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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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

ON PROCESS STABILITY IN WAAM-CMT OF ALUMINUM ALLOYS

Wire-arc additive manufacturing (WAAM) has become a cost-efficient metal additive manufacturing process. However, depositing aluminum with WAAM is challenging due to its sensitivity to heat input (linear energy density), which can cause undesirable surface topology waviness if not controlled. Thus, a process window is needed that can produce stable geometry and deposition conditions while minimizing production times. In this study, 5183 aluminum alloy wire is used to deposit 10-layer walls with varying wire feed speeds (WFS) and traverse speeds (TS) (at a constant WFS/TS ratio) and varying interpass temperature (IPT). In-situ process data consisting of optical contact-tip-workpiece-distance (CTWD) and current/voltage measurements are collected to determine process condition stability throughout the build. Part geometry is measured using a 3D scanner and build porosity is characterized via digital X-ray. A process window is identified that produces stable surface topology and process conditions at a minimal production time.

aluminum alloy↗
DOE OSTI2020

Measuring Thickness-Dependent Relative Light Yield and Detection Efficiency of Scintillator Screens

Digital camera-based neutron imaging systems consisting of a neutron scintillator screen optically coupled to a digital camera are the most common digital neutron imaging system used in the neutron imaging community and are available at any state-of-the-art imaging facility world-wide. Neutron scintillator screens are the integral component of these imaging system that directly interacts with the neutron beam and dictates the neutron capture efficiency and image quality limitations of the imaging system. This work describes a novel approach for testing neutron scintillators that provides a simple and efficient way to measure relative light yield and detection efficiency over a range of scintillator thicknesses using a single scintillator screen and only a few radiographs. Additionally, two methods for correlating the screen thickness to the measured data were implemented and compared. An example 6LiF:ZnS scintillator screen with nominal thicknesses ranging from 0–300 μm was used to demonstrate this approach. The multi-thickness screen and image and data processing methods are not exclusive to neutron scintillator screens but could be applied to X-ray imaging as well. This approach has the potential to benefit the entire radiographic imaging community by offering an efficient path forward for manufacturers to develop higher-performance scintillators and for imaging facilities and service providers to determine the optimal screen parameters for their particular beam and imaging system.

42 ENGINEERING↗
NASA NTRS1983

Classification of journal surfaces using surface topography parameters and software methods to compensate for stylus geometry

Measurements made with a stylus surface tracer which provides a digitized representation of a surface profile are discussed. Parameters are defined to characterize the height (e.g., RMS roughness, skewness, and kurtosis) and length (e.g., autocorrelation) of the surface topography. These are applied to the characterization of crank shaft journals which were manufactured by different grinding and lopping procedures known to give significant differences in crank shaft bearing life. It was found that three parameters (RMS roughness, skewness, and kurtosis) are necessary to adequately distinguish the character of these surfaces. Every surface specimen has a set of values for these three parameters. They can be regarded as a set coordinate in a space constituted by three characteristics axes. The various journal surfaces can be classified along with the determination of a proper wavelength cutoff (0.25 mm) by using a method of separated subspace. The finite radius of the stylus used for profile tracing gives an inherent measurement error as it passes over the fine structure of the surface. A mathematical model is derived to compensate for this error.

Li, C. J.↗
NASA NTRSDate not supplied

Autonomous In-space Construction, Maintenance, and Reconfiguration Using Programmable Meta-Material

