alloy systems, processing conditions, image magnifications, and phase types and morphologies (precipitates, nano-twins, stacking faults, crystalline matrix, and amorphous structures) for verification. This study paves the road for compression, visualization, and translation of raw image structural data into physically relevant information in real-time with minimal human supervision. It shows the promise of enabling high-throughput materials characterization for the acceleration of alloy manufacturing and design.

36 MATERIALS SCIENCE↗
NASA NTRS2013

Process Optimization of Bismaleimide (BMI) Resin Infused Carbon Fiber Composite

Bismaleimide (BMI) resins are an attractive new addition to world-wide composite applications. This type of thermosetting polyimide provides several unique characteristics such as excellent physical property retention at elevated temperatures and in wet environments, constant electrical properties over a vast array of temperature settings, and nonflammability properties as well. This makes BMI a popular choice in advance composites and electronics applications [I]. Bismaleimide-2 (BMI-2) resin was used to infuse intermediate modulus 7 (IM7) based carbon fiber. Two panel configurations consisting of 4 plies with [+45deg, 90deg]2 and [0deg]4 orientations were fabricated. For tensile testing, a [90deg]4 configuration was tested by rotating the [0deg]4 configirration to lie orthogonal with the load direction of the test fixture. Curing of the BMI-2/IM7 system utilized an optimal infusion process which focused on the integration of the manufacturer-recommended ramp rates,. hold times, and cure temperatures. Completion of the cure cycle for the BMI-2/IM7 composite yielded a product with multiple surface voids determined through visual and metallographic observation. Although the curing cycle was the same for the three panellayups, the surface voids that remained within the material post-cure were different in abundance, shape, and size. For tensile testing, the [0deg]4 layup had a 19.9% and 21.7% greater average tensile strain performance compared to the [90deg]4 and [+45deg, 90deg, 90deg,-45degg] layups, respectively, at failure. For tensile stress performance, the [0deg]4 layup had a 5.8% and 34.0% greater average performance% than the [90deg]4 and [+45deg, 90deg, 90deg,-45deg] layups.

Ehrlich, Joshua W.↗
DOE OSTI2015

Maskless Lithography and in situ Visualization of Conductivity of Graphene using Helium Ion Microscopy

The remarkable mechanical and electronic properties of graphene make it an ideal candidate for next generation nanoelectronics. With the recent development of commercial-level single-crystal graphene layers, the potential for manufacturing household graphene-based devices has improved, but significant challenges still remain with regards to patterning the graphene into devices. In the case of graphene supported on a substrate, traditional nanofabrication techniques such as e-beam lithography (EBL) are often used in fabricating graphene nanoribbons but the multi-step processes they require can result in contamination of the graphene with resists and solvents. In this letter, we report the utility of scanning helium ion lithography for fabricating functional graphene nanoconductors that are supported directly on a silicon dioxide layer, and we measure the minimum feature size achievable due to limitations imposed by thermal fluctuations and ion scattering during the milling process. Further we demonstrate that ion beams, due to their positive charging nature, may be used to observe and test the conductivity of graphene-based nanoelectronic devices in situ.

36 MATERIALS SCIENCE↗
DOE OSTI2015

SU-E-J-214: MR Protocol Development to Visualize Sirius MRI Markers in Prostate Brachytherapy Patients for MR-Based Post-Implant Dosimetry

Purpose: The current CT-based post-implant dosimetry allows precise seed localization but limited anatomical delineation. Switching to MR-based post-implant dosimetry is confounded by imprecise seed localization. One approach is to place positive-contrast markers (Sirius) adjacent to the negative-contrast seeds. This patient study aims to assess the utility of a 3D fast spoiled gradient-recalled echo (FSPGR) sequence to visualize Sirius markers for post-implant dosimetry. Methods: MRI images were acquired in prostate implant patients (n=10) on Day 0 (day-of-implant) and Day 30. The post-implant MR protocol consisted of 3D T2-weighted fast-spin-echo (FSE), T2-weighted 2D-FSE (axial) and T1-weighted 2D-FSE (axial/sagittal/coronal). We incorporated a 3D-FSPGR sequence into the post-implant MR protocol to visualize the Sirius markers. Patients were scanned with different number-of-excitations (6, 8, 10), field-of-view (10cm, 14cm, 18cm), slice thickness (1mm, 0.8mm), flip angle (14 degrees, 20 degrees), bandwidth (122.070 Hz/pixel, 325.508 Hz/pixel, 390.625 Hz/pixel), phase encoding steps (160, 192, 224, 256), frequency-encoding direction (right/left, anterior/posterior), echo-time type (minimum-full, out-of-phase), field strength (1.5T, 3T), contrast (with, without), scanner vendor (Siemens, GE), coil (endorectal-coil only, endorectal-and-torso-coil, torsocoil only), endorectal-coil filling (30cc, 50cc) and endorectal-coil filling type (air, perfluorocarbon [PFC]). For post-implant dosimetric evaluation with greater anatomical detail, 3D-FSE images were fused with 3D-FSPGR images. For comparison with CT-based post-implant dosimetry, CT images were fused with 3D-FSPGR images. Results: The 3D-FSPGR sequence facilitated visualization of markers in patients. Marker visualization helped distinguish signal voids as seeds versus needle tracks for more definitive MR-based post-implant dosimetry. On the CT-MR fused images, the distance between the seed on CT to MR images was 3.2±1.6mm in patients with no endorectal coil, 2.3±0.8mm in patients with 30cc-PFC-filled endorectal-coil and 5.0±1.8mm in patients with 50cc-PFC-filled endorectal-coil. Conclusion: An MR protocol to visualize positive-contrast Sirius markers to assist in the identification of negative-contrast seeds was demonstrated. S Frank is a co-founder of C4 Imaging LLC, the manufacturer of the MRI markers.

