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At least 469 records · Page 26

Recent Changes in High-Latitude Glaciers, Ice Caps, and Ice Sheets

The glaciers and ice sheets of the world contain enough ice to raise sea level by approximately 70 meters if they were to disappear entirely, and most of this ice is located in the climatically sensitive polar regions. Fortunately changes of this magnitude would probably take many thousands of years to occur, but recent discoveries indicate that these ice masses are responding to changes in today s climate more rapidly than previously thought. These responses are likely to be of great societal significance, primarily in terms of their implications for sea level, but also in terms of how their discharge of freshwater, through melting or calving, may impact ocean circulation. For millions of years, oceans have risen and fallen as the Earth has warmed and cooled, and ice on land has shrunk and grown. Today is no different in that respect, as sea levels have been rising at a rate of nearly 2 m per year during the last century (Miller and Douglas 2004), and 3 mm/yr in the last 12 years (Leuliette et al. 2004). What is different today, however, is that tens - perhaps hundreds - of millions of people live in coastal areas that are vulnerable to changes in sea level. Rising seas erode beaches, increase flood potential, and reduce the ability of barrier islands and coastal wetlands to mitigate the effects of major storms and hurricanes. The costs associated with a one-meter rise in sea level are estimated to be in the hundreds of billions of dollars in the United States alone. The worldwide costs in human terms would be far greater as some vulnerable low-lying coastal regions would become inundated, especially in poorer nations that do not have the resources to deal with such changes. Such considerations are particularly important in light of the fact that a one meter sea level rise is not significantly outside the 0.09 to 0.88 range of predictions for this century (IPCC 2001), and rises of this magnitude have occurred in the past in as little as 20 years (Fairbanks 1989). While the expansion of the warming oceans is estimated to be about a third of recent sea level rise, (Miller and Douglas 2004) the greatest potential for significantly increasing sea level lies in the Greenland and Antarctic ice sheets. For different reasons, each exhibits characteristics that suggest they are potentially unstable. In Antarctica, large portions of the ice cover rest on a soft bed that lies below sea level, making it vulnerable to runaway retreat. The Greenland ice sheet experiences considerable melt, which has the potential to rapidly accelerate the flow of ice toward the sea. While smaller ice masses, such as the Alaskan Glaciers and the Canadian ice caps, do not have anywhere near the same potential to impact sea level as the vast ice sheets do, many are melting rapidly, posing a significant near-term threat.

Abdalati, Waleed↗

Current sheet Formation in a Conical Theta Pinch Faraday Accelerator with Radio-Frequency Assisted Discharge

The inductive formation of current sheets in a conical theta pinch FARAD (Faraday Accelerator with Radio-frequency Assisted Discharge) thruster is investigated experimentally with time-integrated photography. The goal is to help in understanding the mechanisms and conditions controlling the strength and extent of the current sheet, which are two indices important for FARAD as a propulsion concept. The profiles of these two indices along the inside walls of the conical acceleration coil are assumed to be related to the profiles of the strength and extent of the luminosity pattern derived from photographs of the discharge. The variations of these profiles as a function of uniform back-fill neutral pressure (with no background magnetic field and all parameters held constant) provided the first clues on the nature and qualitative dependencies of current sheet formation. It was found that there is an optimal pressure for which both indices reach a maximum and that the rate of change in these indices with pressure differs on either side of this optimal pressure. This allowed the inference that current sheet formation follows a Townsend-like breakdown mechanism modified by the existence of a finite pressure-dependent radio-frequency-generated electron density background. The observation that the effective location of the luminosity pattern favors the exit-half of the conical coil is explained as the result of the tendency of the inductive discharge circuit to operate near its minimal self-inductance. Movement of the peak in the luminosity pattern towards the upstream side of the cone with increasing pressure is believed to result from the need of the circuit to compensate for the increase in background plasma resistivity due to increasing pressure.

