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All sources NASA NTRS DOE OSTI

DOE OSTI2020

Development of Thermal Tomography Imaging System for In-Service Nondestructive Evaluation of Additively Manufactured Components

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of nuclear reactor parts. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which can introduce internal material flaws, such as pores and anisotropy. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to exposure to high temperature, radiation and corrosive environment in a nuclear reactor. Thermal tomography (TT) provides a capability for non-destructive evaluation of sub-surface defects in arbitrary size structures. We investigate TT of AM stainless steel 316L specimen with imprinted internal porosity defects using relatively low-cost, small form factor infrared (IR) camera based on uncooled micro bolometer detector. Sparse coding related K-means singular value decomposition (SVD) machine learning, image processing algorithms are developed to improve quality of TT images through removal of Additive white Gaussian noise without blurring the images. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact TT can also be used for in-service nondestructive evaluation (NDE). With capability to perform in-service NDE of the AM component lifecycle, TT data can be used for development of a component digital twin. MIT research reactor (MITR) has been identified as a representative environment to perform investigation of feasibility of in-service NDE during shutdown. Preliminary study of radiation level in the MITR viewport, with geometric parameters potentially compatible with compact TT system, has been conducted.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Human Exploration Spacecraft Testbed for Integration and Advancement (HESTIA)

The proposed paper will cover ongoing effort named HESTIA (Human Exploration Spacecraft Testbed for Integration and Advancement), led at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) to promote a cross-subsystem approach to developing Mars-enabling technologies with the ultimate goal of integrated system optimization. HESTIA also aims to develop the infrastructure required to rapidly test these highly integrated systems at a low cost. The initial focus is on the common fluids architecture required to enable human exploration of mars, specifically between life support and in-situ resource utilization (ISRU) subsystems. An overview of the advancements in both integrated technologies, in infrastructure, in simulation, and in modeling capabilities will be presented, as well as the results and findings of integrated testing,. Due to the enormous mass gear-ratio required for human exploration beyond low-earth orbit, (for every 1 kg of payload landed on Mars, 226 kg will be required on Earth), minimization of surface hardware and commodities is paramount. Hardware requirements can be minimized by reduction of equipment performing similar functions though for different subsystems. If hardware could be developed which meets the requirements of both life support and ISRU it could result in the reduction of primary hardware and/or reduction in spares. Minimization of commodities to the surface of mars can be achieved through the creation of higher efficiency systems producing little to no undesired waste, such as a closed-loop life support subsystem. Where complete efficiency is impossible or impractical, makeup commodities could be manufactured via ISRU. Although, utilization of ISRU products (oxygen and water) for crew consumption holds great promise of reducing demands on life support hardware, there exist concerns as to the purity and transportation of commodities. To date, ISRU has been focused on production rates and purities for propulsion needs. The meshing of requirements between all potential users, producers, and cleaners of oxygen and water is crucial to guiding the development of technologies which will be used to perform these functions. Various new capabilities are being developed as part of HESTIA, which will enable the integrated testing of these technologies. This includes the upgrading of a 20' diameter habitat chamber to eventually support long duration (90+ day) human-in-the-loop testing of advanced life support systems. Additionally, a 20' diameter vacuum chamber is being modified to create Mars atmospheric pressures and compositions. This chamber, designated the Mars Environment Chamber (MEC), will eventually be upgraded to include a dusty environment and thermal shroud to simulate conditions on the surface of Mars. In view that individual technologies will be in geographically diverse locations across NASA facilities and elsewhere in the world, schedule and funding constraints will likely limit the frequency of physical integration. When this is the case, absent subsystems can be either digitally or physically simulated. Using the Integrated Power Avionics and Software (iPAS) environment, HESTIA is able to bring together data from various subsystems in simulated surroundings, insert faults, errors, time delays, etc., and feed data into computer models or physical systems capable of reproducing the output of the absent subsystems for the consumption of a local subsystems. Although imperfect, this capability provides opportunities to test subsystem integration and interactions at a fraction of the cost. When a subsystem technology is too immature for integrated testing, models can be produced using the General-Use Nodal Network Solver (GUNNS) capability to simulate the overall system performance. In doing so, even technologies not yet on the drawing board can be integrated and overall system performance estimated. Through the integrated development of technologies, as well as of the infrastructure to rapidly and at a low cost, model, simulate, and test subsystem technologies early in their development, HESTIA is pioneering a new way of developing the future of human space exploration.

