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DOE OSTI2023

Understanding process-microstructure-property relationships in laser powder bed fusion of non-spherical Ti-6Al-4V powder

Powder feedstock is a major cost driver in metal additive manufacturing (AM). Replacing the spherical powder with the cost-efficient non-spherical one can reduce the feedstock cost up to 50% and attract more interest to adopt AM in production and new alloy development. Here, for this paper, a comprehensive study was conducted to understand process-microstructure-property relationships in laser powder bed fusion of hydride-dehydride Ti-6Al-4V powder. We demonstrated that variation of laser scan speed had a significant impact on the grain structure, pore evolution and properties compared to laser power. Dynamic X-ray radiography showed that with decreasing scan speed at a constant laser power, a transition from conduction to keyhole mode laser processing occurred, in which a deeper melt pool at lower scan speed intensified texture. In other words, an increase in laser scan speed resulted in formation of the refined prior β grains with shape factor of ~5, lowering the anisotropy. Furthermore, the degree of variant selection was evaluated based on the analyzed texture as a function of laser power and scan speed. With increasing laser scan speed, the dominant α/α boundary type was altered from type 2 to 4 and the degree of variant selection was noticeably decreased. On the other hand, increasing laser power left the morphology of prior β grains, their size, and the dominant α/α boundary (type 4) unchanged, while the texture and anisotropy were intensified, and the degree of variant selection was slightly decreased. Finally, dependency of surface roughness and microhardness were discussed as a function of laser processing parameters.

variant selection↗

DOE OSTI2021

Adhesive Bonding of Copper Prepared by Laser-Interference near the Interference Structuring Limits

Adhesive bonding requires adequate surface preparation for ensuring an appropriate joint quality. The interest in adhesive joining has recently expanded to thermal systems having a large number of joints employed for manufacturing and assembly. This study presents surface topology of copper 110 produced by a laser-interference setup that would theoretically yield a periodicity of 1.7 μm, which is near the 1.6–2 μm structuring limit that was estimated based on thermal diffusion length scale for an 8 ns laser pulse. The results show that although the expected periodic interference structuring was not attained, the melt-induced texturing was affected by the laser-interference profile. Single-lap shear tests were performed with specimen surfaces prepared by traditional abrasion and laser-interference structuring methods. Several laser processing parameters, such as the laser spot size, density, number of pulses, and raster speed, were studied. Scanning electron microscope and profilometry measurements were used to characterize the processed surface microstructures. Web-like structures, which indicate widespread melting, were shown to be formed at different processing conditions. Based on the surface topologies investigated, two laser raster speeds were selected to make single-lap-joint specimens. Baseline joints were prepared by abrading joining specimens. The shear-lap strength and displacement at maximum load were shown to be higher by 16.8% and 43.8% for the laser-structured specimens than those of the baseline specimens, respectively. Moreover, the load-displacement curves indicated that the laser-structured joints were more ductile than those without laser-structuring. The increased ductility for the laser-structured joints was found to yield an increase in the energy absorbed during shear-lap testing of approximately of 80–90% over those measured for baseline joints. It is another indicator that laser-interference structuring enhanced the bonding performance of single-lap shear joints.

36 MATERIALS SCIENCE↗

NASA NTRS1997

Application of Multitemporal Remotely Sensed Soil Moisture for the Estimation of Soil Physical Properties

This paper demonstrates the use of multitemporal soil moisture derived from microwave remote sensing to estimate soil physical properties. The passive microwave ESTAR instrument was employed during June 10-18, 1992, to obtain brightness temperature (TB) and surface soil moisture data in the Little Washita watershed, Oklahoma. Analyses of spatial and temporal variations of TB and soil moisture during the dry-down period revealed a direct relationship between changes in T and soil moisture and soil physical (viz. texture) and hydraulic (viz. saturated hydraulic conductivity, K(sat)) properties. Statistically significant regression relationships were developed for the ratio of percent sand to percent clay (RSC) and K(sat), in terms of change components of TB and surface soil moisture. Validation of results using field measured values and soil texture map indicated that both RSC and K(sat) can be estimated with reasonable accuracy. These findings have potential applications of microwave remote sensing to obtain quick estimates of the spatial distributions of K(sat), over large areas for input parameterization of hydrologic models.

