In-Situ Femtosecond Micromachining in Laser Powder Bed Fusion Processes
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Reyes, Gonzalo↗
SEARCH · Engineering Papers
Results for “In Situ Processing”
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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Integration of space and in-situ observations to study atmosphere, ocean and land processes
A research investigation was conducted into the possibility of using atmospheric observations made in the past from both terrestrial and space-based platforms to create a global, coherent four dimensional analysis for the purpose of studying atmospheric, oceanic, and land surface processes relevant to climate simulation, monitoring, and change. This investigation consisted of the following tasks: (1) a mature global data assimilation system was obtained from the National Meteorological Center and modified for use on a Cray X-MP computer system; (2) atmospheric observations for the period 20 Nov. 1982 through 1 Mar. 1983, including rawinsonde soundings, aircraft-based measurements, pilot balloons, and temperature soundings from polar orbiting satellites were obtained from several sources; and (3) the global data assimilation system was used to reassimilate the atmospheric observations to produce a new atmospheric analysis which was then compared with the contemporaneous analysis. The global hydrologic cycle, including fluxes between the atmosphere and both the land and ocean surfaces, was estimated. The flux of water from the ocean surface into the atmosphere, its transport in the form of latent heat to remote regions, and its return to the surface in the form of precipitation were estimated globally. In addition, several regional budgets for selected tropical oceanic and extratropical continental areas were also done.
Shukla, J.↗
Development of Low-Noise High Value Chromium Silicide Resistors for Cryogenic Detector Applications
Extremely high sensitivity detectors, such as silicon bolometers are required in many NASA missions for detection of photons from the x-ray to the far infrared regions. Typically, these detectors are cooled to well below the liquid helium (LHe) temperature (4.2 K) to achieve the maximum detection performance. As photoconductors, they are generally operated with a load resistor and a pre-set bias voltage, which is then coupled to the input gate of a source-follower Field Effect Transistor (FET) circuit. It is imperative that the detector system signal to noise performance be limited by the noise of the detector and not by the noise of the external components. The load resistor value is selected to optimize the detector performance. These two criteria tend to be contradictory in that these detectors require load resistors in the hundreds of megaohms, which leads to a higher Johnson noise. Additionally, the physical size of the resistor must be small for device integration as required by such missions as the NASA High Resolution Airborne Wide-Band Camera (HAWC) instrument and the Submillimeter High Angular Resolution Camera (SHARC) for the Caltech Submillimeter Observatory (CSO). We have designed, fabricated and characterized thin film resistors using a CrSi/TiW/Al metal system on optical quality quartz substrates. The resistor values range from 100 megaohms to over 650 megaohms and are Johnson noise limited at LHe temperatures. The resistor film is sputtered with a sheet resistance ranging from 300 ohms to 1600 ohms and the processing sequence developed for these devices allows for chemically fine tuning the sheet resistance in-situ. The wafer fabrication process was of sufficiently high yield (>80%) providing clusters of good resistors for integrated multiple detector channels, a very important feature in the assembly of these two instruments.
Jhabvala, Murzy↗
Real-Time In Situ Monitoring with Molecular Resolution of the Elementary Processes of Crystallization of Apoferritin
No abstract available
Vekilov, Peter G.↗
In-Situ TEM Observations of the Charging and Discharging Processes of Li-Ion Cells .
