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At least 307 records · Page 17

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NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗

NASA NTRSDate not supplied

Performance Evaluation of Clouds and the Earth’s Radiant Energy System (CERES) Instruments in Generating A Stable Earth Radiation Budget Multi-Decadal Data Record

Clouds and the Earth’s Radiant Energy System (CERES) instrument is designed to measure the earth-reflected solar and earth-emitted longwave radiances, two components of the Earth Radiation Budget. CERES instrument measure radiances in 0.3 to 5.0 micron region with Shortwave (SW) sensor, 0.3 to >100 microns with Total (TOT) sensor, and either 8 - 12 micron with Window (WN) sensor or 5 – 35 micron with longwave (LW) sensor. The on-board internal calibration module (ICM) is used to monitor the stability of the sensors and to correct the pre-launch determined sensor gains for radiance calculations. Corrections for spectral changes occurring in different wavelength regions observed through vicarious studies were applied to sensor response function used in radiance determination. The resulting global flux long term trends from each instrument have shown consistent behavior and provided a stable global record of Top of the Atmosphere (TOA) shortwave and longwave fluxes for the Earth radiation budget climate data record.

Clouds and Earth Radiation Energy System (CERES)↗

NASA NTRSDate not supplied

Performance Evaluation of Clouds and the Earth’s Radiant Energy System (CERES) Instruments in Generating A Stable Earth Radiation Budget Multi-Decadal Data Record

Earth Radiation Budget↗

NASA NTRSDate not supplied

Determination of Interfacial Energy for Solid-State Precipitation

Precipitation of strengthening phases from solid state is a critical process for many materials. For example, the high-temperature creep resistance of Ni-based superalloys is governed by ’ precipitates. However, the interfacial energy which controls the precipitation is expensive to determine experimentally. For simulations, the atomic nature of precipitation events necessitates using Molecular Dynamics (MD) so relying on fitting to a-priori experimental behavior is not required. However, the solid-state precipitation takes orders of magnitude longer time than is accessible for traditional MD simulation. Taking inspiration from Kinetic Monte-Carlo (KMC) methods for simulating diffusion on a rigid lattice, we have developed a hybrid KMC-MD approach to enable simulation of solid-state precipitation (and determination of the interfacial energy). Implementing these methods in LAMMPS, we calculated the interfacial energy for the ’ precipitation out of a super-saturated  phase in Ni-based superalloys. The resulting interfacial energy value for the Ni-Al system is well within the accuracy of experimental values, demonstrating the capability of this method. Enabling the calculation of the interfacial energy without a-priori experimental knowledge of the precipitation unlocks a more efficient ICME-based approach for guiding annealing protocols in Ni-based superalloys and other solid-state precipitation systems.

Precipitation↗

NASA NTRSDate not supplied

Space Weather Investigation Frontier (SWIFT) Mission Concept: Continuous Distributed Observations of Geo-Effective, Heliospheric Structures from the Vantage Points of Sun-Earth L1 and Sub- L1

Continuous, in-situ, multi-point observations along the Sun-Earth line at and inside the Lagrange point L1 (sub-L1) will enable a better understanding of the three-dimensional structure and temporal evolution of heliospheric structures that drive terrestrial space weather. The proposed SWIFT (Space Weather Investigation Frontier) mission will use a new solar sail propulsion system developed by NASA to enable a suite of science instruments onboard a smallsat to maintain observations along the Sun-Earth line, sub-L1, for extended periods. Three identically instrumented small spacecraft at L1 will fly in concert with the sailcraft at sub-L1 in an optimized tetrahedron constellation, covering distances between 10 to 100’s of Earth radii. This viewing geometry will enable scientists to distinguish between local and global processes driving space weather by revealing the spatial characteristics, temporal evolution, and geo-effectiveness of small- to meso-scale solar wind structures and substructures of macro-scale structures, such as interplanetary coronal mass ejections (ICMEs) and stream interaction regions (SIRs). In addition, real time measurements of earth-bound heliospheric structures from sub-L1 will improve our current forecasting lead-times by up to 35 percent. This paper will provide an overview of the proposed SWIFT science and mission concept.

