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All sources NASA NTRS DOE OSTI

DOE OSTI2021

Melt Pool and Heat Treatment Optimization for the Fabrication of High-Strength and High-Toughness Additively Manufactured 4340 Steel

Additively manufactured (AM) components offer superior design flexibility compared to their conventionally manufactured counterparts, and optimizing processing parameters is key to achieving high-quality depositions with desirable and predictable mechanical properties. This study was focused on 4340 steel fabricated using laser powder bed fusion (LPBF), and 42 laser power and scan speed combinations have been systematically investigated to determine an optimized melt pool geometry that would ensure fully-dense parts. The AM material was compared with a wrought 4340 equivalent and studied in two customized heat treated conditions, optimized for strength and toughness, respectively. The microstructures of the as-fabricated and heat treated AM and wrought materials were characterized to assess differences introduced by the layer-by-layer fabrication process and subsequent heat treatment. Tensile properties of both materials were also evaluated and demonstrate that the AM materials offer equal or superior properties compared to the wrought equivalents. Differences in fracture surface morphologies indicate the distinct failure mechanisms associated with the materials’ characteristic microstructures, and the role of inclusions in the failures was studied to elucidate these differences. Complementary to the experimental investigations, the dataset was leveraged to make recommendations for future design of experiments to optimize AM build parameters in other material systems. A statistical Monte Carlo analysis was used to predict the interpolation error produced using reduced datasets and to enable informed processing parameters selection. These findings are discussed to make recommendations for the use of AM materials for high-integrity structural applications.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Automated detection of part quality during two-photon lithography via deep learning

Two-photon lithography (TPL) is an additive manufacturing technique for fabricating three-dimensional objects with nanoscale features. A main challenge of TPL is the routine and labor-intensive task of finding suitable light dosage parameters, i.e. writing speed and laser intensity that induce photo-polymerization within a wide variety of candidate photo-curing polymers. Another challenge is the monitoring required during fabrication. In this work, we apply machine learning (ML) models to accelerate the process of identifying optimal light dosage parameters and automate the detection of part quality. We curate TPL videos of different parts fabricated under a range of light dosage parameters using different resins and train spatial-temporal ML models on this data. Our results show that ML models can detect TPL part quality with a 95.1% accuracy in milliseconds. We also evaluate classification failures and identify two operating modes: parameter optimization and part quality detection. Last but not least, we publicly release this labelled dataset so that it may serve as a useful benchmark to the community. Our approach to process optimization and part quality detection addresses important aspects of TPL industrialization, is applicable beyond TPL and should benefit other additive manufacturing techniques with similar barriers to operating at industrial scale.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Parameter estimation techniques based on optimizing goodness-of-fit statistics for structural reliability

New methods are presented that utilize the optimization of goodness-of-fit statistics in order to estimate Weibull parameters from failure data. It is assumed that the underlying population is characterized by a three-parameter Weibull distribution. Goodness-of-fit tests are based on the empirical distribution function (EDF). The EDF is a step function, calculated using failure data, and represents an approximation of the cumulative distribution function for the underlying population. Statistics (such as the Kolmogorov-Smirnov statistic and the Anderson-Darling statistic) measure the discrepancy between the EDF and the cumulative distribution function (CDF). These statistics are minimized with respect to the three Weibull parameters. Due to nonlinearities encountered in the minimization process, Powell's numerical optimization procedure is applied to obtain the optimum value of the EDF. Numerical examples show the applicability of these new estimation methods. The results are compared to the estimates obtained with Cooper's nonlinear regression algorithm.

Starlinger, Alois↗

DOE OSTI2021

Quantum Alternating Operator Ansatz (QAOA) Phase Diagrams and Applications for Quantum Chemistry

Determining Hamiltonian ground states and energies is a challenging task with many possible approaches on quantum computers. While variational quantum eigensolvers are popular approaches for near term hardware, adiabatic state preparation is an alternative that does not require noisy optimization of parameters. Beyond adiabatic schedules, QAOA is an important method for optimization problems. In this work we modify QAOA to apply to finding ground states of molecules and empirically evaluate the modified algorithm on several molecules. This modification applies physical insights used in classical approximations to construct suitable QAOA operators and initial state. We find robust qualitative behavior for QAOA as a function of the number of steps and size of the parameters, and demonstrate this behavior also occurs in standard QAOA applied to combinatorial search. To this end we introduce QAOA phase diagrams that capture its performance and properties in various limits. In particular we show a region in which non-adiabatic schedules perform better than the adiabatic limit while employing lower quantum circuit depth. We further provide evidence our results and insights also apply to QAOA applications beyond chemistry.

