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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Results from the fifth galaxy serpent exercise

Galaxy Serpent is an ongoing series of virtual, web-based international tabletop exercises designed to advance the application of National Nuclear Forensics Libraries (NNFLs) in investigations involving nuclear and other radioactive material found out of regulatory control. Here, this iteration emphasized interactions between scientific teams and mock investigative entities. Participants utilized their provided NNFLs to assess material consistency with a provided database of holdings, assign confidence levels, and identify key characteristics relevant to investigative queries. The exercise highlighted both challenges encountered and lessons learned, and advanced best practices for integrating a NNFL into nuclear forensics as part of an investigation.

Database↗
DOE OSTI2023

A Geo-Data Science Method for Assessing Unconventional Rare-Earth Element Resources in Sedimentary Systems

Abstract Rare-earth elements (REEs) supply raw materials that constitute many of our modern critical infrastructure, defense, technology, and electrification needs. Despite REE accumulations occurring in conventional bedrock and ion-adsorption deposits sourced from weathering of igneous rocks, unconventional host materials such as coal and related sedimentary strata have been identified as promising sources of REEs to meet growing demand. To maximize the potential of unconventional resources such as REE-coal systems, new approaches are needed overcome challenges from mineral systems with no known deposits and areas with sparse geochemical data. This article presents a systematic knowledge-data resource assessment method for predicting and identifying REE resource potential and occurrence in these unconventional systems. The method utilizes a geologic and geospatial knowledge-data approach informed and guided by REE accumulation mechanisms to systematically assess and identify areas of higher enrichment. An assessment of the Powder River Basin is presented as a test case to demonstrate the method workflow and results. The key output is a potential enrichment score map reported with varying confidence levels based on the amount of supporting evidence. Results from the test case indicate several locations with promising potential for different types of coal-REE deposits, demonstrating the viability of the method for exploration and assessment of unconventional REE resources. The method is flexible by design and, with sufficient applicable knowledge and data, can be adapted for assessing critical mineral systems in other sedimentary systems as well.

58 GEOSCIENCES↗
DOE OSTI2021

Estimation of soil classes and their relationship to grapevine vigor in a Bordeaux vineyard: advancing the practical joint use of electromagnetic induction (EMI) and NDVI datasets for precision viticulture

Working within a vineyard in the Pessac Léognan Appellation of Bordeaux, France, this study documents the potential of using simple statistical methods with spatially-resolved and increasingly available electromagnetic induction (EMI) geophysical and normalized difference vegetation index (NDVI) datasets to accurately estimate Bordeaux vineyard soil classes and to quantitatively explore the relationship between vineyard soil types and grapevine vigor. First, co-located electrical tomographic tomography (ERT) and EMI datasets were compared to gain confidence about how the EMI method averaged soil properties over the grapevine rooting depth. Then, EMI data were used with core soil texture and soil-pit based interpretations of Bordeaux soil types (Brunisol, Redoxisol, Colluviosol and Calcosol) to estimate the spatial distribution of geophysically-identified Bordeaux soil classes. A strong relationship (r = 0.75, p < 0.01) was revealed between the geophysically-identified Bordeaux soil classes and NDVI (both 2 m resolution), showing that the highest grapevine vigor was associated with the Bordeaux soil classes having the largest clay fraction. The results suggest that within-block variability of grapevine vigor was largely controlled by variability in soil classes, and that carefully collected EMI and NDVI datasets can be exceedingly helpful for providing quantitative estimates of vineyard soil and vigor variability, as well as their covariation. The method is expected to be transferable to other viticultural regions, providing an approach to use easy-to-acquire, high resolution datasets to guide viticultural practices, including routine management and replanting.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Comparison of PsbQ and Psb27 in photosystem II provides insight into their roles

