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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Materials Characterization: A Primer for Solid Phase Processing Applications

The Pacific Northwest National Laboratory (PNNL) undertook the Materials Characterization, Prediction, and Control (MCPC) Laboratory Directed Research and Development (LDRD) Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems produced via advanced manufacturing methods, such as solid phase processing, for use in national security and advanced energy applications (Smith 2021). As a two-year LDRD investment requiring focused research, the MCPC project applied only a subset of the wide range of available destructive and nondestructive characterization methods to provide data to the predictive modeling and data analytics tasks. The purpose of this report is to review a wide range of destructive and nondestructive characterization methods that are relevant in solid-phase processing (SPP) applications, but not necessarily applied in the MCPC Project as a guide to the planning of characterization activities in future research. Particular attention is given to measured characteristics that can correlate to other material characteristics, with a particular interest in nondestructive evaluation (NDE) that can be applied to samples obtained in the MCPC Project. Destructive examinations include tensile tests, optical and electron microscopy, micro-hardness, and residual stress tests. NDE tests include surface visual inspection, eddy current examination for cracks, 4-point potential drop, ultrasound, x-ray, and computed tomography.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Quantification of the Impact of Acidified Brine on Fracture-Matrix Transport in a Naturally Fractured Shale Using in Situ Imaging and Modeling

Understanding flow, transport, chemical reactions, and hydromechanical processes in fractured geologic materials is key for optimizing a range of subsurface processes including carbon dioxide and hydrogen storage, unconventional energy resource extraction, and geothermal energy recovery. Flow and transport processes in naturally fractured shale rocks have been challenging to characterize due to experimental complexity and the multiscale nature of quantifying continuum scale descriptions of mass exchange between micrometer-scale fractures and nanometer-scale pores. In this study, we use positron emission tomography (PET) to image the transport of a conservative tracer in a naturally fractured Wolfcamp shale core before and after the core was exposed to low pH brine conditions. Image-based experimental observations are interpreted by fitting an analytical transport model to fracture-containing voxels in the core. Results of this analysis indicate subtle increases in matrix diffusivity and a slightly more uniform fracture velocity distribution following exposure to low pH conditions. These observations are compared with a multicomponent one-dimensional reactive transport model that indicates the capacity for a 10% increase in porosity at the fracture-matrix interface as a result of the low pH brine exposure. This porosity change is the result of the dissolution of carbonate minerals in the shale matrix to low pH conditions. Further, this image-based workflow represents a new approach for quantifying spatially resolved fracture-matrix transport processes and provides a foundation for future work to better understand the role of coupled transport, reaction, and mechanical processes in naturally fractured rocks.

58 GEOSCIENCES↗
DOE OSTI2021

Characterization of damage processes in Montney siltstone under triaxial compression using acoustic emission and diagnostic imaging

SUMMARY Crack nucleation and rock failure processes in a fine-grained siltstone (Montney Formation) under triaxial compression are investigated using combined diagnostic techniques, including ultrasonic-wave measurement, acoustic-emission (AE) monitoring, computed tomography (CT) scanning, and thin-section imaging. The sample displays a weak-to-moderate inherent seismic anisotropy and noticeable stress-induced anisotropy prior to failure. No AE event was detected until the applied axial stress reached 95 per cent of the peak value. The signal-to-noise ratio is relatively low, however, and detectable AE events are more diffuse than those observed in highly brittle rocks. The AE locations correlate with a shear fracture zone imaged by CT scanning. AE moment-tensor analysis reveals that events with larger relative magnitudes are characterized by high volumetric (tensile or compressive) components, and the initiation of the failure zone is dominated by combined shear-tensile (ST) failure. Stress inversion of the AE events with high tensile components is in good agreement with the known applied stress. Microscopic imaging of thin sections from the failed sample shows that the failure zone is an en echelon structure consisting of a major fracture with branching micro and minor cracks. This failure mechanism is consistent with a ST source mechanism and is interpreted to be associated with the fine granular structure and mineral composition of Montney siltstone.