Kremenetski, Vladimir↗

NASA NTRS1984

NIMBUS-7 CZCS. Coastal Zone Color Scanner Imagery for Selected Coastal Regions. North America - Europe. South America - Africa - Antarctica. Level 2 Photographic Product

The Nimbus-7 Coastal Zone Color Scanner (CZCS) is the first spacecraft instrument devoted to the measurement of ocean color. Although instruments on other satellites have sensed ocean color, their spectral bands, spatial resolution, and dynamic range were optimized for geographical or meteorological use. In the CZCS, every parameter is optimized for use over water to the exclusion of any other type of sensing. The signal-to-noise ratios in the spectral channels sensing reflected solar radiance are higher than those required in the past. These ratios need to be high because the ocean is such a poor reflecting surface that the majority of the signal seen by the reflected energy channels at spacecraft altitudes is backscattered solar radiation from the atmosphere rather than reflected solar energy from the ocean. The CZCS is a conventional multichannel scanning radiometer utilizing a rotating plane mirror at a 45 deg angle to the optic axis of a Cassegrain telescope. The mirror scans 360 deg; however, only 80 deg of data centered on the spacecraft nadir is collected for ocean color measurements. Spatial resolution at spacecraft nadir is 825x825 m with some degradation at the edges of the scan swath. The useful swath width from a spacecraft altitude of 955 km is 1600 km.

Source record↗

NASA NTRS1993

Development of methodologies for the estimation of thermal properties associated with aerospace vehicles

Thermal stress analyses are an important aspect in the development of aerospace vehicles such as the National Aero-Space Plane (NASP) and the High-Speed Civil Transport (HSCT) at NASA-LaRC. These analyses require knowledge of the temperature within the structures which consequently necessitates the need for thermal property data. The initial goal of this research effort was to develop a methodology for the estimation of thermal properties of aerospace structural materials at room temperature and to develop a procedure to optimize the estimation process. The estimation procedure was implemented utilizing a general purpose finite element code. In addition, an optimization procedure was developed and implemented to determine critical experimental parameters to optimize the estimation procedure. Finally, preliminary experiments were conducted at the Aircraft Structures Branch (ASB) laboratory.

Scott, Elaine P.↗

NASA NTRS1990

Factorization and the synthesis of optimal feedback gains for distributed parameter systems

An approach based on Volterra factorization leads to a new methodology for the analysis and synthesis of the optimal feedback gain in the finite-time linear quadratic control problem for distributed parameter systems. The approach circumvents the need for solving and analyzing Riccati equations and provides a more transparent connection between the system dynamics and the optimal gain. The general results are further extended and specialized for the case where the underlying state is characterized by autonomous differential-delay dynamics. Numerical examples are given to illustrate the second-order convergence rate that is derived for an approximation scheme for the optimal feedback gain in the differential-delay problem.

Milman, Mark H.↗

NASA NTRS1982

Use of optimization to predict the effect of selected parameters on commuter aircraft performance

An optimizing computer program determined the turboprop aircraft with lowest direct operating cost for various sets of cruise speed and field length constraints. External variables included wing area, wing aspect ratio and engine sea level static horsepower; tail sizes, climb speed and cruise altitude were varied within the function evaluation program. Direct operating cost was minimized for a 150 n.mi typical mission. Generally, DOC increased with increasing speed and decreasing field length but not by a large amount. Ride roughness, however, increased considerably as speed became higher and field length became shorter.

Wells, V. L.↗

NASA NTRS1994

Optimal experimental designs for the estimation of thermal properties of composite materials

Reliable estimation of thermal properties is extremely important in the utilization of new advanced materials, such as composite materials. The accuracy of these estimates can be increased if the experiments are designed carefully. The objectives of this study are to design optimal experiments to be used in the prediction of these thermal properties and to then utilize these designs in the development of an estimation procedure to determine the effective thermal properties (thermal conductivity and volumetric heat capacity). The experiments were optimized by choosing experimental parameters that maximize the temperature derivatives with respect to all of the unknown thermal properties. This procedure has the effect of minimizing the confidence intervals of the resulting thermal property estimates. Both one-dimensional and two-dimensional experimental designs were optimized. A heat flux boundary condition is required in both analyses for the simultaneous estimation of the thermal properties. For the one-dimensional experiment, the parameters optimized were the heating time of the applied heat flux, the temperature sensor location, and the experimental time. In addition to these parameters, the optimal location of the heat flux was also determined for the two-dimensional experiments. Utilizing the optimal one-dimensional experiment, the effective thermal conductivity perpendicular to the fibers and the effective volumetric heat capacity were then estimated for an IM7-Bismaleimide composite material. The estimation procedure used is based on the minimization of a least squares function which incorporates both calculated and measured temperatures and allows for the parameters to be estimated simultaneously.