Banker, Brian F.↗

DOE OSTI2023

Superconducting Hyperdimensional Associative Memory Circuit for Scalable Machine Learning

Here we propose a generalized architecture for the first rapid-single-flux-quantum (RSFQ) associative memory circuit. The circuit employs hyperdimensional computing (HDC), a machine learning (ML) paradigm utilizing vectors with dimensionality in the thousands to represent information. HDC designs have small memory footprints, simple computations, and simple training algorithms compared to superconducting neural network accelerators (SNNAs), making them a better option for scalable SFQ machine learning (ML) solutions. The proposed superconducting HDC (SHDC) circuit uses entirely on-chip RSFQ memory which is tightly integrated with logic, operates at 33.3 GHz, is applicable to general ML tasks, and is manufacturable at practically useful scales given current SFQ fabrication limits. Tailored to a language recognition task, SHDC consists of ~ 2-20 M Josephson junctions (JJs) and consumes up to three times less power than an analogous CMOS HDC circuit while achieving 78-84% higher throughput. SHDC is capable of outperforming the state of the art RSFQ SNNA, SuperNPU, by 48-99% for all benchmark NN architectures tested while occupying up to 90% less area and consuming up to nine times less power. To the best of the authors' knowledge, SHDC is currently the only superconducting ML approach feasible at practically useful scales for real-world ML tasks and capable of online learning.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2015

An investigation into factors affecting the precision of CT radiation dose profile width measurements using radiochromic films

Purpose: To investigate the impact of x-ray beam energy, exposure intensity, and flat-bed scanner uniformity and spatial resolution on the precision of computed tomography (CT) beam width measurements using Gafchromic XR-QA2 film and an off-the-shelf document scanner. Methods: Small strips of Gafchromic film were placed at isocenter in a CT scanner and exposed at various x-ray beam energies (80–140 kVp), exposure levels (50–400 mA s), and nominal beam widths (1.25, 5, and 10 mm). The films were scanned in reflection mode on a Ricoh MP3501 flat-bed document scanner using several spatial resolution settings (100 to 400 dpi) and at different locations on the scanner bed. Reflection measurements were captured in digital image files and radiation dose profiles generated by converting the image pixel values to air kerma through film calibration. Beam widths were characterized by full width at half maximum (FWHM) and full width at tenth maximum (FWTM) of dose profiles. Dependences of these parameters on the above factors were quantified in percentage change from the baselines. Results: The uncertainties in both FWHM and FWTM caused by varying beam energy, exposure level, and scanner uniformity were all within 4.5% and 7.6%, respectively. Increasing scanner spatial resolution significantly increased the uncertainty in both FWHM and FWTM, with FWTM affected by almost 8 times more than FWHM (48.7% vs 6.5%). When uncalibrated dose profiles were used, FWHM and FWTM were over-estimated by 11.6% and 7.6%, respectively. Narrower beam width appeared more sensitive to the film calibration than the wider ones (R{sup 2} = 0.68 and 0.85 for FWHM and FWTM, respectively). The global and maximum local background variations of the document scanner were 1.2%. The intrinsic film nonuniformity for an unexposed film was 0.3%. Conclusions: Measurement of CT beam widths using Gafchromic XR-QA2 films is robust against x-ray energy, exposure level, and scanner uniformity. With proper film calibration and scanner resolution setting, it can provide adequate precision for meeting ACR and manufacturer’s tolerances for the measurement of CT dose profiles.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2015