Jia, Suzie Q. (ORCID:0000000326496190)↗
NASA NTRS2011

Material Characterization and Geometric Segmentation of a Composite Structure Using Microfocus X-Ray Computed Tomography Image-Based Finite Element Modeling

This study utilizes microfocus x-ray computed tomography (CT) slice sets to model and characterize the damage locations and sizes in thermal protection system materials that underwent impact testing. ScanIP/FE software is used to visualize and process the slice sets, followed by mesh generation on the segmented volumetric rendering. Then, the local stress fields around several of the damaged regions are calculated for realistic mission profiles that subject the sample to extreme temperature and other severe environmental conditions. The resulting stress fields are used to quantify damage severity and make an assessment as to whether damage that did not penetrate to the base material can still result in catastrophic failure of the structure. It is expected that this study will demonstrate that finite element modeling based on an accurate three-dimensional rendered model from a series of CT slices is an essential tool to quantify the internal macroscopic defects and damage of a complex system made out of thermal protection material. Results obtained showing details of segmented images; three-dimensional volume-rendered models, finite element meshes generated, and the resulting thermomechanical stress state due to impact loading for the material are presented and discussed. Further, this study is conducted to exhibit certain high-caliber capabilities that the nondestructive evaluation (NDE) group at NASA Glenn Research Center can offer to assist in assessing the structural durability of such highly specialized materials so improvements in their performance and capacities to handle harsh operating conditions can be made.

Abdul-Aziz, Ali↗
NASA NTRS2012

High Resolution X-Ray Micro-CT of Ultra-Thin Wall Space Components

A high resolution micro-CT system has been assembled and is being used to provide optimal characterization for ultra-thin wall space components. The Glenn Research Center NDE Sciences Team, using this CT system, has assumed the role of inspection vendor for the Advanced Stirling Convertor (ASC) project at NASA. This article will discuss many aspects of the development of the CT scanning for this type of component, including CT system overview; inspection requirements; process development, software utilized and developed to visualize, process, and analyze results; calibration sample development; results on actual samples; correlation with optical/SEM characterization; CT modeling; and development of automatic flaw recognition software. Keywords: Nondestructive Evaluation, NDE, Computed Tomography, Imaging, X-ray, Metallic Components, Thin Wall Inspection

Roth, Don J.↗
NASA NTRSDate not supplied

Estimation of 3D Woven Design Sensitivities Using a Rapid Multiscale Analysis Technique

Highly-refined finite element models of three-dimension (3D) woven composite systems currently require excessive computational demands that limit their use in sensitivity analysis, uncertainty quantification, and optimization. An alternative analysis methodology was developed using the NASA Multiscale Analysis Tool (NASMAT) where multiscale models of a 3D woven composite (including inter-tow matrix voids and constituent failure) can be completed on a single central processing unit (CPU) on the order of ~30s. To develop inputs and validation data for the NASMAT model, coupon and acid-digesting testing and x-ray computed tomography were performed. The NASMAT inputs were parameterized using a set of 25 input variables and distributions. These inputs were randomly sampled to generate a total of 100,000 NASMAT analyses that could be used to understand the influence of different material and geometric properties on the warp and weft-direction stiffness and strength. These analyses (including pre/post-processing) were performed in less than eight hours on a 120 CPU cluster. The computational efficiency of the NASMAT model enabled a sensitivity analysis to be performed, and dominant input variables were able to be identified. Key results were consistent with theoretical and experimental observations for the specific 3D woven system studied in this work.

NASMAT↗
DOE OSTI2024

Advanced Instrumentation for Metal Additive Manufacturing

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

Penny, Ryan↗
NASA NTRS2012

Biomedical Simulation Models of Human Auditory Processes

Detailed acoustic engineering models that explore noise propagation mechanisms associated with noise attenuation and transmission paths created when using hearing protectors such as earplugs and headsets in high noise environments. Biomedical finite element (FE) models are developed based on volume Computed Tomography scan data which provides explicit external ear, ear canal, middle ear ossicular bones and cochlea geometry. Results from these studies have enabled a greater understanding of hearing protector to flesh dynamics as well as prioritizing noise propagation mechanisms. Prioritization of noise mechanisms can form an essential framework for exploration of new design principles and methods in both earplug and earcup applications. These models are currently being used in development of a novel hearing protection evaluation system that can provide experimentally correlated psychoacoustic noise attenuation. Moreover, these FE models can be used to simulate the effects of blast related impulse noise on human auditory mechanisms and brain tissue.

Bicak, Mehmet M. A.↗
DOE OSTI2024

On the instrument-dependent appearance of ion dissociation events in atom probe tomography mass spectra

The successful application of atom probe tomography (APT) relies on the accurate interpretation of the mass spectrum (i.e. m/z histogram) from a sample. Some materials yield mass spectra that are amenable to a straightforward peak assignment/ranging, however, there are many materials that produce mass spectra with features that defy simple interpretation. One such example is Ga 2 O 3 which yields mass spectra containing several broad and difficult to interpret features. Herein, we study the GaO 2+ → O 1+ + Ga 1+ dissociation and we explain how this dissociation process gives rise to broad and previously unassigned features in the mass spectrum. Trajectory simulations are performed for the dissociation reaction utilizing realistic electrostatic models and compared to experiments using commercially available straight flight and reflectron based local electrode (LE) APT instruments. It is shown that the appearance of these features is strongly dependent on the specific design of the time-of-flight (ToF) mass analyzer. Additionally, we explore how various experimental parameters can affect the appearance of the dissociation process in the one-dimensional (1D) mass spectrum and in the two-dimensional (2D) correlation histogram. While the focus of this work is on a particular dissociation process related to Ga 2 O 3 , the understanding gained in the course of these simulations and experiments should be applicable to the interpretation of dissociation processes in other materials.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Identifying build orientation of 3D-printed materials using convolutional neural networks