Hallock, Ashley K.↗

Advanced Liquid-Cooling Garment Using Highly Thermally Conductive Sheets

This design of the liquid-cooling garment for NASA spacesuits allows the suit to remove metabolic heat from the human body more effectively, thereby increasing comfort and performance while reducing system mass. The garment is also more flexible, with fewer restrictions on body motion, and more effectively transfers thermal energy from the crewmember s body to the external cooling unit. This improves the garment s performance in terms of the maximum environment temperature in which it can keep a crewmember comfortable. The garment uses flexible, highly thermally conductive sheet material (such as graphite), coupled with cooling water lines of improved thermal conductivity to transfer the thermal energy from the body to the liquid cooling lines more effectively. The conductive sheets can be layered differently, depending upon the heat loads, in order to provide flexibility, exceptional in-plane heat transfer, and good through-plane heat transfer. A metal foil, most likely aluminum, can be put between the graphite sheets and the external heat source/sink in order to both maximize through-plane heat transfer at the contact points, and to serve as a protection to the highly conductive sheets. Use of a wicking layer draws excess sweat away from the crewmember s skin and the use of an outer elastic fabric ensures good thermal contact of the highly conductive underlayers with the skin. This allows the current state of the art to be improved by having cooling lines that can be more widely spaced to improve suit flexibility and to reduce weight. Also, cooling liquid does not have to be as cold to achieve the same level of cooling. Specific areas on the human body can easily be targeted for greater or lesser cooling to match human physiology, a warmer external environment can be tolerated, and spatial uniformity of the cooling garment can be improved to reduce vasoconstriction limits. Elements of this innovation can be applied to other embodiments to provide effective heat transfer over a flexible and surface-conformable fashion without the limitation of fluid freeze points.

Ruemmele, Warren P.↗

Combining Modis and Quikscat Data to Delineate Surface and Near-Surface Melt on the Greenland Ice Sheet

Over the last two decades, increasing melt has been measured on the Greenland Ice Sheet, along with mass loss as determined from satellite data, Monitoring the state of the Greenland Ice Sheet becomes critical especially because it is actively losing mass, and the ice sheet has a sea-level rise potential of 7 in. However measurement of the extent of surface melt varies depending on the sensor used, whether it is passive or active microwave or visible or thermal infrared. We have used remote-sensing data products to study surface and near-surface melt characteristics of the Greenland Ice Sheet. We present a blended MODIS-QS melt daily product for 2007 [1]. The products, including Moderate Resolution Imaging Spectroradiometer (MODIS) daily land-surface temperature (LST) and a special daily melt product derived from the QuikSCAT (QS) scatterometer [2,3] show consistency in delineating the melt boundaries on a daily basis in the 2007 melt season [I], though some differences are identified. An assessment of maximum melt area for the 2007 melt shows that the QSCAT product detects a greater amount of melt (862,769 square kilometers) than is detected by the MODIS LST product (766,184 square kilometers). The discrepancy is largely because the QS product can detect both surface and near-surface melt and the QS product captures melt if it occurred anytime during the day while the MODIS product is obtained from a point in time on a given day. However on a daily bases, other factors influence the measurement of melt extent. In this work we employ the digital-elevation model of Bamber et al. [4] along with the National Centers for Environmental Prediction (NCEP) data to study some areas and time periods in detail during the 2007 melt season. We focus on times in which the QS and MODIS LST products do not agree exactly. We use NCEP and elevation data to analyze the atmospheric factors forcing the melt process, to gain an improved understanding of the conditions that lead to melt and melt persistence, and our ability to capture surface melt accurately using MODIS and QS data.

Hall, Dorothy K.↗

Overview of Ice-Sheet Mass Balance and Dynamics from ICESat Measurements

The primary purpose of the ICESat mission was to determine the present-day mass balance of the Greenland and Antarctic ice sheets, identify changes that may be occurring in the surface-mass flux and ice dynamics, and estimate their contributions to global sea-level rise. Although ICESat's three lasers were planned to make continuous measurements for 3 to 5 years, the mission was re-planned to operate in 33-day campaigns 2 to 3 times each year following failure of the first laser after 36 days. Seventeen campaigns were conducted with the last one in the Fall of 2009. Mass balance maps derived from measured ice-sheet elevation changes show that the mass loss from Greenland has increased significantly to about 170 Gt/yr for 2003 to 2007 from a state of near balance in the 1990's. Increased losses (189 Gt/yr) from melting and dynamic thinning are over seven times larger'than increased gains (25 gt/yr) from precipitation. Parts of the West Antarctic ice sheet and the Antarctic Peninsula are losing mass at an increasing rate, but other parts of West Antarctica and the East Antarctic ice sheet are gaining mass at an increasing rate. Increased losses of 35 Gt/yr in Pine Island, Thwaites-Smith, and Marie-Bryd.Coast are more than balanced by gains in base of Peninsula and ice stream C, D, & E systems. From the 1992-2002 to 2003-2007 period, the overall mass balance for Antarctica changed from a loss of about 60 Gt/yr to near balance or slightly positive.

