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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

SCA Tools - SCRM Value Add or Lossy Noise Machines

Software supply chain risk management (SCRM) depends upon accurate information regarding the software components that comprise any given software system. The collection of components included in a software package can be organized within a software bill of materials, or SBOM. SBOMs are ideally generated when the software components are put together, such as at compile time, but for many reasons that has not and is not always possible. For example, legacy or proprietary software packages often do not have SBOMs available to downstream consumers of that software. It’s not just end users that are affected, manufacturers themselves also must deal with this problem. To answer these questions, the market has seen the rise of several commercial software composition analysis (SCA) tools. These tools aim to peer into completed software systems, automatically identifying hidden software dependencies and looking up known vulnerabilities associated with those dependencies to enable end-users to enhance their cyber supply chain risk management processes. These tools are potentially a huge boon to end users of legacy and proprietary software – and a potential bane, depending on how accurate they are. This research asks that question – how accurate are currently available binary SCA tools – and provides answers to several other questions: What does it mean to be “accurate”? What limitations do the tools have in identifying common edge cases that take place in modern software development? Can they help you avoid a devastating supply chain attack, or is it all just noise? After researching SCA tools on the market, we identified three vendors that fit our use case and would provide analysis on compiled binaries. Using these tools, we submitted firmware for critical infrastructure devices for analysis and SBOM generation. The SBOM outputs were then cross referenced with SBOMs generated through manual analysis for comparison. In addition to the firmware samples, we also submitted edge case samples based off a popular open-source library that were specifically crafted to evaluate each tools’ ability to accurately identify components. These samples were customized to be consistent with modifications we have seen in modern software development as well as a couple that are representative of supply chain attacks.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Statistical Tool Size Study for Computer-Controlled Optical Surfacing

Over the past few decades, computer-controlled optical surfacing (CCOS) systems have become more deterministic. A target surface profile can be predictably achieved with a combination of tools of different sizes. However, deciding the optimal set of tool sizes that will achieve the target residual error in the shortest run time is difficult, and no general guidance has been proposed in the literature. In this paper, we present a computer-assisted study on choosing the proper tool size for a given surface error map. First, we propose that the characteristic frequency ratio (CFR) can be used as a general measure of the correction capability of a tool over a surface map. Second, the performance of different CFRs is quantitatively studied with a computer simulation by applying them to guide the tool size selection for polishing a large number of randomly generated surface maps with similar initial spatial frequencies and root mean square errors. Finally, we find that CFR = 0.75 achieves the most stable trade-off between the total run time and the number of iterations and thus can be used as a general criterion in tool size selection for CCOS processes. To the best of our knowledge, the CFR is the first criterion that ties tool size selection to overall efficiency.

36 MATERIALS SCIENCE↗
NASA NTRS2015

The Effectiveness of a Route Crossing Tool in a Simulated New York Airspace

Congested airspace is the cause of many delays in the terminal area and these delays can have a ripple effect on the rest of a nation's airspace. The New York terminal area is an example of where this happens in the U. S. An important goal, therefore, is to increase the efficiency of operations in congested terminal airspace where possible. Modeling studies of arrival and departure flows have shown that sharing of arrival and departure airspace increases efficiency in terminal operations. One source of inefficiency in terminal operations is that departure aircraft are frequently held level under arrival flows when it would be more efficient to climb the departure aircraft earlier. A Route Crossing Tool was developed to help controllers climb Newark (EWR) departures to the south earlier by temporarily sharing airspace with arrivals coming into LaGuardia (LGA) from the south. Instead of flying under the arrivals, a departure to the south could climb earlier by flying through the arrival airspace if there was a suitable gap between arrivals. A Human-in-the-Loop (HITL) simulation was conducted in this environment which compared three tool conditions: Baseline (no tool), a Single Route Crossing tool in which one route through the arrival flow was evaluated for crossing, and a Multi-Route Crossing tool in which five parallel routes were evaluated. In all conditions, the departures could be held level under the arrival flow. The results showed that controllers climbed a higher proportion of departures in the Multi-Route tool condition than in the other two conditions, with a higher proportion of departures climbed in smaller gaps and in front of trailing arrivals. The controllers indicated that the Multi-Route and Single Route tools helped them estimate distances more accurately and rated safety, workload, and coordination in the simulation as acceptable.

