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Biases in Total Precipitable Water Vapor Climatologies from Atmospheric Infrared Sounder and Advanced Microwave Scanning Radiometer

We examine differences in total precipitable water vapor (PWV) from the Atmospheric Infrared Sounder (AIRS) and the Advanced Microwave Scanning Radiometer (AMSR-E) experiments sharing the Aqua spacecraft platform. Both systems provide estimates of PWV over water surfaces. We compare AIRS and AMSR-E PWV to constrain AIRS retrieval uncertainties as functions of AIRS retrieved infrared cloud fraction. PWV differences between the two instruments vary only weakly with infrared cloud fraction up to about 70%. Maps of AIRS-AMSR-E PWV differences vary with location and season. Observational biases, when both instruments observe identical scenes, are generally less than 5%. Exceptions are in cold air outbreaks where AIRS is biased moist by 10-20% or 10-60% (depending on retrieval processing) and at high latitudes in winter where AIRS is dry by 5-10%. Sampling biases, from different sampling characteristics of AIRS and AMSR-E, vary in sign and magnitude. AIRS sampling is dry by up to 30% in most high-latitude regions but moist by 5-15% in subtropical stratus cloud belts. Over the northwest Pacific, AIRS samples conditions more moist than AMSR-E by a much as 60%. We hypothesize that both wet and dry sampling biases are due to the effects of clouds on the AIRS retrieval methodology. The sign and magnitude of these biases depend upon the types of cloud present and on the relationship between clouds and PWV. These results for PWV imply that climatologies of height-resolved water vapor from AIRS must take into consideration local meteorological processes affecting AIRS sampling.

Atmospheric Infrared Sounder (AIRS)↗

Vegetation Effects on Soil Moisture Estimation

Several successful algorithms have been developed to estimate soil moisture of bare surfaces. We previously reported a new algorithm using the tilted Bragg approximation. However, these algorithms are only applicable to bare surfaces. When vegetation is present, soil moisture is typically underestimated by bare surface algorithms. In order to derive soil moisture under vegetation, we have to understand the complex scattering process due to vegetation. Our main interest is to retrieve the global soil moisture information using Hydros L-band polarimetric radar data. The Hydros mission will provide the first global view of land soil moisture using L-band radar and radiometer. The unique characteristics of the Hydros data are the availability of the low resolution soil moisture information from radiometer data and the continuous time series radar data collected at the same incidence angle. In this paper, we will examine a potential inversion algorithm to retrieve soil moisture under vegetation canopies using Hydros L-band polarimetric radar data.

soil moisture↗

Real-Time Application of Multi-Satellite Precipitation Analysis for Floods and Landslides

Satellite data acquired and processed in real time now have the potential to provide the spacetime information on rainfall needed to monitor flood and landslide events around the world. This can be achieved by integrating the satellite-derived forcing data with hydrological models and landslide algorithms. Progress in using the TRMM Multi-satellite Precipitation Analysis (TMPA) as input to flood and landslide forecasts is outlined, with a focus on understanding limitations of the rainfall data and impacts of those limitations on flood/landslide analyses. Case studies of both successes and failures will be shown, as well as comparison with ground comparison data sets-- both in terms of rainfall and in terms of flood/landslide events. In addition to potential uses in real-time, the nearly ten years of TMPA data allow retrospective running of the models to examine variations in extreme events. The flood determination algorithm consists of four major components: 1) multi-satellite precipitation estimation; 2) characterization of land surface including digital elevation from NASA SRTM (Shuttle Radar Terrain Mission), topography-derived hydrologic parameters such as flow direction, flow accumulation, basin, and river network etc.; 3) a hydrological model to infiltrate rainfall and route overland runoff; and 4) an implementation interface to relay the input data to the models and display the flood inundation results to potential users and decision-makers, In terms of landslides, the satellite rainfall information is combined with a global landslide susceptibility map, derived from a combination of global surface characteristics (digital elevation topography, slope, soil types, soil texture, and land cover classification etc.) using a weighted linear combination approach. In those areas identified as "susceptible" (based on the surface characteristics), landslides are forecast where and when a rainfall intensity/duration threshold is exceeded. Results are described indicating general agreement with landslide occurrences.

