BCTC LDRD - 2023 Slides for HQ
This presentation presents an overview of the LDRD project developing a digital twin for the solvent extraction laboratory at Idaho National Lab.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
SEARCH · Engineering Papers
Results for “Digital Materials”
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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Additive manufacturing of mullite ceramic by digital light processing
Mullite material was successfully additively manufactured using digital light processing (DLP). The printed geometry involves a one-step process of pyrolysis, de-binding, and sintering under a plain atmosphere to achieve an average of 76 % ceramic yield and linear shrinkage of 12 %. Furthermore, the thermal profile was carefully controlled to obtain consistent phases in which the XRD shows a mullite phase. Here, in addition, the Weibull analysis was conducted on the sintered flexural specimens, showing a Weibull modulus (m) of 13.05 with a characteristic strength (σ 0 ) of 94.96 MPa. Synchrotron microtomography was performed on the sintered specimens, which showed two distinct porosity distributions (small and large). Large porosity (non-spherical elongated) is the primary cause of decreased material strength, while small porosity (spherical) is the sintering product. The measured thermal conductivity of the specimens was in the range of 2.7–3.1 W/m∙k and decreased with an increase in temperature. Lastly, large-scale prototypes were printed concurrently with a fine resolution of 25 μm without any compromise on the predetermined design and structure.
Additive manufacturing↗
Modeling of Tunable Elastic Ultralight Aircraft
Aircraft weight is one of the most critical factors in the design and operation of modern vehicles. The ability to integrate ultra-light materials into the primary load bearing structures has the potential to reduce aircraft weight significantly. Ultralight materials tend to be lattice-based meta-materials that are difficult and computationally expensive to model. One of the advantages of meta-materials is to be able to tune or "program" their bulk material properties through the placement of heterogeneous components in the material. A large amount of time devoted to the simulation in the development time for the tuning of the material can be a barrier to the adoption of large scale lattice materials. In this paper, we present a workflow and analysis tool-set to provide first-order estimates for rapid development of engineered lattice materials for aerospace applications. We present results for estimating the displacement and maximum structural stresses.
cellular solids↗
Crystal growth of ZnSe and related ternary compound semiconductors by physical vapor transport
The materials to be investigated are ZnSe and related ternary semiconducting alloys (e.g., ZnS(x)Se(1-x), ZnTe(x)Se(1-x), and Zn(1-x)Cd(x)Se). These materials are useful for opto-electronic applications such as high efficient light emitting diodes and low power threshold and high temperature lasers in the blue-green region of the visible spectrum. The recent demonstration of its optical bistable properties also makes ZnSe a possible candidate material for digital optical computers. The investigation consists of an extensive ground-based study followed by flight experimentation, and involves both experimental and theoretical work. The objectives of the ground-based work are to establish the characteristics of the crystals grown on Earth as a basis for subsequent comparative evaluations of the crystals grown in a low gravity environment and to obtain the experimental data and perform the analyses required to define the optimum parameters for the flight experiments. During the six months of the Preliminary Definition Phase, the research efforts were concentrated on the binary compound ZnSe - the purification of starting materials of Se by zone refining, the synthesis of ZnSe starting materials, the heat treatments of the starting materials, the vapor transport rate measurements, the vapor partial pressure measurements of ZnSe, the crystal growth of ZnSe by physical vapor transport, and various characterization on the grown ZnSe crystals.
Su, Ching-Hua↗
Nondestructive Evaluation for the Space Shuttle's Wing Leading Edge
The loss of the Space Shuttle Columbia highlighted concerns about the integrity of the Shuttle's thermal protection system, which includes Reinforced Carbon-Carbon (RCC) on the leading edge. This led NASA to investigate nondestructive evaluation (NDE) methods for certifying the integrity of the Shuttle's wing leading edge. That investigation was performed simultaneously with a large study conducted to understand the impact damage caused by errant debris. Among the many advanced NDE methods investigated for applicability to the RCC material, advanced digital radiography, high resolution computed tomography, thermography, ultrasound, acoustic emission and eddy current systems have demonstrated the maturity and success for application to the Shuttle RCC panels. For the purposes of evaluating the RCC panels while they are installed on the orbiters, thermographic detection incorporating principal component analysis (PCA) and eddy current array scanning systems demonstrated the ability to measure the RCC panels from one side only and to detect several flaw types of concern. These systems were field tested at Kennedy Space Center (KSC) and at several locations where impact testing was being conducted. Another advanced method that NASA has been investigating is an automated acoustic based detection system. Such a system would be based in part on methods developed over the years for acoustic emission testing. Impact sensing has been demonstrated through numerous impact tests on both reinforced carbon-carbon (RCC) leading edge materials as well as Shuttle tile materials on representative aluminum wing structures. A variety of impact materials and conditions have been evaluated including foam, ice, and ablator materials at ascent velocities as well as simulated hypervelocity micrometeoroid and orbital debris impacts. These tests have successfully demonstrated the capability to detect and localize impact events on Shuttle's wing structures. A first generation impact sensing system has been designed for the next Shuttle flight and is undergoing final evaluation for deployment on the Shuttle's first return to flight. This system will employ wireless accelerometer sensors that were qualified for other applications on previous Shuttle flights. These sensors will be deployed on the wing's leading edge to detect impacts on the RCC leading edge panels. The application of these methods will help to insure the continued integrity of the Shuttle wing's leading edge system as the Shuttle flights resume and until their retirement.