terminal airspace↗
NASA NTRS2016

Engineering Design Tools for Shape Memory Alloy Actuators: CASMART Collaborative Best Practices and Case Studies

The primary goal of the Consortium for the Advancement of Shape Memory Alloy Research and Technology (CASMART) is to enable the design of revolutionary applications based on shape memory alloy (SMA) technology. In order to help realize this goal and reduce the development time and required experience for the fabrication of SMA actuation systems, several modeling tools have been developed for common actuator types and are discussed herein along with case studies, which highlight the capabilities and limitations of these tools. Due to their ability to sustain high stresses and recover large deformations, SMAs have many potential applications as reliable, lightweight, solid-state actuators. Their advantage over classical actuators can also be further improved when the actuator geometry is modified to fit the specific application. In this paper, three common actuator designs are studied: wires, which are lightweight, low-profile, and easily implemented; springs, which offer actuation strokes upwards of 200 at reduced mechanical loads; and torque tubes, which can provide large actuation forces in small volumes and develop a repeatable zero-load actuation response (known as the two-way shape memory effect). The modeling frameworks, which have been implemented in the design tools, are developed for each of these frequently used SMA actuator types. In order to demonstrate the versatility and flexibility of the presented design tools, as well as validate their modeling framework, several design challenges were completed. These case studies include the design and development of an active hinge for the deployment of a solar array or foldable space structure, an adaptive solar array deployment and positioning system, a passive air temperature controller for regulation flow temperatures inside of a jet engine, and a redesign of the Corvette active hatch, which allows for pressure equalization of the car interior. For each of the presented case studies, a prototype or proof-of-concept was fabricated and the experimental results and lessons learned are discussed. This analysis presents a collection of CASMART collaborative best practices in order to allow readers to utilize the available design tools and understand their modeling principles. These design tools, which are based on engineering models, can provide first-order optimal designs and are a basic and efficient method for either demonstrating design feasibility or refining design parameters. Although the design and integration of an SMA-based actuation system always requires application- and environment-specific engineering considerations, common modeling tools can significantly reduce the investment required for actuation system development and provide valuable engineering insight.

Design tools↗
DOE OSTI2022

The SENSEI Generic In Situ Interface: Tool and Processing Portability at Scale [Book Chapter]

One key challenge when doing in situ processing is the investment required to add code to numerical simulations needed to take advantage of in situ processing. Such instrumentation code is often specialized, and tailored to a specific in situ method or infrastructure. Then, if a simulation wants to use other in situ tools, each of which has its own bespoke API [4], then the simulation code team will quickly become overwhelmed with having a different set of instrumentation APIs, one per in situ tool or method. In an ideal situation, such instrumentation need happen only once, and then the instrumentation API provides access to a large diversity of tools. In this way, a data producer’s instrumentation need not be modified if the user desires to take advantage of a different set of in situ tools. The SENSEI generic in situ interface addresses this challenge, which means that SENSEI-instrumented codes enjoy the benefit of being able to use a diversity of tools at scale, tools that include Libsim, Catalyst, Ascent, as well as user-defined methods written in C++ or Python. SENSEI has been shown to scale to greater than 1M-way concurrency on HPC platforms, and provides support for a rich and diverse collection of common scientific data models. Furthermore, this chapter presents the key design challenges that enable tool and processing portability at scale, some performance analysis, and example science applications of the methods.

