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At least 541 records · Page 30

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

The Surface Brightness-color Relations Based on Eclipsing Binary Stars: Toward Precision Better than 1% in Angular Diameter Predictions

In this study we investigate the calibration of surface brightness–color (SBC) relations based solely on eclipsing binary stars. We selected a sample of 35 detached eclipsing binaries with trigonometric parallaxes from Gaia DR1 or Hipparcos whose absolute dimensions are known with an accuracy better than 3% and that lie within 0.3 kpc from the Sun. For the purpose of this study, we used mostly homogeneous optical and near-infrared photometry based on the Tycho-2 and 2MASS catalogs. We derived geometric angular diameters for all stars in our sample with a precision better than 10%, and for 11 of them with a precision better than 2%. The precision of individual angular diameters of the eclipsing binary components is currently limited by the precision of the geometric distances (∼5% on average). However, by using a subsample of systems with the best agreement between their geometric and photometric distances, we derived the precise SBC relations based only on eclipsing binary stars. These relations have precisions that are comparable to the best available SBC relations based on interferometric angular diameters, and they are fully consistent with them. With very precise Gaia parallaxes becoming available in the near future, angular diameters with a precision better than 1% will be abundant. At that point, the main uncertainty in the total error budget of the SBC relations will come from transformations between different photometric systems, disentangling of component magnitudes, and for hot OB stars, the main uncertainty will come from the interstellar extinction determination. We argue that all these issues can be overcome with modern high-quality data and conclude that a precision better than 1% is entirely feasible.

79 ASTRONOMY AND ASTROPHYSICS↗

Measuring nonlinearities of a cantilever beam using a low-cost efficient wireless intelligent sensor for strain (LEWIS-S)

In the context of experimental vibration data, strain gauges can obtain linear and nonlinear dynamic measurements. However, measuring strain can be disincentivizing and expensive due to the complexity of data acquisition systems, lack of portability, and high costs. This research introduces the use of a low-cost efficient wireless intelligent sensor for strain (LEWIS-S) that is based on a portable-sensor-design platform that streamlines strain sensing. Additionally, the softening behavior of a cantilever beam with geometric and inertial nonlinearities is characterized by the LEWIS-S based on high force level inputs. Two experiments were performed on a nonlinear cantilever beam with measurements obtained by the LEWIS-S sensor and an accelerometer. First, a sine sweep test was performed through the fundamental resonance of the system, then a ring-down test was performed from a large initial static deformation. Good agreement was revealed in quantities of interest such as frequency response functions, the continuous wavelet transforms, and softening behavior in the backbone curves.

42 ENGINEERING↗

Morpho-Hawk

Morpho-Hawk applies projectional mathematical morphology in a fundamentally new way. Morpho-Hawk extracts object information from digital images by filtering with simple geometrical figures such as rectangles or simple curves. Two core algorithms are used to accomplish this: 1) Object Detection and Feature Extraction from Images: Using projectional morphology, Morpho-Hawk finds features of interest within an image, such as contours, shapes, colors, infrared spectra, and more. Because Morpho-Hawk identifies features based on shape or form, the method can uniquely handle different image or object conditions and directions. MorphoHawk can evaluate all possible images of the analyzed scene using the same transformations that are applied just to one image of that scene. Hence, recognizing a defect within an image or part of an image provides information to assist in recognizing other objects in the image. In addition, known background image information can be morphologically subtracted out in order to focus on the appearance or disappearance of the features of interest. 2) Object Analysis: Upon detection of an object of interest, Morpho-Hawk can analyze the object based learned information from prior images or end-user defined criteria for certain object of special interest by selecting feature (e.g., color, size, shape, apparent volume) and/or symbol (e.g., letter, number). The novel algorithm can analyze targeted objects, even as conditions of such as illumination, shadows, and spectral regions change strongly in following images as compared to the original image. This enables robust recognition, interpolation and prediction. As the analysis shows the presence of these features in the optical signal, the algorithm can make a determination based on user defined probability. The object information can be stored for later analysis using simple morphological data compression methods and/or retention of the original optical images.