Mattikalli, N. M.↗

DOE OSTI2024

Effect of Nucleation Heterogeneity on Mineral Precipitation in Confined Environments

Abstract The formation of new mineral phases in confined environments, especially in porous media, is crucial for various geological processes like mineralization and diagenesis. The nucleation and precipitation of minerals are initiated at the microscale through fluid‐rock interaction, where dissolution of primary phases leads to supersaturated conditions and nucleation and growth of secondary ones. Previous research has focused primarily on either precipitation or nucleation, without fully exploring their combined impact. Our study introduces a computational framework that integrates classical nucleation theory with the micro‐continuum method. We validated our model by comparing with experiments, and discovered that different surface nucleation rate changes the mode of precipitation from a preferential to uniform precipitate textures. Furthermore, our study uncovered that the conventional deterministic precipitation method tends to underestimate the permeability of the porous matrix. In contrast, the new framework significantly improves model accuracy by incorporating preferential precipitation and heterogeneous nucleation.

58 GEOSCIENCES↗

NASA NTRS1980

Development of a high efficiency thin silicon solar cell

Significant improvements in open-circuit voltage and conversion efficiency, even on relatively high bulk resistivity silicon, were achieved by using a screen-printed aluminum paste back surface field. A 4 sq cm 50 micron m thick cell was fabricated from textured 10 omega-cm silicon which had an open-circuit voltage of 595 mV and AMO conversion efficiency at 25 C of 14.3%. The best 4 sq cm 50 micron thick cell (2 omega-cm silicon) produced had an open-circuit voltage of 607 mV and an AMO conversion efficiency of 15%. Processing modifications are described which resulted in better front contact integrity and reduced breakage. These modifications were utilized in the thin cell pilot line to fabricate 4 sq cm cells with an average AMO conversion efficiency at 25 C of better than 12.5% and with lot yields as great as 51% of starts; a production rate of 10,000 cells per month was demonstrated. A pilot line was operated which produced large area (25 cm) ultra-thin cells with an average AMO conversion efficiency at 25 deg of better than 11.5% and a lot yield as high as 17%.

Storti, G.↗

NASA NTRS1987

Cascaded-Blackbody Heat Radiators

New class of heat radiators made of metal or other conductive fin stock, fins of which are textured or covered with smaller fins. Measured from outside, effective emissivity of projected radiator surface greater than, and somewhat independent of, emissivity of flat surface made of same material. Special coatings to enhance emissivity not required, and emissivity not degraded significantly in long term by environmental effects. Intended orginally to radiate excess heat away from spacecraft, new radiators also used on Earth to dissipate heat in vacuum systems.

Keddy, Michael D.↗

NASA NTRS1993

The effects of cloud inhomogeneities upon radiative fluxes, and the supply of a cloud truth validation dataset

A series of cloud and sea ice retrieval algorithms are being developed in support of the Advanced Spaceborne Thermal Emission and Reflection Radiometer (ASTER) Science Team objectives. These retrievals include the following: cloud fractional area, cloud optical thickness, cloud phase (water or ice), cloud particle effective radius, cloud top heights, cloud base height, cloud top temperature, cloud emissivity, cloud 3-D structure, cloud field scales of organization, sea ice fractional area, sea ice temperature, sea ice albedo, and sea surface temperature. Due to the problems of accurately retrieving cloud properties over bright surfaces, an advanced cloud classification method was developed which is based upon spectral and textural features and artificial intelligence classifiers.