NASA ARC's Coded Structures Laboratory (CSL) is developing autonomous construction, maintenance, and reconfiguration technologies to meet long-duration and deep space infrastructure needs, in accordance with long-term NASA goals of "in-space reliance" and "mass-less exploration." We seek to achieve these capabilities by utilizing a "programmable meta-material" approach that integrates emerging advances in materials (mechanical meta-materials), manufacturing (cooperative mobile robotics), and autonomy (multi-agent planning algorithms). Through the ARMADAS project, we have shown assembly of high-performance engineered cellular materials using multiple cooperating mobile robotic assemblers. In this paper, we describe how such a programmable meta-material architecture may shift the paradigm of how we design, build, manufacture, and operate future space infrastructure and assets. The core of a programmable meta-material architecture consists of 3 main technology sub-areas: the structure, the assembly agents, and the assembly algorithms. We co-design these systems to ensure an adaptable system that can create and reconfigure structures from a base set of building block components. From this core technology, we can branch out and expand the capability of the system through additional secondary component types and robotic agents to perform activities such as inspections, maintenance, repair, payload installation, or perform power and communications interconnect. As these technologies mature, future designers will be able to utilize the system to rapidly integrate and operate assets in space or on planetary surfaces from a set of well-tested part library, or create their own modules to integrate into the system. A core trait to the development of this system is the automation approach. Because of the modular and functional discrete (pixel-like) nature of the structural system, a diverse set of powerful algorithms for analysis, planning, and simulation can be adapted and leveraged to optimize construction, maintenance, and dynamic reorganization (as hardware with programmable form and function). With an ability to free the design space from launch vehicle constraints and fundamentally shift how a mission is designed and conducted, we discuss the influence of a programmable meta-material architecture on mission design, build, and operations. For the "design phase", we discuss project lifecycle effects, costs, time, and performance. For the "build phase", we discuss reusability, ISRU, manufacturing, material logistics, and scalability. And for "operations", we discuss autonomy, maintenance and upgrades, reliability, and reconfiguration. Autonomy and modularity are the primary enabling traits of this system. Engineering systems that utilize a modular and reconfiguration building block approach such as digital communication and computation systems, currently lead all other areas of technology in size and complexity scalability. NASA is extending the benefits and flexibility of digital systems to hardware systems, to optimize materials lifecycle management and expand our space exploration mission capabilities.

in space assembly↗
DOE OSTI2017

Tailoring the Properties of a Ni-Based Superalloy via Modification of the Forging Process: an ICME Approach to Fatigue Performance

Traditionally, material design and property modifications are usually associated with compositional changes. However, subtle changes in the manufacturing process parameters can also have a dramatic effect on the resulting material properties. In this work, an integrated computational materials engineering (ICME) framework is adopted to tailor the fatigue performance of a Ni-based superalloy, RR1000. An existing fatigue model is used to identify microstructural features that promote enhanced fatigue life, namely a uniform, fine grain size distribution, random orientation, a distinct grain boundary distribution (specifically high twin boundary density and limited low-angle grain boundaries). A deformation mechanism map and process models for grain boundary engineering of RR1000 are used to identify the optimal thermo-mechanical processing parameters to realize these desirable microstructural features. For validation, small-scale forgings of RR1000 were produced and heat-treated to attain fine grain and coarse grain microstructures that represent the conventionally processed and grain boundary engineered (GBE) conditions, respectively. For each of the four microstructural variants of RR1000, the twin density and grain size were characterized and were in agreement with the desired microstructural attributes. In order to validate the deformation mechanisms and fatigue behavior of the material, high-resolution digital image correlation was performed to generate strain maps relative to the microstructural features. The high density of twin boundaries was confirmed to inhibit the length of slip bands, which is directly attributed to extended fatigue life. Thus, this study demonstrated the successful role of models, both process and performance, in the design and manufacture of Ni-based superalloy disk forgings.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Development of COTS ADC SEE Test System for the ATLAS LArCalorimeter Upgrade

Radiation-tolerant, high speed, high density and low power commercial off-the-shelf (COTS) analog-to-digital converters (ADCs) are planned to be used in the upgrade to the Liquid Argon (LAr) calorimeter front end (FE) trigger readout electronics. Total ionization dose (TID) and single event effect (SEE) are two important radiation effects which need to be characterized on COTS ADCs. In our initial TID test, Texas Instruments (TI) ADS5272 was identified to be the top performer after screening a total 17 COTS ADCs from different manufacturers with dynamic range and sampling rate meeting the requirements of the FE electronics. Another interesting feature of ADS5272 is its 6.5 clock cycles latency, which is the shortest among the 17 candidates. Based on the TID performance, we have designed a SEE evaluation system for ADS5272, which allows us to further assess its radiation tolerance. In this paper, we present a detailed design of ADS5272 SEE evaluation system and show the effectiveness of this system while evaluating ADS5272 SEE characteristics in multiple irradiation tests. According to TID and SEE test results, ADS5272 was chosen to be implemented in the full-size LAr Trigger Digitizer Board (LTDB) demonstrator, which will be installed on ATLAS calorimeter during the 2014 Long Shutdown 1 (LS1).

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS1988

Optical Rotary Joint For Data Transfer

Proposed joint increases bandwidth and reduces errors. Scheme for transferring digital data across rotary joint uses light instead of electrical signals. Optical joint offers greater bandwidth and operates at considerably lower error rate. Concept applied to transfer of highspeed data to rotating antennas or across joints of robots and manipulators in automated manufacturing.

