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At least 631 records · Page 35

Machine‐Learning Spectral Indicators of Topology

Abstract Topological materials discovery has emerged as an important frontier in condensed matter physics. While theoretical classification frameworks have been used to identify thousands of candidate topological materials, experimental determination of materials’ topology often poses significant technical challenges. X‐ray absorption spectroscopy (XAS) is a widely used materials characterization technique sensitive to atoms’ local symmetry and chemical bonding, which are intimately linked to band topology by the theory of topological quantum chemistry (TQC). Moreover, as a local structural probe, XAS is known to have high quantitative agreement between experiment and calculation, suggesting that insights from computational spectra can effectively inform experiments. In this work, computed X‐ray absorption near‐edge structure (XANES) spectra of more than 10 000 inorganic materials to train a neural network (NN) classifier that predicts topological class directly from XANES signatures, achieving F 1 scores of 89% and 93% for topological and trivial classes, respectively is leveraged. Given the simplicity of the XAS setup and its compatibility with multimodal sample environments, the proposed machine‐learning‐augmented XAS topological indicator has the potential to discover broader categories of topological materials, such as non‐cleavable compounds and amorphous materials, and may further inform field‐driven phenomena in situ, such as magnetic field‐driven topological phase transitions.

36 MATERIALS SCIENCE↗

Review of acousto-ultrasonic NDE for composites

Acousto-ultrasonics utilizes simulated stress waves to detect and quantify defect states, damage conditions, and variations of mechanical properties in fiber reinforced composites. The term acousto-ultrasonics denotes a combination of aspects of acoustic emission methodology with ultrasonic materials characterization. The acousto-ultrasonic approach was developed to deal primarily with evaluation of the integrated effect of minor flaws and diffuse flaw populations of subcritical flaws in composite and bonded structures. These factors singly and collectively also influence acousto-ultrasonic measurements that, in turn, correlate with dynamic response and mechanical property variations. Since it was first introduced, the acousto-ultrasonic approach was successfully applied to a variety of materials, including polymeric, metallic, and ceramic matrix composites; adhesively bonded materials; paper and wood products; cable and rope; and also human bone. Examples of applications and limitations of the approach are reviewed. Basic methods and guidelines are discussed. The underlying hypothesis and theory development needs are indicated.

Vary, Alex↗

Bayesian optimal experimental design for constitutive model calibration

Computational simulation is increasingly relied upon for high/consequence engineering decisions, which necessitates a high confidence in the calibration of and predictions from complex material models. However, the calibration and validation of material models is often a discrete, multi-stage process that is decoupled from material characterization activities, which means the data collected does not always align with the data that is needed. To address this issue, an integrated workflow for delivering an enhanced characterization and calibration procedure—Interlaced Characterization and Calibration (ICC)—is introduced and demonstrated. Further, this framework leverages Bayesian optimal experimental design (BOED), which creates a line of communication between model calibration needs and data collection capabilities in order to optimize the information content gathered from the experiments for model calibration. Eventually, the ICC framework will be used in quasi real-time to actively control experiments of complex specimens for the calibration of a high-fidelity material model. This work presents the critical first piece of algorithm development and a demonstration in determining the optimal load path of a cruciform specimen with simulated data. Calibration results, obtained via Bayesian inference, from the integrated ICC approach are compared to calibrations performed by choosing the load path a priori based on human intuition, as is traditionally done. The calibration results are communicated through parameter uncertainties which are propagated to the model output space (i.e. stress–strain). In these exemplar problems, data generated within the ICC framework resulted in calibrated model parameters with reduced measures of uncertainty compared to the traditional approaches.

42 ENGINEERING↗

Parameter extraction approaches for compact modeling of thermoelectric modules

Thermoelectric (TE) cooling has experienced rapid advancements with the foundational understanding of TE materials. TE modules, compact and lightweight devices, have become the prevalent approach for implementing TE technologies. Accurately quantifying TE physical parameters (Seebeck coefficient α, thermal conductivity κ, and thermal resistance ρ) is challenging due to the dynamic temperature changes in operation. Furthermore, extracting lumped property parameters is crucial for designing energy systems using TE modules. Existing research has several limitations, such as lack of comparative analysis between prevalent formulae, reliance on potentially inaccurate vendor-supplied data, disregard for fundamental assumptions, and absence of empirical measurements. Further, this study addresses these gaps by conducting TE material characterization, comparing three existing formulae using vendor datasheets, designing a laboratory test facility for model validation and refinement, and outlining a structured data extraction procedure. The study's novelty lies in multiple key contributions: (1) a detailed comparative analysis of existing formulae for extracting TE property parameter; (2) executing experimental work in a laboratory setting to validate the model and elucidate its limitations; (3) highlighting potential risks; (4) clarifying possible assumptions from both material and engineering perspectives; and (5) considering temperature differential impacts. This comprehensive approach addresses the current research gaps and provides valuable insights into the design and application of TE modules in various energy systems.

