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At least 253 records · Page 14

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗

Alteration Products and Secondary Minerals in Martian Meteorite Allan Hills 84001

The martian meteorites contain alteration products and secondary minerals that are a critical part of understanding their near-surface histories on both Mars and Earth. In some martian meteorites, suspected martian preterrestrial alteration products can be distinguished from terrestrial weathering effects Using scanning electron microscopy (SEM), field emission SEM (FE-SEM), transmission electron microscopy (TEM), and energy-dispersive X-ray analysis (EDS), we are studying natural fracture surfaces of ALH 84001 chips, including samples from both the interior and the exterior of the meteorite. Exterior samples include fusion crust surfaces, which are important in determining the extent of terrestrial weathering of meteorites. The focus of this study is weathering features and secondary minerals other than the distinctive carbonate globules that continue to be studied by many researchers.

Wentworth, S. J.↗

Fully Automated Detection of Cloud and Aerosol Layers in the CALIPSO Lidar Measurements

Accurate knowledge of the vertical and horizontal extent of clouds and aerosols in the earth s atmosphere is critical in assessing the planet s radiation budget and for advancing human understanding of climate change issues. To retrieve this fundamental information from the elastic backscatter lidar data acquired during the Cloud-Aerosol Lidar and Infrared Pathfinder Satellite Observations (CALIPSO) mission, a selective, iterated boundary location (SIBYL) algorithm has been developed and deployed. SIBYL accomplishes its goals by integrating an adaptive context-sensitive profile scanner into an iterated multiresolution spatial averaging scheme. This paper provides an in-depth overview of the architecture and performance of the SIBYL algorithm. It begins with a brief review of the theory of target detection in noise-contaminated signals, and an enumeration of the practical constraints levied on the retrieval scheme by the design of the lidar hardware, the geometry of a space-based remote sensing platform, and the spatial variability of the measurement targets. Detailed descriptions are then provided for both the adaptive threshold algorithm used to detect features of interest within individual lidar profiles and the fully automated multiresolution averaging engine within which this profile scanner functions. The resulting fusion of profile scanner and averaging engine is specifically designed to optimize the trade-offs between the widely varying signal-to-noise ratio of the measurements and the disparate spatial resolutions of the detection targets. Throughout the paper, specific algorithm performance details are illustrated using examples drawn from the existing CALIPSO dataset. Overall performance is established by comparisons to existing layer height distributions obtained by other airborne and space-based lidars.

Vaughan, Mark A.↗

Predictive Sea State Estimation for Automated Ride Control and Handling - PSSEARCH

PSSEARCH provides predictive sea state estimation, coupled with closed-loop feedback control for automated ride control. It enables a manned or unmanned watercraft to determine the 3D map and sea state conditions in its vicinity in real time. Adaptive path-planning/ replanning software and a control surface management system will then use this information to choose the best settings and heading relative to the seas for the watercraft. PSSEARCH looks ahead and anticipates potential impact of waves on the boat and is used in a tight control loop to adjust trim tabs, course, and throttle settings. The software uses sensory inputs including IMU (Inertial Measurement Unit), stereo, radar, etc. to determine the sea state and wave conditions (wave height, frequency, wave direction) in the vicinity of a rapidly moving boat. This information can then be used to plot a safe path through the oncoming waves. The main issues in determining a safe path for sea surface navigation are: (1) deriving a 3D map of the surrounding environment, (2) extracting hazards and sea state surface state from the imaging sensors/map, and (3) planning a path and control surface settings that avoid the hazards, accomplish the mission navigation goals, and mitigate crew injuries from excessive heave, pitch, and roll accelerations while taking into account the dynamics of the sea surface state. The first part is solved using a wide baseline stereo system, where 3D structure is determined from two calibrated pairs of visual imagers. Once the 3D map is derived, anything above the sea surface is classified as a potential hazard and a surface analysis gives a static snapshot of the waves. Dynamics of the wave features are obtained from a frequency analysis of motion vectors derived from the orientation of the waves during a sequence of inputs. Fusion of the dynamic wave patterns with the 3D maps and the IMU outputs is used for efficient safe path planning.