Bethel, E. Wes↗
DOE OSTI2022

A method and tool to determine the colorimetric and photobiological properties of light transmitted through glass and other optical materials

Here we describe a framework and provides a computational tool to characterize the color quality and biological potential of light that is transmitted through glass and other optical materials. The IES TM-30 framework and Excel computation tool were adapted to evaluate color quality, with measures from CIE S 026, UL 24480, and the WELL Building Standard v2 added to evaluate biological potential. The user selects a pre-transmittance spectral power distribution (SPD), such as for a CIE D-Series Illuminant, Planckian radiation, electric lamp, or measurement of daylight at a building site. The tool allows a user to populate a database with spectral data for glazing or other optical materials, comprising spectral transmission and the spectral reflectance of both sides. The user creates a unit with one, two, or three panes of glazing or other optical materials, and the tool calculates the composite spectral transmittance accounting for reflections between materials. The tool computes the transmitted SPD, then determines colorimetric and photobiological outputs using the transmitted SPD as the test source. Glass, window, and skylight manufacturers can employ the tool to optimize glazing spectral transmission to achieve intentional colorimetric and photobiological performance with transmitted light. Electric lighting manufacturers, designers, and researchers can use the tool to evaluate the impact of glazing units and other optical materials on the color quality and biological potential of transmitted light.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Geographic Information System Mapping Tool for Rainwater Harvesting in the United States

The Rainwater Harvesting Tool is a publicly available web-based geographic information system tool developed using geospatial analysis in combination with historic ZIP Code level monthly average precipitation and evapotranspiration data across the United States to help select potential locations for harvesting rainwater. Rainwater harvesting can provide a key source of alternative water for a variety of uses including landscape irrigation, vehicle wash, cooling tower makeup, dust suppression, and toilet flushing. Rainwater harvesting can help support institutional, commercial, and residential buildings in diversifying water sources and offset the use of freshwater. This tool aims to help organizations strategically target locations to implement rainwater harvesting systems. The metric used in the tool is called the rainwater harvesting potential, which is a normalized metric, measured in inches per year. The rainwater harvesting potential describes the amount of rainwater that can be reasonably collected and stored at a specific location. This metric was used to rank areas delineated by ZIP Codes across the US, from lowest to highest to show the relative availability of rainwater for harvesting. Two mapping layers are included in the tool that show the general rainwater harvesting potential for all applications and a layer that specifically shows the potential for harvesting rainwater to supply irrigation The Rainwater Harvesting Tool allows users to view overall trends across the United States, while also allowing the user to zoom in to a scale where ZIP Code boundaries are clearly delineated. The tool can be used to help organizations with buildings located in multiple regions to strategically identify where to install rainwater harvesting systems and prioritize locations that may be optimal for rainwater harvesting.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

A Survey of Open-Source Tools for Transmission and Distribution Systems Research

This work presents a review of open-source electric power transmission and distribution systems analysis tools suitable for use by industry professionals and academic researchers. Due to the high complexity of the electric grid, there exist numerous tools and extensive research pertaining to nearly every aspect of the design, operation, and control of transmission and distribution networks. In addition to the commercial tools, a wide range of free, open-source tools, models, and data usable by the scientific community for related research have been developed by different organizations, including both international and US universities and national laboratories. However, due to the absence of a catalog of available tools, models and data, researchers often lack a knowledge of existing capabilities and may develop duplicative software and tools. Increasing awareness of these available resources seeks to accelerate their broader use, leading to more efficient and standardized grid analysis. This review paper (which is part of a larger survey effort that studied over 400 tools in the transmission, distribution, buildings, and electric vehicles space) outlines selected open-source resources that have been developed in power transmission and distribution systems research. It is anticipated that this work can serve as a guide for industry and academic researchers alike, ensuring that research efforts are well-channeled.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

An Assessment of the Usability of Machine Learning Based Tools for the Security Operations Center

