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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Spatially resolved phase transformation mapping in 410 stainless steel during additive manufacturing visualized via real-time infrared data

Here, in this study, we demonstrate that spatially resolved cooling curves derived from real-time infrared (IR) thermography during additive manufacturing (AM) can capture spatial variations in phase transformation temperatures through cooling curve analysis (CCA). Using this approach, we show that during laser hot-wire deposition of 410 stainless steel (410SS), the martensite start temperature (M s ) evolves dynamically throughout the build. The M s temperature is spatially nonuniform, ranging from 185 °C to 348 °C, with the lowest values toward the build center and higher values toward the upper region of the deposit. In the lower portion of the build, no M s inflection is detected via CCA, consistent with transformation occurring earlier during thermal cycling followed by tempering during subsequent thermal cycles. These trends in M s are corroborated by characterizing the microstructure by electron backscatter diffraction (EBSD). Traditionally, M s is assumed to be constant, and a single interpass temperature is applied during both deposition and residual stress modeling. Our results demonstrate that IR-derived cooling curves provide a route to spatially and temporally resolved transformation temperature tracking for dynamic interpass control and improved residual-stress modeling.

Additive manufacturing↗
DOE OSTI2015

Data visualization methods, data visualization devices, data visualization apparatuses, and articles of manufacture

Data visualization methods, data visualization devices, data visualization apparatuses, and articles of manufacture are described according to some aspects. In one aspect, a data visualization method includes accessing a plurality of initial documents at a first moment in time, first processing the initial documents providing processed initial documents, first identifying a plurality of first associations of the initial documents using the processed initial documents, generating a first visualization depicting the first associations, accessing a plurality of additional documents at a second moment in time after the first moment in time, second processing the additional documents providing processed additional documents, second identifying a plurality of second associations of the additional documents and at least some of the initial documents, wherein the second identifying comprises identifying using the processed initial documents and the processed additional documents, and generating a second visualization depicting the second associations.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2005

Managed Development Environment Successes for MSFC's VIPA Team

This paper outlines the best practices of the Vehicle Design Team for VIPA. VIPA is the Vehicle Integrated Performance Analysis Team at MSFC. This team was created to reconnect the individual engineering disciplines to be able to perform system level technical assessments in support of program decisions. The functions of the VIPA Vehicle Design (VVD) discipline team are to maintain the controlled reference geometry and provide linked, simplified geometry for each of the other discipline analyses. The core of the VVD work, and the approach for VVD s first task of controlling the reference geometry, involves systems engineering, top-down, layout-based CAD modeling within a Product Data Manager (PDM) development environment. The topdown approach allcws for simple contrnl of very large, integrated assemblies and greatly enhances the ability to generate trade configurations and reuse data. The second W D task, model simplification for analysis, is handled within the managed environment through application of the master model concept. In this approach, there is a single controlling, or master, product definition dataset. Connected to this master model are reference datasets with live geometric and expression links. The referenced models can be for drawings, manufacturing, visualization, embedded analysis, or analysis simplification. A discussion of web based interaction, including visualization, between the design and other disciplines is included. Demonstrated examples are cited, including the Space Launch Initiative development cycle, the Saturn V systems integration and verification cycle, an Orbital Space Plane study, and NASA Exploration Office studies of Shuttle derived and clean sheet launch vehicles. The VIPA Team has brought an immense amount of detailed data to bear on program issues. A central piece of that success has been the Managed Development Environment and the VVD Team approach to modeling.