Glazoff, MichaelV.↗

A finite element approach for large motion dynamic analysis of multibody structures in space

A three-dimensional finite element formulation for modeling the transient dynamics of constrained multibody space sructures with truss-like configurations is presented. Convected coordinate systems are used to define rigid-body motion of individual elements in the system. These systems are located at one end of each element and are oriented such that one axis passes through the other end of the element. Deformation of each element, relative to its convected coordinate system, is defined by cubic flexural shape functions as used in finite element methods of structural analysis. The formulation is oriented toward joint dominated structures and places the generalized coordinates at the joint. A transformation matrix is derived to integrate joint degree-of-freedom into the equations of motion of the element. Based on the derivation, a general-purpose code LATDYN (Large Angle Transient DYNamics) was developed. Two examples are presented to illustrate the application of the code. For the spin-up of a flexible beam, results are compared with existing solutions available in the literature. For the deployment of one bay of a deployable space truss (the Minimast), results are verified by the geometric knowledge of the system and converged solution of a successively refined model.

Chang, Che-Wei↗

Electric Current Filamentation Induced by 3D Plasma Flows in the Solar Corona

Many magnetic structures in the solar atmosphere evolve rather slowly, so they can be assumed as (quasi-)static or (quasi-)stationary and represented via magnetohydrostatic (MHS) or stationary magnetohydrodynamic (MHD) equilibria, respectively. While exact 3D solutions would be desired, they are extremely difficult to find in stationary MHD. We construct solutions with magnetic and flow vector fields that have three components depending on all three coordinates. We show that the noncanonical transformation method produces quasi-3D solutions of stationary MHD by mapping 2D or 2.5D MHS equilibria to corresponding stationary MHD states, that is, states that display the same field-line structure as the original MHS equilibria. These stationary MHD states exist on magnetic flux surfaces of the original 2D MHS states. Although the flux surfaces and therefore also the equilibria have a 2D character, these stationary MHD states depend on all three coordinates and display highly complex currents. The existence of geometrically complex 3D currents within symmetric field-line structures provides the basis for efficient dissipation of the magnetic energy in the solar corona by ohmic heating. We also discuss the possibility of maintaining an important subset of nonlinear MHS states, namely force-free fields, by stationary flows. We find that force-free fields with nonlinear flows only arise under severe restrictions of the field-line geometry and of the magnetic flux density distribution.

79 ASTRONOMY AND ASTROPHYSICS↗

Manifold learning for coarse-graining atomistic simulations: Application to amorphous solids

In this work, we introduce a generalized machine learning framework to probabilistically parameterize upper-scale models in the form of nonlinear PDEs consistent with a continuum theory, based on coarse-grained atomistic simulation data of mechanical deformation and flow processes. The proposed framework utilizes a hypothesized coarse-graining methodology with manifold learning and surrogate-based optimization techniques. Coarse-grained high-dimensional data describing quantities of interest of the multiscale models are projected onto a nonlinear manifold whose geometric and topological structure is exploited for measuring behavioral discrepancies in the form of manifold distances. A surrogate model is constructed using Gaussian process regression to identify a mapping between stochastic parameters and distances. Derivative-free optimization is employed to adaptively identify a unique set of parameters of the upper-scale model capable of rapidly reproducing the system's behavior while maintaining consistency with coarse-grained atomic-level simulations. The proposed method is applied to learn the parameters of the shear transformation zone (STZ) theory of plasticity that describes plastic deformation in amorphous solids as well as coarse-graining parameters needed to translate between atomistic and continuum representations. We show that the methodology is able to successfully link coarse-grained microscale simulations to macroscale observables and achieve a high-level of parity between the models across scales.

36 MATERIALS SCIENCE↗

Non-relativistic geometry and the equivalence principle

Abstract We describe a geometric and symmetry-based formulation of the equivalence principle in non-relativistic physics. It applies both on the classical and quantum levels and states that the Newtonian potential can be eliminated in favor of a curved and time-dependent spatial metric. It is this requirement that forces the gravitational mass to be equal to the inertial mass. We identify the symmetry responsible for the equivalence principle as the remnant of time-reparameterization symmetry of the relativistic theory. We also clarify the transformation properties of the Schrödinger wave-function under arbitrary frame changes.