Gartner, a large research and advisory company, anticipates that by 2024 80% of security operation centers (SOCs) will use machine learning (ML) based solutions to enhance their operations. 1 1 https://www.ciodive.com/news/how-data-science-tools-can-lighten-the-load-for-cybersecurity-teams/572209/ In light of such widespread adoption, it is vital for the research community to identify and address usability concerns. This work presents the results of the first in situ usability assessment of ML-based tools. With the support of the US Navy, we leveraged the national cyber range-a large, air-gapped cyber testbed equipped with state-of-the-art network and user emulation capabilities-to study six US Naval SOC analysts' usage of two tools. Our analysis identified several serious usability issues, including multiple violations of established usability heuristics for user interface design. We also discovered that analysts lacked a clear mental model of how these tools generate scores, resulting in mistrust a and/or misuse of the tools themselves. Surprisingly, we found no correlation between analysts' level of education or years of experience and their performance with either tool, suggesting that other factors such as prior background knowledge or personality play a significant role in ML-based tool usage. Our findings demonstrate that ML-based security tool vendors must put a renewed focus on working with analysts, both experienced and inexperienced, to ensure that their systems are usable and useful in real-world security operations settings.

Oesch, T↗
DOE OSTI2024

Novel principal component analysis tool based on python for analysis of complex spectra of time-of-flight secondary ion mass spectrometry

Time-of-flight secondary ion mass spectrometry (ToF-SIMS) is a powerful surface analysis tool, which can simultaneously provide elemental, isotopic, and molecular information with part per million (ppm) sensitivity. However, each spectrum may be composed of hundreds of ion signals, which makes the spectra data complex. Principal component analysis (PCA) is a multivariate analysis technique that has been widely used to figure out the variances among samples in ToF-SIMS spectra data analysis and is showing great success in the explanation of complex ToF-SIMS spectra. So far, several software tools have been developed for PCA of ToF-SIMS spectra; however, none of them are freely available. Such a situation leads to some difficulties in extending applications of PCA to various research fields. More importantly, it has long been challenging for common researchers to understand PCA plots and extract chemical differences among samples. In this work, we developed a new and flexible software tool (named “advanced spectra pca toolbox”) based on python for PCA of complex ToF-SIMS spectra along with an easy-to-read manual. It can generate data analysis reports automatically to explain chemical differences among samples, allowing less experienced researchers to easily understand tricky PCA results. Moreover, it is expandable and compatible with artificial intelligence/machine learning functions. Pure goethite and different lignin adsorbed goethite samples were used as a model system to demonstrate our new software tool, proving that our software tool can be readily used in complex spectra data processing. Our new software tool is open-source, convenient, flexible, and expandable. We expect this open-source tool will benefit the ToF-SIMS community.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Multi-process tooling for discontinuous carbon and hybrid glass fiber thermoplastics

Expensive tooling often constraints the use of composites in the design and development of automotive parts. While there is significant confidence and knowledge in sheet and bulk metals, composite processes are less understood in mass production environment. The processes used to produce composites and resulting properties are influenced by fiber length attrition, resin to fiber ratio, process waste etc. Tool designs are determined very early in the engineering process. It is cost prohibitive to build additional tools, in the event it becomes obvious a better processing method and material would be beneficial, the original decision is not easily changed. In the present work we recognize the bottleneck of tooling costs and provide an approach of multi-process tooling. The innovation of this work is the design and demonstration of a single tool for different processes namely injection, injection-compression and extrusion-compression. The materials used in this study were long and short fiber thermoplastics (LFTs and SFTs). The resulting structure-property relationships have been reported for the materials and processing methods with a battery tray (BT) tool.

