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At least 1,711 records · Page 95

Experimental study on the effect of nozzle hole-to-hole angle on the near-field spray of diesel injector using fast X-ray phase-contrast imaging

Fuel atomization and vaporization process play a critical role in determining the engine combustion and emission. The primary near-nozzle breakup is the vital link between the fuel emerging from the nozzle and the fully atomized spray. In this study, the near-nozzle spray characteristics of diesel injector with different umbrella angle (UA) were investigated using high-speed X-ray phase-contrast imaging and quantitative image processing. A classic ‘dumbbell’ profile of spray width (SW) composed of three stages: opening stage, semisteady stage and closing stage. The SW peak of two-hole injectors was more than twice of that of single-hole injector at the opening and closing stages, corresponding to the hollow-cone spray. This indicated the vortex flow was formed with the increase of the UA. The higher injection pressure had little influence on the SW while led to earlier breakup closer to the nozzle. Significant fuel effect on the SW at higher needle lift was found. However, this effect could be neglect at lower needle lift due to the leading role of internal flow and cavitation on the near-field spray characteristics. In addition, the morphology-based breakup process was observed, which highlighted the important effect of internal flow on the spray development. The possibility of using hollow-cone spray in diesel injector was also discussed.

biodiesel↗

Layer-wise Imaging Dataset from Powder Bed Additive Manufacturing Processes for Machine Learning Applications (Peregrine v2021-03)

This dataset contains layer-wise powder bed images from three different powder bed printing technologies – laser powder bed fusion, electron beam powder bed fusion, and binder jetting. This dataset was collected and annotated using the internally-developed Peregrine software tool and is designed primarily to facilitate research into anomaly defect detection using image segmentation or similar techniques. A total of 20 layers are provided for each printing technology, with each layer of data consisting of one or more calibrated images and an annotation file containing pixel-wise ground truth labels. The ground truths were labeled by domain experts, typically printer technicians. Data in this release were collected at Oak Ridge National Laboratory between 2016 and 2020 and were compiled in March 2021.

36 MATERIALS SCIENCE↗

TEM Video Compressive Sensing

One of the main limitations of imaging at high spatial and temporal resolution during in-situ TEM experiments is the frame rate of the camera being used to image the dynamic process. While the recent development of direct detectors has provided the hardware to achieve frame rates approaching 0.1ms, the cameras are expensive and must replace existing detectors. In this paper, we examine the use of coded aperture compressive sensing methods [1, 2, 3, 4] to increase the framerate of any camera with simple, low-cost hardware modifications. The coded aperture approach allows multiple sub-frames to be coded and integrated into a single camera frame during the acquisition process, and then extracted upon readout using statistical compressive sensing inversion. Our simulations show that it should be possible to increase the speed of any camera by at least an order of magnitude. Compressive Sensing (CS) combines sensing and compression in one operation, and thus provides an approach that could further improve the temporal resolution while correspondingly reducing the electron dose rate. Because the signal is measured in a compressive manner, fewer total measurements are required. When applied to TEM video capture, compressive imaging couled improve acquisition speed and reduce the electron dose rate. CS is a recent concept, and has come to the forefront due the seminal work of Candès [5]. Since the publication of Candès, there has been enormous growth in the application of CS and development of CS variants. For electron microscopy applications, the concept of CS has also been recently applied to electron tomography [6], and reduction of electron dose in scanning transmission electron microscopy (STEM) imaging [7]. To demonstrate the applicability of coded aperture CS video reconstruction for atomic level imaging, we simulate compressive sensing on observations of Pd nanoparticles and Ag nanoparticles during exposure to high temperatures and other environmental conditions. Figure 1 highlights the results from the Pd nanoparticle experiment. On the left, 10 frames are reconstructed from a single coded frame—the original frames are shown for comparison. On the right a selection of three frames are shown from reconstructions at compression levels 10,20,30. The reconstructions, which are not post-processed, are true to the original and degrade in a straightforward manner. The final choice of compression level will obviously depend on both the temporal and spatial resolution required for a specific imaging task, but the results indicate that an increase in speed of better than an order of magnitude should be possible for all experiments. References: [1] P Llull, X Liao, X Yuan et al. Optics express 21(9), (2013), p. 10526. [2] J Yang, X Yuan, X Liao et al. Image Processing, IEEE Trans 23(11), (2014), p. 4863. [3] X Yuan, J Yang, P Llull et al. In ICIP 2013 (IEEE), p. 14. [4] X Yuan, P Llull, X Liao et al. In CVPR 2014. p. 3318. [5] EJ Candès, J Romberg and T Tao. Information Theory, IEEE Trans 52(2), (2006), p. 489. [6] P Binev, W Dahmen, R DeVore et al. In Modeling Nanoscale Imaging in Electron Microscopy, eds. T Vogt, W Dahmen and P Binev (Springer US), Nanostructure Science and Technology (2012). p. 73. [7] A Stevens, H Yang, L Carin et al. Microscopy 63(1), (2014), pp. 41.