Astronomy & Astrophysics↗

Kink mechanism in Cu/Nb nanolaminates explored by $\mathcal{in}$ $\mathcal{situ}$ pillar compression

We report Nano metallic laminates (NMLs) exhibit different failure modes depending on the loading conditions due to their mechanical anisotropies. Kinking is a typical failure mode in many NMLs compressed along a layer-parallel direction. However, a detailed description of the microstructure evolution during kink band (KB) formation and an in-depth understanding of the formation mechanisms are lacking. In this work, the KB process is investigated in Cu/Nb NMLs by in situ micro pillar compression in the scanning electron microscope (SEM) along a layer-parallel direction. Post-mortem S/TEM and transmission Kikuchi diffraction (TKD) analyses show that kink banding leads to significant microstructure changes characterized by an accumulation of geometrically necessary dislocations (GNDs) and of tilt geometrically necessary boundaries (GNBs) near KB boundaries (KBBs). The distinct microstructure evolution implies that KB formation is facilitated by the inhomogeneous microstructures resulting in constrained deformation modes. Specifically, dislocations active on slip planes nearly parallel to the interfaces make a major contribution to kink evolution after the onset of kinking. Once layer-parallel slip systems are activated, preexisting lattice dislocations and dislocations nucleating from interfaces will accumulate as GNDs near KBBs via the stochastic storage of lattice dislocations that have certain Burgers vectors. GNDs can further transform into GNBs via cross-slip and climb driven processes near the KBB. Furthermore, GNBs near KBBs can grow by incorporating more GNDs or by coalescence to accommodate the KB evolution. We further hypothesize that microstructural perturbations and their ensuing stresses can initiate KB formation in Cu/Nb NMLs.

36 MATERIALS SCIENCE↗

Displacement analysis of the interior walls of a pipe using panoramic holo-interferometry

Standard phase-displacement equations, used for both double exposure and real time holo-interferometry, are combined with the geometrical mapping and optical characteristics of panoramic annular lenses to accurately measure surface displacement on the interior wall of a pipe. In this approach, one panoramic annular lens is used to illuminate the surface with coherent light, and the resulting intensity distribution is holographically recorded through a second panoramic annular lens. Interference fringes are obtained in real-time by comparing holograms recorded before and after the pipe is displaced. The annular images and the holographic fringes are acquired and stored digitally in a computer system. Image transformation algorithms are applied to remove optical distortions in the holographic pattern and fringe loci are compared to those predicted on the basis of theory.

Gilbert, John A.↗

Validation of Numerical Models of the Offshore Wind Turbine from the Alpha Ventus Wind Farm Against Full-Scale Measurements Within OC5 Phase III: Preprint

The main objective of the Offshore Code Comparison Collaboration Continuation, with Correlation (OC5) project, is validation of aero-hydro-servo-elastic simulation tools for offshore wind turbines (OWTs) through comparison of simulated results to the response data of physical systems. Phase III of the OC5 project validates OWT models against the measurements recorded on Senvion 5M wind turbine supported by the OWEC Quattropod from the alpha ventus offshore wind farm. The following operating conditions of the wind turbine were chosen for the validation: (1) Idling below the cut-in wind speed; (2) Rotornacelle assembly (RNA) rotation maneuver below the cut-in wind speed; (3) Power production below and above the rated wind speed; and (4) Shut-down. A number of validation load cases were defined based on these operating conditions. The following measurements were used for validation: (1) Strains and accelerations recorded on the support structure; (2) Pitch, yaw, and azimuth angles, generator speed, and electrical power recorded from the RNA. Strains were not directly available from the majority of the OWT simulation tools. Therefore, strains were calculated based on out-of-plane bending moments, axial forces, and geometrical properties of the structural members. Also, a number of issues arose during the validation: (1) The need for a thorough quality check of sensor measurements; (2) The sensitivity of the turbine loads to the controller and airfoil properties, which were only approximated in the modeling approach; (3) The importance of estimating and applying an appropriate damping value for the structure; and (4) The importance of wind characteristics beyond turbulence on the loads. The simulation results and measurements were compared in terms of time series, discrete Fourier transforms (DFTs), power spectral densities (PSDs), probability density functions (PDFs) of strains and accelerometers. A good match was achieved between the measurements and models set up by OC5 Phase III participants.