The advent of additive manufacturing (AM) processes brought with it intense research into various materials and manufacturing processes. At the same time, the need for validation of material properties, as well as study and forecasting of aging, has arisen. Modern imaging techniques, like X-ray computed tomography (XCT), are a convenient vehicle for such studies; however, the large datasets they produce require novel analysis techniques to efficiently extract critical information. Here, we present our work on developing a 3D extension of the ResNet architecture to distinguish between two build orientations of tensile bars produced by AM. Using only information from XCT, our method achieves a 99.3% correct classification at a misidentification of 1%.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Adsorption separation of heavier isotope gases in subnanometer carbon pores

Isotopes of heavier gases including carbon ( 13 C/ 14 C), nitrogen ( 13 N), and oxygen ( 18 O) are highly important because they can be substituted for naturally occurring atoms without significantly perturbing the biochemical properties of the radiolabelled parent molecules. These labelled molecules are employed in clinical radiopharmaceuticals, in studies of brain disease and as imaging probes for advanced medical imaging techniques such as positron-emission tomography (PET). Established distillation-based isotope gas separation methods have a separation factor ( S ) below 1.05 and incur very high operating costs due to high energy consumption and long processing times, highlighting the need for new separation technologies. Here, we show a rapid and highly selective adsorption-based separation of 18 O 2 from 16 O 2 with S above 60 using nanoporous adsorbents operating near the boiling point of methane (112 K), which is accessible through cryogenic liquefied-natural-gas technology. A collective-nuclear-quantum effect difference between the ordered 18 O 2 and 16 O 2 molecular assemblies confined in subnanometer pores can explain the observed equilibrium separation and is applicable to other isotopic gases.

36 MATERIALS SCIENCE↗
DOE OSTI2026

New developments in structure-property and amorphous materials research at the upgraded 16-BM-B Paris-Edinburgh press station at HPCAT

Beamline 16-BM-B of the High-Pressure Collaborative Access Team (HPCAT) at the Advanced Photon Source (APS) provides a Paris-Edinburgh press program to probe the structure and properties of crystalline and amorphous materials up to 12 GPa at room temperature or 7 GPa at 2000°C. During the recent APS upgrade, 16-BM-B undertook major improvements to its instrumentation and measurement techniques. The upgrade includes the addition of a 1.2 m horizontal “condenser” mirror and a new variable-sized collimation system, the combination of which decreases the acquisition time for energy dispersive X-ray diffraction measurements by a factor of 10 when compared to pre-upgrade measurements. The addition of a new Ge energy-sensitive detector and DANTE (XGLab) digital pulse processor allows for processing the increased diffraction counts with minimal deadtime. In addition to upgraded beamline components, new techniques are being developed for eventual release to the user community, including electrical resistivity and tomography measurements.

APS upgrade↗
DOE OSTI2020

We Know Where We Don't Know: 3D Bayesian CNNs for Credible Geometric Uncertainty

Deep learning has been successfully applied to the segmentation of 3D Computed Tomography (CT) scans. Establishing the credibility of these segmentations requires uncertainty quantification (UQ) to identify untrustworthy predictions. Recent UQ architectures include Monte Carlo dropout networks (MCDNs), which approximate deep Gaussian processes, and Bayesian neural networks (BNNs), which learn the distribution of the weight space. BNNs are advantageous over MCDNs for UQ but are thought to be computationally infeasible in high dimension, and neither architecture has produced interpretable geometric uncertainty maps. We propose a novel 3D Bayesian convolutional neural network (BCNN), the first deep learning method which generates statistically credible geometric uncertainty maps and scales for application to 3D data. We present experimental results on CT scans of graphite electrodes and laser-welded metals and show that our BCNN outperforms an MCDN in recent uncertainty metrics. The geometric uncertainty maps generated by our BCNN capture distributions of sigmoid values that are interpretable as confidence intervals, critical for applications that rely on deep learning for high-consequence decisions.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2017

Structure from Motion Photogrammetry and Micro X-Ray Computed Tomography 3-D Reconstruction Data Fusion for Non-Destructive Conservation Documentation of Lunar Samples