Huntsberger, Terrance L.↗

Particle transport in Markov stochastic mixtures with spatial gradients

Markov geometries are a prototype class of stochastic media that are widely used to model complex disordered systems. In a series of recent works, we have shown that spatially homogeneous (but possibly non-isotropic) Poisson tessellations can be conveniently used in order to generate three-dimensional realizations of Markov media and thus characterize the features of particle transport e.g. in fragmented fuel elements following severe nuclear accidents or Rayleigh-Taylor turbulent mixing for inertial confinement fusion. In this paper we show that Poisson tessellations can be extended to take into account the presence of spatial gradients, which commonly occur in real-world applications due to material stratification. For this purpose, we will provide an explicit construction of spatially-non-homogeneous Poisson tessellations, fully characterize their statistical properties, and finally illustrate the behaviour of particle transport in such random media. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Design of a high-resolution Rayleigh-Taylor experiment with the Crystal Backlighter Imager on the National Ignition Facility

The Rayleigh-Taylor (RT) instability affects a vast range of High Energy Density (HED) length scales, spanning from supernova explosions (10 13 m) to inertial confinement fusion (10 -6 m). In inertial confinement fusion, the RT instability is known to induce mixing or turbulent transition, which in turn cools the hot spot and hinders ignition. The fine-scale features of the RT instability, which are difficult to image in HED physics, may help determine if the system is mixing or is transitioning to turbulence. Earlier diagnostics lacked the spatial and temporal resolution necessary to diagnose the dynamics that occur along the RT structure. A recently developed diagnostic, the Crystal Backlighter Imager (CBI), [1,2] can now produce an x-ray radiograph capable of resolving the fine-scale features expected in these RT unstable systems. This paper describes an experimental design that adapts a well-characterized National Ignition Facility (NIF) platform to accommodate the CBI diagnostic. Simulations and synthetic radiographs highlight the resolution capabilities of the CBI in comparison to previous diagnostics. Furthermore, the improved resolution of the system can provide new observations to study the RT instability's involvement in mixing and the transition to turbulence in the HED regime.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Simultaneous access to high normalized density, current, pressure, and confinement in strongly-shaped diverted negative triangularity plasmas

Strongly-shaped diverted negative triangularity (NT) plasmas in the DIII-D tokamak demonstrate simultaneous access to high normalized density, current, pressure, and confinement. NT plasmas are shown to exist across an expansive parameter space compatible with high fusion power production, revealing surprisingly good core stability properties that compare favorably to conventional positive triangularity plasmas in DIII-D. Non-dimensionalizing the key parameters, expanded operating spaces featuring edge safety factors below 3, normalized betas above 3, Greenwald density fractions above 1, and high-confinement mode (H-mode) confinement qualities above 1 are observed, even simultaneously, and all with a robustly stable edge free from deleterious edge-localized mode instabilities. Scaling of the confinement time with engineering parameters reveals at least a linear dependence on plasma current although with significant power degradation, both in excess of expected H-mode scalings. These results increase confidence that NT plasmas are a viable approach to realize fusion power and open directions for future detailed study.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Physics-Based Optical Neuromorphic Classification

Typical approaches to classify scenes from light convert the light field to electrons to perform the computation in the digital electronic domain. This conversion and downstream computational analysis require significant power and time. Diffractive neural networks have recently emerged as unique systems to classify optical fields at lower energy and high speeds. Previous work has shown that a single layer of diffractive metamaterial can achieve high performance on classification tasks. In analogy with electronic neural networks, it is anticipated that multilayer diffractive systems would provide better performance, but the fundamental reasons for the potential improvement have not been established. In this work, we present extensive computational simulations of two - layer diffractive neural networks and show that they can achieve high performance with fewer diffractive features than single layer systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Microstructural Characterization of Laser Powder Bed Fusion (L-PBF) Additively Manufactured Inconel 718 for Aerospace Application

Alloy 718 (Inconel 718) is used for aerospace applications because of its excellent corrosion resistance and mechanical properties. This alloy is particularly applicable in manufacturing components subjected to high temperatures in rocket engines, aero-engines, and gas turbines. Properties for this alloy when processing on systems from similar and different Laser Powder Bed Fusion (L-PBF) machines provide subtle differences due to process parameters, feedstock, and machine configurations. A series of sixteen L-PBF AM Inconel 718 geometric feature build plates have been evaluated for microstructure using optical microscopy. This study presents the details of the microstructure analysis concerning geometry and different machine platforms. Microstructural investigations of these samples included average grain width measurement for all the X-Y and Y-Z build layers and are accompanied by process parameters and powder characterization. The present work concludes with a discussion on the importance of captured differences among builds to understand the practical limitations among AM platforms.