Zwally, H. Jay↗

Validation of a Climate-Data Record of the "Clear-Kky" Surface Temperature of the Greenland Ice Sheet

Surface temperatures on the Greenland Ice Sheet have been studied on the ground, using automatic weather station (AWS) data from the Greenland-Climate Network (GC-Net), and from analysis of satellite sensor data. Using Advanced Very High Frequency Radiometer (AVHRR) weekly surface temperature maps, warming of the surface of the Greenland Ice Sheet has been documented since 1981. We extended and refined this record using higher-resolution Moderate-Resolution Imaging Spectroradiometer (MODIS) data from March 2000 to the present. We developed a daily and monthly climate-data record (CDR) of the "clear-sky" surface temperature of the Greenland Ice Sheet using an ice-surface temperature (1ST) algorithm developed for use with MODIS data. Validation of this CDR is ongoing. MODIS Terra swath data are projected onto a polar stereographic grid at 6.25-km resolution to develop binary, gridded daily and mean-monthly 1ST maps. Each monthly map also has a color-coded image map that is available to download. Also included with the monthly maps is an accompanying map showing number of days in the month that were used to calculate the mean-monthly 1ST. This is important because no 1ST decision is made by the algorithm for cells that are considered cloudy by the internal cloud mask, so a sufficient number of days must be available to produce a mean 1ST for each grid cell. Validation of the CDR consists of several facets: 1) comparisons between ISTs and in-situ measurements; 2) comparisons between ISTs and AWS data; and 3) comparisons of ISTs with surface temperatures derived from other satellite instruments such as the Thermal Emission and Reflection Radiometer (ASTER) and Enhanced Thematic Mapper Plus (ETM+). Previous work shows that Terra MODIS ISTs are about 3 C lower than in-situ temperatures measured at Summit Camp, during the winter of 2008-09 under clear skies. In this work we begin to compare surface temperatures derived from AWS data with ISTs from the MODIS CDR. The Greenland Ice Sheet 1ST CDR will be useful for monitoring surface-temperature trends and can be used as input or for validation of climate models. The CDR can be extended into the future using MODIS Terra, Aqua and NPOESS Preparatory Project Visible Infrared Imager Radiometer Suite (VII RS) data.

Hall, Dorothy K.↗

Sheet Membrane Spacesuit Water Membrane Evaporator

A document describes a sheet membrane spacesuit water membrane evaporator (SWME), which allows for the use of one common water tank that can supply cooling water to the astronaut and to the evaporator. Test data showed that heat rejection performance dropped only 6 percent after being subjected to highly contaminated water. It also exhibited robustness with respect to freezing and Martian atmospheric simulation testing. Water was allowed to freeze in the water channels during testing that simulated a water loop failure and vapor backpressure valve failure. Upon closing the backpressure valve and energizing the pump, the ice eventually thawed and water began to flow with no apparent damage to the sheet membrane. The membrane evaporator also serves to de-gas the water loop from entrained gases, thereby eliminating the need for special degassing equipment such as is needed by the current spacesuit system. As water flows through the three annular water channels, water evaporates with the vapor flowing across the hydrophobic, porous sheet membrane to the vacuum side of the membrane. The rate at which water evaporates, and therefore, the rate at which the flowing water is cooled, is a function of the difference between the water saturation pressure on the water side of the membrane, and the pressure on the vacuum side of the membrane. The primary theory is that the hydrophobic sheet membrane retains water, but permits vapor pass-through when the vapor side pressure is less than the water saturation pressure. This results in evaporative cooling of the remaining water.

Bue, Grant↗

Evidence for Two Separate Heliospheric Current Sheets of Cylindrical Shape During Mid-2012

During the reversal of the Sun's polar fields at sunspot maximum, outward extrapolations of magnetograph measurements often predict the presence of two or more current sheets extending into the interplanetary medium, instead of the single heliospheric current sheet (HCS) that forms the basis of the standard 'ballerina skirt' picture. By comparing potential-field source-surface models of the coronal streamer belt with white-light coronagraph observations, we deduce that the HCS was split into two distinct structures with circular cross sections during mid-2012. These cylindrical current sheets were centered near the heliographic equator and separated in longitude by roughly 180 deg; a corresponding four-sector polarity pattern was observed at Earth. Each cylinder enclosed a negative-polarity coronal hole that was identifiable in extreme ultraviolet images and gave rise to a high-speed stream. The two current sheet systems are shown to be a result of the dominance of the Sun's nonaxisymmetric quadrupole component, as the axial dipole field was undergoing its reversal during solar cycle 24.