Stevens, Andrew↗

FEASIBILITY OF HELIOSPHERIC IMAGING FROM NEAR EARTH

Imaging solar wind structures via Thomson scattered sunlight has proved important to understanding the inner heliosphere. The principal challenge of heliospheric imaging is background subtraction: typical solar wind features are fainter than the zodiacal light and starfield by 2-3 orders of magnitude. Careful post-processing is required to separate the solar wind signal from the static background. Remnant background, and not photon noise, is the dominant noise source in current STEREO data. We demonstrate that 10× shorter exposure times would not strongly affect the noise level in these data. Further, we demonstrate that current processing techniques are sufficient to separate not only the existing background of the STEREO images but also diffuse variable backgrounds such as are expected to be seen from low Earth orbit. We report on a hare-and-hounds style study, demonstrating blind signal extraction from STEREO/HI-2 data that have been degraded by the addition of large-scale, time-dependent artifacts to simulate viewing through airglow or high-altitude aurora. We demonstrate removal of these effects via image processing, with little degradation compared to the original. Even with as few as three highly degraded source images over 48 hr, it is possible to detect and track large coronal mass ejections more than 40° from the Sun. This implies that neither the high altitude aurora discovered by Coriolis/SMEI, nor airglow effects seen from low Earth orbit, are impediments to a hypothetical next-generation heliospheric imager in low Earth orbit; and also that post-processing is as important to heliospheric image qualitiy as are optical contamination effects.

79 ASTRONOMY AND ASTROPHYSICS↗

TH-AB-209-04: 3D Light Sheet Luminescence Imaging with Cherenkov Radiation

Purpose: To recover a three-dimensional density distribution of luminescent molecular probes located several centimeters deep within a highly scattering tissue. Methods: We developed a novel sheet beam Cherenkov-excited luminescence scanned imaging (CELSI) methodology. The sample was irradiated by a horizontally oriented, vertically scanned 6 MV X-ray sheet beam (200mm × 5mm, 0.2mm vertical step) from a radiotherapy linear accelerator. The resulting Cherenkov light emission – and thus luminescent probe excitation – occurred exclusively along the irradiation plane due to a short diffusion path of secondary particles and Cherenkov photons. Cherenkov-excited luminescence was detected orthogonally to the sheet beam by gated, intensified charge coupled device camera. Analogously to light sheet microscopy, a series of luminescence images was taken for varied axial positions (depths) of the Cherenkov light sheet in sample. Knowledge of the excitation plane position allowed a 3D image stack deconvolution and depth-variant attenuation correction. The 3D image post-processing yielded a true spatial density distribution of luminescent molecules in highly scattering tissue. Results: We recovered a three-dimensional shape and position of 400 µL lesion-mimicking phantom tubes containing 25 µM solution of PtG4 molecular probe from 3 centimeter deep tissue-like media. The high sensitivity of CELSI also allowed resolving 100 micron capillaries of test solution. Functional information of partial oxygen pressure at the site of PtG4 molecular probe was recovered from luminescence lifetime CELSI. Finally, in-vivo sheet beam CELSI localized milimeter-sized PtG4-labelled tumor phantoms in multiple biological objects (hairless mice) from single scan. Conclusion: Presented sheet beam CELSI technique greatly extended the useful depth range of luminescence molecular imaging. More importantly, the light sheet microscopy approach was successfully adapted to CELSI, providing means to recover a completely attenuation-corrected 3D image of luminescent probe distribution. Gated CELSI acquisition yielded functional information of a spatially resolved oxygen concentration map of deep lying targets. This work was supported by NIH research grant R01CA109558 and R21EB017559, as well as by Pilot Grant Funds from the Norris Cotton Cancer Center.