Additive Manufacturing↗

Low power and privacy preserving sensor platform for occupancy detection

A low-cost, low-power, stand-alone sensor platform having a visible-range camera sensor, a thermopile array, a microphone, a motion sensor, and a microprocessor that is configured to perform occupancy detection and counting while preserving the privacy of occupants. The platform is programmed to extract shape/texture from images in spatial domain; motion from video in time domain; and audio features in frequency domain. Embedded binarized neural networks are used for efficient object of interest detection. The platform is also programmed with advanced fusion algorithms for multiple sensor modalities addressing dependent sensor observations. The platform may be deployed for (i) residential use in detecting occupants for autonomously controlling building systems, such as HVAC and lighting systems, to provide energy savings, (ii) security and surveillance, such as to detect loitering and surveil places of interest, (iii) analyzing customer behavior and flows, (iv) identifying high performing stores by retailers.

Velipasalar, Senem↗

Proximity-based proteomics reveals the thylakoid lumen proteome in the cyanobacterium Synechococcus sp. PCC 7002

Abstract Cyanobacteria possess unique intracellular organization. Many proteomic studies have examined different features of cyanobacteria to learn about the intracellular structures and their respective functions. While these studies have made great progress in understanding cyanobacterial physiology, the conventional fractionation methods used to purify cellular structures have limitations; specifically, certain regions of cells cannot be purified with existing fractionation methods. Proximity-based proteomics techniques were developed to overcome the limitations of biochemical fractionation for proteomics. Proximity-based proteomics relies on spatiotemporal protein labeling followed by mass spectrometry of the labeled proteins to determine the proteome of the region of interest. We performed proximity-based proteomics in the cyanobacterium Synechococcus sp. PCC 7002 with the APEX2 enzyme, an engineered ascorbate peroxidase. We determined the proteome of the thylakoid lumen, a region of the cell that has remained challenging to study with existing methods, using a translational fusion between APEX2 and PsbU, a lumenal subunit of photosystem II. Our results demonstrate the power of APEX2 as a tool to study the cell biology of intracellular features and processes, including photosystem II assembly in cyanobacteria, with enhanced spatiotemporal resolution.

59 BASIC BIOLOGICAL SCIENCES↗

Proximity-based proteomics reveals the thylakoid lumen proteome in the cyanobacterium Synechococcus sp. PCC 7002

Cyanobacteria possess unique intracellular organization. Many proteomic studies have examined different features of cyanobacteria to learn about the intracellular structures and their respective functions. While these studies have made great progress in understanding cyanobacterial physiology, the conventional fractionation methods used to purify cellular structures have limitations; specifically, certain regions of cells cannot be purified with existing fractionation methods. Proximity-based proteomics techniques were developed to overcome the limitations of biochemical fractionation for proteomics. Proximity-based proteomics relies on spatiotemporal protein labeling followed by mass spectrometry of the labeled proteins to determine the proteome of the region of interest. We performed proximity-based proteomics in the cyanobacterium Synechococcus sp. PCC 7002 with the APEX2 enzyme, an engineered ascorbate peroxidase. We determined the proteome of the thylakoid lumen, a region of the cell that has remained challenging to study with existing methods, using a translational fusion between APEX2 and PsbU, a lumenal subunit of photosystem II. Our results demonstrate the power of APEX2 as a tool to study the cell biology of intracellular features and processes, including photosystem II assembly in cyanobacteria, with enhanced spatiotemporal resolution.