60 APPLIED LIFE SCIENCES↗
NASA NTRS1977

Inexpensive low-voltage solid-state alarm

Monitor/alarm with audio and visual warning output can be used to warn when prescribed limits of temperature, liquid level, pressure, or similar properties are exceeded. Device is more compact, lighter, and less expensive to manufacture than typical alarm circuits.

Hardy, D. H.↗
DOE OSTI2012

X-ray Vision for Aerosol Scientists: LCLS Snapshots of Soot (Narrated)

This short conceptual animation depicts how scientists can now simultaneously capture fractal morphology (structure), chemical composition and nanoscale imagery of individual aerosol particles in flight. These particles, known as "PM2.5" because they are smaller than 2.5 microns in diameter, affect climate by interacting with sunlight and impact human health by entering the lungs. The single LCLS laser pulses travel to the Atomic, Molecular and Optical Sciences (AMO) laboratory in the Near Experimental Hall. As we zoom in, we see deep inside a simplified aerosol inlet, where the complex fractal structure of the soot particles, each one completely unique, is shown. Individual soot particles are then delivered into the pulses of the LCLS beam, which destroys them. X-rays are scattered to the detector before the particle is destroyed, giving information about the morphology of the particle. Ion fragments released in the explosion are sent into a mass spectrometer, which measures their mass-to-charge ratio -- giving scientists information about the chemical composition of the particle. Many different particles are analyzed in this manner, allowing scientists to probe variations in the particles due to changes in their environment before being sent through the aerosol inlet. The final visual of aerosols emitted from a factory is representative of the goal that such LCLS aerosol dynamics experiments can provide critical feedback into modeling and understanding combustion, aerosol processes in manufacturing or aerosol effects on climate change.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Non-visual analysis of miniaturized melt wire arrays for in-pile measurement of peak irradiation temperature

As a part of the in-pile instrumentation program, the Idaho National Laboratory (INL) has established in-house capabilities to fabricate and test new advanced manufactured printed sensors for measurement of peak temperature inside the harsh environment of a nuclear test reactor. Although nuclear test reactors may use standard methods that can provide real-time temperature information, such as thermocouples, the need for feedthroughs for real-time measurements greatly increases the cost of the experiment. Some experiments also present the problem of limited space available for instrumentation. To address this need, INL is working to improve temperature detection options for such applications. The lab is developing advanced manufactured melt wire arrays to determine peak temperatures in experiments with limited space. Furthermore, capabilities to print multiple melt wires with different melting properties on a single miniaturized unit is being established. Recent results and knowledge from this ongoing work have made it possible to develop unique temperature sensors that can accomplish user specific temperature ranges inside the harsh environments experienced during radiation testing.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Advances in In-Situ Inspection of Automated Fiber Placement Systems

The advent of Automated Fiber Placement (AFP) systems have aided the rapid manufacturing of composite aerospace structures. One of the challenges that AFP systems present is the uniformity of the deposited prepreg tape layers, which are prone to laps, gaps, overlaps and twists. The current detection modus operandi involves halting fabrication and performing a time consuming visual inspection of each tape layer. Typical AFP systems use a quartz lamp to heat the base layer to make the surface tacky as it deposits another tape layer. The idea was proposed to use the preheated base layer as a through transmission heat source and to inspect the newly added tape layer using a thermographic camera. As a preliminary study of this concept a laboratory proof of concept device was designed and constructed to simulate the through transmission heat source. Using the proof of concept device, we inspected an AFP-built uncured composite specimen with artificial manufacturing defects. This paper will discuss the results of this preliminary study and the implications involved with deploying a full-scale AFP inspection system.

Juarez, Peter D.↗