Eric I Madaras↗
Harnessing ferro-valleytricity in pentalayer rhombohedral graphene for memory and compute
Two-dimensional materials with multiple degrees of freedom, including spin, valleys, and orbitals, open up an exciting avenue for engineering multifunctional devices. Beyond spintronics, these degrees of freedom can lead to novel quantum effects such as valley-dependent Hall effects and orbital magnetism, which could revolutionize next-generation electronics. However, achieving independent control over valley polarization and orbital magnetism has been a challenge due to the need for large electric fields. A recent breakthrough involving pentalayer rhombohedral graphene has demonstrated the ability to individually manipulate anomalous Hall signals and orbital magnetic hysteresis, forming what is known as a valley-magnetic quartet. Here, we leverage the electrically tunable ferro-valleytricity of pentalayer rhombohedral graphene to develop nonvolatile memory and in-memory computation applications. We propose an architecture for a dense, scalable, and selector-less nonvolatile memory array that harnesses the electrically tunable ferro-valleytricity. In our designed array architecture, nondestructive read and write operations are conducted by sensing the valley state through two different pairs of terminals, allowing for independent optimization of read/write peripheral circuits. The power consumption of our PRG-based array is remarkably low, with only ∼6 nW required per write operation and ∼2.3 nW per read operation per cell. This consumption is orders of magnitude lower than that of the majority of state-of-the-art cryogenic memories. Additionally, we engineer in-memory computation by implementing majority logic operations within our proposed nonvolatile memory array without modifying the peripheral circuitry. In conclusion, our framework presents a promising pathway toward achieving ultra-dense cryogenic memory and in-memory computation capabilities.
2D materials↗
Aircraft jolts from lightning bolts
The trend toward the use of composite materials and digital electronics has renewed the need to quantify the effects of lightning strikes to airplanes, since composite structures do not provide shielding equivalent to that of metal aircraft, and digital systems are potentially more susceptible to upset by electrical transients than are analog electronic systems. A research program, called the Storm Hazards Program, has been run by the National Aeronautics and Space Administration (NASA) for the past eight years and has provided the first statistically significant measurements of the electromagnetic interaction between lightning and aircraft. A NASA-owned F-106B airplane has been flown through thunderstorms about 1500 times at altitudes between 5,000 and 40,000 feet (1,500 to 12,000 meters). The airplane, lightning-hardened and outfitted with special instruments, was hit by lightning 714 times. The types of measurements made and the results are described.
Pitts, Felix L.↗
RF surface resistance of YBa2Cu3O(7-x) thin films
The excitement engendered by the discovery of the new T sub c oxide superconductors has led to much speculation about practical applications of thin films of these materials in digital and analog electronic devices. Most of these envisioned applications involve high frequency signals for which a detailed knowledge of the surface impedance of the novel superconductors is very important. We have measured the surface resistance of thin films of YBaCuO in the frequency range 0.5 less than f less than 17 GHz using a stripline-resonator method. The stripline procedure also was used to measure the surface resistance of high quality gold and aluminum films; the resistance values obtained agree with values predicted from the measured dc resistance using the Pippard formalism for the anomalous skin effect. The YBaCuO were produced by a multilayer deposition process. The films are formed by e-beam evaporation of 24 layers of Y, Ba, and Cu. Films with the highest transition temperature were obtained using yttria-stabilized zirconia (YSZ) substrates. After deposition, the films are transferred to a furnace where they are annealed in flowing O2 at 850 C for 2h. The furnace then is turned off and allowed to cool to 100 C in about 16 h. Auger profiling of the films made by this process shows that the concentrations of Y, Ba, Cu, and O are uniform to within 1 percent throughout the thickness of the film.