CORONA↗

Deployable Sheet Material Systems and Methods

Exemplary deployable sheet material systems may be configured to stow and deploy sheet material. The systems may include one or more masts, one or more extendable booms, and one or more guys wires configured to function in conjunction with each other to deploy the sheet material and then to maintain the sheet material in the deployed configuration.

Abrams, John L.↗

Measuring Multiple Cosmogenic Nuclides in Glacial Cobbles Sheds Light on Greenland Ice Sheet Processes

The extent and erosivity of the Greenland Ice Sheet during the Pleistocene remain uncertain due to the paucity of evidence predating the Last Glacial Maximum. Here, we employ a novel approach, cosmogenic nuclide analysis of individual subglacial cobbles, which allows us to infer the behavior of the ice sheet over time and space. From three locations in western Greenland, we collected 86 cobbles from the current ice sheet margin and nine cobbles exposed on the modern proglacial land surface. We measured the concentration of in situ 10Be in all cobbles (n= 95) and 26Al and 14C in a subset (n= 14). Cobbles deposited during Holocene retreat have 10Be exposure ages generally consistent with the timing of ice retreat determined by other means. Conversely, most of the 86 subglacial cobbles contain very low concentrations of 10Be (median 1.0 x 10^3 atoms g-1), although several have ~10^4 and one has ~10^5 atoms g-1. The low concentrations of 10Be in most subglacial cobbles imply that their source areas under the Greenland Ice Sheet are deeply eroded, preserving minimal evidence of surface or near-surface exposure. The presence of measurable 14C in ten of the cobbles requires that they experienced cosmogenic nuclide production within the past ~30 ka; however, 14C/10Be ratios of ~6 suggest that production occurred beneath thin overlying rock, sediment, and/or ice, where the muon component of 14C production dominates. Only two of the 86 subglacial cobbles definitively have cosmogenic nuclide concentrations consistent with prior surface exposure during times of reduced ice extent. Overall, isotopic analysis of subglacial cobbles indicates that western Greenland's subglacial landscape is characterized by deep erosion and minimal subaerial exposure.

Pliocene↗

Measuring multiple cosmogenic nuclides in glacial cobbles sheds light on Greenland Ice Sheet processes

The behavior of the Greenland Ice Sheet during the Pleistocene remains uncertain due to the paucity of evidence predating the Last Glacial Maximum. Here, we employ a novel approach, cosmogenic nuclide analysis of individual subglacially-derived cobbles, which allows us to make inferences about ice sheet processes and subglacial erosion. From three locations in western Greenland, we collected 86 cobbles from the current ice sheet margin and nine cobbles exposed on the modern proglacial land surface. We measured the concentration of in situ 10Be in all cobbles (n =95) and 26Al and 14C in a subset (n =14). Cobbles deposited during Holocene retreat have 10Be exposure ages generally consistent with the timing of ice retreat determined by other methods. Conversely, most of the 86 subglacial cobbles contain very low concentrations of 10Be (median 1.0×10^3atoms/g), although several have ∼104and one has ∼10^5atoms/g. The low concentrations of 10Be in most subglacial cobbles imply that their source areas under the Greenland Ice Sheet are deeply eroded, preserving minimal evidence of surface or near-surface exposure. The presence of measurable 14C in ten of the cobbles requires that they experienced cosmogenic nuclide production within the past ∼30 ka; however, 14C/10Be ratios of ∼6 suggest that nuclide production occurred during shielding by overlying material. Only two of the 86 subglacial cobbles definitively have cosmogenic nuclide concentrations consistent with prior surface exposure. Overall, isotopic analysis of subglacial cobbles indicates that much of western Greenland’s subglacial landscape is characterized by deep erosion and minimal subaerial exposure.

cosmogenic nuclides↗

Radiometric Calibration of A Non-Imaging Airborne Spectrometer To Measure the Greenland Ice Sheet Surface