Spacecraft Propulsion↗

NASA NTRSDate not supplied

Space Weather Investigation Frontier (SWIFT)

Continuous, in-situ, multi-point observations along the Sun-Earth line at and inside the Lagrange point L1 (sub-L1) will enable a better understanding of the three-dimensional structure and temporal evolution of heliospheric structures that drive terrestrial space weather. The proposed SWIFT (Space Weather Investigation Frontier) mission will use a new solar sail propulsion system developed by NASA to enable a suite of science instruments onboard a smallsat to maintain observations along the Sun-Earth line, sub-L1, for extended periods. Three identically instrumented small spacecraft at L1 will fly in concert with the sailcraft at sub-L1in an optimized tetrahedron constellation, covering distances between 10 to 100’s of Earth radii. This viewing geometry will enable scientists to distinguish between local and global processes driving space weather by revealing the spatial characteristics, temporal evolution, and geo-effectiveness of small-to meso-scale solar wind structures and substructures of macro-scale structures, such as interplanetary coronal mass ejections (ICMEs) and stream interaction regions (SIRs). In addition, real time measurements of earth-bound heliospheric structures from sub-L1 will improve our current forecasting lead-times by up to 35 percent. This paper will provide an overview of the proposed SWIFT science and mission concept.

Heliophysics↗

NASA NTRSDate not supplied

Managing the Digital Thread for Structural Applications With Fit for Purpose Materials

With the increased emphasis on reducing the cost and time to market of new materials, the need for analytical tools that enable the virtual design and optimization of materials throughout their processing - internal structure - property - performance envelope, along with the capturing and storing of the associated material and model information across its lifecycle, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. Consequently, at NASA Glenn Research Center a robust information management system that manages the digital thread across the full material life (i.e., capture, analysis, maintenance, and dissemination of data) cycle directed at the design of ‘fit-for-purpose materials’ is under development. To this end the Application Table has been incorporated within NASA Glenn Research Center’s ICME Information Management framework within the ANSYS Granta MI tool. The Application Table provides a place where material and structural application information/requirements can be linked to marry the “design-the-material” (structural engineering) and the “design-with-material” (material science) paradigms and thereby enable application-driven design and optimization of materials and structures. In additional several associated toolsets, specifically: AIMAOS (Automated Information Management Across Organizations and Scales), Py MILab, and JARIMIS (Just A Rather Intelligent Material Interrogation System) are also under development to assist in the judicious automation of this process. AIMOAS offers users an interactive graphical user interface for connecting material information management systems with both commercial and in-house simulation tools at various length scales to enable such automation in the handoff across scales and maintenance of material digital twins and the digital thread. Py MILab, is an automatic framework for the capture, analysis, maintenance, and storage of material test data. Py MILab uses a modular approach for capturing raw data, analyzing the data, and storing the data in a database, interfaced by neutral file structures, to promote plug-and-play capabilities for various analysis types. Finally, JARIMIS is an expert system that integrates various materials informatics tools (e.g., MicroNet, Surrogate ML models, ANSYS Granta MI, etc.) to enable inverse design of materials and facilitate the application of machine learning (ML) and data science with human in the loop decision making to rapidly discover and optimize new materials.