Finckenor, Jeff↗
NASA NTRS2005

Managed Development Environment Successes for MSFC's VIPA Team

This paper outlines the best practices of the Vehicle Design Team for VIPA. The functions of the VIPA Vehicle Design (VVD) discipline team are to maintain the controlled reference geometry and provide linked, simplified geometry for each of the other discipline analyses. The core of the VVD work, and the approach for VVD s first task of controlling the reference geometry, involves systems engineering, top-down, layout-based CAD modeling within a Product Data Manager (PDM) development environment. The top- down approach allows for simple control of very large, integrated assemblies and greatly enhances the ability to generate trade configurations and reuse data. The second VVD task, model simplification for analysis, is handled within the managed environment through application of the master model concept. In this approach, there is a single controlling, or master, product definition dataset. Connected to this master model are reference datasets with live geometric and expression links. The referenced models can be for drawings, manufacturing, visualization, embedded analysis, or analysis simplification. A discussion of web based interaction, including visualization, between the design and other disciplines is included. Demonstrated examples are cited, including the Space Launch Initiative development cycle, the Saturn V systems integration and verification cycle, an Orbital Space Plane study, and NASA Exploration Office studies of Shuttle derived and clean sheet launch vehicles. The VIPA Team has brought an immense amount of detailed data to bear on program issues. A central piece of that success has been the Managed Development Environment and the VVD Team approach to modeling.

Finckenor, Jeff↗
NASA NTRS2003

Optical Tweezers Array and Nimble Tweezers Probe Generated by Spatial- Light Modulator

An optical tweezers is being developed at the NASA Glenn Research Center as a visiblelight interface between ubiquitous laser technologies and the interrogation, visualization, manufacture, control, and energization of nanostructures such as silicon carbide (SiC) nanotubes. The tweezers uses one or more focused laser beams to hold micrometer-sized particles called tools (sometimes called tips in atomic-force-microscope terminology). A strongly focused laser beam has an associated light-pressure gradient that is strong enough to pull small particles to the focus, in spite of the oppositely directed scattering force; "optical tweezers" is the common term for this effect. The objective is to use the tools to create carefully shaped secondary traps to hold and assemble nanostructures that may contain from tens to hundreds of atoms. The interaction between a tool and the nanostructures is to be monitored optically as is done with scanning probe microscopes. One of the initial efforts has been to create, shape, and control multiple tweezers beams. To this end, a programmable spatial-light modulator (SLM) has been used to modify the phase of a laser beam at up to 480 by 480 points. One program creates multiple, independently controllable tweezer beams whose shapes can be tailored by making the SLM an adaptive mirror in an interferometer (ref. 1). The beams leave the SLM at different angles, and an optical Fourier transform maps these beams to different positions in the focal plane of a microscope objective. The following figure shows two arrays of multiple beams created in this manner. The patterns displayed above the beam array control the intensity-to-phase transformation required in programming the SLM. Three of the seven beams displayed can be used as independently controllable beams.

Decker, Arthur J.↗
DOE OSTI2019

Next-Generation Analysis and Visualization Platform for Manufacturing and Engineering Workflows (Final Report)

Advanced manufacturing and engineering are fundamental to the economic strength and national security of the United States. With the introduction of advanced modeling and simulation practices in manufacturing and engineering over the last several decades, we are producing better products, more quickly, and at decreased cost. Through the adoption of high-performance computing (HPC) enabled workflows, in small- to medium-sized manufacturers and engineering firms, which employ fewer than 500 people, is renewing United States manufacturing and engineering. Despite successes, there are significant barriers to widespread adoption of these tools. Our Phase I SBIR project, Next-Generation Analysis and Visualization Platform for Manufacturing and Engineering Workflows, aims to address several of these barriers. Our project helped us evaluate the feasibility and benefits and mitigate risks of asynchronous processing for analysis and visualization workflows. We evaluated the impact of asynchronous, non-blocking communication can have on the user experience in a complex visualization application. Besides the impact on users, we wanted to understand the impacts on developers (development application programming interfaces (APIs))and generated applications (robustness and stability). Any asynchronous platform implementation is bound to rely on multiple threads which can make the programming model extraordinarily complex and prone to bugs. If not managed carefully, the complexity and resulting instability would be an unacceptable evolution for widely used production tools like ParaView and putting the success of the Phase II project at risk.