Scott, Elaine P.↗

DOE OSTI2024

Spatially Resolved Raman Spectroscopic Investigation of Uranyl Fluoride: A Case Study in the Importance of Instrument Optimization

Raman spectroscopy is an emerging technique for rapid and nondestructive analysis of nuclear materials for forensic and nonproliferation applications as it is a powerful tool for distinguishing multiple chemical forms of materials with similar stoichiometries. Recent developments in spectroscopic software have enabled rapid data collection with high-speed Raman spectroscopic mapping capabilities. However, some uranium-rich materials are susceptible to degradation in humid air and/or laser-induced phase transformations. To mitigate environmental or measurement-related sample degradation of potential samples of interest, we have taken a systematic approach to define optimized data collection parameters for high-throughput measurements of uranyl fluoride (UO 2 F 2 ), which is an important intermediate material in the nuclear fuel cycle. First, we systematically describe the influence of optical magnification (5× to 100×), laser power, and exposure time on obtained signal for identical particles of UO 2 F 2 and find that at low laser power and exposure times, comparable signal is obtained regardless of optical magnification. Second, we ensure sample integrity during data collection, and third, collect spectroscopic maps that employ optimized parameters to reduce the time required to obtain spatially resolved spectroscopic information. Reductions of 90% and 99% in measurement times are discussed as they relate to differences in resolving spectroscopic features of particles in identical mapping areas. Finally, during this work, we found that additional data processing options were needed and thus developed a customized Python script for importing, processing, analyzing, and visualizing Raman spectroscopic map data.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1992

Multidisciplinary design optimization using response surface analysis

Aerospace conceptual vehicle design is a complex process which involves multidisciplinary studies of configuration and technology options considering many parameters at many values. NASA Langley's Vehicle Analysis Branch (VAB) has detailed computerized analysis capabilities in most of the key disciplines required by advanced vehicle design. Given a configuration, the capability exists to quickly determine its performance and lifecycle cost. The next step in vehicle design is to determine the best settings of design parameters that optimize the performance characteristics. Typical approach to design optimization is experience based, trial and error variation of many parameters one at a time where possible combinations usually number in the thousands. However, this approach can either lead to a very long and expensive design process or to a premature termination of the design process due to budget and/or schedule pressures. Furthermore, one variable at a time approach can not account for the interactions that occur among parts of systems and among disciplines. As a result, vehicle design may be far from optimal. Advanced multidisciplinary design optimization (MDO) methods are needed to direct the search in an efficient and intelligent manner in order to drastically reduce the number of candidate designs to be evaluated. The payoffs in terms of enhanced performance and reduced cost are significant. A literature review yields two such advanced MDO methods used in aerospace design optimization; Taguchi methods and response surface methods. Taguchi methods provide a systematic and efficient method for design optimization for performance and cost. However, response surface method (RSM) leads to a better, more accurate exploration of the parameter space and to estimated optimum conditions with a small expenditure on experimental data. These two methods are described.