Digital Transformation↗

NASA NTRSDate not supplied

Maturation of In-space Welding in Reduced Gravity and Reduced Pressure Environments Through Progression to Suborbital Flight Experiments

Development of in-space welding (ISW) is a key and enabling manufacturing technology as welding is currently involved in producing approximately 90% of durable goods, and this trend is expected to hold for in-space manufacturing as well. ISW is critical to a sustainable space economy. To mature in-space welding, numerous gaps must be closed since NASA has not made a weld in space in 50 years. Advancing laser beam welding (LBW) towards a suborbital flight demonstration will help mature the process for in-space assembly & manufacturing (ISAM) through demonstration in relevant environments and achieving technology readiness milestones. LBW technologies and science improved by this work will benefit in-space manufacturing, long-term sustainability of space structures & operations, and the overall space economy. Ground-based welding of aerospace hardware requires an Edisonian approach to qualify a welding process; however, this approach is infeasible for ISW qualification due to mass, volume, logistic, and cost challenges inherent to the space environment. To address this challenge, we are conducting ground and suborbital tests with partners performing parabolic flights to gather data on LBW processes and infuse them into NASA & partner missions. This progression from ground to flight experiments will elucidate relevant physics during LBW: 1) reduced gravity, 2) reduced pressure, and 3) extreme temperature. Data from post-flight evaluation and in situ instrumentation will feed integrated computational materials engineering (ICME) tools to reduce the burden of ISW infusion by establishing a link between space and terrestrial environments, ultimately accelerating the qualification of LBW in space.

in-space welding↗

NASA NTRSDate not supplied

Analysis of the Heliospheric Conditions Leading to the February 2022 Geomagnetic Storm Event

The February 2022 geomagnetic storm was a moderate but extended event that may have been associated with two interplanetary coronal mass ejection (ICME) arrivals. The first of these coronal mass ejections (CMEs) was first visible in SOHO LASCO C2 coronagraph imagery on 29 January and may be associated with the arrival of an interplanetary shock at L1 late on 1 February, followed by the separate arrival of a flux rope at L1 approximately one day afterward. The second CME was first visible in SOHO LASCO C2 coronagraph imagery on 1 February and may be associated with the arrival of a weaker interplanetary shock at L1 late on 3 February, just hours after the SpaceX launch. While the second arrival was relatively weak, it further enhanced geomagnetic conditions that had resulted from the first arrival. This work analyzes the two CMEs, their propagation into interplanetary space, and their associated geomagnetic impacts.

Coronal Mass Ejection↗

DOE OSTI2024

Development of creep resistant ferritic-martensitic steels for operation at 650°C

Creep resistant ferritic-martensitic steels capable of operating at 650°C have long been under development for electricity generation. This presentation will showcase the design and development of alloys CPJ-7 and JMP with approximately 420,000 h of in-house creep testing, the equivalent of ~50 years of cumulative creep tests. Approximately fifty different alloy compositions were manufactured as part of an ICME approach. CPJ-7 present superior creep properties compared to COST alloys for steam turbine and P91/92 for boiler applications. The prolonged creep life was attributed to slowing down the destabilization of fine precipitates at 650°C. The JMP steels were designed with higher Co for solid solution strengthening and increased W for matrix strength and stability. The creep life compared to CPJ-7 increased between 118 and 150% at 650°C depending on the stress. On a Larson-Miller plot, the performance of the JMP steels surpasses that of MARBN steel. Composition-microstructure-properties relationships will be discussed.

Detrois, Martin↗

DOE OSTI2025

Microscopic insights into the solvation of polyethylene glycol chains in water: A machine learning potential approach

Polyethylene glycol (PEG) is a structurally simple, nontoxic, and water-soluble polymer widely utilized in medical and pharmaceutical applications. Notably, when a PEG chain is immersed in water, the surrounding water molecules play a key role in driving conformational changes of this macromolecule. In this study, we explore the solvation behavior of PEG under mechanical strain using molecular dynamics simulations, with an interatomic potential obtained from machine learning. Our focus is on the transition from the favored coil-like conformation to an extended one under external force. Through analyses of radial distribution functions, hydrogen bonding, and solvation dynamics, we uncover how mechanical stretching influences the local hydration environment. Furthermore, we disentangle the enthalpic and entropic contributions to the conformational stability of PEG in water. Surprisingly, our neural network potential model identifies dewetting of PEG C-atoms, and not water H-bonding with PEG O-atoms, as the main enthalpic driving force for the coiling of PEG in water.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Improved loss functions for machine-learned atomic potentials