Welch, Ronald M.↗

DOE OSTI2025

Interface‐Induced Stability of Nontrivial Topological Spin Textures: Unveiling Room‐Temperature Hopfions and Skyrmions

Topological spin configurations, such as soliton-like spin texture and Dirac electron assemblies, have recently emerged in fundamental science and technology. Achieving stable topological spin textures at room temperature is crucial for their use as long-range information carriers. However, their creation and manipulation are hindered by multi-step field training and competing interactions. Thus, a spontaneous ground state for multidimensional topological spin textures is desirable, with skyrmions forming swirling, hedgehog-like spin structures in two dimensions and hopfions as their twisted 3D counterparts. Here, the first observation of robust and reproducible topological spin textures of hopfions and skyrmions observed at room temperature and in zero magnetic field is reported, which are stabilized by geometric confinement and protected by interfacial magnetism in a ferromagnet/topological insulator/ferromagnet trilayer heterostructure. These skyrmion-hopfion configurations are directly observed at room temperature with Lorenz transmission electron microscopy. Using micromagnetic modeling, the experimental observations of hopfion-skyrmion assemblies are reproduced. This model reveals a complete picture of how spontaneously organized skyrmion lattices encircled by hopfion rings are controlled by surface electrons, uniaxial anisotropy, and Dzyaloshinskii-Moriya interaction. This study provides evidence that topological chiral spin textures can facilitate the development of magnetic topological carriers, paving the way for ultralow-power and high-density information processing.

hopfions↗

NASA NTRS1987

Sulfur in vacuum - Sublimation effects on frozen melts, and applications to Io's surface and torus

Vacuum sublimation effects on solid sulfur yield a form of the element that is white at room temperature, is fluffy in texture, and forms on frozen sulfur in vacuum through differential evaporation of molecular species in the solid. This vacuum sulfur should exist in large quantity on Io, if the solid free sulfur there has solidified from a melt; a sulfur volcanism model for Io is accordingly developed on this basis which implies that the color and spectra of different sulfur regions of Io could indicate their relative crystallization ages and cooling histories. The flux of sublimating hotspot sulfur appears consistent with estimated turnover rates of the Io surface.

Nash, Douglas B.↗

NASA NTRS1997

Analysis of Texture Using the Fractal Model

Properties such as the fractal dimension (FD) can be used for feature extraction and classification of regions within an image. The FD measures the degree of roughness of a surface, so this number is used to characterize a particular region, in order to differentiate it from another. There are two basic approaches discussed in the literature to measure FD: the blanket method, and the box counting method. Both attempt to measure FD by estimating the change in surface area with respect to the change in resolution. We tested both methods but box counting resulted computationally faster and gave better results. Differential Box Counting (DBC) was used to segment a collage containing three textures. The FD is independent of directionality and brightness so five features were used derived from the original image to account for directionality and gray level biases. FD can not be measured on a point, so we use a window that slides across the image giving values of FD to the pixel on the center of the window. Windowing blurs the boundaries of adjacent classes, so an edge-preserving, feature-smoothing algorithm is used to improve classification within segments and to make the boundaries sharper. Segmentation using DBC was 90.8910 accurate.

Navas, William↗

NASA NTRSDate not supplied

Evaluation of South Dakota Aggregate as Martian Simulants

This research investigates aggregate sources in South Dakota to simulate martian aggregate for use in future martian concrete infrastructure. This effort supports the Moon to Mars Planetary Autonomous Construction Technology (MMPACT) project lead by the National Aeronautics and Space Administration (NASA). Currently, martian simulants are not produced in large quantities or from many geologic sources. Previous work has primarily focused on tholeiitic basalt even though the martian surface has diverse geology especially in crater locations. Various landing sites were selected to explore martian regolith compositions and textural characteristics. From these results, it was determined that locations with basaltic andesite would best match geological sources in South Dakota. These local regolith sources were then collected and characterized. A comparison between the local and martian aggregate is provided. Ultimately, this work will contribute to binder production for Additive Construction using In-Situ Resource Utilization (ISRU) processing for surface construction.