36 MATERIALS SCIENCE↗

Role of NDE and In-Situ Process Monitoring in Managing Risk of AM Space Hardware

The recently published NASA-STD-6030 defines the Additive Manufacturing (AM) Requirements for Spaceflight Systems. Key aspects of the certification approach include the development of a qualified material process (QMP) and material characterization determined by part classification. Nondestructive evaluation (NDE) of the full surface and volume is required for all part classifications except those with negligible risk. NASA is exploring the use of in-process monitoring data to improve risk posture and supplement post-build inspection for complex parts. Currently, the most challenging obstacle to overcome is linking the indications in the monitoring data to the physics of the process and the final material state of the finished part. NASA is undertaking studies to understand and quantify this relationship for various monitoring methods. The desired goal is to develop a protocol to establish this correlation for any monitoring method. Once this correlation is known, the critical defect size can be linked to a representative indication in the monitoring data, and the capability of the monitoring system can be tested using the 90/95 probability of detection requirement for NDE methods. This would enable the use of in-process monitoring as a defect screening activity for AM part certification. Many high-criticality components built with AM have high complexity and therefore limited inspectability, so using in-process monitoring can help address this certification gap. The use of adaptive, closed-loop monitoring systems that alter the locked process will require a new approach to the QMP.

additive manufacturing↗

Role of NDE and In-Situ Process Monitoring in Managing Risk of AM Space Hardware

The recently published NASA-STD-6030 defines the Additive Manufacturing (AM) Requirements for Spaceflight Systems. Key aspects of the certification approach include the development of a qualified material process (QMP) and material characterization determined by part classification. Nondestructive evaluation (NDE) of the full surface and volume is required for all part classifications except those with negligible risk. NASA is exploring the use of in-process monitoring data to improve risk posture and supplement post-build inspection for complex parts. Currently, the most challenging obstacle to overcome is linking the indications in the monitoring data to the physics of the process and the final material state of the finished part. NASA is undertaking studies to understand and quantify this relationship for various monitoring methods. The desired goal is to develop a protocol to establish this correlation for any monitoring method. Once this correlation is known, the critical defect size can be linked to a representative indication in the monitoring data, and the capability of the monitoring system can be tested using the 90/95 probability of detection requirement for NDE methods. This would enable the use of in-process monitoring as a defect screening activity for AM part certification. Many high-criticality components built with AM have high complexity and therefore limited inspectability, so using in-process monitoring can help address this certification gap. The use of adaptive, closed-loop monitoring systems that alter the locked process will require a new approach to the QMP.

advanced manufacturing↗

Property-Graded Stainless Steel 316L by Selective Laser Melting: Characterization & Design

Abstract The purpose of this research work is to characterize and inform the design of (mechanical) property-graded bulk structures made from a single metallic alloy via a laser powder bed fusion (LPBF) process, with an end goal of creating repeatable/reproducible functionally-graded additively manufactured (FGAM) parts. This paper specifically investigates the manufacture of stainless steel (SS) 316L structures via a pulsed selective laser melting (SLM) process, and the underlying causes of property variations (within a functionally-acceptable range) through various material characterization techniques. For this, a design of experiments spanning the volumetric energy density (VED) based process parameter design space was utilized to investigate the range of functionally-acceptable physical/mechanical properties achievable in SS 316L. Five sample conditions (made via different process parameter combinations) were down-selected for in-depth microstructure analysis and mechanical/physical property characterization; these were suitably selected to impart a wide and controllable property range (209–318 HV hardness, 90–99.9% relative density, and 154–211 GPa modulus). It was observed that property variations resulted from combinations of porosity types/amounts, martensitic phase fractions, and grain sizes. Based on these findings, property-graded standard test specimens were designed and manufactured for further investigation—tensile specimens having a monotonic hardness change along its gauge length, four-point bending specimens with varying elastic moduli as a function of the distance from the neutral axis, and Moore’s rotating beam fatigue specimens with moduli variations based on the distance from the center. Altogether, this work lays the foundation for understanding and designing the local and global mechanical performance of FGAM bulk structures.