Unal, Resit↗

DOE OSTI2020

Sensitivity and Uncertainty Quantification of Transition Scenario Simulations

This report documents the first collective attempt at developing and applying capabilities to quantify uncertainties, assess parametric sensitivities, and optimize multiple parameters and metrics in fuel cycle simulations generated by the SA&I Campaign. To do this, external codes that were designed to perform sensitivity analysis and uncertainty quantification (SA&UQ) needed to be coupled to the SA&I Campaign’s nuclear fuel cycle simulators (NFCS). In FY20, two approaches were pursued: 1) coupling Cyclus to an ORNL-internal code called MOT (Metaheuristic Optimization Tool) and 2) coupling DYMOND to the opensource SA&UQ tool kit Dakota. The primary objective of having these NFCS/SA&UQ coupled capabilities is to better inform DOE-NE and other stakeholders on the results generated from the NFCS. For a given set of fuel cycle strategies, policies, and technology assumptions that make up a fuel cycle scenario, these NFCS have traditionally been used by the SA&I Campaign to provide quantitative answers in terms of year-by-year mass flows, infrastructure requirements, costs, etc. With these newly developed coupled capabilities, the SA&I Campaign can now efficiently simulate hundreds or thousands of these scenarios, sample large ranges of parameters and assumptions, and use the unique features of the SA&UQ tools to process the data. This enables providing answers with known and propagated uncertainties, determining the sensitivity of important metrics to different parameters and assumptions, quantifying how much fuel cycle and technology parameters impact each other, and producing optimized fuel cycle strategies for single and multiple variables. To demonstrate these new capabilities, the Cyclus/MOT was used to model several scenarios ranging from simple fleet retirements to transitions to advanced reactors. Specifically, for a transition scenario from LWRs to SFRs and advanced LWRs, uncertainty quantification, sensitivity analysis, and optimization studies were applied to cases involving single and multiple parameter (input) and single and multiple metric (output) variations. In addition, a similar transition scenario was modeled to demonstrate how to optimize the reprocessing capacity parameter to minimize two performance metrics while taking into account uncertainties from two other parameters. Lastly, a depletion module based on SCALE/ORIGEN was added in Cyclus to simulate the third scenario that was designed to quantify the impact of the modeling assumption that all LWR used nuclear fuel have the same burnup. The newly developed DYMOND/Dakota capability was also applied to a transition scenario from the existing fleet to small modular reactors and fast reactors. This particular scenario involves not only explicit isotopic depletion via ORIGEN-2, but also includes multirecycling and utilizing the criticality search feature to determine the fresh fuel composition of recycled fuel, a feature unique to the DYMOND NFCS. A large database of simulations were run with 4 main parameters that were sampled: start date of reprocessing, reprocessing capacity, energy demand growth rate, and advanced reactor share of the fleet. The 4 main metrics were uranium consumption, enrichment requirements, waste generation, and levelized cost of electricity using data from the Cost Basis Report. The demonstrated SA&UQ results include those that inform on how to choose parameters to avoid “failed” scenarios, Sobol’ indices that inform on the importance of various parameters individually and synergistically, and Analysis of Variance (ANOVA) studies that decompose parameter ranges into groups and informs on whether variations are statistically significant.

Feng, B.↗

DOE OSTI2021

Optimal dynamic control for a maglev vehicle moving on multi-span guideway girders

Abstract An optimal control algorithm using a virtual tuned mass damper called virtual TMD to control the levitation force of a magnetic system is developed for resonance suppression of a maglev vehicle moving on multi-span guideway girders. Since the optimal dynamic parameters of a TMD in vibration control are well developed, the optimal tuning gains required to control the magnetic oscillations of the maglev bogie can be directly used and fed back to the maglev control system. To address the dynamic interaction analysis from the maglev vehicle to the guideway girders and vice versa, the entire coupling system is decomposed into two subsystems, one is the moving vehicle subsystem and another the stationary guideway subsystem. Then, an incremental–iterative procedure associated with the Newmark method is presented to solve the two sets of subsystem equations. Finally, the control effectiveness and parametric studies of the optimal virtual TMD scheme on resonance reduction of the moving maglev vehicle are demonstrated.

Liu, Linya↗

NASA NTRS1993

Modal characterization of the ASCIE segmented optics testbed: New algorithms and experimental results

New frequency response measurement procedures, on-line modal tuning techniques, and off-line modal identification algorithms are developed and applied to the modal identification of the Advanced Structures/Controls Integrated Experiment (ASCIE), a generic segmented optics telescope test-bed representative of future complex space structures. The frequency response measurement procedure uses all the actuators simultaneously to excite the structure and all the sensors to measure the structural response so that all the transfer functions are measured simultaneously. Structural responses to sinusoidal excitations are measured and analyzed to calculate spectral responses. The spectral responses in turn are analyzed as the spectral data become available and, which is new, the results are used to maintain high quality measurements. Data acquisition, processing, and checking procedures are fully automated. As the acquisition of the frequency response progresses, an on-line algorithm keeps track of the actuator force distribution that maximizes the structural response to automatically tune to a structural mode when approaching a resonant frequency. This tuning is insensitive to delays, ill-conditioning, and nonproportional damping. Experimental results show that is useful for modal surveys even in high modal density regions. For thorough modeling, a constructive procedure is proposed to identify the dynamics of a complex system from its frequency response with the minimization of a least-squares cost function as a desirable objective. This procedure relies on off-line modal separation algorithms to extract modal information and on least-squares parameter subset optimization to combine the modal results and globally fit the modal parameters to the measured data. The modal separation algorithms resolved modal density of 5 modes/Hz in the ASCIE experiment. They promise to be useful in many challenging applications.