Aggregate↗

NASA NTRS2006

Irradiating of Bulk Soybeans: Influence on Their Functional and Sensory Properties for Soyfood Processing

Soybeans were chosen for lunar and planetary missions, where soybeans will be supplied in bulk or grown locally, due to their nutritive value and ability to produce oil and protein for further food applications. However, soybeans must be processed into foods prior to consumption. Radiation that soybeans would be exposed to during bulk storage prior to and during a Mars mission may influence their germination and functional properties. The influence of radiation includes the affect of surface pasteurization to ensure the astronauts safety from food-borne illnesses (HACCP, CCP), and the affect of the amount of radiation the soybeans receive during a Mars mission. Decreases in the amount of natural antioxidants free radical formation, and oxidation-induced changes in the soybean will influence the nutritional value, texture, color, and aroma of soyfoods. The objective of this study was to determine the influence of pasteurization and sterilization surface radiation on whole soybeans using gamma and electron beam radiation. The influence of 0, 1, 5, 10, and 30kGy on microbial load, germination rate, ease of processing, and quality of soymilk and tofu were determined. Surface radiation of whole dry soybeans using electron beam or gamma rays from 1-30kGy did provide microbial safety for the astronauts. However, the lower dose levels had surviving yeasts and molds. These doses caused oxidative changes that resulted in soymilk and tofu with rancid aromas. GC-MS of the aroma compounds using SPME Headspace confirmed the presence of lipid oxidation compounds. Soybean germination ability was reduced as radiation dosage increased. While lower doses may reduce these problems, the ability to insure microbial safety of bulk soybeans will be lost. Counter measures could include vacuum packaging, nitrogen flushing, added antioxidants, and radiating under freezing conditions. Doses below 1kGy need to be investigated further to determine the influence of the radiation encountered during Mars missions.

Chia, Chiew-Ling↗

NASA NTRS1994

The Large Impact Process Inferred from the Geology of Lunar Multiring Basins

The study of the geology of multiring impact basins on the Moon over the past ten years has given us a rudimentary understanding of how these large structures have formed and evolved on the Moon and other bodies. Two-ring basins on the Moon begin to form at diameters of about 300 km; the transition diameter at which more than two rings appear is uncertain, but it appears to be between 400 and 500 km in diameter. Inner rings tend to be made up of clusters or aligned segments of massifs and are arranged into a crudely concentric pattern; scarp-like elements may or may not be present. Outer rings are much more scarp-like and massifs are rare to absent. Basins display textured deposits, interpreted as ejecta, extending roughly an apparent basin radius exterior to the main topographic rim. Ejecta may have various morphologies, ranging from wormy and hummocky deposits to knobby surfaces; the causes of these variations are not known, but may be related to the energy regime in which the ejecta are deposited. Outside the limits of the textured ejecta are found both fields of satellitic craters (secondaries) and light plains deposits. Impact melt sheets are observed on the floors of relatively unflooded basins. Samples of impact melts from lunar basins have basaltic major-element chemistry, characterized by K, rare-earth elements (REE), P, and other trace elements of varying concentration (KREEP); ages are between 3.8 and 3.9 Ga. These lithologies cannot be produced through the fusion of known pristine (plutonic) rock types, suggesting the occurrence of unknown lithologies within the Moon. These melts were probably generated at middle to lower crustal levels. Ejecta compositions, preservation of pre-basin topography, and deposit morphologies all indicate that the excavation cavity of multiring basins is between about 0.4 and 0.6 times the diameter of the apparent crater diameter. Basin depths of excavation can be inferred from the composition of basin ejecta. A variety of mechanisms has been proposed to account for the formation of basin rings but none of them are entirely plausible. Mechanisms can be divided into two broad groups: (1) forcible uplift due to fluidization of the target; (2) concentric, brittle, fracturing and failure of the target, on regional (megaterraces) to global scales (lithospheric fracturing). Most basin rings are spaced at a constant factor on all planets. Evidence supports divergent ringforming models, so it may be that the ring-locating mechanism differs from the ring-forming mechanism. Thus, large-scale crustal foundering (megaterracing) could occur along concentric zones of weakness created by some type of resonant wave mechanism (fluidization and uplift); such immediate crustal adjustment could then be followed by long-term adjustment of the fractured lithosphere.