Abstract Not Provided
Huang, Jian Yu↗
Phase I Final Technical Report Topic 26 Technologies for characterizing and monitoring complex subsurface systems including the rhizosphere subtopic A: Real-Time, In-situ Measurements of Hydro-biogeochemical and Microbial Processes in Watersheds and Subsurface Systems
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Monitoring, electrical resistivity, hyporheic zone↗
Establishing an acoustic-property relationship in laser powder bed fusion with machine learning
Quality control of Laser Powder Bed Fusion (PBF-LB) additively manufactured parts is an important hurdle inhibiting the technology’s use structural applications. Acoustic monitoring of the laser powder bed fusion process can detect defects in-situ that are known to degrade mechanical properties. However, processing-structure-property (PSP) relationships are required to extrapolate from detected defects to part performance. Here, this study explores how acoustics may be a suitable signature linking processing conditions to properties, thus effectively substituting for structure in the PSP relationship. Establishing such a relationship would enable a part’s mechanical performance to be directly predicted from its acoustic signature, reducing the need for destructive testing or microstructural analysis to ensure a part will meet performance requirements. One hundred CoCrFeMnNi high entropy alloy tensile bars were printed across 13 process conditions in a series of 6 prints. The acoustic signatures of these tensile bars were used to train machine learning models to predict each part’s mechanical properties. By using both process information and acoustic information to predict mechanical properties, yield strength was predicted 18% more accurately and ductility to failure was predicted 10% more accurately than is achieved when using duplicate parts to predict part performance. Finally, individual acoustic frequencies were investigated to determine why acoustic signatures improve mechanical property predictions and the potential physical origins of these signatures. This work demonstrates how blending acoustics, process information, and machine learning can provide in-situ diagnostics of mechanical properties and improve the reliability of the PBF-LB process.
Acoustic emission↗
Monitoring and flaw detection during wire-based directed energy deposition using in-situ acoustic sensing and wavelet graph signal analysis
The goal of this work is to detect flaw formation in the wire-based directed energy deposition (W-DED) process using in-situ sensor data. The W-DED studied in this work is analogous to metal inert gas electric arc welding. The adoption of W-DED in industry is limited because the process is susceptible to stochastic and environmental disturbances that cause instabilities in the electric arc, eventually leading to flaw formation, such as porosity and suboptimal geometric integrity. Moreover, due to the large size of W-DED parts, it is difficult to detect flaws post-process using non-destructive techniques, such as X-ray computed tomography. Accordingly, the objective of this work is to detect flaw formation in W-DED parts using data acquired from an acoustic (sound) sensor installed near the electric arc. To realize this objective, we develop and apply a novel wavelet integrated graph theory approach. The approach extracts a single feature called graph Laplacian Fiedler number from the noise-contaminated acoustic sensor data, which is subsequently tracked in a statistical control chart. Using this approach, the onset of various types of flaws are detected with a false alarm rate less-than 2%. This work demonstrates the potential of using advanced data analytics for in-situ monitoring of W-DED.
42 ENGINEERING↗
Development of a co-anneal process for double-side TOPCon precursor fabricated by ex-situ POCI3 and APCVD boron diffusion
The aim of this study was to develop a simple and industrially attractive co-anneal process to fabricate a high-quality DS-TOPCon precursor with textured n-TOPCon on front and planar p- TOPCon on rear by ex-situ POCI3 and APCVD boron diffusion. This requires only one high temperature anneal with no additional masking steps. Excellent iVOC of 733mV and iFF of ~86% were achieved after SiNX passivation on both sides, prior to contact firing. Our device modeling projects that this precursor in combination with a manufacturing-friendly poly-Si patterning technique on front can enable> 25% DS-TOPCon cells at low-cost.
APCVD↗
Feasibility of in situ controlled heat treatment (ISHT) of Inconel 718 during electron beam melting additive manufacturing
A novel technique was developed to control the microstructure evolution in Alloy 718 processed using Electron Beam Melting (EBM). In situ solution treatment and aging of Alloy 718 was performed by heating the top surface of the build after build completion scanning an electron beam to act as a planar heat source during the cool down process. Results demonstrate that the measured hardness (478 ± 7 HV) of the material processed using in situ heat treatment similar to that of peak-aged Inconel 718. Large solidification grains and cracks formed, which are identified as the likely mechanism leading to failure of tensile tests of the in situ heat treatment material under loading. Despite poor tensile performance, the technique proposed was shown to successively age Alloy 718 (increase precipitate size and hardness) without removing the sample from the process chamber, which can reduce the number of process steps in producing a part. Lastly, tighter controls on processing temperature during layer melting to lower process temperature and selective heating during in situ heat treatment to reduce over-sintering are proposed as methods for improving the process.