60 APPLIED LIFE SCIENCES↗

Initial Stage of Nanoscale Imaging in Positive Tone Extreme UV Photoresists: The Influence of the Polymer Sequence

Photolithographic patterning using extreme ultraviolet (EUV, 92.5 eV) light is a radiolytic process that initially forms electrons, radical cations, anions, and neutral radicals in the polymeric photoresist matrix. These species may participate in the chemical reactions that define the ultimate resolution of the printed image, and their concentrations and nanometer-scale stochastic variations in their formation influence printed image quality. Proposals have been made that polymer chain uniformity may be advantageous in reducing stochastics due to spatial inhomogeneities, and this aspect of radiolysis is examined in this work. We have simulated the initial subpicosecond stages of the imaging process for a series of photoresist films that are identical in composition but vary in their polymer chain structures. We use detailed, physically accurate stochastic reaction-diffusion calculations to evaluate the influence of defined sequence and random copolymer structures on radiolytic spur formation, i.e., a cluster of species formed by electron-polymer interactions that defines the initial spatial characteristic of the imaging process. Predictions of electron thermalization in the present work are shown to be consistent with the literature, indicating that our overall computational approach for ultrafast nanoscale processes is sound. The computational results show that the polymer sequence has no significant effect on the spur composition. This suggests that any potential imaging improvements to be gained by sequence control must originate from postimaging lithographic process steps.

Absorption↗

Coupled Transport, Reactivity, and Mechanics in Fractured Shale Caprocks

Abstract Shales are low‐permeability caprocks that confine fluid, such as CO 2 , nuclear waste, and hydrogen, in storage formations. Stress‐induced fractures in shale caprocks provide pathways for fluid to leak and potentially contaminate fresh water aquifers. Fractured shales are also increasingly considered as resources for CO 2 sequestration, enhanced geothermal, and unconventional energy recovery. Injecting reactive fluids into shales introduces chemical disequilibrium, causing an onset of a series of dissolution, precipitation, and fines mobilization mechanisms. The reactions have rapid kinetics and significant impact on porosity and permeability; consequently, flow and storage properties of caprocks. While previous research has explored the separate effects of these reactions, this study aims to uncover their simultaneous occurrence and collective influence. This study unveils these highly coupled transport and reactivity mechanisms by tracking and visualizing the reaction‐induced alterations in the matrix, microcracks, and fractures of shales over time. We conducted brine injection experiments sequentially at pH 4 and 2 in a naturally fractured Wolfcamp shale sample while simultaneously imaging the dynamic processes using X‐ray computed tomography (CT). CT images are validated by finer resolution images obtained using micro‐CT and scanning electron microscopy. We also tracked the sample permeability and fluid chemistry using brine permeability and inductively coupled plasma mass spectrometry, respectively. Findings show that fluid primarily flowed through fractures, dissolving reactive minerals and mobilizing fines on fracture surfaces. Dissolution of fracture asperities under confining stress resulted in the closing of fractures. Clogging in narrow fracture pathways, caused by fines accumulation, diverted fluid flow into matrix pores.