Engineering↗

Ultrasonic Characterization of Ethylene Vinyl Acetate (EVA) Crosslinking for Quality Assurance and Lamination Process Control (US-Xlink)

Module makers strive to cut lamination processing times to enhance production throughput and reduce costs. If overdone, this might lead to poor EVA quality due to incomplete EVA crosslinking and a large concentration of potentially harmful reactants. Those deficiencies are frequently missed during production quality testing as initially their impact on power output is small. Additionally, the crosslinking agent is frequently inhomogeneously dispersed across the EVA foils such that local destructive characterization procedures such as differential scanning calorimetry (DSC), Soxhlet extraction, swelling methods, or mechanical tests provide only a limited amount of information. However, these defects and inhomogeneities can become considerably more important during field operation, dramatically reducing long-term power yield, and increasing LCOE. Examples of typical long-term module degradation modes relating to poor lamination process conditions include cell breakage, corrosion of the metallization, delamination, and local quality deficiencies. To provide reliable material characterization in a manufacturing setting, we devised a non-destructive technology that uses ultrasound to evaluate the quality of interface adhesion and the degree of crosslinking. As a calibration reference, DSC measurements were employed. Although the potential of ultrasonic approaches for this purpose has already been noted, those previous methods were generally limited to local qualitative measurements. Furthermore, variations in EVA thickness and temperature had a substantial impact on them. The solution we propose solves these limitations by employing ultrasonic absorption rather than relying solely on sound velocity data.

14 SOLAR ENERGY↗

Elevated temperature fatigue testing of metals

Material characterization and evaluation conducted for the purpose of calculating fatigue crack initiation lives of components operating at elevated temperatures are discussed. The major technology areas needed to perform a life prediction of an aircraft turbine engine hot section component and the steps required for life prediction are outlined. These include: the determination of the operating environment, the calculation of the thermal and mechanical loading of the component, the cyclic stress strain and creep behavior of the material required for structural analysis, the structural analysis to determine the local stress strain temperature time response of the material at the critical location in the component, and from a knowledge of the fatigue, creep, and failure resistance of the material, a prediction of the life of the component.

Hirschberg, M. H.↗

Design, Development and Hotfire Testing of Monolithic Copper and Bimetallic Additively Manufactured Combustion Chambers

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM) otherwise commonly referred to as additive manufacturing. The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for the GRCop-84 copper-alloy commensurate with powder bed additive manufacturing, evaluate bimetallic deposition and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. As a direct spin off of this program, NASA is working with industry partners to further develop the printing process for the GRCop-84 material in addition to the C-18150 (CuCrZr) material. To advance the process further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic additively manufactured chambers. A 1.2k sized thrust-chamber was designed and developed to compare the printing process of the GRCop-84 and C-18150 SLM materials. A series of similar MCC liners also completed development with an Inconel 625 jacket bonded to the GRcop-84 liner evaluating direct metal deposition (DMD) laser and arc-based techniques. This paper describes the design, development, manufacturing and testing of these combustion chambers and associated lessons learned throughout the design and development process.

Gradl, Paul↗

NSUF FY24 Program Overview and Updates

The Nuclear Science User Facilities (NSUF) is one of a diverse number of U.S. Department of Energy (DOE) user facilities established to provide researchers with the most advanced tools of modern science. The NSUF was established to provide access to unique capabilities to a broad range of researchers to address the important issues relevant to irradiation effects in nuclear fuels and materials. The NSUF represents a consortium of capabilities distributed across the U.S. at twenty institutions. The NSUF is centered at the Idaho National Laboratory, but it coordinates activities at nineteen “partner” institutions. These institutions have capabilities that include neutron, ion, and gamma irradiation, hot cells, advanced material characterization, and high-performance computing. The NSUF goal is to provide access these capabilities at no cost to nuclear energy researchers to produce the highest quality research results to increase understanding of advanced nuclear energy technologies important to DOE-NE.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Long-range magnetic order with disordered spin orientations in a high-entropy antiferromagnet