Vaidya, Uday↗
DOE OSTI2020

GADRAS Batch Inject Tool User Guide

Gamma Detector Response and Analysis Software (GADRAS) is used by the radiation detection and emergency response community to perform modeling and spectral analysis for gamma detector systems. Built into GADRAS is the ability to define a detector, geometry, background characteristics and source composition to generate synthetic spectra for drills and exercises (injects). Consequence Management is currently in development of a sample result data simulator tool in which a deposition model is probed for source conditions at moments in time and locations in space. These values are used to generate realistic sample results for use in drills and exercises. In addition to sample results, there is a need to simulate the actual spectra that would be observed in the field by downlooking HPGe instruments given a deposition activity. This way, the FRMAC Gamma Spectroscopist can practice their process of generating quantified results from spectra on realistic data as well. Recognizing the decades of work done in GADRAS to accurately generate synthetic spectra, this team decided to build a link between the new simulator and GADRAS to generate these spectra quickly and easily. The simulator tool will generate a file that specifies the name of the spectra, its location, date/time of measurement, duration of measurement, height off the ground, and the deposition activity and age for every radionuclide in the simulation. Then, a new tool within the Inject Tab of GADRAS was developed to read in this file given a detector selection and generate In-Situ spectra for each row in the file in any file format the user chooses. This way, simulation cell staff can take these files and then upload them to the appropriate data system (RAMS or RadResponder) for use during drills and exercises. An advanced feature of this tool allows for generating any spectra given an appropriate model and mapping of source to model layer in the batch inject tool. This way, spectra from field sample counts, mobile laboratories, or even fixed laboratories can be generated in bulk given an estimate of the radioactivity concentration or total radioactivity in an import file. This expands the capabilities of this tool a great deal and will make it a more useful tool for CM and others to help estimate detector response for nearly any situation. This user guide will explain the steps needed to perform a batch inject file generation.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2022

Energy Storage Valuation: A Review of Use Cases and Modeling Tools

An enticing prospect that drives adoption of energy storage systems (ESS) is its ability to be used in a diverse set of use cases and the potential to take advantage of multiple unique value streams. The Energy Storage Grand Challenge (ESGC) technology development pathways for storage technologies draw from a set of use cases in the electrical power system, each with their own specific cost and performance needs. In addition to the need for cost and performance improvements for storage technologies, there a need for robust valuation methods to enable effective policy, investment, business models, and resource planning. There are numerous storage valuation tools available to the public, many of which can analyze the value of an ESS project with inputs and characteristics that reflect a specific storage use case. To effectively reach ESS stakeholders that may be interested in learning about valuation models, this report will draw from publicly available tools developed by the Department of Energy (DOE) and frame their functionalities and capabilities within the context of three distinct use case families. This report examines three of the ESGC use case families in depth and provides a methodology in which interested stakeholders can determine which DOE modeling tool is best suited to value ESS for their specific case. The high-level objectives for this report include: (1) Provide specific sub use-cases for each use case family for further characterization; (2) Provide technical parameters and relevant data for three example use cases that could be used in a valuation tool; (3) Identify a list of publicly available DOE tools that can provide energy storage valuation insights for ESS use case stakeholders; (4) Provide information on the capabilities and different options in each modeling tool; (5) Make conclusions on which are best suited for valuing certain functional/performance requirements and which tools might be applicable to other use cases; and (6) Show the methodology that informs a Model Selection Platform (MSP) framework that educates stakeholders on different DOE models and provides a streamlined way to choose the right model that most closely matches their needs.

25 ENERGY STORAGE↗
DOE OSTI2021

Autonomous Tools for Attack Surface Reduction (Final Report)