Adler, Robert↗

Application of Multi-Satellite Precipitation Analysis to Floods and Landslides

Satellite data acquired and processed in real time now have the potential to provide the spacetime information on rainfall needed to monitor flood and landslide events around the world. This can be achieved by integrating the satellite-derived forcing data with hydrological models and landslide algorithms. Progress in using the TRMM Multi-satellite Precipitation Analysis (TMPA) as input to flood and landslide forecasts is outlined, with a focus on understanding limitations of the rainfall data and impacts of those limitations on flood/landslide analyses. Case studies of both successes and failures will be shown, as well as comparison with ground comparison data sets both in terms of rainfall and in terms of flood/landslide events. In addition to potential uses in real-time, the nearly ten years of TMPA data allow retrospective running of the models to examine variations in extreme events. The flood determination algorithm consists of four major components: 1) multi-satellite precipitation estimation; 2) characterization of land surface including digital elevation from NASA SRTM (Shuttle Radar Terrain Mission), topography-derived hydrologic parameters such as flow direction, flow accumulation, basin, and river network etc.; 3) a hydrological model to infiltrate rainfall and route overland runoff; and 4) an implementation interface to relay the input data to the models and display the flood inundation results to potential users and decision-makers. In terms of landslides, the satellite rainfall information is combined with a global landslide susceptibility map, derived from a combination of global surface characteristics (digital elevation topography, slope, soil types, soil texture, and land cover classification etc.) using a weighted linear combination approach. In those areas identified as "susceptible" (based on the surface characteristics), landslides are forecast where and when a rainfall intensity/duration threshold is exceeded. Results are described indicating general agreement with landslide occurrences. However, difficulties in comparing landslide event information (mostly from news reports) with the satellite-based forecasts are analyzed.

Adler, Robert↗

An Experimental System for a Global Flood Prediction: From Satellite Precipitation Data to a Flood Inundation Map

Floods impact more people globally than any other type of natural disaster. It has been established by experience that the most effective means to reduce the property damage and life loss caused by floods is the development of flood early warning systems. However, advances for such a system have been constrained by the difficulty in estimating rainfall continuously over space (catchment-. national-, continental-. or even global-scale areas) and time (hourly to daily). Particularly, insufficient in situ data, long delay in data transmission and absence of real-time data sharing agreements in many trans-boundary basins hamper the development of a real-time system at the regional to global scale. In many countries around the world, particularly in the tropics where rainfall and flooding co-exist in abundance, satellite-based precipitation estimation may be the best source of rainfall data for those data scarce (ungauged) areas and trans-boundary basins. Satellite remote sensing data acquired and processed in real time can now provide the space-time information on rainfall fluxes needed to monitor severe flood events around the world. This can be achieved by integrating the satellite-derived forcing data with hydrological models, which can be parameterized by a tailored geospatial database. An example that is a key to this progress is NASA's contribution to the Tropical Rainfall Measuring Mission (TRMM), launched in November 1997. Hence, in an effort to evolve toward a more hydrologically-relevant flood alert system, this talk articulates a module-structured framework for quasi-global flood potential naming, that is 'up to date' with the state of the art on satellite rainfall estimation and the improved geospatial datasets. The system is modular in design with the flexibility that permits changes in the model structure and in the choice of components. Four major components included in the system are: 1) multi-satellite precipitation estimation; 2) characterization of land surface including digital elevation from NASA SRTM, topography-derived hydrologic parameters such as flood direction. flow accumulation, basin, and river network etc.; 3) spatially distributed hydrological models to infiltrate rainfall and route overland runoff; and 4) an implementation interface to relay thc input data to the models and display the flood inundation results to the users and decision-makers. Early results appear reasonable in terms of location and frequency of events. Case studies of this experimental system are evaluated with surface runoff data and other river monitoring systems. such as Dartmouth Flood Observatory's "Surface Water Watch" array of river reaches that are measured daily via other satellite remote sensing data. A major outcome of this progress will be the availability of a global overview of flood alerts that should consequently improve the performance of Decision Support System. We expect these developments in utilization of satellite remote sensing technology to offer a practical solution to the challenge of building a cost-effective early warning system for data scarce and under-developed areas.