59 BASIC BIOLOGICAL SCIENCES↗

Analysis of Waste Material Feedstocks Using Laser-Induced Breakdown Spectroscopy and Machine Learning

Predicting properties such as heating value, ash fusion temperature, and mineral ash composition from Laser-Induced Breakdown Spectroscopy (LIBS) data can make gasifiers more flexible to different feedstocks. Understanding these feedstock properties in-situ improves feedstock conversion modelling methods that allow for consistent operation, higher carbon conversion, and reduced fouling and erosion rates. The purpose of this study is to demonstrate methods for model creation that take LIBS data as predictor features and estimate higher order material properties as a function of feedstock material properties. Six samples were chosen to represent a mixture of abundant and carbon rich waste materials. LIBS measurements were performed on these samples for elemental wavelengths and intensity values. Laboratory analytical results were obtained for each sample’s heating value, proximate and ultimate analysis, mineral ash composition, ash fusion temperatures, and viscosity temperatures. Thermal conductivity was measured using a HotDisk TPS 2500S. LIBS measurements were processed and used as predictor features for machine learning (ML) models to predict the sample’s material properties. Predictor feature selection algorithms, particularly minimum redundancy maximum relevance (mRMR), reduced the dimensionality of ML models. Many modelling methods such as Gaussian process regression (GPR), regression tree, neural networks (NN), and support vector machines (SVM) were demonstrated to be effective at predicting higher order properties; however, mRMR with GPR stood out as a clear winning combination.

01 COAL, LIGNITE, AND PEAT↗

Developments and Challenges in the Design of the ITER DRGA

We report the ITER Diagnostic Residual Gas Analyzer (DRGA) will measure the distribution of gas species, i.e., deuterium (D), tritium (T), and impurities, in the divertor exhaust stream and in the plasma periphery, with time resolution relevant to fusion plasma–wall particle dynamics. The uniqueness of the DRGA, over previous implementations of plasma dynamics residual gas analysis, is an integrated approach, combining mass and low-temperature plasma-activated optical spectroscopy, in a differentially pumped analysis station. A further unique feature of the ITER divertor-specific DRGA is an ~8-m separation of the analysis station from the sampled pumping duct, while still maintaining a ~1-s response time for hydrogen isotopic concentrations. ITER DRGA final design activities are strongly benefiting from testing of prototypical DRGA components and methods on present fusion devices, most currently on JET and W7-X. DRGA systems are implemented on both these devices and include sensors (and pumping methods) that are directly relevant to the ITER DRGA design. The recent JET-DTE2 campaign has provided the first experience on operating the combined ITER DRGA sensors with D-T plasmas. While enhancing system design for ITER, this experience on operating devices has also revealed additional engineering challenges, which further guide the continuing final design project. Meanwhile, the recent determination that the ITER DRGA, with slight optimization, will resolve the helium isotopes well enough to support an ITER pre-DT, He-3-based heating scheme, has greatly increased ITER Research Program interest in the DRGA and its implementation well ahead of the DT phase.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Optimization of Processing, Microstructure, and Hardness of an Al–Ce–Ni–Mn–Zr Alloy With Laser Additive Manufacturing

Here, this study examines the processing behavior, microstructure, surface roughness, and hardness properties of an aluminum alloy containing 8.2 Ce, 4.5 Ni, 0.5 Mn, and 0.7 Zr (wt%) fabricated using laser powder bed fusion. Sixty samples were produced across a range of laser powers, scan speeds, and hatch spacings to evaluate their effect on porosity, hardness, and microstructural features. Porosity was measured using X-ray computed tomography, while microstructure and surface roughness were characterized by scanning electron (SEM) and laser confocal microscopy. High dense and cracking-free Al–Ni–Ce alloy was successfully manufactured. Porosity showed a U-shaped dependence on energy input, increasing under both insufficient and excessive melting conditions. Hardness increased with cooling rate due to finer cellular structures and solute redistribution. A general statistical model was developed to capture the relationships between processing parameters and material response. Results identify a narrow processing window defined by laser powers between 350 and 370 W, scan speeds from 1400 to 1800 mm/s, and hatch distances between 0.14 and 0.18 mm. Within this window, porosity is minimized (below 0.01%) and hardness is maximized (up to 160 HV), demonstrating that careful control of these parameters enables dense, high strength aluminum components suitable for demanding structural applications.

