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At least 595 records · Page 33

On the efficacy of post-build thermomechanical treatments to improve properties of Zirconium fabricated using ultrasonic additive manufacturing

Here, hot-isostatic pressing has been applied to Zirconium plate fabricated using the ultrasonic additive manufacturing (UAM) technique to enhance interfacial bond quality. Specimens heated to 800 C for 1 h at 100 MPa pressure showed grain growth across many prior foil-to-foil interfaces, thereby increasing foil adhesion. In addition to the material softening induced by a loss of Hall-Petch strengthening, premature failure of specimens loaded parallel to the build direction was observed. Premature specimen failure was attributed to the local delamination at prior foil-to-foil boundaries where grain growth was pinned by Ti impurities introduced during the UAM process via the interaction between a Ti-alloy buffer foil and the welded Zr-foils underneath. In addition, the presence of Ti along select foil interfaces resulted in the nucleation and growth of secondary (Zr,Ti)(Fe,Cr) laves phases during higher-temperature thermomechanical processing. Using a combination of micro-scale X-ray computed tomography, fractography, and in-situ digital image correlation, the effect of defects along prior foil-to-foil boundaries was revealed as delamination-assisted plasticity accelerated specimen failure in preferred tensile orientations. These findings underscore the importance of impurity control when optimizing weld quality of higher-strength material systems using ultrasonic welding.

36 MATERIALS SCIENCE↗

Experimental data for damage mechanics simulation challenge

While there are many computational approaches for simulating damage in rock and other materials, few have been ground truth tested with either known experimental data or with blind data sets. Here, in this work, we present a bench-mark laboratory data set for a damage mechanics challenge to compare computational approaches on damage evolution in brittle-ductile materials. The samples were fabricated through additive manufacturing to produce repeatable specimens designed to fail in controlled ways. The failure was induced in the samples using a 3-point bending test to produce different Modes such as Mode I and mixed Modes including I-II, I-III and I-II-III Modes to generate a calibration data set and a blind challenge data set. Data collected included spatial and temporal measurements from traditional digital load–displacement sensors, 2D digital image correlation measurement to map surface deformations, 3D X-ray microscopy to ground-truth the crack-failure geometry, and laser profilometry to capture surface roughness. The data sets are available, on a data repository, to the community to advance computational models to improve our ability to predict damage in brittle-ductile materials.

3-point bending↗

Silicon Carbide Being Developed for High-Definition Television (HDTV) Transmitter Modules

Through a Space Act Agreement, the NASA Lewis Research Center has helped develop the base silicon carbide (SiC) epitaxial growth technology for Westinghouse's efforts to bring silicon carbide products to the marketplace. SiC is a high-temperature, high-voltage semiconductor that can deliver greater than three times the power of conventional silicon devices. The technology was initially disclosed in the 1994 R&T report. NASA Lewis High Temperature Integrated Electronics and Sensors (HTIES) team is developing SiC as a material for advanced semiconductor electronic device applications because SiC-based electronics and sensors can operate in hostile environments where conventional silicon-based electronics cannot function. SiC transmitters hold great promise for television stations because they can convert broadcasts from analog to digital signals. A modular solid-state design provides broadcasters with an option to gradually add modules, increasing the power of their transmitters as they expand their high-definition television (HDTV) coverage. Using these high-power transistors will significantly reduce the space needed for high-power transmitters at television stations and will offer a solid-state solution, reducing long-term maintenance costs. Thus, transmitter manufacturers will be able to abandon their reliance on tube-based technology for high-power transmitters and will be able to build smaller, high-power, solid-state transmitters.

Costello, Donald E.↗

Dynamic Analysis Methods for Detecting Anomalies in Asynchronously Interacting Systems

Detecting modifications to digital system designs, whether malicious or benign, is problematic due to the complexity of the systems being analyzed. Moreover, static analysis techniques and tools can only be used during the initial design and implementation phases to verify safety and liveness properties. It is computationally intractable to guarantee that any previously verified properties still hold after a system, or even a single component, has been produced by a third-party manufacturer. In this paper we explore new approaches for creating a robust system design by investigating highly-structured computational models that simplify verification and analysis. Our approach avoids the need to fully reconstruct the implemented system by incorporating a small verification component that dynamically detects for deviations from the design specification at run-time. The first approach encodes information extracted from the original system design algebraically into a verification component. During run-time this component randomly queries the implementation for trace information and verifies that no design-level properties have been violated. If any deviation is detected then a pre-specified fail-safe or notification behavior is triggered. Our second approach utilizes a partitioning methodology to view liveness and safety properties as a distributed decision task and the implementation as a proposed protocol that solves this task. Thus the problem of verifying safety and liveness properties is translated to that of verifying that the implementation solves the associated decision task. We develop upon results from distributed systems and algebraic topology to construct a learning mechanism for verifying safety and liveness properties from samples of run-time executions.