Methods to radiometrically calibrate a non-imaging airborne visible-to-shortwave infrared (VSWIR) spectrometer to measure the Greenland ice sheet surface are presented. Airborne VSWIR measurement performance for bright Greenland ice and dark bare rock/soil targets is compared against the MODerate resolution atmospheric TRANsmission (MODTRAN ® ) radiative transfer code (version 6.0), and a coincident Landsat 8 Operational Land Imager (OLI) acquisition on 29 July 2015 during an in-flight radiometric calibration experiment. Airborne remote sensing flights were carried out in northwestern Greenland in preparation for the Ice, Cloud, and land Elevation Satellite 2 (ICESat-2) laser altimeter mission. A total of nine science flights were conducted over the Greenland ice sheet, sea ice, and open-ocean water. The campaign's primary purpose was to correlate green laser pulse penetration into snow and ice with spectroscopic-derived surface properties. An experimental airborne instrument configuration that included a nadir-viewing (looking downward at the surface) non-imaging Analytical Spectral Devices (ASD) Inc. spectrometer that measured upwelling VSWIR (0.35 to 2.5 µm) spectral radiance (Wm −2 sr −1 µm −1 ) in the two-color Slope Imaging Multi-polarization Photon-Counting Lidar's (SIMPL) ground instantaneous field of view, and a zenith-viewing (looking upward at the sky) ASD spectrometer that measured VSWIR spectral irradiance (W m −2 nm −1 ) was flown. National Institute of Standards and Technology (NIST) traceable radiometric calibration procedures for laboratory, in-flight, and field environments are described in detail to achieve a targeted VSWIR measurement requirement of within 5 % to support calibration/validation efforts and remote sensing algorithm development. Our MODTRAN predictions for the 29 July flight line over dark and bright targets indicate that the airborne nadir-viewing spectrometer spectral radiance measurement uncertainty was between 0.6 % and 4.7 % for VSWIR wavelengths (0.4 to 2.0 µm) with atmospheric transmittance greater than 80 %. MODTRAN predictions for Landsat 8 OLI relative spectral response functions suggest that OLI is measuring 6 % to 16 % more top-of-atmosphere (TOA) spectral radiance from the Greenland ice sheet surface than was predicted using apparent reflectance spectra from the nadir-viewing spectrometer. While more investigation is required to convert airborne VSWIR spectral radiance into atmospherically corrected airborne surface reflectance, it is expected that airborne science flight data products will contribute to spectroscopic determination of Greenland ice sheet surface optical properties to improve understanding of their potential influence on ICESat-2 measurements.

Christopher J. Crawford↗

Effect of Ice Sheet Thickness on Formation of the Hiawatha Impact Crater

The discovery of a large putative impact crater buried beneath Hiawatha Glacier along the margin of the northwestern Greenland Ice Sheet has reinvigorated interest into the nature of large impacts into thick ice masses. This circular structure is relatively shallow and exhibits a small central uplift, whereas a peak-ring morphology is expected. This discrepancy may be due to long-term and ongoing subglacial erosion but may also be explained by a relatively recent impact through the Greenland Ice Sheet, which is expected to alter the final crater morphology. Here we model crater formation using hydrocode simulations, varying pre-impact ice thickness and impactor composition over crystalline target rock. We find that an ice-sheet thickness of 1.5 or 2 km results in a crater morphology that is consistent with the present morphology of this structure. Further, an ice sheet that thick substantially inhibits ejection of rocky material, which might explain the absence of rocky ejecta in most existing Greenland deep ice cores if the impact occurred during the late Pleistocene. From the present morphology of the putative Hiawatha impact crater alone, we cannot distinguish between an older crater formed by a pre-Pleistocene impact into ice-free bedrock or a younger, Pleistocene impact into locally thick ice, but based on our modeling we conclude that latter scenario is possible.

Elizabeth A. Silber↗

Reconnection and particle acceleration in 3D current sheet evolution in moderately-magnetized astrophysical pair plasma

Magnetic reconnection, a plasma process converting magnetic energy to particle kinetic energy, is often invoked to explain magnetic energy releases powering high-energy flares in astrophysical sources including pulsar wind nebulae and black hole jets. Reconnection is usually seen as the (essentially 2D) nonlinear evolution of the tearing instability disrupting a thin current sheet. To test how this process operates in 3D, we conduct a comprehensive particle-in-cell simulation study comparing 2D and 3D evolution of long, thin current sheets in moderately-magnetized, collisionless, relativistically-hot electron- positron plasma, and find dramatic differences. We first systematically characterize this process in 2D, where classic, hierarchical plasmoid-chain reconnection determines energy release, and explore a wide range of initial configurations, guide magnetic field strengths, and system sizes. We then show that 3D simulations of similar configurations exhibit a diversity of behaviours, including some where energy release is determined by the nonlinear relativistic drift-kink instability. Thus, 3D current-sheet evolution is not always fundamentally classical reconnection with perturbing 3D effects, but, rather, a complex interplay of multiple linear and nonlinear instabilities whose relative importance depends sensitively on the ambient plasma, minor configuration details, and even stochastic events. It often yields slower but longer-lasting and ultimately greater magnetic energy release than in 2D. Intriguingly, nonthermal particle acceleration is astonishingly robust, depending on the upstream magnetization and guide field, but otherwise yielding similar particle energy spectra in 2D and 3D. Though the variety of underlying current-sheet behaviours is interesting, the similarities in overall energy release and particle spectra may be more remarkable.