Adler, Robert↗

Stream Flow Prediction by Remote Sensing and Genetic Programming

A genetic programming (GP)-based, nonlinear modeling structure relates soil moisture with synthetic-aperture-radar (SAR) images to present representative soil moisture estimates at the watershed scale. Surface soil moisture measurement is difficult to obtain over a large area due to a variety of soil permeability values and soil textures. Point measurements can be used on a small-scale area, but it is impossible to acquire such information effectively in large-scale watersheds. This model exhibits the capacity to assimilate SAR images and relevant geoenvironmental parameters to measure soil moisture.

Chang, Ni-Bin↗

CBSIT 2009: Airborne Validation of Envisat Radar Altimetry and In Situ Ice Camp Measurements Over Arctic Sea Ice

The past few years have seen the emergence of satellite altimetry as valuable tool for taking quantitative sea ice monitoring beyond the traditional surface extent measurements and into estimates of sea ice thickness and volume, parameters that arc fundamental to improved understanding of polar dynamics and climate modeling. Several studies have now demonstrated the use of both microwave (ERS, Envisat/RA-2) and laser (ICESat/GLAS) satellite altimeters for determining sea ice thickness. The complexity of polar environments, however, continues to make sea ice thickness determination a complicated remote sensing task and validation studies remain essential for successful monitoring of sea ice hy satellites. One such validation effort, the Arctic Aircraft Altimeter (AAA) campaign of2006. included underflights of Envisat and ICESat north of the Canadian Archipelago using NASA's P-3 aircraft. This campaign compared Envisat and ICESat sea ice elevation measurements with high-resolution airborne elevation measurements, revealing the impact of refrozen leads on radar altimetry and ice drift on laser altimetry. Continuing this research and validation effort, the Canada Basin Sea Ice Thickness (CBSIT) experiment was completed in April 2009. CBSIT was conducted by NOAA. and NASA as part of NASA's Operation Ice Bridge, a gap-filling mission intended to supplement sea and land ice monitoring until the launch of NASA's ICESat-2 mission. CBIST was flown on the NASA P-3, which was equipped with a scanning laser altimeter, a Ku-band snow radar, and un updated nadir looking photo-imaging system. The CB5IT campaign consisted of two flights: an under flight of Envisat along a 1000 km track similar to that flown in 2006, and a flight through the Nares Strait up to the Lincoln Sea that included an overflight of the Danish GreenArc Ice Camp off the coast of northern Greenland. We present an examination of data collected during this campaign, comparing airborne laser altimeter measurements with (1) Envisat RA-2 returns retracked optimally for sea ice and (2) in situ measurements of sea ice thickness and snow depth gathered from ice camp surveys. Particular attention is given to lead identification and classification using the continuous photo-imaging system along the Envisat underflight as well as the performance of the snow radar over the ice camp survey lines.

Connor, Laurence↗

Analysis and Results from a Flush Airdata Sensing System in Close Proximity to Firing Rocket Nozzles

This paper presents information regarding the nosecap Flush Airdata Sensing (FADS) system on Orion’s Pad Abort 1 (PA-1) vehicle. The purpose of the nosecap FADS system was to test whether or not useful data could be obtained from a FADS system if it was placed in close proximity to firing rocket nozzles like the Attitude Control Motor (ACM) nozzles on the PA-1 Launch Abort System. The nosecap FADS system used pressure measurements from a series of pressure ports which were arranged in a cruciform pattern and flush with the surface of the vehicle to estimate values of angle of attack, angle of sideslip, Mach number, impact pressure, and freestream static pressure. This paper will present the algorithms employed by the FADS system along with the development of the calibration datasets and a comparison of the final results to the Best Estimated Trajectory (BET) data for PA-1. Also presented in this paper is a Computational Fluid Dynamics (CFD) study to explore the impact of the ACM on the nosecap FADS system. The comparison of the nosecap FADS system results to the BET and the CFD study showed that more investigation is needed to quantify the impact of the firing rocket motors on the FADS system.