Becker, Fred J.↗
NASA NTRS2023

Factories-in-Space for Servicing, Assembly, & Manufacturing

Space 2.0 is a promising frontier for scientific exploration and the advancement of commerce, security, and technology. To effectively harness this potential, it is imperative to establish a multifunctional, resilient, and sustainable infrastructure that enables the maintenance and production of space-based systems. This capability is a driver for mission success on-orbit and for interplanetary travel to other celestial bodies. Central to this infrastructure is the establishment of orbital manufacturing facilities, referred to as 'factories-in-space' (FiS), which serve as critical nodes in the supply chain for the servicing, assembly, and production of systems essential for space-based operations. This paper presents a framework for understanding the key principles and design considerations underpinning FiS.

Technology↗
DOE OSTI2024

Radiation-Hard Smart-Pixel Detector ASIC ReadOut with Digital AI in 28nm

Detectors at future high energy colliders will face enormous technical challenges. Disentangling the unprecedented numbers of particles expected in each event will require highly granular silicon pixel detectors with billions of readout channels. With event rates as high as 40 MHz, these detectors will generate petabytes of data per second. To enable discovery within strict bandwidth and latency constraints, future trackers must be capable of fast, power efficient, and radiation hard data-reduction at the source. This effort is pursuing the co-design development of high-performance readout smart pixel ASICs for a future Phase III High Luminosity upgrade of the Large Hadron Collider. A 1.6mm2 ASIC prototype was designed by Fermilab in CMOS 28 nm bulk process and submitted for manufacturing in February 2024. It leverages the analog front-end pixel design of a previous prototype fabricated and tested in 2023, which achieved a simulated detection level of ~400e- with 30fF input capacitance. The ROIC consists of two matrices of 16×16 smart pixels, each 25×25 μm2 in size. Each smart pixel contains a charge-sensitive preamplifier with leakage current compensation and three auto-zero comparators for a 2-bit flash-type ADC. There is digital space for the integration of our fully combinatorial AI that performs momentum classification at the bunch crossing rate. The total power consumption is ∼6μW per pixel, which corresponds to ~1mW/cm2. The ASIC incorporates programmable front-end charge injection circuitry to generate pixel cluster charges during characterization. The cluster profile will be generated to duplicate hit characteristics of various momentum (pT). We will present early results from chip testing.

Parpillon, Benjamin↗
DOE OSTI2023

Additive Manufacturing of Self‐Sensing Carbon Fiber Composites

Carbon fiber-reinforced polymer (CFRP) composites have gained substantial attention across various industries owing to their exceptional mechanical properties and lightweight nature. The emergence of additive manufacturing technologies brings new opportunities to the industry, offering advantages such as design freedom, rapid prototyping, and customization. However, the fabrication of CFRP composites through 3D printing techniques poses challenges pertaining to low resolution and limitations in complex geometry realization. This work introduces digital light processing printing as a versatile, high-resolution method ideal for CFRP composite fabrication. Furthermore, the development and characterization of CFRP are focused on and the manipulation of mechanical properties through variations in matrix resins and fiber loadings is investigated, showcasing the versatility of CFRP composites for tailored applications. Additionally, the integration of self-sensing capabilities in CFRP structures is explored, which opens up opportunities for applications in smart components for automotive and structural health monitoring.

carbon fiber composites↗
DOE OSTI2023

Signal Decomposition for Intrusion Detection in Reliability Assessment in Cyber Resilience (Summary Report)

The complexity of assuring cyber resilience for physical process interactions in connected systems such as energy grids increases dramatically as the coupling between processes becomes more direct and responsive. An example of this growing complexity is provided by Integrated Energy Systems (IES), in which various processes such as nuclear heat generation and commodity production are being directly coupled for increased responsiveness to highly variable signals such as market pricing or electricity demand. As such, the potential attack surface of the coupled processes is larger than the two processes independently. Securing these complex systems requires two-fold monitoring: cybersecure monitoring for potential malicious incursion, and physics monitoring for system tampering. Physics monitoring includes analyzing the behavior of the signals within the system for anomalous behavior. This analysis has been shown to be insufficient if approached by only data-driven machine learning and artificial intelligence (MLAI) techniques or only low-level model comparison. Previous efforts at Purdue University suggested combining high-fidelity models with MLAI algorithms as a basis for a software tool for detecting anomalies in physical processes. This work built on that suggestion, developing an advanced library for signal decomposition and analysis using both MLAI and high-fidelity physics algorithms for greatly improved anomaly detection, especially false data injection. This software can be used as part of a secure imbedded intelligence (SEI) system designed under Consequence-driven Cyber-informed Engineering (CCE) for complex coupled systems. This library established a foundation for online and posteriori analysis of digital signals for the purpose of detecting potential malicious tampering in digital signals representing physical processes. Demonstrations carried out throughout the development highlight the effective use of characterization algorithms to detect signal perturbations, particularly triangle attack-style perturbations, in three wide-ranging applications: seismic monitoring, nuclear thermal hydraulics system simulation, and custom manufacturing.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