36 MATERIALS SCIENCE↗
Model form and sensitivity analysis of CALPHAD-based nucleation models in b-stabilized Ti alloys
Accurate prediction of α-phase nucleation and growth in β-stabilized titanium alloys is crucial for designing heat treatments to optimize mechanical properties in additively manufactured lightweight components. Ideally, predictions of nucleation and growth would incorporate both top-down observations of past experimental heat treatments and bottom-up modeling of phase transformations; however, the appropriate method of combining these information sources is not self-evident. Combining top-down and bottom-up information requires a unified form of model that can connect between spatiotemporal scales, as well as sets of fitting parameters that can be identified by each data source. The selection of which parameters to fit to which data source can be made based on expert opinion, or by performing a sensitivity analysis. In solid-solid nucleation, direct observation of the nucleation and growth process is challenging. Most data on the heat treatment-controlled phase transformations are not in-situ. To predict the process and outcome of the nucleation, growth and coarsening of precipitates, theoretical models of the nucleation pathway are used to bridge the gap. Many sources of uncertainty affect the modeling of this nucleation process. It can be influenced by small variations in the thermomechanical processing history, chemical composition, and initial microstructure. If molecular dynamics (MD) simulations are used to determine thermodynamic quantities and inform CALPHAD modeling, additional uncertainty can be introduced and accounted for using Bayesian methods. Top-down uncertainties require additional steps to quantify. The influence of nucleation model form on the sensitivity of predictions to input parameters and physical conditions is the focus of this study. Classical nucleation theory (CNT) allows modeling to formulate the nucleation as homogeneous or, more commonly, heterogeneous. Non-classical nucleation models are also increasingly explored as a means of reconciling top-down and bottom-up data. In this study, the sensitivity of the intragranular nucleation of α in a β-annealed, slow-cooled aging (BASCA) heat treatment of β-stabilized Ti5553 alloy is explored using CNT and both heterogeneous and homogeneous assumptions. The Kampmann-Wagner Numerical model of precipitate nucleation and growth is employed. Using open-source tools (pyCalphad and thermodynamic modeling of TiMo as a surrogate system, a sensitivity analysis is performed to measure variations in key parameters, including chemical driving force, interfacial energy, and diffusivity, as they relate to predictions of precipitate number density. The inclusion of top-down and bottom-up data in selection of nucleation model form is discussed.
Rodriguez Negron, A. M.↗
Marangoni effect and its potential utilization in supporting lunar habitats and other extraterrestrial endeavors
Tears of wine is a phenomenon frequently observed as a ring of wine formed near the top of the glass generates droplets that fall back into the wine. This phenomenon can be explained by the Marangoni effect driven by the surface tension created via gradient on concentration and temperature along with the interface between two phases. Besides being observed while drinking wine, the Marangoni effect is crucial for welding metals, manufacturing integrated circuits, and growing crystals; the Marangoni effect might be also crucial in supporting lunar habitats and other extraterrestrial endeavors as vacuum and reduced gravity are expected to augment the Marangoni effect on extraterrestrial molten soil leading to sustainable extraterrestrial in-situ resources utilization (ISRU). Preliminary Marangoni effect assessment on molten lunar regolith was conducted via JSC-1A lunar regolith simulant under vacuum yielding a spontaneous upwards migration of a uniform molten thin-film front that climbed the crucible wall covering the entire wall’s surface and reaching the crucible’s top end. A temperature gradient within the melt’s bulk and along the crucible’s wall generates a surface tension large enough not only to form a meniscus within the three-phase junction (crucible’s wall, bulk melt, and vacuum) but also to supersede the gravitational force to create the upwards migration of a thin film front originated on the meniscus. The observed extensive wettability of the melt with the crucible surface, an additional key factor besides surface tension necessary to sustain upwards migration, is atypical to what it has been witnessed on molten JSC-1A lunar regolith simulant under non-vacuum conditions and smaller sample sizes. The unique formation and self-migration of a thin-film front could enable key ISRU processes such as thin-film coating, crystal growth, and feedstock generation for additive 3D printing. Further assessment on the higher-temperature vacuum-driven decomposition of the uniform thin-film front as it climbed the crucible’s wall revealed a significant decomposition of various simulant’s metal-oxide components into their respective oxygen and metal elements strengthening the feasibility of extraterrestrial generation and fractional separation of oxygen and metals/alloys with none or minimal need for terrestrial precursors. The Marangoni effect assessment on molten JSC-1A lunar regolith simulant clearly opens novel pathways in future extraterrestrial ISRU endeavors including manufacturing and mining. Extraterrestrial mining will require an operational approach completely different from the terrestrial one that heavily relies on not only mechanical excavation and transportation but also post-processing; an in-situ all-in-one process might be feasible via these two coupled phenomena, self-migration and decomposition.