17 WIND ENERGY↗

Robust nonlinear control of vectored thrust aircraft

An interdisciplinary program in robust control for nonlinear systems with applications to a variety of engineering problems is outlined. Major emphasis will be placed on flight control, with both experimental and analytical studies. This program builds on recent new results in control theory for stability, stabilization, robust stability, robust performance, synthesis, and model reduction in a unified framework using Linear Fractional Transformations (LFT's), Linear Matrix Inequalities (LMI's), and the structured singular value micron. Most of these new advances have been accomplished by the Caltech controls group independently or in collaboration with researchers in other institutions. These recent results offer a new and remarkably unified framework for all aspects of robust control, but what is particularly important for this program is that they also have important implications for system identification and control of nonlinear systems. This combines well with Caltech's expertise in nonlinear control theory, both in geometric methods and methods for systems with constraints and saturations.

Doyle, John C.↗

A universal method to compare parts from STEP files

Abstract Model Based Definition (MBD) captures the complete specification of a part in digital form and leverages (at least) the universal “Standard for the Exchange of Product” (STEP) file format. MBD has revolutionized manufacturing due to time and cost savings associated with containing all engineering data within a single digital source. This work presents a novel method to transform digital definitions in any given STEP file into a tensor-like structure that is unique for each part and can be used to regenerate the original STEP file completely. Resulting STEP tensors are amenable to part comparison based on various part specifications in a general and straightforward manner. Here, part similarity is evaluated among sets of parts according to specific geometry, material composition, and design intent. Importantly, specification similarity can be quantified using only the tensors’ structure. As such, this approach is not limited to families of geometric shapes, part types, or fabrication methods; nor does it require any prior knowledge about the parts being compared.

36 MATERIALS SCIENCE↗

A mechanistic study of the dopant-induced breakdown in halide perovskites using solid state energy storage devices

Doping halide perovskites (HPs) with extrinsic species, such as alkali metal ions, plays a critical, albeit often elusive role in optimising optoelectronic devices. Here, we use solid state lithium ion battery inspired devices with a polyethylene oxide-based polymer electrolyte to dope HPs controllably with lithium ions. We perform a suite of operando material analysis techniques while dynamically varying Li doping concentrations. We determine and quantify three doping regimes; a safe regime, with doping concentrations of <10 20 cm –3 (2% Li : Pb mol%) in which the HP may be modified without detrimental effect to its structure; a minor decomposition regime, in which the HP is partially transformed but remains the dominant species; and a major decomposition regime in which the perovskite is superseded by new phases. We provide a mechanistic description of the processes mediating between each stage and find evidence for metallic Pb (0) , LiBr and LiPbBr 2 as final decomposition products. Combining results from synchrotron X-ray diffraction measurements with in situ photoluminescence and optical reflection microscopy studies, we distinguish the influences of free charge carriers and intercalated lithium independently. We find that the charge density is equally as important as the geometric considerations of the dopant species and thereby provide a quantitative framework upon which the future design of doped-perovskite energy devices should be based.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Magnetization-induced shape transformations in flexible ferromagnetic rings

Flexible ferromagnetic rings are spin-chain magnets, in which the magnetic and mechanical subsystems are coupled. The coupling is achieved through the tangentially oriented anisotropy axis. The possibility to operate the mechanics of the nanomagnets by controlling their magnetization is an important issue for the nanorobotics applications. A minimal model for the deformable curved anisotropic Heisenberg ferromagnetic wire is proposed. An equilibrium phase diagram is constructed for the closed loop geometry: (i) A vortex state with vanishing total magnetic moment is typical for relatively large systems; in this case, the wire has the form of a regular circle. (ii) A topologically trivial onion state with the planar magnetization distribution is realized in small enough systems; magnetic loop is elliptically deformed. By varying geometrical and elastic parameters, a phase transition between the vortex and onion states takes place. The detailed analytical description of the phase diagram is well confirmed by numerical simulations.