Photosystem II (PSII) catalyzes the oxidation of water at its active site that harbors a high-valent inorganic Mn 4 CaO x cluster called the oxygen-evolving complex (OEC). Extrinsic subunits generally serve to protect the OEC from reductants and stabilize the structure, but diversity in the extrinsic subunits exists between phototrophs. Recent cryo-electron microscopy experiments have provided new molecular structures of PSII with varied extrinsic subunits. We focus on the extrinsic subunit PsbQ, that binds to the mature PSII complex, and on Psb27, an extrinsic subunit involved in PSII biogenesis. PsbQ and Psb27 share a similar binding site and have a four-helix bundle tertiary structure, suggesting they are related. Here, we use sequence alignments, structural analyses, and binding simulations to compare PsbQ and Psb27 from different organisms. We find no evidence that PsbQ and Psb27 are related despite their similar structures and binding sites. Evolutionary divergence within PsbQ homologs from different lineages is high, probably due to their interactions with other extrinsic subunits that themselves exhibit vast diversity between lineages. This may result in functional variation as exemplified by large differences in their calculated binding energies. Psb27 homologs generally exhibit less divergence, which may be due to stronger evolutionary selection for certain residues that maintain its function during PSII biogenesis which is consistent with their more similar calculated binding energies between organisms. Previous experimental inconsistencies, low confidence binding simulations, and recent structural data suggest that Psb27 is likely to exhibit flexibility that may be an important characteristic of its activity. Furthermore, the analysis provides insight into the functions and evolution of PsbQ and Psb27, and an unusual example of proteins with similar tertiary structures and binding sites that probably serve different roles.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

A quantitative assessment of (bacterio)chlorophyll assignments in the cryo-EM structure of the Chloracidobacterium thermophilum reaction center

Chlorophylls and bacteriochlorophylls are the primary pigments used by photosynthetic organisms for light-harvesting, energy transfer, and electron transfer. Many molecular structures of (bacterio)chlorophyll-containing protein complexes are available, some of which contain mixtures of different (bacterio)chlorophyll types. Differentiating these, which sometimes are structurally similar, is challenging but is required for leveraging structural data to gain functional insight. The reaction center complex from Chloroacidobacterium thermophilum has a hybrid (bacterio)chlorophyll antenna system containing both chlorophyll a and bacteriochlorophyll a molecules. The recent availability of its cryogenic electron microscopy (cryo-EM) structure provides an opportunity for a quantitative analysis of their identities, and chemical environments. Here, we describe a theoretical basis for differentiating chlorophyll a and bacteriochlorophyll a in a cryo-EM map, and apply the approach to the experimental cryo-EM maps of the (bacterio)chlorophyll sites of the chloroacidobacterial reaction center. The comparison reveals that at ~2.2-Å resolution, chlorophyll a and bacteriochlorophyll a are easily distinguishable, but the orientation of the bacteriochlorophyll a acetyl moiety is not; however, the latter can confidently be assigned by identifying a hydrogen bond donor from the protein environment. Furthermore, this study reveals the opportunities and challenges in assigning (bacterio)chlorophyll types in structural biology, the accuracy of which is vital for downstream investigations.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Applying queueing theory to evaluate wait-time-savings of triage algorithms

Abstract In the past decade, artificial intelligence (AI) algorithms have made promising impacts in many areas of healthcare. One application is AI-enabled prioritization software known as computer-aided triage and notification (CADt). This type of software as a medical device is intended to prioritize reviews of radiological images with time-sensitive findings, thus shortening the waiting time for patients with these findings. While many CADt devices have been deployed into clinical workflows and have been shown to improve patient treatment and clinical outcomes, quantitative methods to evaluate the wait-time-savings from their deployment are not yet available. In this paper, we apply queueing theory methods to evaluate the wait-time-savings of a CADt by calculating the average waiting time per patient image without and with a CADt device being deployed. We study two workflow models with one or multiple radiologists (servers) for a range of AI diagnostic performances, radiologist’s reading rates, and patient image (customer) arrival rates. To evaluate the time-saving performance of a CADt, we use the difference in the mean waiting time between the diseased patient images in the with-CADt scenario and that in the without-CADt scenario as our performance metric. As part of this effort, we have developed and also share a software tool to simulate the radiology workflow around medical image interpretation, to verify theoretical results, and to provide confidence intervals for the performance metric we defined. We show quantitatively that a CADt triage device is more effective in a busy, short-staffed reading setting, which is consistent with our clinical intuition and simulation results. Although this work is motivated by the need for evaluating CADt devices, the evaluation methodology presented in this paper can be applied to assess the time-saving performance of other types of algorithms that prioritize a subset of customers based on binary outputs.