Machine learning (ML) has become an invaluable tool across a wide array of domains in science as researchers find new ways to leverage its predictive power. This is especially true in chemistry, where ML is used to fit chemical properties or desirable attributes to the local structure of molecules and materials. In the pursuit of greater accuracy, it is relatively simple to increase the size or complexity of such models, although this often requires simultaneously seeking larger datasets in order to both fit and interpret the larger number of parameters. However, it is equally important to assess the quality and relative importance of the data and how these factors impact the training process. We, therefore, investigate the impact of using different loss functions for training neural network potentials (NNPs), as the loss function defines the error and parameter gradients used to train the NNP. In particular, we test the mean-squared error and Huber loss functions and, using insight from these functions, derive a new loss function based on the Asinh function, which yields significant improvement in the accuracy and generality of NNPs. We show that by discounting/minimizing errors and anomalies in the optimization process, both the Huber and Asinh loss functions improve the training of NNPs, leading to a final potential with a greater effective dimensionality.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Thermodynamics and kinetics of precipitation and austenite reversion during aging of Ti-free grade 300 maraging steel manufactured by laser powder bed fusion (LPBF)

Austenite reversion and intermetallic precipitation are two key phase transformations in maraging steels which determine the strength and ductility. Usually, an optimum aging temperature/time is determined using trial and error approach with inputs from thermodynamic databases and a-posteriori microscopy/hardness evaluations. In this study, a thermo-kinetic model is developed to predict the precipitation and austenite reversion kinetics during various post-fabrication heat treatments in a Ti-free variant of grade 300 maraging steel manufactured using laser powder bed fusion. The thermo-kinetic model was based on the principles of Scheil solidification and the classical nucleation theory. The predictions from the thermo-kinetic model were verified using suitable microscopy techniques, and the results from the thermo-kinetic model agree well with the experimental measurements. Overall, results highlight the fact that an Integrated Computational Materials Engineering approach can be used to predict the precipitation and austenite reversion kinetics, and be used as an input for an efficient design of heat treatments for achieving optimum mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Solving Stochastic Inverse Problems for Property–Structure Linkages Using Data-Consistent Inversion and Machine Learning

Determining process–structure–property linkages is one of the key objectives in material science, and uncertainty quantification plays a critical role in understanding both process–structure and structure–property linkages. In this work, we seek to learn a distribution of microstructure parameters that are consistent in the sense that the forward propagation of this distribution through a crystal plasticity finite element model matches a target distribution on materials properties. This stochastic inversion formulation infers a distribution of acceptable/consistent microstructures, as opposed to a deterministic solution, which expands the range of feasible designs in a probabilistic manner. Furthermore, to solve this stochastic inverse problem, we employ a recently developed uncertainty quantification framework based on push-forward probability measures, which combines techniques from measure theory and Bayes’ rule to define a unique and numerically stable solution. This approach requires making an initial prediction using an initial guess for the distribution on model inputs and solving a stochastic forward problem. To reduce the computational burden in solving both stochastic forward and stochastic inverse problems, we combine this approach with a machine learning Bayesian regression model based on Gaussian processes and demonstrate the proposed methodology on two representative case studies in structure–property linkages.

36 MATERIALS SCIENCE↗

DOE OSTI2020

An active learning high-throughput microstructure calibration framework for solving inverse structure–process problems in materials informatics