Projection Microstereolithography for Architected Materials

Stereolithography (SL) is a prominent paradigm in the realm of additive manufacturing (AM) technologies, which refers to fabrication approaches that build “bottom up” by adding material. Pioneered in 1984 by Chuck Hull, SL relies on light-activated solidification of a liquid photosensitive resin in a layer-by-layer fashion, with the geometry of each layer defined by sectioning a three-dimensional (3D) computer model by closely-spaced parallel planes. The maturation of the technology over nearly three subsequent decades has resulted in the wide availability of commercial SL products, such as the ProJet series from 3D Systems, Inc. (which uses the proprietary acronym SLA to refer to SL technology), which routinely produces parts with 50-100 µm resolution in all three axes, and overall dimensions of 0.25-0.5 m. In the most general terms, advancements in SL technology have generally been aimed at achieving four goals: decreasing (1) system cost and (2) minimum feature size (i.e. improving resolution), while (3) increasing overall part size and (4) build speed. SL systems can be broadly categorized into two classes, by the way in which they deliver illumination to produce the shape of each object layer to be fabricated: laser-scanning and mask projection approaches. Commercially-available SL systems incorporate the laser-scanning approach, following the original scheme described by Hull, since digital image projection technology has only emerged relatively recently as a viable alternative. A significant limitation of laser scanning is the relatively slow speed of rastering the laser to form each layer’s pattern, highlighting the need for a dynamic mask-based approach to polymerize larger areas in a single exposure. The recent proliferation of digital display technologies (referred to as spatial light modulators or SLMs) has enabled the implementation of such “dynamic masking,” increasing system throughput by allowing a complete image layer to be cross-linked simultaneously. These mask projection SL systems are gaining greater prominence, and the landscape of some of the parameters available for system design, as implemented in recent work by a variety of investigators, has been reviewed by Lambert et al.

36 MATERIALS SCIENCE↗

DOE OSTI2014

SU-E-T-276: Radiochromic Film Dosimetry: Solving the Lateral Response Puzzle

Purpose: A known factor affecting the accuracy of radiochromic film dosimetry is the lateral response artifact induced by off-center placement of film on flatbed scanners. This work reports a practical solution to eliminate such artifacts for IMRT dose QA. Methods: EBT3 film calibration strips (3.5×32cm{sup 2}) were exposed at a depth of 5cm on a Varian Trilogy to a 40×40cm{sup 2} open field at six doses between 120 and 900cGy using 6MV photons. A sheet of film was similarly exposed with a large IMRT field. Together with a strip of unexposed film from the same lot the films were digitized at different lateral positions on an Epson 10000XL scanner. The calibration strips covered nearly the full width of the scanner window. Calibration and response data were used to generate the IMRT dose map using multi-channel dosimetry. The scanner response was determined as a function of lateral position of the scanned film. The response at any lateral position L is related to the response at the center, C, of the scanner by Response(C,D) = aL+bL*Response(L,D) where D is dose and the coefficients aL and bL are constant for each lateral location. The coefficients aL and bL were determined by measuring films exposed to different doses at the center of the scanner and various lateral positions. Results: Applying this relationship to raw calibration responses, the values at any lateral position can be corrected to an equivalent response as if that film was located centrally. Our study found that calibration curves at the different lateral positions are correlated by a simple two-point re-scaling and thereby the correction could be made. Conclusion: The work reported elaborates on the process and demonstrates improvements in radiochromic film dosimetry using this simple procedure to eliminate the lateral response artifact. Acknowledgements: Supported in part by a grant from Ashland Inc. D Lewis is an employee of Ashland Inc., the manufacturer of radiochromic film; M Chan is supported in part by a grant from Ashland Inc.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2021

Assessment of task‐based performance from five clinical DBT systems using an anthropomorphic breast phantom

Purpose Digital breast tomosynthesis (DBT) is a limited‐angle tomographic breast imaging modality that can be used for breast cancer screening in conjunction with full‐field digital mammography (FFDM) or synthetic mammography (SM). Currently, there are five commercial DBT systems that have been approved by the U.S. FDA for breast cancer screening, all varying greatly in design and imaging protocol. Because the systems are different in technical specifications, there is a need for a quantitative approach for assessing them. In this study, the DBT systems are assessed using a novel methodology with an inkjet‐printed anthropomorphic phantom and four alternative forced choice (4AFC) study scheme. Method A breast phantom was fabricated using inkjet printing and parchment paper. The phantom contained 5‐mm spiculated masses fabricated with potassium iodide (KI)‐doped ink and microcalcifications (MCs) made with calcium hydroxyapatite. Images of the phantom were acquired on all five systems with DBT, FFDM, and SM modalities where available using beam settings under automatic exposure control. A 4AFC study was conducted to assess reader performance with each signal under each modality. Statistical analysis was performed on the data to determine proportion correct (PC), standard deviations, and levels of significance. Results For masses, overall detection was highest with DBT. The difference in PC was statistically significant between DBT and SM for most systems. A relationship was observed between increasing PC and greater gantry span. For MCs, performance was highest with DBT and FFDM compared to SM. The difference between PC of DBT and PC of SM was statistically significant for all manufacturers. Conclusions This methodology represents a novel approach for evaluating systems. This study is the first of its kind to use an inkjet‐printed anthropomorphic phantom with realistic signals to assess performance of clinical DBT imaging systems.