Thompson, Yee Lam Elim (ORCID:0000000196537707)↗
DOE OSTI2023

Comparative Analysis of Imaging and Measurements of Micrometer-Scale Fracture Aperture Fields Within a Heterogeneous Rock Using PET and X-ray CT

Knowledge of the spatial distribution of fracture apertures is essential for reliable characterization of flow and transport processes in fractured systems and for better understanding of physicochemical matrix–fracture interactions. Here, we propose and test two image-based methods, thereby extending the current experimental capabilities to characterize aperture size distribution in structurally heterogeneous geologic porous media noninvasively. The first approach utilizes an inversion method based on the dataset acquired from positron emission tomography (PET) and the second approach considers an extension of the classic missing attenuation technique that relies on clinical X-ray computed tomography (X-ray CT). Independent sets of imaging experiments are conducted on a fractured basalt core with heterogeneous matrix properties and aperture distributions to compare the two methodologies. A repeat of each experiment is conducted to verify the proposed workflows. The performance of these two imaging techniques is systematically evaluated through the analysis of signal-to-noise ratio, minimum fracture size detectability, and measurement errors. While both approaches provide a reliable estimation of fracture aperture distributions, PET yields a signal-to-noise ratio that is substantially higher than the corresponding X-ray CT measurements. Furthermore, uncertainties of the aperture values for PET are considerably lower ($\bar {\sigma}_{\text {d}} = 15\%$) compared to those obtained from X-ray CT ($\bar {\sigma}_{\text {d}} = 29\%$), allowing for the detection of minimum aperture sizes of 20 $\mu$m with 70% confidence level. Finally, these approaches provide key experimental tools for better understanding dynamic hydromechanical fracture properties in geologic systems.

58 GEOSCIENCES↗
DOE OSTI2020

CALPHAD Uncertainty Quantification and TDBX

CALPHAD uncertainty quantification (UQ) is the foundation of materials design with quantified confidence. We report a framework and software packages to enable CALPHAD UQ assessment and calculation using commercial CALPHAD software (Thermo-Calc). This Bayesian inference framework is coupled with a Markov chain Monte Carlo algorithm to establish uncertainty traces with a given thermodynamic database file (TDB) and corresponding experimental data points. This general framework is demonstrated with the Ni–Cr binary system. The algorithm is firstly validated on synthetic data with known ground truth. Then it is applied to real experimental data to generate posterior traces. We develop a file format named TDBX, which provides a single source of truth by combining the original TDB content and the traces for each assessed Gibbs energy parameter. CALPHAD UQ calculations are performed based on the TDBX file, from which uncertainties for phase boundaries, enthalpy curves, and solidification range are collected as examples of basic design parameters. This TDBX file with corresponding scripts are made open-source. Finally, the combination of CALPHAD UQ assessments and calculations connected by TDBX supports uncertainty-assisted modeling, enabling the integrated application of modern design with uncertainty methodologies to computational materials design.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Scientific Foundations and Approaches for Qualification of Additively Manufactured Structural Components

Additive manufacturing (AM) maintains a wide process window that enables complex designs otherwise unattainable via conventional production technologies. However, the lack of confidence in qualifying AM parts that leverage AM process–structure–property–performance (PSPP) relationships stymies design optimization and adoption of AM. While continuing efforts to map fundamental PSPP relationships that cover the potential design space, we first need pragmatic and then long-term solutions that overcome challenges associated with qualifying AM-designed parts. Two pragmatic solutions include: (1) AM material specifications to substantiate process reproducibility, and (2) component risk categorization to associate system risk relative to part performance and required part quality. A novel qualification paradigm under development involves efficient prediction of part performance over wide-ranging PSPP relationships through targeted testing and computational simulation. Here this paper describes projects at Sandia National Laboratories on PSPP relationship discovery, these pragmatic approaches, and the novel qualification approach.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Creep Deformation and Damage Mechanisms in an Advanced High-Temperature Additively Manufactured Nickel-Base Superalloy