Source record↗
Investigation Organizer
Contents include the folloving:Overview of the Application; Input Data; Analytical Process; Tool's Output; and Application of the Results of the Analysis.The tool enables the first element through a Web-based application that can be accessed by distributed teams to store and retrieve any type of digital investigation material in a secure environment. The second is accomplished by making the relationships between information explicit through the use of a semantic network-a structure that literally allows an investigator or team to "connect -the-dots." The third element, the significance of the correlated information, is established through causality and consistency tests using a number of different methods embedded within the tool, including fault trees, event sequences, and other accident models. And finally, the evidence gathered and structured within the tool can be directly, electronically archived to preserve the evidence and investigative reasoning.
Panontin, Tina↗
Geometry Systems for Lattice-Based Reconfigurable Space Structures
We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.
lattice geometry↗
Geometry Systems for Lattice-Based Reconfigurable Space Structures
We describe analytic methods for the design of the discrete elements of ultralight lattice structures. This modular building block strategy allows for relatively simple element manufacturing as well as relatively simple robotic assembly of low mass-density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small, mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.
digital materials↗
LDRD Poster Symposium
Poster for LDRD Symposium. Topic is on a NNP application, but no specific mechanisms for it are included.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Integrated Computational Materials Engineering (ICME) Capability Maturity Levels for Ecosystems Enabling Digital Transformation
Digital engineering (DE) and integrated computational materials engineering (ICME) are widely recognized as critical enablers of faster, more affordable, and more reliable aerospace systems. However, many organizations have struggled to realize the promised return on investment (ROI) from digital initiatives. A primary reason is the absence of a shared, decision-focused framework that distinguishes simple digitization of existing workflows from true digital transformation that fundamentally changes how engineering decisions are made. This paper introduces an ICME capability maturity framework that fills this gap. The framework defines six cumulative ICME capability maturity levels (CMLs), explicitly tied to decision authority, engineering integration, optimization, and uncertainty management across material, process, structure, and performance scales. It is designed to complement established readiness metrics such as technology readiness levels (TRLs), manufacturing readiness levels (MRLs), and integration readiness levels (IRLs), by addressing a missing dimension: the conditions required for model-informed decision authority across scales. A unifying figure and capability table illustrate the six-level ICME Capability Maturity Framework, showing how organizations progress from digitization—with limited or negative ROI—to true digital transformation, where ICME-enabled workflows deliver measurable improvements in decision quality, cycle time, risk reduction, and reuse. The framework is intended for both technical practitioners and executive leadership, providing a common language to assess current state, guide roadmaps, align software ecosystem investments, and set realistic expectations for digital transformation outcomes. A regulatory-relevant statement clarifying the relationship between ICME capability and existing certification frameworks is provided.
ICME↗
A proposed magnetic digital temperature transducer, volume 1
A study has been made of the feasibility of using the discontinuous permeability versus temperature characteristics of some magnetic materials for a digital temperature transducer and a thermally controlled ON-OFF switch. Simple logic converts the number of output pulse to a digital word recognizable by the system. Efforts have been concentrated on materials with Curie temperatures between 0 and 100 C. One compound has the composition Mn(5-x)Fe(x)Ge3 where the amount of iron determines the transition temperature. The other compound is Ni-Zn ferrite and has the compositon Ni(1-x)Zn(x)Fe(1.95)O4 where the nickel: zinc ratio determines the transition temperature. A detailed report of materials prepared is presented. Toroidal inductors of the material have been constructed and the change in inductance with temperature measured. In view of these initial measurements, it is felt that a transducer utilizing the permeability versus temperature characteristics of these materials has promise as a reliable and sensitive solid state digital temperature transducer.