Gregory R. Werner↗

Equilibrium Selection via Current Sheet Relaxation and Guide Field Amplification

Although there is a continuous spectrum of current sheet equilibria, how a particular equilibrium is selected by a given system remains a mystery. Yet, only a limited number of equilibrium solutions are used for analyses of magnetized plasma phenomena. Here we present the exact process of equilibrium selection, by analyzing the relaxation process of a disequilibrated current sheet under a finite guide field. It is shown via phase-space analyses and particle-in-cell simulations that the current sheet relaxes in such a way that the guide field is locally amplified, yielding a mixed equilibrium from the spectrum. Comparisons to spacecraft observations and solar wind current sheet statistics demonstrate that such mixed equilibria are ubiquitous and exist as underlying local structures in various physical environments.

Young-Dae Yoon↗

Methods of supporting a graphene sheet disposed on a frame support

This disclosure provides systems, methods, and apparatus related to graphene. In one aspect, a method includes submerging a frame support in an etching solution that is contained in a container. A growth substrate, a graphene sheet disposed on the growth substrate, and a primary support disposed on the graphene sheet is placed on a surface of the etching solution. The growth substrate is dissolved in the etching solution to leave the graphene sheet and the primary support floating on a surface of the etching solution. The etching solution in the container is replaced with a washing solution. The washing solution is removed from the container so that the graphene sheet becomes disposed on the frame support.

Han, Bong-Gyoon↗

Liquid-free covalent reinforcement of carbon nanotube dry-spun yarns and free-standing sheets

Carbon nanotubes (CNTs) possess exceptional mechanical properties, surpassing stiffness and strength metrics of common materials such as steel alloys by 100× at the nanoscale. However, when myriads of individual CNTs are bundled together into macroscopic ensembles like fibers or sheets, the result is a 100-fold drop in strength compared to its individual components. Here we present a general strategy aimed to close this gap in property scaling. By using vapor-phase polymerization of a crosslinkable polymer, we reinforced the weak interlinkages among individual CNTs within both yarns and sheets to promote a better transference of mechanical load across the structure. Furthermore, after the treatment, dry-spun, low-density 2.3 μm thin yarns increased their elastic moduli by at least 300%, and free-standing CNT sheets exhibited a 10× boost. In-situ synchrotron small-angle X-ray scattering revealed that polymer-reinforced yarns undergo limited CNT bundle rearrangement when subjected to tensile loads compared to pristine yarns. This evidence supports the hypothesis that the polymer hinders CNTs slippage, the root cause of the poor scaling of mechanical properties in these materials. While we demonstrated this reinforcement method for CNT structures, it is not specific to CNTs and could be used in a wide variety of other hierarchical nanostructured ensembles.

36 MATERIALS SCIENCE↗

Design, performance, and cost savings of using GF-PC additively manufactured tooling for stamping of HSS 590 sheet metal

Conventional sheet metal forming tooling in the automotive industry is made up of hardened steel and used for mass-production. Prototype tooling made of metal is durable, but it is only used for a small number of parts despite its high cost, contributing heavily to the vehicle development cost. Additive Manufacturing (AM) offers a low-cost alternative for fabricating tooling suitable for low-volume production. Here, this study investigates the feasibility of using AM polymer composite tooling for the stamping of 1.5mm thickness HSS 590 steel sheets through a two-pronged approach – experimental and numerical analysis. Sheet metal stamping experiments were conducted with glass fiber reinforced polycarbonate (GF-PC) AM polymer tooling and their performance was evaluated based on various metrics such as tool deformation and part accuracy. Finite element simulations of the stamping process were performed, which accurately captured the tool deformations seen in experiments with the use of anisotropic material models. The effective use of simulations in optimizing process parameters to achieve the desired final part geometry is also demonstrated. The GF-PC AM polymer composite tooling was found to be well suited for low volume production applications with potential cost savings.

36 MATERIALS SCIENCE↗