Abstract This research investigates the processing–structure–properties–performance relationship in a novel nickel-base superalloy, ABD ® -900AM, designed for extreme environments. Specifically tailored for additive manufacturing (AM), ABD ® -900AM maintains mechanical integrity at high temperatures and is comparable to other nickel-based superalloys with a 30–40% gamma-prime volume fraction. A comprehensive study was conducted using laser-beam powder bed fusion and electron-beam powder bed fusion methods. Factors such as heat treatment, porosity, build orientation, and hot isostatic pressing were evaluated to understand their effects on microstructure and mechanical performance. Microstructural characterization revealed significant differences in grain size and orientation across build processes and heat treatments. High-temperature mechanical testing indicated that grain size, heat treatment, and orientation significantly influence creep behavior. A super-solvus heat treatment led to recrystallization and grain growth, significantly improving creep properties compared to a near-solvus heat treatment. Various creep mechanisms were identified across different conditions, and creep rupture models were developed for each build process. Post-test microstructural analysis showed grain boundary damage, with differences in creep cavitation morphology under varying stress conditions. It was shown that MC carbides grow at the expense of gamma-prime near grain boundaries, leading to precipitate-free zones in specimens tested at higher temperatures. This study fills a significant gap in fundamental research by offering a deeper insight into the high-temperature mechanical behavior of additively manufactured nickel-base superalloys. It also explores critical research questions regarding the role of carbides and the significance of heat treatment. The insights gained enhance confidence in the industry adoption of ABD ® -900AM and similar alloys for high-temperature applications, bridging the knowledge gap and supporting the development of reliable AM processes for extreme environments.

Bridges, Alex (ORCID:000000030338759X)↗
DOE OSTI2021

Total Blood Mercury Predicts Methylmercury Exposure in Fish and Shellfish Consumers

Abstract Many studies evaluating methylmercury (MeHg) toxicity rely on whole blood total mercury (THg) measurements to estimate MeHg exposure. However, whole blood THg includes other forms of mercury (Hg), such as inorganic Hg, which have different exposure sources and toxicological effects than MeHg. Therefore, estimating the whole blood MeHg/THg ratio is critical to predicting MeHg exposure and, subsequently, efforts to establish an exposure–response relationship for use in risk assessment. A large, representative dataset (National Health and Nutrition Examination Survey (NHANES) 2011–2016) was used to determine the whole blood MeHg/THg ratio among (a) self-reported fish and shellfish consumers, ≥ 15 years of age (the “full adult” population ( N = 5268 training dataset; N = 2336 test dataset)) and (b) female fish and shellfish consumers, 15–44 years of age (the “women of reproductive age” population ( N = 1285 training dataset; N = 560 test dataset)). Unadjusted and adjusted linear and spline models with direct measurements for both THg and MeHg were evaluated. The mean whole blood MeHg/THg ratio was 0.75 (95% confidence interval (CI): 0.74, 0.75). This ratio was significantly higher among those with higher THg concentrations. All models exhibited excellent fit (adjusted R 2 from 0.957 to 0.982). Performance was slightly improved in spline versus linear models. For the full adult population and women of reproductive age, the unadjusted spline model predicted whole blood MeHg concentrations of 5.65 µg/L and 5.55 µg/L, respectively, when the THg concentration was 5.80 µg/L. These results suggest that whole blood THg is a good predictor of whole blood MeHg among fish and shellfish consumers.

Wells, Ellen M.↗
DOE OSTI2020

Simulation and Emulation of X-Ray Diffraction from Dynamic Compression Experiments

Many important aspects of the dynamic thermo-mechanical response of materials occur at the mesoscale, i.e. a physical scale of interactions smaller than what can be adequately described by homogenous behaviors, yet larger than the scale of the atomic lattice. Concurrent advancements in computational power, continuum theory, and experimental diagnostics are enabling unprecedented understanding of such interactions. However, we cannot develop a sufficient level of confidence in such mesoscale capability until the constitutive description of the underlying constituents is reliably representative of their actual physical behavior. Therefore, there is a strong need to combine experimental, modeling, and data-science techniques to validate models of the thermomechanical response of individual single crystals. One experimental diagnostic with high potential impact to shock physics and materials science is in-situ x-ray diffraction. This paper is primarily focused on simulation of x-ray diffraction in shock physics, but with an aim toward quantifying parametric uncertainty of simulation models. Here, we develop and demonstrate a data-science and model-driven approach to constrain the parameterization of continuum models of crystal lattice deformation associated with the shock response of crystalline materials. The framework is built around the connection between continuum hydrodynamic simulations of lattice deformation and a new Bragg diffraction simulation code, BarberShop. The dynamic deformation of a crystal lattice is modeled using the DiscoFlux model within an arbitrary Lagrangian-Eulerian hydrodynamic code, FLAG. These detailed continuum simulations of lattice deformation can be computationally slow, thus a statistical model is used to emulate the evolution of lattice deformation fields in time and across the considered model parameter space. Emulated lattice deformation fields can then be generated rapidly for any combination of physics model parameters. In turn, these fields can be fed into BarberShop to realize a rapid prediction of Bragg diffraction patterns associated with particular values of physics model parameters. The framework enables parameterization of the single crystal model to obtain Bragg diffraction patterns that most closely resemble a corresponding measurement. Furthermore, the framework naturally provides sensitivities of the lattice deformation to the physics parameters. We highlight the utility of this framework through the application to a synthetic closed-loop inverse problem leading to the parameterization of a single crystal material model. As a model problem, we consider the dynamic response of the energetic molecular crystal, cyclotrimethylenetrinitramine (or RDX), under dynamic compression induced by simulated flyer plate impact experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Injury severity analysis of truck-involved crashes under different weather conditions