Disorder in magnetic systems typically suppresses long-range order, promoting short-range states such as spin glasses and magnetic clusters. This is particularly prominent in high-entropy materials, characterized by the random distributions of local magnetic entities and exchange interactions. However, in rare exceptions, long-range magnetic order can persist in high-entropy systems, while the microscopic characters and underlying mechanisms remain elusive, especially the magnetic behaviors of individual elements. Here, combining neutron diffraction and resonant soft x-ray scattering, we have conducted an element-specific investigation into the magnetic order of a high-entropy honeycomb-lattice van der Waals material (Mn 1/4 Fe 1/4 Co 1/4 Ni 1/4 )PS 3 . Despite significant atomic disorder, long-range zigzag antiferromagnetic order is observed below 72 K, with all four transition-metal elements participating in a unified phase transition. However, the spin orientations of various elements are distinct, attributed to the competition between single-ion anisotropies and exchange interactions. Our findings showcase a novel form of long-range magnetic order with disordered spin orientations, which is synergically stabilized by distinct magnetic elements in a high entropy magnet, offering a new paradigm for understanding complex magnetic systems.

Shen, Yao [Chinese Academy of Sciences (CAS), Beij↗

An Improved Technique for the Preparation of Mounted or Unmounted Carbon/Epoxy Specimens

As carbon/epoxy materials became more prevalent in the aerospace industry, microstructural analysis demanded specimen preparation techniques that led to better polished surfaces, achievable in a shorter time, and using fewer steps. The desire to use image analysis for material characterization also helped drive the goal for defect free surfaces. At NASA-Langley (LaRC), carbon/epoxy specimens had been historically prepared in 1 inch diameter Bakelite mounts. Carbon/epoxy specimens that were 1/8 to 1/4 inch thick were not affected by the heat and pressure required for mounting in Bakelite, however thinner specimens were crushed during mounting. A two-part room temperature curing epoxy was chosen as an alternative but sometimes voids developed between the specimen and the mounting material. This was prevented by either heating the epoxy to 140 degrees F to lower the viscosity of the epoxy or by using a vacuum impregnation apparatus. Both techniques helped facilitate flow and allowed the epoxy to penetrate crevices.

Edahl, Robert A., Jr.↗

Material and Design Optimization of Printed Melt Wire Arrays

Recent work conducted by the Advanced Sensors and Instrumentation (ASI) program at Idaho National Laboratory resulted in the establishment of in-house capabilities for fabricating and testing new advanced manufactured sensors for measuring irradiation temperatures inside a nuclear test reactor. Though current methods of real-time temperature monitoring (e.g., thermocouples) can still be used, the complexity of the feedthroughs and attachments needed for collecting real time measurements greatly increases the experiment-related costs. On the other hand, passive monitoring techniques can be used for collecting post irradiation temperature measurements by inferring reactor temperatures, based on the melting points of well-characterized materials (i.e., standard melt wires). However, challenges have arisen due to the limited space available for including instrumentation in experiments. To resolve this issue, the ASI program expanded its temperature detection capabilities to include advance manufactured melt wires for post-irradiation temperature measurements. These melt wires can determine reactor temperatures while also accommodating space limitations in irradiation experiments. To improve performance reliability and enhance melt wire readability following irradiation, FY-22 efforts have focused on optimizing the materials used in the encapsulation and printed melt wire array. This report details the design and fabrication tasks, along with the subsequent x ray computed tomography (XCT) evaluation process. The melt wire array consisted of indium with a melting point of 157°C, indium/silver (96/4 at%) with a melting point of 219°C, and tin with a melting point of 230°C. The encapsulation disc was made of vanadium due to its low activation properties and radiation resistance when deployed in nuclear reactors. Additionally, the melt wire design consisted of a ceramic sublayer (alumina disc) to further enhance the XCT post melting images of the printed melt wires. However, when sealing the vanadium container, all three melt wires melted, reflecting the temperature limitations that must be considered when employing metal containers in the sealing process.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Understanding the Role of Extrinsic Impurities in Bulk Nb SRF Cavities

High gradient and high quality factor superconducting radiofrequency (SRF) cavities are essential for efficient particle acceleration in next-generation accelerators. This work demonstrates that the superconducting performance of bulk niobium can be enhanced through a controlled introduction of interstitial oxygen and nitrogen. Thermal and chemical surface treatments modify the concentration and distribution of these impurities, enabling systematic tuning of SRF cavity performance. By combining cavity RF measurements with quantitative materials characterizations, we isolate the impact of impurity concentration on BCS surface resistance and identify the mechanisms by which interstitial impurities alter the superconducting properties of niobium. We find that nitrogen is an order of magnitude more effective than oxygen in reducing BCS resistance at 16 MV/m and that the reduction arises from a combination of mean free path optimization and superconducting gap enhancement. Using these insights, we develop a predictive model that estimates cavity performance directly from room temperature sample material studies, reducing the reliance on full-scale cryogenic tests for surface treatment development. We then apply this model to explore co-doping strategies, demonstrating that combining interstitial oxygen and nitrogen achieves a synergistic reduction in BCS resistance. These results establish co-doping as a viable path for the development of surface-engineered niobium for future high quality factor SRF applications.