J A Dominguez↗
Visualizing time-dependent microstructural and chemical evolution during molten salt corrosion of Ni-20Cr model alloy using correlative quasi in situ TEM and in situ synchrotron X-ray nano-tomography
In situ monitoring of corrosion processes is important to fundamentally understand the kinetics and evolution of materials in harsh environments. A quasi in situ transmission electron microscopy technique was utilized to study microstructural and chemical evolution of a Ni-20Cr disc sample 6 exposed to molten KCl-MgCl 2 salt for 60 s in consecutive 20 s iterations. In situ synchrotron X-ray nano-tomography was performed to characterize the morphological evolution of a Ni-20Cr microwire exposed to molten KCl-MgCl 2 . Here, both techniques captured key corrosion events and revealed mechanisms at different time and length scales, potentially bringing greater insights and 10 deeper understanding beyond conventional analysis.
36 MATERIALS SCIENCE↗
In-situ Inspection of Reflowable-Interface Composite Joints During Cure in an Autoclave
In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bonded performance. Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy-matrix resins to enable reflow and diffusion of the resin at the joint interface during a secondary bonding and cure process. The reflow and intermixing of the matrix resin during assembly can eliminate the material discontinuity at the interface, thereby removing the dependence of bond performance on adhesion at a nearly two-dimensional boundary. AERoBOND process development has evaluated a multitude of parameters including the materials used, the stoichiometric offset of the epoxy resins, time and temperature of cure, and thickness of each ply. Without in-situ process monitoring, the condition of a test article is unknown until mechanical testing is completed. This presentation describes the use of an in-situ ultrasonic inspection system to monitor the joining of two composite parts assembled using the AERoBOND technique. This work quantifies the elimination of the interface by measuring the wave reflection, or lack thereof, at the joint throughout the cure cycle. In addition, the results indicate when reflow and cure of the epoxy resin at the joint occurred. By using the recently developed in-situ inspection with a mobile ultrasonic transducer, localized results can be obtained across a large portion of the joint with high resolution.
Tyler B Hudson↗
In-situ Inspection of Reflowable-Interface Composite Joints During Cure in an Autoclave
In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bonded performance. Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy-matrix resins to enable reflow and diffusion of the resin at the joint interface during a secondary bonding and cure process. The reflow and intermixing of the matrix resin during assembly can eliminate the material discontinuity at the interface, thereby removing the dependence of bond performance on adhesion at a nearly two-dimensional boundary. AERoBOND process development has evaluated a multitude of parameters including the materials used, the stoichiometric offset of the epoxy resins, time and temperature of cure, and thickness of each ply. Without in-situ process monitoring, the condition of a test article is unknown until mechanical testing is completed. This presentation describes the use of an in-situ ultrasonic inspection system to monitor the joining of two composite parts assembled using the AERoBOND technique. This work quantifies the elimination of the interface by measuring the wave reflection, or lack thereof, at the joint throughout the cure cycle. In addition, the results indicate when reflow and cure of the epoxy resin at the joint occurred. By using the recently developed in-situ inspection with a mobile ultrasonic transducer, localized results can be obtained across a large portion of the joint with high resolution.