36 MATERIALS SCIENCE↗

Opening of an interface flaw in a layered elastic half-plane under compressive loading

A static analysis is given of the problem of an elastic layer perfectly bonded, except for a frictionless interface crack, to a dissimilar elastic half-plane. The free surface of the layer is loaded by a finite pressure distribution directly over the crack. The problem is formulated using the two dimensional linear elasticity equations. Using Fourier transforms, the governing equations are converted to a pair of coupled singular integral equations. The integral equations are reduced to a set of simultaneous algebraic equations by expanding the unknown functions in a series of Jacobi polynomials and then evaluating the singular Cauchy-type integrals. The resulting equations are found to be ill-conditioned and, consequently, are solved in the least-squares sense. Results from the analysis show that, under a normal pressure distribution on the free surface of the layer and depending on the combination of geometric and material parameters, the ends of the crack can open. The resulting stresses at the crack-tips are singular, implying that crack growth is possible. The extent of the opening and the crack-top stress intensity factors depend on the width of the pressure distribution zone, the layer thickness, and the relative material properties of the layer and half-plane.

Kennedy, J. M.↗

Element Library for Three-Dimensional Stress Analysis by the Integrated Force Method

The Integrated Force Method, a recently developed method for analyzing structures, is extended in this paper to three-dimensional structural analysis. First, a general formulation is developed to generate the stress interpolation matrix in terms of complete polynomials of the required order. The formulation is based on definitions of the stress tensor components in term of stress functions. The stress functions are written as complete polynomials and substituted into expressions for stress components. Then elimination of the dependent coefficients leaves the stress components expressed as complete polynomials whose coefficients are defined as generalized independent forces. Such derived components of the stress tensor identically satisfy homogenous Navier equations of equilibrium. The resulting element matrices are invariant with respect to coordinate transformation and are free of spurious zero-energy modes. The formulation provides a rational way to calculate the exact number of independent forces necessary to arrive at an approximation of the required order for complete polynomials. The influence of reducing the number of independent forces on the accuracy of the response is also analyzed. The stress fields derived are used to develop a comprehensive finite element library for three-dimensional structural analysis by the Integrated Force Method. Both tetrahedral- and hexahedral-shaped elements capable of modeling arbitrary geometric configurations are developed. A number of examples with known analytical solutions are solved by using the developments presented herein. The results are in good agreement with the analytical solutions. The responses obtained with the Integrated Force Method are also compared with those generated by the standard displacement method. In most cases, the performance of the Integrated Force Method is better overall.

Kaljevic, Igor↗

Effect of Al substitution on the magnetocaloric properties of Ni-Co-Mn-Sn multifunctional alloys

Ni-Mn-based metamagnetic shape memory alloys have been extensively studied due to their multifunctional properties including magnetocaloric effect (MCE), magnetoresistance effect, and magnetic-field-induced strain. However, the large intrinsic thermal hysteresis of these alloys sets a limit on further development for practical applications. Here, with a few atomic percent Al substitution, we greatly reduced the thermal hysteresis and transformation temperature interval while maintaining the large magnetization difference (ΔM) between austenite and martensite. The simultaneous achievement of a large ΔM and low thermal hysteresis leads to a remarkable enhancement in MCE upon Al substitution, and a maximum magnetic entropy change of 31.6 J/kg K is achieved under a field of 5 T in Ni 39 Co 11 Mn 40 Sn 8 Al 2 . Furthermore, our in situ high-energy X-ray diffraction experiments show that the Ni 39 Co 11 Mn 40 Sn 8 Al 2 has good geometric compatibility between austenite and martensite, which accounts for the reduced thermal hysteresis in this alloy. This study is instructive for the development of high-performance magnetocaloric materials in the metamagnetic shape memory alloys.

36 MATERIALS SCIENCE↗