Flush Air Data Sensing System↗

Analysis and Results from a Flush Airdata Sensing (FADS) System in Close Proximity to Firing Rocket Nozzles

This presentation presents information regarding the nose-cap flush airdata sensing (FADS) system on Orion's Pad Abort 1 (PA-1) vehicle. The purpose of the nose-cap FADS system was to test whether or not useful data could be obtained from a FADS system if it was placed in close proximity to firing rockets nozzles like the attitude control motor (ACM) nozzles on the PA-1 launch abort system (LAS). The nose-cap FADS systems use pressure measurements from a series of pressure ports which are arranged in a cruciform pattern and flush with the surface of the vehicle to estimate values of angle of attack, angle of side-slip, Mach number, impact pressure and free-stream static pressure.

Pad Abort 1↗

Unsteady Thick Airfoil Aerodynamics: Experiments, Computation, and Theory

An experimental, computational and theoretical investigation was carried out to study the aerodynamic loads acting on a relatively thick NACA 0018 airfoil when subjected to pitching and surging, individually and synchronously. Both pre-stall and post-stall angles of attack were considered. Experiments were carried out in a dedicated unsteady wind tunnel, with large surge amplitudes, and airfoil loads were estimated by means of unsteady surface mounted pressure measurements. Theoretical predictions were based on Theodorsen's and Isaacs' results as well as on the relatively recent generalizations of van der Wall. Both two- and three-dimensional computations were performed on structured grids employing unsteady Reynolds-averaged Navier-Stokes (URANS). For pure surging at pre-stall angles of attack, the correspondence between experiments and theory was satisfactory; this served as a validation of Isaacs theory. Discrepancies were traced to dynamic trailing-edge separation, even at low angles of attack. Excellent correspondence was found between experiments and theory for airfoil pitching as well as combined pitching and surging; the latter appears to be the first clear validation of van der Wall's theoretical results. Although qualitatively similar to experiment at low angles of attack, two-dimensional URANS computations yielded notable errors in the unsteady load effects of pitching, surging and their synchronous combination. The main reason is believed to be that the URANS equations do not resolve wake vorticity (explicitly modeled in the theory) or the resulting rolled-up un- steady flow structures because high values of eddy viscosity tend to \smear" the wake. At post-stall angles, three-dimensional computations illustrated the importance of modeling the tunnel side walls.

Strangfeld, C.↗

Ice-Covered Lakes in Gale Crater Mars: The Cold and Wet Hypothesis

Recent geological discoveries from the Mars Science Laboratory provide evidence that Gale crater may have intermittently hosted a fluvio-lacustine environment during the Hesperian, with individual lakes lasting for a period of tens to hundreds of thousands of years. (Grotzinger et al., Science, 350 (6257), 2015). Estimates of the CO2 content of the atmosphere at the time the Gale sediments formed are far less than needed by any climate model to warm early Mars (Bristow et al., Geology, submitted), given the low solar energy input available at Mars 3.5 Gya. We have therefore explored the possibility that the lakes in Gale during the Hesperian were perennially covered with ice using the Antarctic Lakes as an analog. Using our best estimate for the annual mean surface temperature at Gale at this time (approx. 230K) we computed the thickness of an ice-covered lake. These thickness range from 10-30 meters depending on the ablation rate and ice transparency and would likely inhibit sediments from entering the lake. Thus, a first conclusion is that the ice must not be too cold. Raising the mean temperature to 245K is challenging, but not quite as hard as reaching 273K. We found that a mean annual temperature of 245K ice thicknesses range from 3-10 meters. These values are comparable to the range of those for the Antarctic lakes (3-6 m), and are not implausible. And they are not so thick that sediments cannot penetrate the ice. For the ice-covered lake hypothesis to work, however, a melt water source is needed. This could come from subaqueous melting of a glacial dam in contact with the lakes (as is the case for Lake Untersee) or from seasonal melt water from nearby glaciers (as is the case for the Dry Valley lakes). More work is needed to better assess these possibilities. However, the main advantage of the ice-covered lake model (and the main reason we pursued it) is that it relaxes the requirement for a long-lived active hydrological cycle involving rainfall and runoff, which no climate model is able to produce given known constraints on the early Mars environment.