This paper investigates truck-involved crashes to determine the statistically significant factors that contribute to injury severity under different weather conditions. The analysis uses crash data from the state of Ohio between 2011 and 2015 available from the Highway Safety Information System. To determine if weather conditions should be considered separately for truck safety analyses, parameter transferability tests are conducted; the results suggest that weather conditions should be modeled separately with a high level of statistical confidence. To this end, three separate mixed logit models are estimated for three different weather conditions: normal, rain and snow. The estimated models identify a variety of statistically significant factors influencing the injury severity. Different weather conditions are found to have different contributing effects on injury severity in truck-involved crashes. Rural, rear-end and sideswipe crash parameters were found to have significantly different levels of impact on injury severity. Based on the findings of this study, several countermeasures are suggested: 1) safety and enforcement programs should focus on female truck drivers, 2) a variable speed limit sign should be used to lower speeds of trucks during rainy condition, and 3) trucks should be restricted or prohibited on non-interstates during rainy and snowy conditions. These countermeasures could reduce the number and severity of truck-involved crashes under different weather conditions.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

A comprehensive diffusion mobility database comprising 23 elements for magnesium alloys

We report that reliable experimental diffusion coefficients of 10 key alloying elements in Mg obtained by the present authors together with experimental data in the literature enabled us to perform a systematic test of the reliability of diffusion coefficients obtained from DFT calculations. The computed activation energy values were found to be quite accurate (mostly within 0.2 eV) but the computed pre-factors were less reliable. Such insights allowed us to develop a practical and yet robust strategy to perform diffusion mobility assessments by adopting the computed activation energy while fitting only the pre-factor when available experimental data are limited to a narrow temperature range. The overall good agreement between the DFT data and experimental data also gave us the confidence to employ the computed data for those that were still missing or inaccessible from experimental measurements. A systematic assessment of both the measured and computed diffusion data in hcp Mg was performed using the above holistic approach to yield the most comprehensive open Mg mobility database to date, comprising 23 elements (Mg, Ag, Al, Be, Ca, Cd, Ce, Cu, Fe, Ga, Gd, In, La, Li, Mn, Nd, Ni, Pu, Sb, Sn, U, Y, Zn). This more reliable mobility database will contribute to future development of advanced Mg alloys. The holistic approach developed in this study will be very beneficial to the future establishment of reliable mobility databases for other alloy systems as well.

36 MATERIALS SCIENCE↗
DOE OSTI2026

From bulk to surface: Structure and dynamics of amorphous alumina from deep potential molecular dynamics

Understanding the atomic-scale structure and dynamics of amorphous oxide surfaces is essential for interpreting their chemical reactivity, mechanical stability, and interfacial behavior, yet direct experimental characterization remains challenging. We employ Deep Potential (DP) molecular dynamics to generate large-scale, ab initio -quality models of amorphous Al 2 O 3 bulk glasses and melt-quenched free surfaces, enabling a quantitative analysis of both structure and relaxation dynamics with statistical confidence inaccessible to direct ab initio simulation. The trained DP model reproduces experimental liquid and glass structure, captures the cooling-rate dependence of the bulk glass transition, and corrects systematic biases in the polyhedral populations predicted by widely used classical force fields. At the free surface, mass density recovers to bulk values over ~10 Å, while local coordination requires a slightly wider subsurface region to fully converge. The outermost layer is oxygen-enriched, exhibits altered polyhedral connectivity with contracted Al–O bonds, and hosts a broad population of under-coordinated motifs (notably AlO 3 and OAl 2 ) whose abundances are governed by glass stability. These under-coordinated surface motifs exhibit distinct vibrational signatures and occur as locally paired Lewis acid and Brønsted base sites consistent with bond-valence compensation, yet remain spatially dispersed rather than aggregating into extended clusters. Despite this pronounced structural heterogeneity, surface relaxation and the glass-transition temperature remain comparable to their bulk counterparts, suggesting that the disordered surface is kinetically stable once formed. Together, these results establish a molecular-level picture of amorphous alumina surfaces and demonstrate the capability of machine-learned potentials to resolve structure–property relationships in disordered oxide interfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Effects of spatial energy distribution-induced porosity on mechanical properties of laser powder bed fusion 316L stainless steel