Tyler B Hudson↗
Using Molecular Dynamics to quantify the electrical double layer and examine the potential for its direct observation in the in-situ TEM
Understanding the fundamental processes taking place at the electrode-electrolyte interface in batteries will play a key role in the development of next generation energy storage technologies. One of the most fundamental aspects of the electrode-electrolyte interface is the electrical double layer (EDL). Given the recent development of high spatial resolution in-situ electrochemical cells for scanning transmission electron microscopy (STEM), there now exists the possibility that we can directly observe the formation and dynamics of the EDL. In this paper we predict electrolyte structure within the EDL using classical models and atomistic Molecular Dynamics (MD) simulations. The MD simulations show that the classical models fail to accurately reproduce concentration profiles that exist within the electrolyte. It is thus suggested that MD must be used in order to accurately predict STEM images of the electrode-electrolyte interface. Using MD and image simulations together for a high contrast electrolyte (the high atomic number CsCl electrolyte), it is determined that, for a smooth interface, concentration profiles within the EDL should be visible experimentally. When normal experimental parameters such as rough interfaces and low-Z electrolytes (like those used in Li-ion batteries) are considered, observation of the EDL appears to be more difficult.
25 ENERGY STORAGE↗
In-situ Inspection of Reflowable-Interface Composite Joints During Cure in an Autoclave
In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded primary-structures to alleviate the inability to certify bonded performance. To address this issue, the NASA Convergent Aeronautics Solutions (CAS): Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy-matrix resins to enable reflow and diffusion of the resin at the joint interface during a secondary bonding and cure process. The reflow and intermixing of the matrix resin during assembly can eliminate the material discontinuity at the interface, thereby removing the dependence of bond performance on adhesion at a nearly two-dimensional boundary. AERoBOND process development has evaluated a multitude of parameters including the materials used, the stoichiometric offset of the epoxy resins, time and temperature of cure, and thickness of each ply. Without in-situ process monitoring, the condition of a test article is unknown until mechanical testing is completed. This paper describes the use of an in-situ ultrasonic inspection system to monitor the joining of two composite parts assembled using the AERoBOND technique. This work quantifies the interface by measuring the wave reflection, or lack thereof, at the joint throughout the cure cycle. In addition, the results indicate when reflow and cure of the epoxy resin at the joint occurred. By using the recently developed in-situ inspection method with a mobile ultrasonic transducer, localized results can be obtained across a large portion of the joint with high resolution.
Tyler B Hudson↗
In Situ Sample Environment for Studying Corrosion of Nuclear Materials
Currently there is lack of fundamental understanding of kinetics and reaction mechanisms that occur at nuclear cladding-steam interface under extreme environments in the nuclear reactors. Such understanding is vital to design and develop advanced cladding materials for more economical and safer nuclear power. We present advanced in situ sample environment for probing solid-fluid interfaces using high resolution synchrotron methods for studying early stages of corrosion including development of oxide layer as corrosion proceeds. Both X-ray diffraction and X-ray fluorescence methods will be discussed to probe structural and elemental composition changes under steam environment using corrosion resistant cell at high temperatures. High intensity and brightness of synchrotron coupled with advanced in situ sample environment developed, presents an opportunity to understand the fundamental interfacial processes involved in degradation of materials. The in situ sample environment is optimized for XRD and XRF data collection at NSLS-II and will be available to all users through the proposal process. The in situ sample environment is built to study the interfacial interactions at temperatures and pressures up to 400 deg. C and 1500 psi. It consists of three main parts; the distribution manifold, the pressure vessel, and the reaction cell as shown in Figure 1. Water is allowed to heat up to 350 deg. C inside the pressure vessel to produce steam which is delivered to reaction cell using insulated delivery system. The cell design is adapted from J. Diefenbacher, et. al. However, it is modified for corrosion applications in steam environments. The reaction cell and sample holder are made from hastelloy due to its high corrosion resistance. The reaction cell is surrounded by copper heating block to control its temperature independently from the rest of the system. Lab view based platform is developed for remote monitoring of pressure and temperature. The sample environment was commissioned at 6-IDD beamline in the Advanced Photon Source, for grazing incidence XRD corrosion studies. Metallic Zr sample (200 μm thickness) was used due to its faster oxidation kinetics as compared to Zircaloy. Sample was exposed to steam at 350 deg. C and 50 psi for a total time of 64 hours. Results showed the presence of α-Zr as the dominant phase. After 32 hours of exposure to steam, three oxide peaks in the low diffraction angle side started to develop with time. These peaks are attributed to the growth of substoichiometric zirconium oxide phases (Zr{sub 3}O and Zr{sub 3}O{sub 1-x}). (authors)
36 MATERIALS SCIENCE↗