42 ENGINEERING↗
DOE OSTI2017

Falcon: Visual analysis of large, irregularly sampled, and multivariate time series data in additive manufacturing

Flexible visual analysis of long, high-resolution, and irregularly sampled time series data from multiple sensor streams is a challenge in several domains. In the field of additive manufacturing, this capability is critical for realizing the full potential of large-scale 3D printers. Here, we propose a visual analytics approach that helps additive manufacturing researchers acquire a deep understanding of patterns in log and imagery data collected by 3D printers. Our specific goals include discovering patterns related to defects and system performance issues, optimizing build configurations to avoid defects, and increasing production efficiency. We introduce Falcon, a new visual analytics system that allows users to interactively explore large, time-oriented data sets from multiple linked perspectives. Falcon provides overviews, detailed views, and unique segmented time series visualizations, all with adjustable scale options. To illustrate the effectiveness of Falcon at providing thorough and efficient knowledge discovery, we present a practical case study involving experts in additive manufacturing and data from a large-scale 3D printer. The techniques described are applicable to the analysis of any quantitative time series, though the focus of this paper is on additive manufacturing.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

Visual inspection reliability for precision manufactured parts

Sandia National Laboratories conducted an experiment for the National Nuclear Security Administration to determine the reliability of visual inspection of precision manufactured parts used in nuclear weapons. In addition visual inspection has been extensively researched since the early 20th century; however, the reliability of visual inspection for nuclear weapons parts has not been addressed. In addition, the efficacy of using inspector confidence ratings to guide multiple inspections in an effort to improve overall performance accuracy is unknown. Further, the workload associated with inspection has not been documented, and newer measures of stress have not been applied.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2021

The Virtual Blast Furnace - An Integrated High Performance Computing Modeling, Simulation, and Visualization Capability for Steel Manufacturing (Final Report)

Many manufacturing industries require substantial capital and utilize energy intensive processes that involve complex phenomena. One example of such an industry is the steel industry, which is the fourth largest energy consuming industry in the U.S. By harnessing the power of High-Performance Computing (HPC) to enhance current simulation and visualization methods in the steel industry, it should be possible to increase resolution and/or decrease time of these methods by a factor of 1000. In this way, information can be obtained in a time frame that is useful for making business and engineering decisions, optimizing manufacturing processes and, ultimately, improving the completeness of U.S. industries. For example, if coke usage in blast furnaces were optimized such that the average coke rate was reduced from 797 lb/net tonne of hot metal (NTHM) to 604 lb/NTHM, costs could be reduced by $894 million/year. Additionally, members of the steel industry need the flexibility to efficiently operate blast furnaces at a range of production rates in order to meet fluctuating market demands. Large scale parameter studies can be utilized to discover workable operating parameters at a range of production rates.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2012

Elements of Nondestructive Examination for the Visual Inspection of Composite Structures

Visual inspection (VI) of composite structures provides an effective, wide field survey to ensure design and material compliance is maintained for the entire service life of the manufactured component. Visual inspection is one of the most commonly used nondestructive inspection methods to assess surface defects on composites. By applying visual inspection elements, mechanical damage that could affect component residual strength can be identified and a disposition reached before a potentially catastrophic event occurs. This technique is non-contact and applied at all stages of the composite structure s processing and use. Additionally, VI is required to be performed in all service environments until decommission. By following Level I and Level II damage accept/reject criteria set forth in this document, the material review (MR) process can be initiated. This nondestructive evaluation (NDE) method should be complemented with additional NDE methods to best understand the nature of the observed indications. When VI identification is followed by interrogation using effective complimentary NDE methods, the final Material Review Board (MRB) disposition of the component can be effectively achieved. Although elements of the visual inspection method are discussed and expressly required by the various range standards (KNPR 8715.3 and AFSPCMAN 91-710), emphasis should be placed on supporting the interpretation of recorded visual observations. Sound engineering practices and procedures should be applied with the interpretation of nondestructive testing (NDT) results when the residual strength data specific to a vessel design is incomplete or absent.