Aluminum alloys↗

Plasma Wall Interaction with 3-D Plasma Boundaries

The interaction of the edge plasma and the material surfaces is one of the most critical challenges on the path to harness fusion power as new, fundamental energy source. This challenge typically combines the thrust to reach high density, low temperature (detached) plasmas in front of the divertor target plates as well as understanding the plasma material interaction (PMI) in particular in this regime. The combination of both research thrusts represents an extraordinarily challenging subject encompassing spatial scales spanning nanometers to meters in all states of matter and across a broad energy range. Modeling capabilities, which help to interpret data from nowadays experiments and enable extrapolation to future devices are urgently required. This is in particular true for toroidal magnetic confinement devices with three-dimensional (3D) plasma boundaries. Such plasma boundary geometries occur in tokamaks, when small amplitude magnetic perturbations are used to stabilize the unruly edge plasma or in stellarators, that are inherently 3D plasma confinement devices. In this project, the impact of 3D plasma boundaries on the plasma material interaction (PMI) was assessed. This work focused on plasma boundary conditions, in which high-density conditions at the material surfaces yield mitigation of the otherwise immense heat and particle loads that these materials would see. These so-called high recycling and eventually detached plasma regimes are of great interest for future reactor operation. In the project, key features that are unique to 3D boundaries were explored in comparison to canonically assumed axisymmetric plasma edge situations in tokamaks. In particular, the relevance of the 3D boundary situation in the extrapolation to the plasma boundary solution at ITER, the next step fusion energy experiment under construction as a multi-national, world-wide large-science experiment in southern France, has been explored. The EMC3-EIRENE plasma edge fluid and kinetic neutral transport code has been advanced to cope with the challenging and unprecedented conditions in the ITER boundary plasma including 3D fields that are planned to be used to suppress harmful edge instabilities, the so-called edge localized modes. This is a vital integration challenge for ITER and the results from this grant have provide a leading capability for this assessment. It was shown that the detachment process in a 3D edge solution for ITER follows the recycling regimes that are known from axisymmetric solutions, but that multiple plasma exhaust channels connected to the material surfaces are established which feature individual recycling characteristics. Because these channels touch the material surfaces in the divertor in a 3D geometry, the compatibility with the plasma material interaction (PMI), including erosion and impurity generation has been found to be an important part of the integration challenge. To address this, the fully 3D plasma material interaction code ERO2 has been adapted to these ITER specific geometries and a homogeneous mixing model was implemented, that allows to consider the mixing of Be and Was used at ITER in the PMI modeling. This model enhancement has been used to study non-local migration of Be in the JET ITER like wall configuration and it has been shown that with this model such complex migration processes in ITER relevant plasma shapes and with ITER relevant plasma boundary conditions can be addressed. The combined modeling approach using EMC3-EIRENE as a plasma boundary transport code and the ERO2 specialized PMI model will be an asset for the continued preparations of ITER operation as well as for Fusion Pilot Plant efforts that have emerged in the U.S. during the evolution of this grant. The predictive capability of this numerical tool has been validated at the DIII-D US national fusion facility. Here, dedicated plasma edge diagnostics were implemented to measure the impurity household around a 3D edge plasma during ELM suppression by 3D fields. Dedicated experiments with local material probes using these diagnostics and the state-of-the-art suite of boundary measurements at DIII-D have shown that the 3D perturbation of the plasma edge that is excreted by such 3D control fields yield a perturbation of the plasma boundary flux structure and hence also of the resulting PMI. The 3D boundary plasma is composed out of helical magnetic flux channels that intersect the divertor targets at an angle relative to the main guiding field, i.e., the toroidal magnetic field component of the tokamak. A similar effect has been measured as well on limiter surfaces during the startup campaign at the new stellarator experiment Wendelstein 7-X. These experiments ad initial analysis with the ERO plasma material interaction model, suggested that the place of erosion for a given particle from the surface and its re-deposition can be different in such 3D field geometries yielding potentially a significant level of net-erosion. This is not the case for axisymmetric solutions, where it was shown in the past that the eroded particles are effectively re-deposited into gaps produced by erosion at the same position and hence the net-erosion levels are small. For ITER, the quest to suppress the ELMs and at the same time maintain the integrity of the divertor is an issue, which these fundamental findings will help to resolve. The coupling of this work to the extrapolation in the ITER program has been addressed by both the PI and the lead numerical scientist being ITER Science Fellows in the duration of the contract and forward. A second focus in the exploration of 3D boundary effects on tokamaks and stellarators has been set on the measurement of helium exhaust features with such 3D fields. This is important because He represents the ash of the fusion process and needs to be exhausted. It was shown that 3D field application compatible with suppression of ELMs yields an increase of the helium exhaust performance. The ratio of the effective helium confinement time over the energy confinement time was reduced by almost 50% which demonstrated that the impact of helium accumulation in the plasma core with respect to the confinement of energy to sustain the fusion reaction is significantly improved with such 3D control fields. It was shown that this is the case for tokamaks as well as stellarators. At the Large helical Device in Japan, a similar enhancement of the helium exhaust features when small amplitude additional 3D fields were applied was measured. This is an important additional function of 3D field application and its impact on ITER is presently being studied in combination with investigations of helium exhaust in 3D field geometries of stellarator devices.