Determining a process–structure–property relationship is the holy grail of materials science, where both computational prediction in the forward direction and materials design in the inverse direction are essential. Problems in materials design are often considered in the context of process–property linkage by bypassing the materials structure, or in the context of structure–property linkage as in microstructure-sensitive design problems. However, there is a lack of research effort in studying materials design problems in the context of process–structure linkage, which has a great implication in reverse engineering. In this paper, given a target microstructure, we propose an active learning high-throughput microstructure calibration framework to derive a set of processing parameters, which can produce an optimal microstructure that is statistically equivalent to the target microstructure. The proposed framework is formulated as a noisy multi-objective optimization problem, where each objective function measures a deterministic or statistical difference of the same microstructure descriptor between a candidate microstructure and a target microstructure. Furthermore, to significantly reduce the physical waiting wall-time, we enable the high-throughput feature of the microstructure calibration framework by adopting an asynchronously parallel Bayesian optimization to exploit high-performance computing resources. Case studies in additive manufacturing and grain growth are used to demonstrate the applicability of the proposed framework, where kinetic Monte Carlo (kMC) simulation is used as a forward predictive model, such that for a given target microstructure, the target processing parameters that produced this microstructure are successfully recovered.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Multi-objective materials bayesian optimization with active learning of design constraints: Design of ductile refractory multi-principal-element alloys

We report Bayesian Optimization (BO) has emerged as a powerful framework to efficiently explore and exploit materials design spaces. To date, most BO approaches to materials design have focused on the materials discovery problem as if it were a single expensive-to-query ‘black box’ in which the target is to optimize a single objective (i.e., material property or performance metric). Also, such approaches tend to be constraint agnostic. Here, we present a novel multi-information BO framework capable of actively learning materials design as a multiple objectives and constraints problem. We demonstrate this framework by optimally exploring a Refractory Multi-Principal-Element Alloy (MPEA) space, here specifically, the system Mo-Nb-Ti-V-W. The MPEAs are explored to optimize two density-functional theory (DFT) derived ductility indicators (Pugh’s Ratio and Cauchy pressure) while learning design constraints relevant to the manufacturing of high-temperature gas-turbine components. Alloys in the BO Pareto-front are analyzed using DFT to gain an insight into fundamental atomic and electronic underpinning for their superior performance, as evaluated within this framework.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Denoising diffusion probabilistic models for generative alloy design

Inverse material design is an extremely challenging optimization task made difficult by, in part, the highly nonlinear relationship linking performance with composition. Quantitative approaches have improved significantly owing to advances in high throughput experimentation and computational thermodynamics. However, existing physics-based tools are mostly forward models; input a chemistry and obtain a prediction. More recently the materials community has leveraged advances in the machine learning community to establish novel inverse design frameworks. Very recently denoising diffusion probabilistic models have been shown to be extremely powerful generators producing synthetic data of various modalities e.g. images, text, audio, tables, etc.. In this work a novel framework for alloy design and optimization is proposed leveraging these class of models. Five key generative tasks are demonstrated (1) unconditional generation (2) composition conditioned generation (3) property conditioned generation (4) multi-feedstock conditioned generation and (5) generative optimization. These methods were tested on three case studies: high entropy alloy design, superalloy binder jet additive manufacturing, and in-situ dual-feedstock wire-arc additive manufacturing. Results indicate that the established models are extremely flexible, expressive, and robust. The architecture’s flexibility and training procedure empower the model to learn complex intra-compositional and composition-property relationships. Furthermore, the probabilistic nature of these models makes them well suited for addressing solution non-uniqueness and tackling uncertainty quantification tasks. While the fidelity and quantity of the underlying training data is paramount, we envision that future alloy design frameworks will make extensive use of these kinds of machine learning models as “search” tools bolstering the utility of experimental and computational approaches.

36 MATERIALS SCIENCE↗

DOE OSTI2024

An integrated modeling framework with open architecture for phase field simulation of multi-component alloys

An integrated modeling framework (PanPhaseField) has been developed, which enables a direct and fast coupling between CALPHAD calculations and large-scale phase field simulations for multi-component alloys. Further, it adopts an open architecture allowing for integration of user-defined phase field models in a plug-and-play manner by taking full advantage of the user-friendly graphical interface of Pandat software. The developed modeling platform becomes an enabling tool that can be used to simulate the evolution of spatially varying microstructures of industrial complex alloys for various engineering applications.

36 MATERIALS SCIENCE↗