Tommy B. Yoder↗
DOE OSTI2024

Operando visualization of porous metal additive manufacturing with foaming agents through high-speed x-ray imaging

Porous metals find extensive applications in soundproofing, filtration, catalysis, and energy-absorbing structures, thanks to their unique internal pore structure and high specific strength. In recent years, there has been an increasing interest in fabricating porous metals using additive manufacturing (AM), leveraging its unique advantages, including improved design freedom, spatial material control, and cost-effective small-batch production. In this study, we conducted pioneering operando visualization of AM porous metal using a laser powder bed fusion (L-PBF) setup combined with a high-speed synchrotron x-ray imaging system. Single track printing experiments using Ti6Al4V (Ti64) combined with titanium hydride (TiH 2 ) and sodium carbonate (Na 2 CO 3 ) as foaming agents, with varying mixing ratios were performed under different processing conditions. Here. the results elucidate the dynamic development of porosity formation. The average pore size is significantly influenced by the particle size of foaming agents when pore coalescence is absent. For all foaming agent content tested in the current study, the number of pores is found to be more sensitive to changes in laser power than in laser scanning speed. Increasing linear energy density (increasing laser power or reducing laser scanning speed) promotes the foaming agent activation thereby porosity formation. However, high linear energy density skews pore distribution towards the surface despite forming deeper melt pools. In addition, the impact of additional factors including foaming agent's laser absorptivity and decomposition kinetics with respect to AM time scales should be carefully considered to avoid ineffective activation of foaming agents during the AM of porous metals.

36 MATERIALS SCIENCE↗
DOE OSTI2025

LatticeAnalytics: Strut-Level Visualization and Inspection of Additively Manufactured Lattice Structures

Additive manufacturing (AM) is revolutionizing the production of custom components with complex internal geometries, essential for high-performance applications in diverse fields such as medicine and defense. These AM parts optimize strength while minimizing weight by utilizing internal lattice structures consisting of large quantities of small interconnected struts. However, the complexity of these structures, combined with the challenges of using X-ray Computed Tomography (XCT) data, makes validation of part reliability difficult. This ultimately inhibits the development of novel parts for our collaborating material scientists. Here, we introduce LatticeAnalytics, a novel framework specifically designed for visual inspection of defects in these lattice structures. Our framework offers an end-to-end solution that includes the data management of XCT scans, enables remote access for geographically dispersed teams through a web-based dashboard, and incorporates novel visualizations. Our analysis is facilitated by a coarse alignment between the lattice’s nominal model, a spatial graph, and the XCT data. We employ a simple VR-based approach for fast and rough alignment, followed by an offline registration and identification of the struts. With the nodes and struts aligned and identified in the volume, our framework allows querying of subvolumes containing a single strut at multiple resolutions. This avoids computation over the entire lattice and also allow for easy parallelization of down-stream computations, such as strut-specific metrics. To depict a fast overview of the strut quality, we introduce two innovative visual encodings, crucial for our collaborators’ research in creating novel AM parts: the Contour View and the Roughness Map, which depict critical geometrical and surface features of individual struts in standardized two 2D views. We evaluated the integrated system through expert interviews. The feedback confirms the framework’s practicality and its effectiveness in enhancing current inspection workflows. It solves major bottlenecks for our collaborators, ultimately helping them create novel parts with advanced properties.

Miao, Haichao [Lawrence Livermore National Laborat↗
DOE OSTI2016

SU-G-IeP1-09: MRI Evaluation of a Direction-Modulated Brachytherapy (DMBT) Tandem Applicator for Cervical Cancer On 3T

Purpose: To assess image quality and artifact extent of a novel direction modulated brachytherapy (DMBT) tandem applicator on a 3T MRI using various clinical imaging sequences. Methods: The tandem applicator is composed of a tungsten alloy with 6 peripheral grooves covered with a PEEK tip. An MR-compatible phantom with similar dimensions to the female pelvis was manufactured. To visually assess the spatial shift of the applicator’s tip, a mountable radial-fiducial with 4 plastic rods, each of 3mm diameter, was designed to tightly fit on the applicator. The rods are separated by 16 mm and mounted at 90-degree relative to one another. The pelvis phantom was filled with a solution of MnCl2 to mimic T2 relaxation time of the cervix (60-80 ms at 3T).Imaging was performed on a 3T Philips Achieva using a 16-channel Torso coil array. Four MR sequences were tested: T2-weighted fast spin-echo (T2w-FSE), proton density weighted FSE (PDw-FSE), T1-weighted FSE (T1w-FSE) and T1 weighted spoiled gradient echo (T1w-GE). The spatial resolution was kept the same between all sequences: 0.6 × 0.6 × 3 mm{sup 3} with no slice gaps. Para-sagittal images were acquired with the applicator fixed at a 30-degree angle anterior to the B0- field to mimic clinical settings. Results: Minimal artifacts were observed on T2w-FSE, PDw-FSE and T1-FSE, while significant artifacts were seen on T1w-GE images. Artifacts induced in all 3 FSE sequences did not hinder accurate localisation of the tip and the applicator boundaries. The drift of the applicator’s centreline from the radial fiducials was measured and found to be < 1 mm for the 3 FSE sequences. Conclusion: The tungsten–based DMBT applicator can be potentially used on 3T with various clinical sequences without inducing significant artifacts. Further validation on patients as well as the evaluation of relative SNR among the different sequences is required.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Invertible Temper Modeling using Normalizing Flows and the Effects of Structure Preserving Loss