58 GEOSCIENCES↗

Fast Active-Set Thresholding Method for Nonnegative Least Squares

Nonnegative Least Squares (NNLS) is a fundamental constrained optimization problem encountered in many applications such as image deblurring, signal processing, nonnegative matrix factorization, magnetic microscopy, and hyperspectral imaging. Active-set based methods are a common class of algorithms for solving NNLS which identify the optimal variable set of the NNLS solution. They do so by iteratively solving a series of unconstrained least squares problems, identifying which variables violate the nonnegativity constraints, and then swapping variables in/out of consideration until the optimal set of variables is found. Several variations improving upon this method exist in the literature. In this work, we propose an active-set swap heuristic which further improves upon existing active-set based methods for NNLS. Our optimizations are based upon adding multiple variables to the passive set within a threshold of the smallest gradient value and removing variables within a similar threshold of the closest boundary constraint. We leverage these optimizations to yield a Fast Active-Set Thresholding NNLS (FAST-NNLS) algorithm which significantly outperforms the existing state-of-the-art NNLS algorithms for a wide range of problems. Rigorous convergence guarantees are proven for the proposed method. We demonstrate the effectiveness of our proposed method on multiple synthetic datasets and two realworld text analysis applications. In doing so, we present the most comprehensive NNLS solver comparison in the literature to date.

Cobb, Benjamin [Georgia Institute of Technology]↗

Lensless X-Ray Nanoimaging: Revolutions and opportunities

Lensless x-ray nanoimaging is providing 3D views of a wide range of materials with a spatial resolution better than 20 nanometers. These advances are enabled in part by dramatic gains in coherent x-ray flux, but they also rely on advances in signal processing to obtain images from coherent diffraction data. Here, we outline the various imaging approaches, the associated reconstruction methods, and highlight opportunities for future advances.

42 ENGINEERING↗

SU-E-I-01: Iterative CBCT Reconstruction with a Feature-Preserving Penalty

Purpose: Low-dose CBCT is desired in various clinical applications. Iterative image reconstruction algorithms have shown advantages in suppressing noise in low-dose CBCT. However, due to the smoothness constraint enforced during the reconstruction process, edges may be blurred and image features may lose in the reconstructed image. In this work, we proposed a new penalty design to preserve image features in the image reconstructed by iterative algorithms. Methods: Low-dose CBCT is reconstructed by minimizing the penalized weighted least-squares (PWLS) objective function. Binary Robust Independent Elementary Features (BRIEF) of the image were integrated into the penalty of PWLS. BRIEF is a general purpose point descriptor that can be used to identify important features of an image. In this work, BRIEF distance of two neighboring pixels was used to weigh the smoothing parameter in PWLS. For pixels of large BRIEF distance, weaker smooth constraint will be enforced. Image features will be better preserved through such a design. The performance of the PWLS algorithm with BRIEF penalty was evaluated by a CatPhan 600 phantom. Results: The image quality reconstructed by the proposed PWLS-BRIEF algorithm is superior to that by the conventional PWLS method and the standard FDK method. At matched noise level, edges in PWLS-BRIEF reconstructed image are better preserved. Conclusion: This study demonstrated that the proposed PWLS-BRIEF algorithm has great potential on preserving image features in low-dose CBCT.

60 APPLIED LIFE SCIENCES↗

Data Archive and Portal (DAP) Platform for Solid Phase Processing Technologies

The scale and speed of data generated by modern scientific experiments have constantly challenged the research community to store, curate, manage and optimally use it to drive scientific discoveries. In this work, we have developed a data archive and portal (DAP) platform including analytics capabilities to collect, curate, and manage data and metadata stream for solid phase processing (SPP) techniques. We successfully hosted around ~347K files of data related to processing parameters, microscopic images, and spectroscopic data related to solid phase processing. The DAP platform for SPP will establish an enduring capability to support machine learning and grow collaboration at the intersection of materials science and data science.