Structural Evaluation of Complex Subcomponents Manufactured by Large Scale Extrusion Deposition of Carbon Fiber Reinforced ABS

The large scale extrusion deposition process has recently been commercialized in the form of additive manufacturing machines such as the BAAM from Cincinnati Inc., which enables layered production of chopped fiber reinforced thermoplastic polymer systems. The application of this process to the automotive market is being pursued by Local Motors to enable rapid design to market cycles and build on-demand capability for a wide range of vehicle styles from a distributed network of micro-factories. This endeavor will require an understanding of the structural performance of components with complex geometries, where the properties are known to vary as a function of printing conditions, as well as orientation and shape. In order to rapidly build a database of structural performance, a beam specimen with outer dimensions of 914 x 305 x 64 mm3 was selected to be subjected to bending, torsion, and shear loading with full field displacement measurement by digital image correlation (DIC). A total of 25 different specimen configurations were designed including variation of print geometry, reinforcement by foam filling, and overwrapping with advanced composites. This work documents the results of the study and presents the relative performance of the structures in addition to the approach to simulation that is being initiated to serve as a framework for efficient design of structures manufactured in this way. The results are presented as a table of structural efficiency including stiffness and strength as functions of mass for each design. Additional results will also be provided in the form of surface displacements from DIC; future work will utilize this data to better optimize simulations for predicting structural performance of articles manufactured by this process.

Bedsole, Robert↗
DOE OSTI2023

The INTERSECT Open Federated Architecture for the Laboratory of the Future

A federated instrument-to-edge-to-center architecture is needed to autonomously collect, transfer, store, process, curate, and archive scientific data and reduce human-in-the-loop needs with (a) common interfaces to leverage community and custom software, (b) pluggability to permit adaptable solutions, reuse, and digital twins, and (c) an open standard to enable adoption by science facilities world-wide. The Selfdriven Experiments for Science/Interconnected Science Ecosystem (INTERSECT) Open Architecture enables science breakthroughs using intelligent networked systems, instruments and facilities with autonomous experiments, “self-driving” laboratories, smart manufacturing and artificial intelligence (AI) driven design, discovery and evaluation. It creates an open federated architecture for the laboratory of the future using a novel approach, consisting of (1) science use case design patterns, (2) a system of systems architecture, and (3) a microservice architecture.

Engelmann, Christian↗
DOE OSTI2024

A development of wide dynamic-range halo monitor for 8 GeV proton beams at FNAL

The FNAL accelerator complex has been upgrading in increasing beam intensity and beam quality. A new beam halo diagnostic device is required in the beam transport line between booster and Recycler. For this purpose, it was decided to introduce the wide dynamic range monitor technique that was developed in 2012 and has been in operation at the J-PARC beam transport line. The device is a two-dimensional beam profile monitor, and it has a dynamic range of approximately six digits of magnitude by using of Optical Transition Radiation and fluorescence screens. Eliminating harmful beam halos is the most important technique for high-intensity proton accelerators. Therefore, beam halo diagnosis is indispensable and becomes more and more important. New FNAL device has been manufactured in a collaboration between J-PARC and FNAL as a part of U.S.-Japan Science and Technology Cooperation Program in High Energy Physics. The equipment will be manufactured at J-PARC and will be shipped to FNAL in 2025.We designed the device to satisfy FNAL specifications: the beam energy, intensity, and size. Currently, most of the equipments are under construction. The large-aperture optical system has been completed and its optical characteristics are being evaluated at J-PARC. We have been also investigating measurement methods corresponding to FNAL bunch trains. This paper reports on the current status of these developments.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