Hu, Hannah [Chicago U.]↗

Performance Evaluation of LPBF Manufactured 316H Components

This work represents the continuation of a benchmark study that includes modeling, fabrication and characterization as demonstration to support industry’s adoption of advanced manufacturing processes in a variety of structures. This comprehensive study investigated the feasibility of using additive manufacturing (AM) technologies, specifically Laser Powder Direct Energy Deposition (LP-DED) and Laser Powder Bed Fusion (LPBF), to produce complex nuclear microreactor components using 316H stainless steel. The research focused on manufacturing an expanded elbow pipe component with transitioning sections, which are traditionally difficult and costly to produce through conventional manufacturing methods. The overall study’s primary objectives are therefore demonstrating AM viability for nuclear applications, optimizing process parameters, developing comprehensive material characterization protocols, validating computational modeling approaches, and establishing manufacturing guidelines for complex geometries. Although the initial work included the phased approach of cubical, upscaled cylindrical components, it is to enable to obtain more knowledge for the printing of the expanded elbow structure. The project achieved significant progress in process development by successfully optimizing LP-DED parameters to achieve 99.16-99.97% relative density in 316H stainless steel components. Through systematic evaluation of sixteen cube samples with varied laser powers (400-700W) and scan speeds (600-900 mm/min), optimal processing windows were identified at 500-550W with 600-700 mm/min or 650-700W with 650-900 mm/min scan speeds. The DED manufactured 316H demonstrated mechanical properties comparable or superior to wrought materials, with Young's modulus ranging from 153-208 GPa and controlled microstructural characteristics including greater than 95% face-centered cubic (FCC) phases and engineered cellular structures with sizes between 3.23-6.17 µm.

36 MATERIALS SCIENCE↗

Preparation for microgravity: The role of the microgravity materials science laboratory

A laboratory dedicated to ground based materials processing in preparation for space flight was established at the NASA Lewis Research Center. Experiments are performed to delineate the effects of gravity on processes of both scientific and commercial interest. Processes are modeled physically and mathematically. Transport model systems are used where possible to visually track convection, settling, crystal growth, phase separation, agglomeration, vapor transport, diffusive flow, and polymers reactions. The laboratory contains apparatus which functionally duplicates apparatus available for flight experiments and other pieces instrumented specifically to allow process characterization. Materials addressed include metals, alloys, salts, glasses, ceramics, and polymers. The Microgravity Materials Science Laboratory is staffed by engineers and technicians from a variety of disciplines and is open to users from industry and academia as well as the government. Examples will be given of the laboratory apparatus typical experiments and results.

Johnston, J. Christopher↗

Multi-scale characterization of supersolidus liquid phase sintered H13 tool steel manufactured via binder jet additive manufacturing

Additive manufacturing (AM) of H13 tool steel by binder jet 3D printing (BJ3DP) followed by pressureless supersolidus liquid phase sintering (SLPS) provides a low-cost alternative manufacturing method for components with intricate geometric features. However, the microstructure-mechanical property relationships for BJ3DP-SLPS produced H13 tool steel are not well understood, which makes it challenging to develop printing and post-processing methods that maximize part performance. In this work, we leverage atom probe tomography and transmission electron microscopy along with thermodynamic calculations to rationalize the microstructure-mechanical property relationships in as-sintered BJ3DP H13 tool steel. Here, we report for the first time, the presence of a continuous eutectic film-like carbide in H13 along with the more commonly observed cuboidal MX carbides in the prior liquid channels of the microstructure. Further, atom probe tomography revealed the interconnected nature of the MX carbides that appear to be discrete in two-dimensional micrographs. These continuous eutectic carbides and interconnected MX carbides result in brittle failure of the material. Characterization of these microstructural features will be critical in developing appropriate post-processing heat treatments for the improved mechanical performance of BJ3DP H13.

36 MATERIALS SCIENCE↗