Our team is developing a modern, cross-disciplinary approach to documentation and preservation of astromaterials, specifically lunar and meteorite samples stored at the Johnson Space Center (JSC) Lunar Sample Laboratory Facility. Apollo Lunar Sample 60639, collected as part of rake sample 60610 during the 3rd Extra-Vehicular Activity of the Apollo 16 mission in 1972, served as the first NASA-preserved lunar sample to be examined by our team in the development of a novel approach to internal and external sample visualization. Apollo Sample 60639 is classified as a breccia with a glass-coated side and pristine mare basalt and anorthosite clasts. The aim was to accurately register a 3-dimensional Micro X-Ray Computed Tomography (XCT)-derived internal composition data set and a Structure-From-Motion (SFM) Photogrammetry-derived high-fidelity, textured external polygonal model of Apollo Sample 60639. The developed process provided the means for accurate, comprehensive, non-destructive visualization of NASA's heritage lunar samples. The data products, to be ultimately served via an end-user web interface, will allow researchers and the public to interact with the unique heritage samples, providing a platform to "slice through" a photo-realistic rendering of a sample to analyze both its external visual and internal composition simultaneously.

Beaulieu, K. R.↗
NASA NTRS2021

Residual Stresses Induced due to Curing of the Bulk Matrix in a Simplified Three-Dimensional (3D) Woven Repeating Unit Cell

It has been observed that 3D woven materials are highly susceptible to processes induced defects including tow misalignment, intratow and intertow cracking and/or voids. Adequate process modeling of 3D woven Polymer Matrix Composites (PMCs) is necessary to predict and estimate the effects of the manufacturing process on these defects. A preliminary step towards this is achieved with the commercial Finite Element Analysis (FEA) tool Abaqus complemented with written user subroutines to account for the effect of shrinkage and thermoelastic properties evolution as a function of the degree of cure of the bulk matrix phase in a 3D woven composite repeating unit cell (RUC). As a pathfinder, the process modeling framework is demonstrated on a simplified 3D woven RUC of an AS4/RIMR 135 system. Curing simulations are performed on the 3D woven RUC to observe the processing induced residual stresses. The results of the analysis show that high stress concentrations, present within the 3D intertow matrix bordering the binder tow, coincide with X-Ray computed tomography (X-Ray-CT) scan data depicting cracking in the same location

3D Woven↗
NASA NTRSDate not supplied

Overview of Nondestructive Evaluation Capabilities at NASA MSFC

Nondestructive evaluation (NDE) methods examine material integrity without impairing its usefulness. The NDE team at NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama is responsible for applying existing methods to new hardware designs and material systems, probability of detection studies to quantify detection capabilities, overseeing NDE requirements for flight hardware, inspecting development articles and flight hardware, engineering support for failure investigations, and investigating emerging NDE methods. NASA MSFC has been on the cutting edge of developing new NDE techniques, first for the space shuttle, then for composite structures, and most recently for additive manufacturing (AM). Standard in-house inspection capabilities include eddy current, magnetic particle, liquid penetrant, ultrasonic, and radiographic testing (including computed tomography). Other advanced inspection capabilities include infrared flash thermography, shearography, acoustic emission, and microwave/millimeter wave testing. Some recent research studies include AM probability of detection testing, investigating in-situ process monitoring methods for AM, and correlating the NDE response of true fatigue cracks with artificial notches.

nondestructive evaluation↗
NASA NTRSDate not supplied

Estimation of 3D Woven Design Sensitivities Using a Rapid Multiscale Analysis Technique

Highly-refined finite element models of three-dimension (3D) woven composite systems currently require excessive computational demands that limit their use in sensitivity analysis, uncertainty quantification, and optimization. An alternative analysis methodology was developed using the NASA Multiscale Analysis Tool (NASMAT) where multiscale models of a 3D woven composite (including inter-tow matrix voids and constituent failure) can be completed on a single central processing unit(CPU)on the order of ~30 s. To develop inputs and validation data for the NASMAT model, coupon and acid-digesting testing and x-ray computed tomography were performed. The NASMAT inputs were parameterized using a set of 25 input variables and distributions. These inputs were randomly sampled to generate a total of 100,000 NASMAT analyses that could be used to understand the influence of different material and geometric properties on the warp and weft-direction stiffness and strength. These analyses (including pre/post-processing) were performed in less than eight hours on a 120 CPU cluster. The computational efficiency of the NASMAT model enabled a sensitivity analysis to be performed, and dominant input variables were able to be identified. Key results were consistent with theoretical and experimental observations for the specific 3D woven system studied in this work.

NASMAT↗