The Energy and Operational Impacts of Using 0-10V Control for LED Streetlights

LED lighting is becoming widely adopted and displacing most traditional lighting technologies. However, the traditional methods used to control light sources have not seen similar displacement. Lighting systems have historically utilized either a proprietary control method, or one of a handful of standardized methods (e.g., 0-10V, DALI, DMX512). The utility and market success of the standardized methods has been limited for a variety of reasons. Analog 0-10V methods have long been popular due to their simplicity and low cost of implementation and are presently the most commonly available control interface for indoor and outdoor LED products in North America. The emergence of “connected lighting systems” with more modern network interfaces and luminaire-level sensors and intelligence was anticipated by many to mark the beginning of the end of analog control. However, 0-10V interfaces continue to be prevalent with these more “digital” systems. The use of 0-10V methods has significant tradeoffs. 0-10V standards have historically not explicitly defined the relationship between the luminaire input control signal and output luminous flux for the full control signal range. As a result, it is difficult to predict relative luminaire light output and input power at any particular control voltage, and in practice the performance across LED drivers and the luminaires power is inconsistent. While this inconsistency has long been acknowledged by experts in the field, it is not accounted for in standard practice deployment, and end-users continue to regularly see unexpected and undesirable performance. It is hoped that the results from this study will help the lighting industry and standards developing organizations better understand and possibly resolve the shortcomings of 0-10V products, and consider what is best for the industry – additional incremental improvements to this fundamentally limited analog technology, or fully moving on to existing digital approaches, such as DALI D4i, that deliver accurate and consistent dimming performance across all luminaires in the system and thus guarantee the delivery of expected light levels, and energy and cost savings. Recommendations consistent with these goals are made to lighting and driver manufacturers, lighting software developers, standard developing organizations, and system designers and specifiers.

0-10V↗
NASA NTRS1994

Large angle magnetic suspension test fixture

Over the past few decades, research has proven the feasibility of the concept of noncontacting magnetic bearing systems which operate with no wear or vibration. As a result, magnetic bearing systems are beginning to emerge as integral parts of modern industrial and aerospace systems. Further applications research is still required. NASA has loaned an existing magnetic bearing device, the Annular Suspension and Pointing System (ASPS), to ODU to permit student design teams the opportunity to pursue some of these studies. The ASPS is a protoype for a high-accuracy space payload pointing and vibration isolation system. The project objectives are to carry out modifications and improvements to the ASPS hardware to permit recommissioning in a 1-g (ground-based) environment. Following recommissioning, new applications will be studied and demonstrated, including a rotary joint for solar panels. The first teams designed and manufactured pole shims to reduce the air-gaps and raise the vertical force capability as well as on control system studies. The most recent team concentrated on the operation of a single bearing station, which was successfully accomplished with a PC-based digital controller. The paper will review the history and technical background of the ASPS hardware, followed by presentation of the progress made and the current status of the project.

Britcher, Colin P.↗
NASA NTRS2000

Evaluation of DVD-R for Archival Applications

For more than a decade, CD-ROM and CD-R have provided an unprecedented level of reliability, low cost and cross-platform compatibility to support federal data archiving and distribution efforts. However, it should be remembered that years of effort were required to achieve the standardization that has supported the growth of the CD industry. Incompatibilities in the interpretation of the ISO-9660 standard on different operating systems had to be dealt with, and the imprecise specifications in the Orange Book Part n and Part Hi led to incompatibilities between CD-R media and CD-R recorders. Some of these issues were presented by the authors at Optical Data Storage '95. The major current problem with the use of CD technology is the growing volume of digital data that needs to be stored. CD-ROM collections of hundreds of volumes and CD-R collections of several thousand volumes are becoming almost too cumbersome to be useful. The emergence of Digital Video Disks Recorder (DVD-R) technology promises to reduce the number of discs required for archive applications by a factor of seven while providing improved reliability. It is important to identify problem areas for DVD-R media and provide guidelines to manufacturers, file system developers and users in order to provide reliable data storage and interchange. The Data Distribution Laboratory (DDL) at NASA's Jet Propulsion Laboratory began its evaluation of DVD-R technology in early 1998. The initial plan was to obtain a DVD-Recorder for preliminary testing, deploy reader hardware to user sites for compatibility testing, evaluate the quality and longevity of DVD-R media and develop proof-of-concept archive collections to test the reliability and usability of DVD-R media and jukebox hardware.

Martin, Michael D.↗