Antarctic lakes↗

Photographic Volume Estimation of CPAS Main Parachutes

Capsule Parachute Assembly System (CPAS) flight tests regularly stage a helicopter to observe inflation of 116 ft D o ringsail Main parachutes. These side views can be used to generate 3-D models of inflating canopies to estimate enclosed volume. Assuming a surface of revolution is inadequate because reefed canopies in a cluster are elongated due to mutual aerodynamic interference. A method was developed to combine the side views with upward looking HD video to account for non-circular cross sections. Approximating the cross sections as elliptical greatly improves accuracy. But since that correction requires manually tracing projected outlines, the actual irregular shapes can be used to generate high fidelity models. Compensation is also made for apparent tilt angle. Validation was accomplished by comparing perimeter and projected area with known line lengths and/or high quality photogrammetry.

Ray, Eric S.↗

MERRA-2 Ocean: The NASA Global Modeling and Assimilation Office's Weakly Coupled Atmosphere-Ocean Reanalysis Using GEOS-S2S Version 3

The NASA Modern Era Reanalysis for Research and Applications (MERRA2) has been a respected and widely used reanalysis that has so far been restricted to the atmosphere. Now a newly released version of the atmosphere/ocean coupled data assimilation system (AODAS) has been developed by the NASA/Goddard Global Modeling and Assimilation Office to perform a retrospective ocean reanalysis from 1982 to present. In addition to assimilating all available in situ data (e.g. Argo, mooring, XBT and CTD data) and altimetry information into the ocean, the new version (GEOS-S2S Version 3) model includes a higher resolution, eddy-permitting ocean model than previous versions, a more realistic implementation of the atmosphere-ocean interface layer, and an improved coupling between glacier and ocean (among other improvements). In addition, this ocean data assimilation was expanded to include the assimilation of satellite sea surface salinity. The MERRA-2 AODAS will be described, and preliminary results will be shown from the assimilation reanalysis and from retrospective forecasts issued using a new ensemble strategy. Following the Global Ocean Data Assimilation Experiment (GODAE) protocols, we will present Class 1 through Class 4 validation results from the ocean reanalysis. Results indicate an improved ocean mixed layer depth, improved salinity near Greenland, an improved diurnal cycle of the sea surface skin temperature, an improved estimate of ocean evaporation, and better representation of western boundary currents (e.g. Gulf Stream) from our new ocean reanalysis. One of the motivations of this project is to provide optimal initial states for ENSO forecasting. Therefore, we will also present some preliminary results of retrospective ENSO forecasts. After thorough testing, it is expected that the GEOS-S2S Version 3 will replace our contributions to North American Multi-Model Ensemble (NMME), WCRP Subseasonal to Seasonal (S2S), and IRI seasonal prediction forecast projects.