Ikejimba, Lynda C.↗

DOE OSTI2023

Inventory of Public Key Cryptography in US Electric Vehicle Charging

Electric vehicles (EVs) and charging infrastructure are networked systems, which employ high-level communications in support of charging and grid service decisions. Public key cryptography (PKC) underlies much of the security and privacy protections of the information exchange. We are entering a new epoch where quantum computing threats must be seriously considered. A sufficiently large quantum computer, so named Cryptographically Relevant Quantum Computer (QRQC), will be able to perform the mathematical operations to efficiently attack the underpinnings of traditional PKC, thus jeopardizing the digital foundations for trust, communications security, and data security. Estimates suggest a QRQC can break public key encryption and digital signatures in the manner of tens to hundreds of hours, compared to traditional computing that would demand more than 10 18 years in a brute force-style attack. A consensus belief of quantum theorists, quantum experimenters, and cryptographers suggest that the quantum threat will be likely realized in the next twenty years. To address the threat, post-quantum cryptography, which is cryptosystems that are designed to be secure against both traditional and quantum computing threats, must be adopted. Migration from traditional PKC to quantum-resilient cryptography is a global undertaking and likely represents the largest transition in computing history. The nascent state of EV public key infrastructure, combined with limited adoption of the vehicle secure charging features, presents an opportunity to establish a preference for quantum-resistant cryptography as a step on the migration path. Delays will stunt the efforts as rapidly accelerating EVs sales and huge infrastructure investments will create large growing bases of long-lived vehicles and infrastructure. Migration preparations can commence while NIST continues the process to standardize post-quantum cryptography (PQC), which are quantum-resilient algorithms designed to be secure against traditional and quantum computing threats. The first step in preparing EV charging is to identify the presence of traditional public key cryptography algorithms and applications. With this objective in mind, this report is intended to advise the vehicle manufacturers, charging station manufacturers, charging station operators, charge network providers and other EV charging stakeholders with information on traditional PKC application and the potential risks when PKC becomes insecure. This report, the first in a series of reports discussing the topics existing at the confluence of post-quantum cryptography adoption and EV charging, identifies traditional public key applications employed and identifies potential consequences of leaving EV charging infrastructure vulnerable to quantum computing. The focus remains squarely on the of EV charging and infrastructure with respect to PKC and is believed by the authors to complement the NIST SP 1800-38 Migration to Post-Quantum Cryptography. While the report is centered on infrastructure, there are implications to vehicles.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

How Can Construction Process Simulation Modeling Aid the Integration of Lean Principles in the Factory-Built Housing Industry?

New and existing factories that produce and deliver factory-built housing can benefit from construction process simulation modeling to explore the integration of Lean principles in their operations. Construction process simulation modeling provides digital or virtual recreations of the real-world factory environments to visualize, quantify, analyze, and optimize their underlying behavior, including factory productivity, material flow, labor dynamics, bottlenecks, and work scope. One of the key benefits of process simulation modeling is the ability to create and compare "what-if" scenarios, including integrating Lean principles such as reducing waste (for example, transportation, waiting), line balancing, and just-in-time concepts. In general, three process simulation methods are widely used: discrete event simulation (DES), agentbased modeling (ABM), and system dynamics (SD). Myriad process simulation software also is available, but depending on the industry, complexity of the system, and purposes of the simulation, some software might be more appropriate. Similar to how computer-aided design (CAD) software such as AutoCAD and Rhinoceros enable building design of modular or factory-built housing, process simulation modeling software such as jStrobe, ProModel, and AnyLogic can enable factory design of new and existing factories to deliver modular affordable housing at scale, as opposed to traditional site-built construction. Software with DES capabilities can help generate a process model that is a logical representation of resources and activities in a factory. Software with CAD-DES integration can leverage product-process data integration to help spatially visualize a DES model of the factory in the CAD environment. Software with multimethod simulation capabilities, widely used in the manufacturing industry, brings together DES, ABM, and SD in a single platform that allows visualization, quantification, analyses, and optimization at varying data fidelities. Near-real-time data from an existing factory can be directly plugged into multimethod simulation software so that the construction process simulation model is a near-accurate representation of the real-world factory conditions. This report provides insights into the use of simulation as an aid to integrate Lean concepts in factories, including guidelines for selecting the appropriate process simulation modeling method and software. These insights have been developed as part of ongoing process simulation modeling research, development, and demonstration projects at the U.S. Department of Housing and Urban Development, the U.S. Department of Energy, and the National Renewable Energy Laboratory focused on how process simulation models can enable better integration of resilience, energy efficiency, and low-carbon design strategies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2013