Spudis, Paul D.↗

NASA NTRS1999

Orientation Effects in ZnO Films Using Off-Axis Sputtering Deposition

ZnO is a wide-band-gap oxide material and has been used in numerous applications. It is also a good substrate for fabricating GaN-based (a blue laser candidate) devices. Off-axis sputtering technique is one of the best techniques in synthesizing oxide materials because negative ion bombardment and particle kinetic energy is greatly reduced when adatoms condense on substrates. Since the sputtered material from the target arrive on the substrate surface at a 90 deg. configuration, which differs from the normal sputtering geometry, it is expected that the film uniformity and composition distributions will be affected. However, the details of these properties and mechanisms have not been well studied. ZnO films are synthesized on (0001) sapphire and quartz substrates by off-axis sputtering deposition in various oxygen/argon mixture ratios and pressures at different temperatures. Substrates and sputtering sources are placed at three different orientations that are orthogonal to each other. The normal direction of a substrate is parallel to the gravity vector and the other is perpendicular to it. Film thickness profiles at different growth orientations are determined using a profimeter. All films grown at high temperatures have highly textured structures on quartz substrates and epitaxially grow on sapphire substrates. Because of this process, the film surface is very smooth. X-ray diffraction, scanning probe microscopy, and Fourier transfer infrared spectroscopy, and electrical measurements will be used to characterize these films. Detailed results will be discussed in the presentation.

Zhu, Shen↗

NASA NTRS1999

Mars 2001 Lander Mission: Measurement Synergy Through Coordinated Operations Planning And Implementation

The 2001 Mars Surveyor Program Mission includes an orbiter with a gamma ray spectrometer and a multispectral thermal imager, and a lander with an extensive set of instrumentation, a robotic arm, and the Marie Curie Rover. The Mars 2001 Science Operations Working Group (SOWG) is a subgroup of the Project Science Group that has been formed to provide coordinated planning and implementation of scientific observations, particularly for the landed portion of the mission. The SOWG will be responsible for delivery of a science plan and, during operations, generation and delivery of conflict-free sequences. This group will also develop an archive plan that is compliant with Planetary Data System (PDS) standards, and will oversee generation, validation, and delivery of integrated archives to the PDS. In this report we cover one element of the SOWG planning activities, the development of a plan that maximizes the scientific return from lander-based observations by treating the instrument packages as an integrated payload. Scientific objectives for the lander mission have been defined. They include observations focused on determining the bedrock geology of the site through analyses of rocks and also local materials found in the soils, and the surficial geology of the site, including windblown deposits and the nature and history of formation of indurated sediments such as duricrust. Of particular interest is the identification and quantification of processes related to early warm, wet conditions and the presence of hydrologic or hydrothermal cycles. Determining the nature and origin of duricrust and associated salts is -very important in this regard. Specifically, did these deposits form in the vadose zone as pore water evaporated from soils or did they form by other processes, such as deposition of volcanic aerosols? Basic information needed to address these questions includes the morphology, topography, and geologic context of landforms and materials exposed at the site, together with quantitative information on material mineralogy, chemistry, and physical properties (rock textures; soil grain size and shape distributions; degree and nature of soil induration; soil magnetic properties). The calibration targets provide radiometric and mineralogical control surfaces. The magnets allow observations of magnetic phases. Patch plates are imaged to determine adhesive and abrasive properties of soils. Coordinated mission planning is crucial for optimizing the measurement synergy among the packages included on the lander. This planning has already begun through generation of multi-sol detailed operations activities. One focus has been to develop a scenario to use the arm to dig a soil trench to a depth of tens of centimeters. The activity will be monitored through use of Pancam and RAC to ensure nominal operations and to acquire data to determine subsurface physical properties (e.g., angle of repose of trench walls). Pancam and Mini-TES observations would also provide constraints on mineralogy and texture for the walls and bottom of the trench during excavation. If desired, soils excavated at depth could be deposited on the surface and Mossbauer and APXS measurements could be acquired for these materials. Soil samples from various depths would be delivered to MECA for characterization of aqueous geochemistry and physical properties of soil grains, particularly size, shape, and hardness. These physical properties would be determined by optical and atomic force microscopy. When completed, detailed information of soil properties as a function of depth would be obtained. These various data sets would constrain our understanding of whether or not there are systematic variations in soil characteristics as a function of depth. These variations might be related, for example, to evaporative moisture losses and formation of salt deposits, thereby indicating water transport processes occurred fairly recently. Many other value-added measurement scenarios are being developed. For example, characterizing the nature and dynamics of dust deposition will be done using MIP/DART to provide deposition rates, Pancam and RAC imaging of lander and rover surfaces to extrapolate these measurements to other areas, and a variety of measurements to determine if the bulk loose soil has the same characteristics as dust that accumulates during the mission. Bedrock geology of the site is primarily an APEX-focus setting, mineralogy, and texture, and APXS data to be we interest will be to determine the extent to which rock hydrothermal processes, given that APEX is the precursor 4 and 2005 rover missions. Additional information is contained in the original.