3D plasma edge transport↗

Influence of Process Parameter and Build Rate Variations on Defect Formation in Laser Powder Bed Fusion SS316L

Laser powder bed fusion (LPBF) is an additive manufacturing process that has gained interest for its material fabrication due to multiple advantages, such as the ability to print parts with small feature sizes, good mechanical properties, reduced material waste, etc. However, variations in the key process parameters in LPBF may result in the instantiation of porosity defects and variation in build rate. Particularly, volumetric energy density (VED) is a variable that encapsulates a number of those parameters and represents the amount of energy input from the laser source to the feedstock. VED has been traditionally used to inform the quality of the printed part but different values of VED are presented as optimal values for certain material systems. An optimal VED value can be maintained by changing the key process parameters so that various combinations yield a constant value. In this study, an optimal constant VED value is maintained while printing SS316L with variable key processing parameters. Porosity analysis is performed using optical microscopy, as well as X-ray computed tomography, to reveal the volume density and distribution of those pores. Two primary defect categories are identified, namely lack of fusion and porosity induced by balling defects. The findings indicate that, even at optimal VED, variations in process parameters can significantly influence defect type, underscoring the sensitivity of defect formation to the variation of these parameters. Furthermore, a minor change in the build rate, driven by adjustments in process parameters, was found to influence defect categories. These findings emphasize that fine tuning the process parameters and build rate is essential to minimize defects. Finally, fiducial marks have been identified as a source of unintentional porosity defects. These results enable the refinement of process parameters, ultimately optimizing LPBF to achieve enhanced material density and expedite the printing.

36 MATERIALS SCIENCE↗

Raptor

Raptor is an efficient Python-based tool for predicting the formation and morphology of stochastic lack of fusion defects in metal AM processes. A major obstacle for the qualification and certification of additively manufactured parts in critical applications continues to be performance variability caused in part by porosity-related defects. High-fidelity process models that could predict these defect features are currently too computationally expensive for component-level analysis. To address this, Raptor employs a high-performance geometric method to model the dynamic melt pool rather than relying on computationally intensive thermal fluid dynamics. This allows Raptor to rapidly identify regions of unmelted material that correspond to lack of fusion pores. The efficiency of this approach significantly reduces the time and resources needed for generating 3D defect predictions, which enables users to conduct large-scale parameter studies and evaluate how process variations affect part quality. The framework offers operational flexibility; users can execute simulations through a simple command line interface or integrate core functions as a library within larger computational workflows. Simulation outputs include 3D porosity maps for visualization and tools for quantitative morphological analysis. These results are suitable for direct comparison with experimental characterization data from methods such as X-ray computed tomography and can be used for statistical process optimization.

Subraveti, Vamsi [Vanderbilt Univ., Nashville, TN ↗