97 MATHEMATICS AND COMPUTING↗

Influence of Spindle Wobble in a Lathe on the Tool’s Deformational-Displacement Trajectory

Attention focuses here on the conversion of the trajectory of spindle-group wobble in a lathe into deformational displacement of the tool and the associated modification of the shaping trajectory. This process depends on the change in dynamic properties of the system due to the wobble. On the basis of simulation and digital experiments, it may be concluded that the wobble changes the stability of the trajectories and that various attractive sets are formed in the system (such as limit cycles, invariant tori, and chaotic attractors). The wobble does not change the shaping trajectory directly, but rather through the formation of attractive deformational-displacement sets. Therefore, the attractive sets affect the geometric topology of the workpiece surface and the limiting feasible manufacturing precision.

42 ENGINEERING↗

Modular Rapidly Manufactured Small Satellite (MRMSS)

The Modular Rapidly Manufactured Small Satellite (MRMSS) project applies modular building block systems to space applications. The need to reduce mass for spaceflight applications and reuse resources is a critical technology for long duration space missions. Mass reduction and reuse of material will help bring down costs for spaceflight missions and open up more possibilities for exploration and research. The MRMSS project consists of two major components: A basic research component demonstrating electronic digital materials, and a technology demonstration applying the modular building block based systems concept to the CubeSat form factor. This paper describes the core technologies developed to enable the modular system as well the first flight demonstration on a sounding rocket.

Modular Architecture↗

Robotically Assembled Aerospace Structures: Digital Material Assembly using a Gantry-Type Assembler

This paper evaluates the development of automated assembly techniques for discrete lattice structures using a multi-axis gantry type CNC machine. These lattices are made of discrete components called "digital materials." We present the development of a specialized end effector that works in conjunction with the CNC machine to assemble these lattices. With this configuration we are able to place voxels at a rate of 1.5 per minute. The scalability of digital material structures due to the incremental modular assembly is one of its key traits and an important metric of interest. We investigate the build times of a 5x5 beam structure on the scale of 1 meter (325 parts), 10 meters (3,250 parts), and 30 meters (9,750 parts). Utilizing the current configuration with a single end effector, performing serial assembly with a globally fixed feed station at the edge of the build volume, the build time increases according to a scaling law of n4, where n is the build scale. Build times can be reduced significantly by integrating feed systems into the gantry itself, resulting in a scaling law of n3. A completely serial assembly process will encounter time limitations as build scale increases. Automated assembly for digital materials can assemble high performance structures from discrete parts, and techniques such as built in feed systems, parallelization, and optimization of the fastening process will yield much higher throughput.

Manufacturing↗

A Radiation Hard Multi-Channel Digitizer ASIC for Operation in the Harsh Jovian Environment