Arvidson, R.↗

DOE OSTI2022

Boiling Transitions During Droplet Contact on Superheated Nano/Micro-Structured Surfaces

Manipulating surface topography is one of the most promising strategies for increasing the efficiency of numerous industrial processes involving droplet contact with superheated surfaces. In such scenarios, the droplets may immediately boil upon contact, splash and boil, or could levitate on their own vapor in the Leidenfrost state. In this work we report the outcomes of water droplets coming in gentle contact with designed nano/micro-textured surfaces at a wide range of temperatures as observed using high-speed optical and X-ray imaging. Further, we report a paradoxical increase in the Leidenfrost temperature ($T_{\text{LFP}}$) as the texture spacing is reduced below a critical value (~10 μm) that represents a minima in $T_{\text{LFP}}$. Although droplets on such textured solids appear to boil upon contact, our studies suggest that their behavior is dominated by hydrodynamic instabilities implying that the increase in $T_{\text{LFP}}$ may not necessarily lead to enhanced heat transfer. On such surfaces, the droplets display a new regime characterized by splashing accompanied by a vapor jet penetrating through the droplets before they transition to the Leidenfrost state. We provide a comprehensive map of boiling behavior of droplets over a wide range of texture spacings that may have significant implications towards applications such as electronics cooling, spray cooling, nuclear reactor safety and containment of fire calamities.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1972

Experimental petrology and origin of Fra Mauro rocks and soil

Melting experiments over the pressure range 0 to 20 kilobars were conducted on Apollo 14 igneous rocks 14310 and 14072 and on comprehensive fines 14259. The mineralogy and textures of rocks 14310 and 14072 are presumed to be the result of near-surface crystallization. The chemical compositions of the samples show special relationships to multiply-saturated liquids in the system: anorthite-forsterite-fayalite-silica at low pressure. Partial melting of a lunar crust consisting largely of plagioclase, low calcium pyroxene, and olivine, followed by crystal fractionation at the lunar surface is proposed as a mechanism for the production of the igneous rocks and soil glasses sampled by Apollo 14.

Walker, D.↗

NASA NTRS1983

Remote sensing of soil moisture - Recent advances

Recent advancements in microwave remote sensing of soil moisture include a method for estimating the dependence of the soil dielectric constant on its texture, the use of a percent of field capacity to express soil moisture magnitudes independently of soil texture, methods of estimating soil moisture sampling depth, and models for describing the effect of surface roughness on microwave response in terms of surface height variance and horizontal correlation length, as well as the verification of radiative transfer model predictions of microwave emission from soils and methods for the estimation of vegetation effects on the microwave response to soil moisture. Such researches have demonstrated that it is possible to remotely sense soil moisture in the 0-5 cm soil surface layer, and simulation studies have indicated how remotely sensed surface soil moisture may be used to estimate evapotranspiration rates and root-zone soil moisture.

Schmugge, T. J.↗