Molod, Andrea↗

The Next-Generation Version 3 GPCP Products

The long-standing Global Precipitation Climatology Project (GPCP) recently introduced its next-generation Version 3.1 Monthly product, , which covers the period 1983-2019. Notable improvements include higher spatial resolution (0.5°x0.5°), geosynchronous IR estimates extended to the latitude band 60°N-S and based on the Precipitation Estimation from Remotely Sensed Information using Artificial Neural Networks-Climate Data Record (PERSIANN-CDR) algorithm, and high-latitude (outside 60ºN-S) precipitation estimates based on improved calibrations of Television-Infrared Operational Satellite (TIROS) Operational Vertical Sounder (TOVS) and Advanced Infrared Sounder (AIRS) data. The satellite-only estimate is adjusted to the best available monthly climatologies, namely the Tropical Combined Climatology (TCC) at lower latitudes and the Merged CloudSat, TRMM, and GPM (MCTG) climatology at higher latitudes. Finally, V3.1 merges these climatologically-adjusted satellite-only estimates with the Global Precipitation Climatology Centre (GPCC) gauge analyses at 1°x1°. In addition to the V3.1 Monthly product, the GPCP team is working towards a global Version 3 Daily product based on Integrated Multi-satellitE Retrievals for Global Precipitation Measurement (GPM) mission (IMERG) Final Run V06 estimates, where available, calibrated to the GPCP V3.1 Monthly estimate. Rescaled TOVS/AIRS data are used in high-latitude areas that lack IMERG estimates, which occur over snowy/icy surfaces outside 60°N-S. Since IMERG currently extends back to June 2000, daily PERSIANN-CDR data are used for the period January 1983–May 2000 to complete the record. This presentation will provide early results for, and the latest status of, the Monthly and Daily GPCP products as a function of time and region. Key points include examining homogeneity over time and across boundaries between input datasets. One goal is to determine the suitability of the V3 products while we continue to produce the Version 2 GPCP products for on-going use.

precipitation↗

HydroCube Mission Concept: P-Band Signals of Opportunity for Remote Sensing of Snow and Root Zone Soil Moisture

We have developed the HydroCube mission concept with a constellation of small satellites to remotely sense Snow Water Equivalent (SWE) and Root Zone Soil Moisture (RZSM). The HydroCube satellites would operate at sun-synchronous 3-day repeat polar orbits with a spatial resolution of about 1-3 Km. The mission goals would be to improve the estimation of terrestrial water storage and weather forecasts. Root-zone soil moisture and snow water storage in land are critical parameters of the water cycle. The HydroCube Signals of Opportunity (SoOp) concept utilizes passive receivers to detect the reflection of strong existing P-band radio signals from geostationary Mobile Use Objective System (MUOS) communication satellites. The SWE remote sensing measurement principle using the P-band SoOp is based on the propagation delay (or phase change) of radio signals through the snowpack. The time delay of the reflected signal due to the snowpack with respect to snow-free conditions is directly proportional to the snowpack SWE. To address the ionospheric delay at P-band frequencies, the signals from both MUOS bands (360-380 MHz and 250-270 MHz) would be used. We have conducted an analysis to trade off the spatial resolution for a space-based sensor and measurement accuracy. Through modeling analysis, we find that the dual-band MUOS signals would allow estimation of soil moisture and surface roughness together. From the two MUOS frequencies at 260 MHz and 370 MHz, we can retrieve the soil moisture from the reflectivity ratio scaled by wavenumbers using the two P-band frequencies for MUOS. A modeling analysis using layered stratified model has been completed to determine the sensitivity requirements of HydroCube measurements. For mission concept demonstration, a field campaign has been conducted at the Fraser Experimental Forest in Colorado since February 2016. The data acquired has provided support to the HydroCube concept.