In 1995, the Galileo spacecraft arrived at Jupiter to conduct follow-up experiments on pathfinder Pioneer and key Voyager discoveries especially at Io, Europa, Ganymede and Callisto. These new observations helped expand our scientific knowledge of the prominent Galilean satellites; studies revealed diversity with respect to their geology, internal structure, evolution and degree of past and present activity. Jupiter's diverse Galilean satellites, of which three are believed to harbor internal oceans, are central to understanding the habitability of icy worlds. Galileo provided for the first time compelling evidence of a near-surface global ocean on Europa. Furthermore, by understanding the Jupiter system and unraveling the history of its evolution from initial formation to the emergence of possible habitats and life, gives insight into how giant planets and their satellite systems form and evolve. Most important, new light is shed on the potential for the emergence and existence of life in icy satellite oceans. In 2009, NASA released a detailed Jupiter Europa Mission Study (EJSM) that proposed an ambitious Flagship Mission to understand more fully the satellites Europa and Ganymede within the context of the Jovian system. Key to EJSM is the NASA led Jupiter Europa Orbiter (JEO) and the ESA led Jupiter Ganymede Orbiter (JGO). JEO and JGO would execute a choreographed exploration of the Jovian system before settling into orbit around Europa and Ganymede, respectively. The National Academies Planetary Decadal Survey, 2011 has listed the NASA-led JEO as the second highest priority mission for the decade 2013-2022, and if chosen it would be launched in 2020 with arrival at Jupiter in 2025. If the JEO mission is not chosen it is anticipated that there will be opportunities in future decadal cycles. Jupiter Orbit Insertion (JOI) begins a 30-month Jovian system tour followed by nine months of science mapping after Europa Orbit Insertion (EOI) in July 2028. The orbiter will ultimately impact the surface of Europa after the mission is completed. The current JEO mission concept includes a range of instruments on the payload, to monitor dynamic phenomena (such as Io's volcanoes and Jupiters atmosphere), map the Jovian magnetosphere and its interactions with the Galilean satellites, and characterize water oceans beneath the ice shells of Europa and Ganymede. The payload includes a low mass (3.7 Kg) and low power (< 5 W) Thermal Instrument (TI) concept for measuring possible warm thermal anomalies on Europa s cold surface caused by recent (< 10,000 years) eruptive activity. Regions of anomalously high heat flow will be identified by thermal mapping using a nadir pointing, push-broom filter radiometer that provides far-IR imagery in two broad band spectral wavelength regions, 8-20 m and 20-100 m, for surface temperature measurements with better than a 2 K accuracy and a spatial resolution of 250 m/pixel obtained from a 100 Km orbit. The temperature accuracy permits a search for elevated temperatures when combined with albedo information. The spatial resolution is sufficient to resolve Europa's larger cracks and ridge axial valleys. In order to accomplish the thermal mapping, the TI uses sensitive thermopile arrays that are readout by a custom designed low-noise Multi-Channel Digitizer (MCD) ASIC that resides very close to the thermopile linear array outputs. Both the thermopile array and the MCD ASIC will need to show full functionality within the harsh Jovian radiation environment, operating at cryogenic temperatures, typically 150 K to 170 K. In the following, a radiation mitigation strategy together with a low risk Radiation-Hardened-By-Design (RHBD) methodology using commercial foundry processes is given for the design and manufacture of a MCD ASIC that will meet this challenge.

Aslam, Shahid↗

Report on Progress of correlation of in-situ and ex-situ data and the use of artificial intelligence to predict defects

The Transformational Challenge Reactor (TCR) program is leveraging additive manufacturing (AM) technologies to fabricate nuclear components which will be assembled into a fully functional microreactor core. Compared with traditional manufacturing technologies, AM technologies allow (1) real-time observation of the manufacturing process at a much higher resolution using in-situ monitoring technologies to capture the sensor signatures that scientifically describe each event occurring over time and space and (2) validation of the manufacturing process quality using domain-informed data analytics techniques as a potential qualification and certification methodology for the final component. This report provides an update on the program work on in-situ and ex-situ data correlation and associated data analytics results. Examples are provided to illustrate progress with respect to laser powder bed fusion (L-PBF), binder jetting, computed tomography (CT) reconstruction, and mechanical testing. Elements of the Digital Thread and data management infrastructure are discussed in the main document, and an extensive supplemental appendix is provided detailing the Digital Platform, as well as its implementation and subcomponents. In conclusion, the path forward for the next fiscal year is also discussed.

42 ENGINEERING↗

Electro-optic architecture (EOA) for sensors and actuators in aircraft propulsion systems

Results of a study to design an optimal architecture for electro-optical sensing and control in advanced aircraft and space systems are described. The propulsion full authority digital Electronic Engine Control (EEC) was the focus for the study. The recommended architecture is an on-engine EEC which contains electro-optic interface circuits for fiber-optic sensors on the engine. Size and weight are reduced by multiplexing arrays of functionally similar sensors on a pair of optical fibers to common electro-optical interfaces. The architecture contains common, multiplex interfaces to seven sensor groups: (1) self luminous sensors; (2) high temperatures; (3) low temperatures; (4) speeds and flows; (5) vibration; (6) pressures; and (7) mechanical positions. Nine distinct fiber-optic sensor types were found to provide these sensing functions: (1) continuous wave (CW) intensity modulators; (2) time division multiplexing (TDM) digital optic codeplates; (3) time division multiplexing (TDM) analog self-referenced sensors; (4) wavelength division multiplexing (WDM) digital optic code plates; (5) wavelength division multiplexing (WDM) analog self-referenced intensity modulators; (6) analog optical spectral shifters; (7) self-luminous bodies; (8) coherent optical interferometers; and (9) remote electrical sensors. The report includes the results of a trade study including engine sensor requirements, environment, the basic sensor types, and relevant evaluation criteria. These figures of merit for the candidate interface types were calculated from the data supplied by leading manufacturers of fiber-optic sensors.