36 MATERIALS SCIENCE↗

WE-EF-207-10: Striped Ratio Grids: A New Concept for Scatter Estimation

Purpose: To propose a new method for estimating scatter in x-ray imaging. We propose the “striped ratio grid,” an anti-scatter grid with alternating stripes of high scatter rejection (attained, for example, by high grid ratio) and low scatter rejection. To minimize artifacts, stripes are oriented parallel to the direction of the ramp filter. Signal discontinuities at the boundaries between stripes provide information on local scatter content, although these discontinuities are contaminated by variation in primary radiation. Methods: We emulated a striped ratio grid by imaging phantoms with two sequential CT scans, one with and one without a conventional grid, and processed them together to mimic a striped ratio grid. Two phantoms were scanned with the emulated striped ratio grid and compared with a conventional anti-scatter grid and a fan-beam acquisition, which served as ground truth. A nonlinear image processing algorithm was developed to mitigate the problem of primary variation. Results: The emulated striped ratio grid reduced scatter more effectively than the conventional grid alone. Contrast is thereby improved in projection imaging. In CT imaging, cupping is markedly reduced. Artifacts introduced by the striped ratio grid appear to be minimal. Conclusion: Striped ratio grids could be a simple and effective evolution of conventional anti-scatter grids. Unlike several other approaches currently under investigation for scatter management, striped ratio grids require minimal computation, little new hardware (at least for systems which already use removable grids) and impose few assumptions on the nature of the object being scanned.

60 APPLIED LIFE SCIENCES↗

Simulation tools for atom probe tomography: A path for diagnosis and treatment of image degradation

The ideal picture of a near-perfect 3D microscope often presented regarding Atom Probe Tomography faces several issues. These issues degrade the metrological performance of the instrument and find their roots in the phenomena acting at the atomic to the mesoscopic level in the vicinity of the surface of a field emitter. From the field evaporation process at the atomic scale, to the macroscopic scale of the instrument, the path to model the imaging process and to develop more accurate and reliable reconstruction algorithms is not a single lane road. This paper focused on the numerical methods used to understand, treat, and potentially heal imaging issues commonly affecting the data in atom probe experiments. A lot of room for improvement exists in solving accuracy problems observed in complex materials by means of purely electrostatic models describing the image formation in a classical approach. Looking at the sample at the atomic scale, the phenomena perturbing the imaging process are subtle. An examination of atomic scale modifications of the sample surface in the presence of a high surface electric field is therefore mandatory. Atomic scale molecular dynamic models integrating the influence of the high surface electric are being developed with this aim. It is also demonstrated that the complex behavior of atoms and molecules in high fields, and consequences on collected data, can be understood through the use of accurate ab-initio models modified to include the impact of the extreme surface electric field.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

High-speed Synchrotron X-ray Imaging of Laser Powder Bed Fusion Process

In additive manufacturing (AM) processes, materials are selectively added in layer-wise fashion to build three-dimensional objects. This approach provides several advantages over conventional manufacturing, including the ability to manufacture complex parts, design flexibility, shorter lead times, reduced inventory of spares, and on-demand manufacturing [1]. With these advantages, applications of AM are increasing rapidly in the medical, aerospace, automobile, and defense industries [2, 3]. Currently, laser powder bed fusion (LPBF) is the most extensively used AM technique for manufacturing metal parts. In a typical LPBF process, a high-power laser beam is scanned across a thin layer of powder, melting and subsequently fusing it to the previous layer. Highly transient interactions between the laser, powder particles, and the bottom layer lead to defects in the AM materials. These defects include porosity, residual stresses, surface roughness, and undesirable microstructures [1, 4]. Additionally, several in situ techniques have been developed to capture these interactions in real time, including high-speed visible light and infra-red imaging [5]. However these techniques are limited to surface observations. Most of the important phenomena that govern the quality of the AM parts, such as dynamics of the vapor depression and melt pool, occur sub-surface and hence cannot be captured using traditional optical techniques. Recently, a synchrotron-based high-speed X-ray imaging technique has been developed to record the sub-surface dynamics of metallic materials during the LPBF process. The unprecedented spatial and temporal resolutions afforded by the synchrotron sources allow direct observation of many important phenomena in AM for the first time [6–9]. Further, high-speed X-ray diffraction and optical imaging techniques are also being applied to capture the crystallographic and thermal information of the material, respectively, as they undergo melting, solidification, and cooling [6, 9]. In this contribution, we introduce the recent developments at the Advanced Photon Source (APS) for in situ and operando study of LPBF processes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Quantifying element incorporation in multispecies biofilms using nanoscale secondary ion mass spectrometry image analysis