Advanced manufacturing research and development is typically small-scale, owing to costly experiments associated with these novel processes. Deep learning techniques could help accelerate this development cycle but frequently struggle in small-data regimes like the advanced manufacturing space. While prior work has applied deep learning to modeling visually plausible advanced manufacturing microstructures, little work has been done on data-driven modeling of how microstructures are affected by heat treatment, or assessing the degree to which synthetic microstructures are able to support existing workflows. We propose to address this gap by using invertible neural networks (normalizing flows) to model the effects of heat treatment, e.g., tempering. The model is developed using scanning electron microscope imagery from samples produced using shear-assisted processing and extrusion (ShAPE) manufacturing. This approach not only produces visually and topologically plausible samples, but also captures information related to a sample’s material properties or experimental process parameters. We also demonstrate that topological data analysis, used in prior work to characterize microstructures, can also be used to stabilize model training, preserve structure, and improve downstream results. We assess directions for future work and identify our approach as an important step towards end-to-end deep learning system for accelerating advanced manufacturing research and development.

Howland, Sylvia↗
DOE OSTI2018

Defect Identification and Mitigation Via Visual Inspection in Large-Scale Additive Manufacturing

Defect identification and mitigation is an important avenue of research to improve the overall quality of objects created using additive manufacturing (AM) technologies. Identifying and mitigating defects takes on additional importance in large-scale, industrial AM. In large-scale AM, defects that result in failed prints are extremely costly in terms of time spent and material used. To address these issues, researchers at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility investigated the use of a laser profilometer and thermal camera to collect data concerning an object as it was constructed. These data provided feedback for an in situ control system to adjust object construction. Adjustments were made in the form of automated height control. This paper presents results for both a polymer- and metal-based system. Object construction for both systems was improved significantly, and the resulting objects were more geometrically identical to the ideal 3D representation.

42 ENGINEERING↗
DOE OSTI2022

Data Mining and Visualization of High-Dimensional ICME Data for Additive Manufacturing

Integrated computational materials engineering (ICME) methods combining CALPHAD with process-based simulations can produce rich, high-dimensional data for alloy and process design. In ICME methods for metallurgical applications, the visualization and interpretation of such high-dimensional data has previously been through heat maps represented in 2 or 3 dimensions. While such an approach is ideal when one variable is varied at a time, in the case of high-dimensional data with multiple variables varied simultaneously, as is the case in additive manufacturing, interpreting the trends through two- or three-dimensional heat maps becomes challenging. Here, we propose a strategy of mixed visual data mining and quantitative analysis for high-dimensional metallurgical and process data using high-throughput thermodynamic calculations. Two case studies show the application of the proposed approach. The first case study investigated the effects of feedstock chemistry on the δ ferrite formation in 316L stainless steel powders used for binder jet additive manufacturing. The second case study linked Scheil–Gulliver calculations to a process model for dissimilar joining of aluminum alloys 5356 and 6111 during laser hot-wire additive manufacturing. Both cases contained thousands of calculated data points, showcasing the utility of visual data analysis through parallel coordinate plotting, Pearson correlation coefficient matrices, and scatter matrices compared to traditional process maps. These visualization techniques can be extended to many additive manufacturing problems to capture process–structure–property relationships for additively manufactured components.

36 MATERIALS SCIENCE↗