Carrier, Alain C.↗

NASA NTRS1992

Emissions reduction by varying the swirler airflow split in advanced gas turbine combustors

A rich burn/quick mix/lean burn (RQL) combustor concept for reducing pollutant emissions is currently under investigation at the NASA Lewis Research Center. The current study investigates the effect of varying the mass flow rate split between the swirler passages for an equivalance ratio of 2.0 on fuel distribution, temperature distribution, and emissions for the fuel nozzle/rich burn section of an RQL combustor. It is seen that optimizing these parameters can substantially improve combustor performance and reduce combustor emissions. The optimal mass flow rate split for reducing NO(x) emissions based on the numerical study was the same as found by experiment.

Micklow, Gerald J.↗

NASA NTRS1994

Retrieval of Forest Canopy Parameters for OTTER Using an Optimized Technique

An inversion algorithm based on a nonlinear optimization technique is used to retrieve a subset of forest canopy parameters that can be used in ecosystem modeling. The inversion algorithm uses a parametric model derived from a discrete component forest scattering model which includes all major scattering contributions to radar backscatter. The parametric model, however, is derived for cases where only one mechanism dominates the scattering process, in this case, branch layer volume scattering.The inversion algorithm is shown to be a useful tool in the quantative monitoring of canopy moisture status, as well as a building block of its future versions which will include a more comprehensive set of forest scattering parameters as unknowns.

forest↗

NASA NTRS2022

Design of Materials with Alchemite

Machine learning models that establish the relationships between materials processing and properties can enable inverse design of materials through active learning. Alchemite is a commercial software that can perform inverse materials design on sparse data. Here we evaluate Alchemite’s performance on a dataset of shape memory alloys and a dataset of heat exchangers compared to baseline random forest models. Alchemite had higher accuracy when making predictions on sparse data and was more accurate or nearly as accurate as random forests on complete datasets while also quantifying uncertainty. The software was also used to suggest processing steps and design parameters to optimize properties and performance; however, physical validation of the suggested design parameters was beyond the scope of this work. Several useful design insights were gained about the impact of the design parameters on properties and performance including the importance of dopant choice and amount for shape memory alloys and the importance of height and weight on the thermal resistance of heat exchangers.

Machine learning↗

DOE OSTI2024

Experimental and statistical study on the effect of process parameters on the quality of continuous fiber composites made via additive manufacturing

Ongoing research in additive manufacturing towards structural and industrial application has led to the use of commingled roving as a manufacturing feedstock for printing high fiber volume fraction composites. The prospects of using this technology for high performance applications necessitates the need for a comprehensive experimental investigation into the effects of processing parameters on the quality of an additively manufactured composite printed from commingled roving feedstock. Here, in this work, transverse flexure and void fraction matrix pyrolysis testing are both performed to evaluate composite quality. The transverse flexure test is a testing approach that evaluates the quality of the interfacial fiber-matrix bond while the void fraction test estimates the void content in the printed composite. A full observational study consisting of 27 different test combinations is done to investigate the effects of three different process parameters namely, temperature, pressure, and print speed across three different levels. Composite samples were made from commingled roving of E-glass and amorphous PET using an in-house built continuous fiber composite digital manufacturing system. Least squares regression analysis is performed to study the main, interaction and quadratic effects of process parameters. A statistical regression model having an R2 adjusted value of 80.1% is generated from the transverse flexure study, which is used to explain main and interaction effects and also predict performance. Response surface plots are also generated and are used to optimize process parameters which can subsequently be of help in scaling up composite manufacturing. Results show that all three process parameters are highly statistically significant at the 0.01 level of significance. Pressure * Temperature and Pressure * Printspeed are significant interaction terms. Pressure plays a weightier role when print speed is increased or temperature is decreased as it closes more voids that would ordinarily have been introduced because of drop in polymer melt viscosity. Micrographic analysis is also performed.

36 MATERIALS SCIENCE↗