The electric power grid is a complex critical infrastructure that forms the lifeline of modern society, and its secure and reliable operation is of paramount importance to national security and economic wellbeing. However, recent findings documented in authoritative sources indicate the threat of cyber-based attacks growing in numbers and sophistication. However, securing the grid against stealthy cyberattacks is a challenging task due to legacy nature of the infrastructure coupled with dynamic nature of threat landscape and ever-growing sophistication of the adversaries. Additionally, the grid’s attack surface continues to grow with the increased dependence on digital communications and control that now extends to each consumer through smart meters and distributed energy resources. Unfortunately, this expansive surface increases the grid’s vulnerability and further exposes critical control systems in both substations and control centers. To respond to this emerging need, we had successfully assembled an interdisciplinary team with academic- industry partnership to successfully conduct research, development, evaluation, demonstration, and commercialization of attack surface reduction tools, whose goal was to significantly reduce the cyber attack surface in the North American power grid. Our proposed project was a synergistic collaborative effort leveraging the synergistic expertise of the team members across power systems, cyber security and CPS security, testbeds, field deployments and demonstration, and successful commercialization. The following are the specific tasks that have been successfully completed two phases (2016-2020). Phase I: Task 1: Developed and implemented a robust Project Management and Data Management Plan, coupled with a well thought out Risk Mitigation Plan. Task 2.1: Developed a comprehensive framework that continually assesses and autonomously reduces the attack surface for the power grid control environment spanning across substations, control center and the SCADA network to significantly reduce the risks of cyber attacks. Task 2.2: Developed attack surface analysis techniques, metrics, and tools that assess the attack surface at multiple levels including the control center, substations, and the SCADA network. Task 2.3: Developed attack surface reduction techniques and tools that dynamically reduce attack surface and hence increase attacker’s cost without interfering in the critical functions of the system. Task 2.4: Prototyped, implemented, and quantitatively evaluated/validated the techniques and tools on a realistic industrial CPS security testbed environment by leveraging the unique resources of the team. Task 3: Developed Commercialization plan to transition the developed tools into power system industry stakeholders for a broader adoption by leveraging the expertise of our industrial members. Phase II: Task 4: Successfully completed field demonstration, verification, and evaluation of the effectiveness of the attack surface analysis and reduction techniques on a realistic utility testbed environment. This also involved the development of realistic scenarios, sound metrics, data sets, evaluation criteria, and documentation. Technology integration & Field demonstration: The project had significantly advanced the state-of-the-art research and practice in improving the cybersecurity of our nation’s power grid infrastructure against cyber threats. In particular, the proposed, designed, and deployed attack surface analysis and reduction algorithms and tools have contributed to significantly reducing the exposure and risk of the devices, substations, and the integrated SCADA/EMS/ DMS grid environment to cyber threat. Strong demonstration and evaluation techniques have verified the feasibility of the developed techniques on realistic cyber-physical testbeds and utility partner's real grid environment, and collaborative research and evaluation of attack surface reduction techniques (for wide-are monitoring and control) within a vendor (GE) EMS platform. The Attack Host Analyzer (AHA) tool that was developed through this project was made available through GitHub.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

The REPACT Tool: User Manual [Slides]

Reuse of Existing Pipelines for Adapted Carbon Transport (REPACT) is an Excel-based screening tool. This tool enables the user to determine whether a pipeline originally deployed for natural gas transport, can be reused for CO 2 transport. The tool along with its associated users manual walk through an intended usage statement, setup instructions, a list of inputs and outputs in the tool, and frequently used protocols. Please note that this is a first-pass screening tool. The approach presented within this tool is valid for high-level evaluation only and should not be used to make engineering, financial, and/or regulatory decisions. Access the tool here: https://www.netl.doe.gov/energy-analysis/details?id=c699a604-ded1-45cd-b1c0-247b1405aeeb

03 NATURAL GAS↗
DOE OSTI2024

Advances on CHP District Energy and Microgrids Deployment: Simplified Tool for Rapidly Deploying Feasibility Analytics for the Non-Technical User (Final Technical Report)

Community energy systems have proven to have the potential to improve cost efficiency, resilience, and decarbonize. However, investing in community energy systems such as community microgrids or district energy systems is a complex decision due to the high initial investment and the uncertainties associated with the long development time and lifecycle of the project. Tools that make feasibility assessments accessible to non-technical users like investors, policymakers, and other stakeholders will result in more feasibility analyses completed, more candidate projects identified, and more community energy systems deployed. The pilot tool developed under this award is named Energy Fellow. Energy Fellow allows technical and non-technical users to complete feasibility analyses for district energy systems and community microgrids. This is the first software tool of its kind designed for non-technical users and available at no cost. Its scope was adjusted to a 25x25-mile region within the Houston area in Texas to make its development compatible with the funding available. However, the findings and models developed make this pilot tool easily scalable to the US. The lessons learned during the design, implementation, and testing stages have helped find trade-off solutions to software and hardware challenges related to implementing 3D models in online tools. Green software strategies has been successfully applied to the design and operations of the tool, and the team has researched the aspects of the (non-technical) user experience that will make commercial developments of this tool even more impactful.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE-20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ̊C.This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE- 20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ˚C. This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

36 MATERIALS SCIENCE↗