Elucidating nutrient exchange in microbial communities is an important step in understanding the relationships between microbial systems and global biogeochemical cycles, but these communities are complex and the interspecies interactions that occur within them are not well understood. Phototrophic consortia are useful and relevant experimental systems to investigate such interactions as they are not only prevalent in the environment, but some are cultivable in vitro and amenable to controlled scientific experimentation. Nanoscale secondary ion mass spectrometry (NanoSIMS) is a powerful, high spatial resolution tool capable of visualizing the metabolic activities of single cells within a biofilm, but quantitative analysis of the resulting data has typically been a manual process, resulting in a task that is both laborious and susceptible to human error. In this work, the authors describe the creation and application of a semiautomated image-processing pipeline that can analyze NanoSIMS-generated data, applied to phototrophic biofilms as an example. The tool employs an image analysis process, which includes both elemental and morphological segmentation, producing a final segmented image that allows for discrimination between autotrophic and heterotrophic biomass, the detection of individual cyanobacterial filaments and heterotrophic cells, the quantification of isotopic incorporation of individual heterotrophic cells, and calculation of relevant population statistics. The authors demonstrate the functionality of the tool by using it to analyze the uptake of 15 N provided as either nitrate or ammonium through the unicyanobacterial consortium UCC-O and imaged via NanoSIMS. The authors found that the degree of 15N incorporation by individual cells was highly variable when labeled with 15 NH 4 + , but much more even when biofilms were labeled with 15 NO 3 – . In the 15 NH 4 + -amended biofilms, the heterotrophic distribution of 15 N incorporation was highly skewed, with a large population showing moderate 15 N incorporation and a small number of organisms displaying very high 15 N uptake. The results showed that analysis of NanoSIMS data can be performed in a way that allows for quantitation of the elemental uptake of individual cells, a technique necessary for advancing research into the metabolic networks that exist within biofilms with statistical analyses that are supported by automated, user-friendly processes.

59 BASIC BIOLOGICAL SCIENCES↗

Process Control Plan to Monitor Acceptable Levels of Flux and other residues

IPC J-STD –001G, Amendment 1 requires that the assembler have a sampling plan to assure that the process remains in control once qualified and validated. It is well documented that electrochemical failures occur at component sites where flux residues are not fully activated. It is also well known that specific components have a higher risk of electrochemical failure. Selecting a control plan that monitors the process and its performance on challenging components provides assurance that the process maintains control once established during process qualification. The test board used to qualify the process establishes an upper and lower spec limit for each of the component types on the test board. Surface Insulation Resistance upper and lower control limits, using challenging components that are representative of production hardware, represent a golden process condition. The golden image is a measure of process deviations that represents the performance of a resistance curve within a specific period. The objective is to judge whether the process in or out of control.

42 ENGINEERING↗

Nuclear Canister Corrosion Detection

The software titled "nccd" is used for running residual neural networks (ResNets) on images of nuclear canisters. The software provides only the code for the implementation (based on the fastai library), but it does not share the image data. The compute code allows the use of residual nets (and more generally of other deep learning models) for classifying images from nuclear canisters as corroded. or intact. An image is considered to be corroded if it contains pitting or stress corrosion cracks. The code trains ResNets on image tiles extracted from original images from nuclear canisters, and then implements a classification rule, which can be applied to a validation set to decide if each original image is corroded or intact. The software automates the process of using images taken from nuclear canisters to detect corrosion. It provides also scope for future research directions on the basis of the existing research and code.

Papamarkou, Theodore↗

Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