Laser powder bed fusion (LPBF) additive manufacturing (AM) offers a variety of advantages over traditional manufacturing, however its usefulness for manufacturing of high-performance components is currently hampered by internal defects (porosity) created during the LPBF process that have an unknown impact on global mechanical performance. By inducing porosity distributions through variations in print energy density and inspecting the resulting tensile samples using computed tomography, nearly 50,000 pores across 75 samples were identified. Porosity characteristics were quantitatively extracted from inspection data and compared with mechanical properties to understand the strength of relationships between porosity and global tensile performance. Useful porosity characteristics were identified for prediction of part performance. Results indicate that ductility and strain at ultimate tensile strength are the global tensile properties most significantly impacted by porosity and can be predicted with reasonable accuracy using simple porosity shape descriptors such as volume, diameter, and surface area. Moreover, it was found that the largest pores influenced behavior most significantly. Specifically, pores in excess of 125 µm in diameter were found to be a sufficient threshold for property estimation. These results establish an initial understanding of the complex defect-performance relationship in AM 316L stainless steel and can be leveraged to develop certification standards and improve confidence in part quality and reliability for the broader set of engineering alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Nanoparticle-enhanced absorptivity of copper during laser powder bed fusion

We report laser powder bed fusion (LPBF) of pure copper for thermal and electrical applications is hampered by its low near-infrared absorptivity and high thermal diffusivity. These material properties make it very difficult to localize the thermal energy needed to produce high density 3D printed parts. Modification of metal powders via nanoparticle additives is a promising approach to increasing absorptivity, but the effect of nanoparticles on absorptivity and melting behavior during LPBF is not well understood. In this study, we developed an in situ calorimetry system to measure effective absorptivity during LPBF on copper substrates. We decorated copper substrates using three nanoparticle systems (CuS, TiB 2 , multilayer graphene flakes) and demonstrated an enhanced absorptivity of the decorated substrates relative to pure copper. Graphene nanoflakes resulted in the highest improved absorption relative to pure copper from 0.09 to 0.48, due to their stability at high laser scanning powers. A thermomechanical model with convective heat transfer provided confidence in the measurements by reproducing the experimental melt pool traces. Full 3D cylindrical prints demonstrated an improvement in relative density of the copper-graphene powder prints (in the range of 0.930–0.992), relative to that of as-purchased copper powder prints (in the range of 0.854–0.972). This work provides a fundamental study of nanoparticle-enabled LPBF of highly reflective metals and demonstrates a viable route for expanding the library of reliably printable metals.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Scalable in situ non-destructive evaluation of additively manufactured components using process monitoring, sensor fusion, and machine learning

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. However, the current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques, which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. In this work, an in situ NDE (INDE) system was engineered to detect subsurface flaws detected in X-Ray Computed Tomography (XCT) directly from process monitoring data. A multilayer, multimodal data input allowed the INDE system to detect numerous subsurface flaws in the size range of 200–1000µm using a novel human-in-the-loop annotation procedure. Furthermore, a framework was established for generating probability-of-detection (POD) and probability-of-false-alarm (PFA) curves compliant with NDE standards by systematically comparing instances of detected subsurface flaws to post-build XCT data. Here, we also introduce for the first time in the AM in situ sensing literature the a 90/95 – the flaw size corresponding to a 90% detection rate on the lower 95% confidence interval of the POD curve. The INDE system successfully demonstrated POD capabilities commensurate with traditional NDE methods. Traditional ML performance metrics were also shown to be inadequate for assessing the ability of the INDE system’s flaw detection performance. It is the hope of the authors that future studies will adopt the POD and PFA approach outlined here to provide better insight into the utility of process monitoring for AM.

36 MATERIALS SCIENCE↗