Glomb, W. L., Jr.↗

Technology Assessment of High Capacity Data Storage Systems: Can We Avoid a Data Survivability Crisis

The density of digital storage media in our information-intensive society increases by a factor of four every three years, while the rate at which this data can be migrated to viable long-term storage has been increasing by a factor of only four every nine years. Meanwhile, older data stored on increasingly obsolete media, are at considerable risk. When the systems for which the media were designed are no longer serviced by their manufacturers (many of whom are out of business), the data will no longer be accessible. In some cases, older media suffer from a physical breakdown of components - tapes simply lose their magnetic properties after a long time in storage. The scale of the crisis is compatible to that facing the Social Security System. Greater financial and intellectual resources to the development and refinement of new storage media and migration technologies in order to preserve as much data as possible.

Halem, M.↗

Design of a Low-Cost, Submersible, Digital Holographic Microscope for in Situ Microbial Imaging

The methodologies for studying marine microbiology typically consist of utilizing instrumentation within a laboratory. This typically requires extracting a sample from its place of origin prior to examination, which may be days after collection. Oftentimes, the solution is to bring the lab to the ocean, which may be costly and provide further limitations for a sterile and stable laboratory environment. Here we present a low-cost, submersible, digital holographic microscope (DHM) designed to image marine microorganisms (such as bacteria and plankton) in their natural underwater environment. Our instrument eliminates the need to transport samples and allows for instantaneous data collection of microbes in-situ. The DHM achieves sub-micron spatial resolution and is paired with artificial intelligence for the detection and tracking of specimens to reduce the overall collected data. This instrument also aims to reduce the cost of manufacturing and field expenses relative to marine microbiological research. “Off the shelf” components were selected in the design process of this instrument which allows us to achieve precise results without sacrificing data quality. The DHM itself costs under one thousand dollars and features a low-cost high-resolution camera, the Arducam MT9J001. Included in the design were five main subsystems: optical, mechanical, electrical, power, and machine learning. Our on board computer and artificial intelligence consist of a Raspberry Pi 4 (8 Gb) and Google Coral USB Tensorflow accelerator. Instrument testing has successfully proven our abilities of data acquisition for at least two hours in depths of at least forty meters below sea level. Additionally, our artificial intelligence system is currently capable of tracking up to ten areas of interest in a fraction of a second with over ninety percent confidence via the neural net driven by the tensor cores on the Google Coral. Furthermore, we have demonstrated the versatility of our instrument by mounting it on an ocean-going ROV, the BlueRov2 by BlueRobotics. Our tests on the BlueRov2 exemplified the cost-effective nature of a submersible and reusable instrument that can be implemented in moderate environments and on most vessels.

Wallace, James Kent↗

High polarization InAlGaAs/AlGaAs photocathodes grown using MBE

Strained superlattices of GaAs/GaAsP grown using molecular beam epitaxy (MBE) have been used for more than 20 years to generate high polarization electron beams for nuclear physics. GaAs/GaAsP superlattices have several manufacturing challenges, including the thick graded layer required for the virtual GaAsP substrate, the significant difference in optimal growth temperatures for GaAs and GaAsP, and the scarcity of MBE systems using phosphorus. InAlGaAs/AlGaAs strained superlattice photocathode are an alternative structure that eliminates many of hurdles to growing GaAs/GaAsP in MBE systems. Measurements of quantum efficiency and polarization from InAlGaAs/AlGaAs will be presented. These include studies on a variety of growth parameters to optimize performance, including digital alloys, growth temperature variations, and variation in structure.

Stutzman, Marcy L↗

Characterization of a double-sided silicon strip detector autoradiography system

Purpose: The most commonly used technology currently used for autoradiography is storage phosphor screens, which has many benefits such as a large field of view but lacks particle-counting detection of the time and energy of each detected radionuclide decay. A number of alternative designs, using either solid state or scintillator detectors, have been developed to address these issues. The aim of this study is to characterize the imaging performance of one such instrument, a double-sided silicon strip detector (DSSD) system for digital autoradiography. A novel aspect of this work is that the instrument, in contrast to previous prototype systems using the same detector type, provides the ability for user accessible imaging with higher throughput. Studies were performed to compare its spatial resolution to that of storage phosphor screens and test the implementation of multiradionuclide ex vivo imaging in a mouse preclinical animal study. Methods: Detector background counts were determined by measuring a nonradioactive sample slide for 52 h. Energy spectra and detection efficiency were measured for seven commonly used radionuclides under representative conditions for tissue imaging. System dead time was measured by imaging {sup 18}F samples of at least 5 kBq and studying the changes in count rate over time. A line source of {sup 58}Co was manufactured by irradiating a 10 μm nickel wire with fast neutrons in a research reactor. Samples of this wire were imaged in both the DSSD and storage phosphor screen systems and the full width at half maximum (FWHM) measured for the line profiles. Multiradionuclide imaging was employed in a two animal study to examine the intratumoral distribution of a {sup 125}I-labeled monoclonal antibody and a {sup 131}I-labeled engineered fragment (diabody) injected in the same mouse, both targeting carcinoembryonic antigen. Results: Detector background was 1.81 × 10{sup −6} counts per second per 50 × 50 μm pixel. Energy spectra and detection efficiency were successfully measured for seven radionuclides. The system dead time was measured to be 59 μs, and FWHM for a {sup 58}Co line source was 154 ± 14 μm for the DSSD system and 343 ± 15 μm for the storage phosphor system. Separation of the contributions from {sup 125}I and {sup 131}I was performed on autoradiography images of tumor sections. Conclusions: This study has shown that a DSSD system can be beneficially applied for digital autoradiography with simultaneous multiradionuclide imaging capability. The system has a low background signal, ability to image both low and high activity samples, and a good energy resolution.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Target-Tracking Camera for a Metrology System