Collier, T. E.↗
Feasibility study - On-line digital computer for Analytical Operations Division, Applied Technology Branch, Materials Analysis Section of Quality and Reliability Assurance Laboratory
On-line digital computer system for real time acquisition and processing of data at Materials Analysis Section of Quality and Reliability Assurance Laboratory
Newberry, M. H.↗
Growth of Ge-Sn Digital Alloys toward Group IV Topological Materials
Poster for NAMBE
Bradicich, Adelaide Maria [Sandia National Laborat↗
In-Situ Scanning Electron Microscope Experiments for Microscale Mechanical Testing and Validated Modeling of Fiber Reinforced Thermoplastics
A novel, in-situ, scanning electron microscope (SEM) mechanical testing capability for materials at the microscale which provides experimental validation to a machine learning (ML) toolset for full-field validation of physics-based micromechanics models is being developed by researchers at NASA Glenn Research Center. These are enabling technologies for the integration of multiscale digital twins for materials into system level models which will result in the improved performance, material discovery, reduced production cost and time, rapid characterization, and prognostic structural health monitoring (SHM) for materials and structures for extreme environments in support of NASA space exploration missions. In order to bridge the material structure-to-system gap for digital twins, physics-based models must be experimentally validated at multiple length scales. Seminal microscale experiments, conducted at the Air Force Research Laboratory (AFRL), were limited to transverse compression of single-layer, unidirectional thermoset polymer matrix composite (PMC) micropillar specimens [1]. The early phases of the current project followed those initial results and setup to reproduce the compression testing of PMC material on the custom-built piezoelectric actuated micromechanical testing rig built by MicroTesting Solutions LLC. In this work, samples of thermoplastic PMC material were first machined into 3 mm cubes, and then further machining and final milling was done using a Focused Ion Beam (FIB). The initial experiment was done on a pillar roughly 20 µm x 20 µm x 40 µm tall. Additional pillars were milled with final sizes ranging from 20 µm x 20 µm x 40 µm tall to 40 µm x 40 µm x 65 µm tall. A speckle pattern for in-situ full-field measurements using Digital Image Correlation (DIC) was applied with platinum, which was coated on the surface, and then the FIB was used to mill away some of the coating to produce an irregular pattern of Pt on the pillar surface. The samples were loaded into the custom testing rig and placed into the SEM and loaded under compression until failure. Images were collected in the SEM during testing. Post-processing of the images was conducted using DIC to obtain full-field displacement and strain measurements elucidating the role of the matrix as well as fiber-fiber interaction at the microscale within the composite subjected to compression loading well into the non-linear regime of the material. Moreover, the evolution of fiber-matrix debonding and matrix cracking is observed in-situ at the microscale. This data, along with images segmented with a newly developed ML toolset [2], was used to create and validate physics-based micromechanics models. An image of the failed micropillar is shown in Figure 1. The techniques developed in the initial compression experiment was tailored to the validation needs of the models and expanded to include different sized samples as well as possibly tension and fatigue.
Laura Wilson↗
NASA GRC ICME Schema for Materials Data Management: An Executive Summary
Integrated Computational Materials Engineering (ICME) has received a growing emphasis in attention due its potential impact on rapid material design, reduction in cost and time to market for new applications, and the promise of ‘fit-for-purpose’ materials coupled with recent advances in high performance computing and material characterization tools. However, for an organization to implement ICME practices for material discovery and design, a series of both technical and cultural challenges must be overcome to foster an environment that enables efficient, traceable, and predictive multiscale simulations of material behavior to enable virtual design of materials. In 2016, NASA sponsored a 2040 Vision study to define the potential 25-year future state required for integrated multiscale modeling of materials and systems to improve both the associated time and cost for aerospace and aeronautical innovation. The study envisions a cyber-physical-social ecosystem of experimentally validated computational models, tools, and techniques, along with the associated digital tapestry, that can enable rapid, optimized, ‘fit-for-purpose’ design of materials, components, and systems. A key requirement for such an ecosystem is the development of a robust information management system for materials across their full lifecycle, including material pedigree, experimental (real) and virtual (simulation) data, developed material models, and the implementation of models in engineering applications, such that process-structure-property-performance relationships can be established, thereby enabling the virtual design and optimization of materials. Such an information management system must be able to effectively capture: i) material information at each length scale; ii) test data and analysis; iii) associated material models; and iv) material and model deployment in engineering applications. These systems must also provide traceability between experimental and virtual representations of the material to ensure, when appropriate, the material digital twin is maintained. Additionally, this robust material information management system must be able to seamlessly connect with both commercial and an organization’s in-house software tools, be they analysis tools, other material databases, product lifecycle management (PLM) or simulation data management (SDM) tools, etc., such that automation of the design and analysis of a material across multiple length scales is possible. In this paper, an executive summary of the NASA GRC ICME Schema for materials information management is presented. The database best practices and schema design philosophy specifically for ICME materials data management and an overview description of each element in the schema is given, along with its associated role in an ICME workflow. Additionally, auxiliary tools that interact with the database and provide judicious automation with regards to importing, exporting, and analyzing materials data are presented. Such tools are critical to an ICME ecosystem, not only for their role in enabling optimization, but also in relieving users of tedious manual tasks, thus helping to promote adoption and combat the cultural challenges organizations face in enabling ICME.
Materials↗