Derksen, Chris↗

Inter-Calibration of Nine UV Sensing Instruments Over Antarctica and Greenland Since 1980

Nadir-viewed intensities (radiances) from nine UV sensing satellite instruments are calibrated over the East Antarctic Plateau and Greenland during summer. The calibrated radiances from these UV instruments ultimately will provide a global long-term record of cloud trends and cloud response from ENSO events since 1980. We first remove the strong solar zenith angle dependence from the intensities using an empirical approach rather than a radiative trans-fer model. Then small multiplicative adjustments are made to these solar zenith angle normalized intensities in order to minimize differences when two or more instruments tempo-rally overlap. While the calibrated intensities show a negligible long-term trend over Antarctica and a statistically in-significant UV albedo trend of−0.05 % per decade over the interior of Greenland, there are small episodic reductions in intensities which are often seen by multiple instruments. Three of these darkening events are explained by boreal forest. Other events are caused by surface melting or volcanoes. We estimate a 2-sigma uncertainty of 0.35% for the calibrated radiances

Nadir-viewed intensities (radiances) from nine UV ↗

Compound High Temperature and Low Chlorophyll Extremes in the Ocean Over the Satellite Period

Ocean extreme events severely impact marine organisms and ecosystems. Of particular concern are compoundevents, i.e., when conditions are extreme for multiple potential ocean ecosystem stressors such as temperature and chlorophyll.Yet, little is known about the occurrence, intensity and duration of such compound high temperature (aka marine heatwaves -MHWs) and low chlorophyll (LChl) extreme events, whether their distributions have changed in the past decades and what thepotential drivers are. Here we use satellite-based sea surface temperature and chlorophyll concentration estimates to provide a5first assessment of such compound extreme events. We reveal hotspots of compound MHW and LChl events in the equatorialPacific, along the boundaries of the subtropical gyres, in the northern Indian Ocean, and around Antarctica. In these regions,compound events that typically last one week occur three to seven times more often than expected under the assumption ofindependence between MHWs and LChl events. The occurrence of compound MHW and LChl events varies on seasonalto interannual timescales. At the seasonal timescale, most compound events occur in summer in both hemispheres. At the10interannual timescale, the frequency of compound MHW and LChl events is strongly modulated by large-scale modes of naturalclimate variability such as the El Niño-Southern Oscillation, whose positive phase is associated with increased compoundevent occurrence in the eastern equatorial Pacific and in the Indian Ocean by a factor of up to four. Our results provide a firstunderstanding of where, when and why compound MHW and LChl events occur. Further studies are needed to identify theexact physical and biological drivers of these potentially harmful events in the ocean and their evolution under global warming.

High Temperature↗

Advanced Instrumentation for Metal Additive Manufacturing

Laser powder bed fusion (LPBF) is the most widely used process for metal additive manufacturing (AM), particularly where complex geometries provide performance advantages unattainable with traditional manufacturing techniques. However, LPBF is highly sensitive to innate variability in both the powder spreading and fusion steps, often leading to defects such as pores that are difficult to detect yet significantly impair component mechanical properties and fatigue life. This thesis presents a range of novel instruments enabling both precise assessment of powder layer characteristics and in-situ thermal metrology of metal AM to advance the quality control of LPBF. First, leveraging a custom X-ray microscope and a radiation-transport model developed through this work, transmission X-ray imaging is used to study spreading of thin metal powder layers. Effective layer depth is directly mapped at a process-relevant size scale, surpassing optical techniques that can only estimate local deposition from layer surface topography. Layer packing density and quality are shown to be influenced by powder flowability and particle size relative to nominal powder layer thickness. Layer quality is additionally connected to the geometry of the spreading implement and its velocity. This technique and its presented findings enable pairing feedstocks with spreading strategies that create layers with consistent packing density and uniformity. Second, a twofold approach is employed to optically interrogate the laser fusion step of LPBF for observing signatures of defect formation. Aperture division multiplexing is conceptualized, providing for simultaneous laser delivery and high-fidelity infrared (IR) process monitoring through a common optic. In-situ microscopy at 50 μm spatial resolution and at mid-wave IR wavelengths is proven readily achievable with the first purpose-built optic of this type. Next, a bespoke imaging spectrometer, along with a temperature-emissivity separation technique, is used to retrieve accurate process temperatures over a 1000 K range. Data from these instruments are correlated to porosity as fine as 4.3 μm in two LPBF test artifacts, as verified using computed tomography (CT), establishing the viability of robust optically-based component qualification.

Penny, Ryan↗

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