An analog electronic camera that is part of a metrology system measures the varying direction to a light-emitting diode that serves as a bright point target. In the original application for which the camera was developed, the metrological system is used to determine the varying relative positions of radiating elements of an airborne synthetic aperture-radar (SAR) antenna as the airplane flexes during flight; precise knowledge of the relative positions as a function of time is needed for processing SAR readings. It has been common metrology system practice to measure the varying direction to a bright target by use of an electronic camera of the charge-coupled-device or active-pixel-sensor type. A major disadvantage of this practice arises from the necessity of reading out and digitizing the outputs from a large number of pixels and processing the resulting digital values in a computer to determine the centroid of a target: Because of the time taken by the readout, digitization, and computation, the update rate is limited to tens of hertz. In contrast, the analog nature of the present camera makes it possible to achieve an update rate of hundreds of hertz, and no computer is needed to determine the centroid. The camera is based on a position-sensitive detector (PSD), which is a rectangular photodiode with output contacts at opposite ends. PSDs are usually used in triangulation for measuring small distances. PSDs are manufactured in both one- and two-dimensional versions. Because it is very difficult to calibrate two-dimensional PSDs accurately, the focal-plane sensors used in this camera are two orthogonally mounted one-dimensional PSDs.

Liebe, Carl↗

Requirements Document for a Replacement Data Acquisition System

A flight vehicle is in the developmental stages. While in development flight testing is required by both the manufacturer and customer to rate design performance. The performance of the vehicle must fulfill the agreed upon requirements. Testing of a flight vehicle during operation requires various sensors in order to record and monitor performance for evaluation. A Data Acquisition System (DAQ) is needed in order to control and capture data from various sensors placed throughout the vehicle during flight. This DAQ will receive the analog data from the suite of sensors and convert them to a digital signal that can be transmitted to a recording station where the data will later be analyzed by test experts. Some of the key features to be included in the DAQ will be a self-check operation to verify the health of all sensors including the DAQ. The DAQ will also have the capability to store sensor calibration data files loaded during assembly and transmit those files to the recording station during flight. Breakthroughs in new technologies has allowed for higher resolution recording systems and faster sampling rates. Improved sensor data using a new Data Acquisition System (DAQ) can provide important answers to questions discovered during the last few flight tests. These questions arose when the flight system expressed unexpected behaviors. Having the capability of the new DAQ in flight tests would allow for more high-fidelity data to be captured from the system during flight tests and ultimately reducing the number of required flight test. Reducing the number of flight tests also reduce developmental cost and schedule.

42 ENGINEERING↗

High fidelity, radiation tolerant analog-to-digital converters

Techniques for an analog-to-digital converter (ADC) using pipeline architecture includes a linearization technique for a spurious-free dynamic range (SFDR) over 80 deciBels. In some embodiments, sampling rates exceed a megahertz. According to a second approach, a switched-capacitor circuit is configured for correct operation in a high radiation environment. In one embodiment, the combination yields high fidelity ADC (>88 deciBel SFDR) while sampling at 5 megahertz sampling rates and consuming <60 milliWatts. Furthermore, even though it is manufactured in a commercial 0.25-.mu.m CMOS technology (1 .mu.m=12.sup.-6 meters), it maintains this performance in harsh radiation environments. Specifically, the stated performance is sustained through a highest tested 2 megarad(Si) total dose, and the ADC displays no latchup up to a highest tested linear energy transfer of 63 million electron Volts square centimeters per milligram at elevated temperature (131 degrees C.) and supply (2.7 Volts, versus 2.5 Volts nominal).

Wang, Charles Chang-I↗