Common Practice Lightning Strike Protection Characterization Technique to Quantify Damage Mechanisms on Composite Substrates

To support FAA certification airworthiness standards, composite substrates are subjected to lightning direct-effect electrical waveforms to determine performance characteristics of the lightning strike protection (LSP) conductive layers used to protect composite substrates. Test results collected from independent LSP studies are often incomparable due to variability in test procedures & applied practices at different organizations, which impairs performance correlations between different LSP data sets. Under a NASA supported contract, The Boeing Company developed technical procedures and documentation as guidance in order to facilitate a test method for conducting universal common practice lightning strike protection test procedures. The procedures obtain conformity in future lightning strike protection evaluations to allow meaningful performance correlations across data sets. This universal common practice guidance provides the manufacturing specifications to fabricate carbon fiber reinforced plastic (CFRP) test panels, including finish, grounding configuration, and acceptable methods for pretest nondestructive inspection (NDI) and posttest destructive inspection. The test operations guidance elaborates on the provisions contained in SAE ARP5416 to address inconsistencies in the generation of damage protection performance data, so as to provide for maximum achievable correlation across capable lab facilities. In addition, the guidance details a direct effects test bed design to aid in quantification of the multi-physical phenomena surrounding a lightning direct attachment supporting validation data requirements for the development of predictive computational modeling. The lightning test bed is designed to accommodate a repeatable installation procedure to secure the test panel and eliminate test installation uncertainty. It also facilitates a means to capture the electrical waveform parameters in 2 dimensions, along with the mechanical displacement and thermal heating parameters which occur during lightning attachment. Following guidance defined in the universal common practice LSP test documents, protected and unprotected CFRP panels were evaluated at 20, 40 and 100KAmps. This report presents analyzed data demonstrating the scientific usefulness of the common practice approach. Descriptions of the common practice CFRP test articles, LSP test bed fixture, and monitoring techniques to capture the electrical, mechanical and thermal parameters during lightning attachment are presented here. Two methods of measuring the electrical currents were evaluated, inductive current probes and a newly developed fiberoptic sensor. Two mechanical displacement methods were also examined, optical laser measurement sensors and a digital imaging correlation camera system. Recommendations are provided to help users implement the common practice test approach and obtain LSP test characterizations comparable across data sets.

Szatkowski, George N.↗

NASA NTRSDate not supplied

Short Circuiting the Controller – Missteps in Maintenance and Inspection of Process and Wiring in STS-93

The primary objective of the Space Transportation System mission 93 (STS-93) was to deploy the Chandra X-Ray Observatory. Chandra, the world's most powerful X-Ray telescope, allowed scientists from around the world to study some of the most distant and dynamic objects in the universe. Stripped of nearly 7,000 pounds of its own gear to make room for the payload, the orbiter assigned to this mission was Space Shuttle Columbia. Prior to STS-93, Columbia had flown 25 flights and was NASA's oldest and heaviest orbiter. On July 23, 1999, after two prior launch scrubs, Eileen Collins and her crew of four launched from Kennedy Space Center. About five seconds after launch, Mission Control at Johnson Space Center detected a voltage drop on one of Columbia's electrical buses. As a result of this power fluctuation, a primary and back-up Main Engine controller dropped offline. Given design redundancy, the two remaining controllers supported all three engines. If there had been any other AC bus issues, one engine of the three on the Orbiter would have shut down. The redundant set of digital computer units in each engine controller saved Columbia and her crew from a very risky contingency abort. Post-flight inspection revealed soot on a screw head and a hole in an adjacent Kapton insulated wire. The single strand of polyimide wire was located nearly half-way down the payload bay. The Shuttle Independent Assessment Team (SIAT) reported that the wire had rubbed and chaffed against a burred screw head. The burr was later determined to be the result of overtightening of the screw by a technician during a maintenance refurbishment. Alone, the burr may not have been problematic, but later, during another ground processing event, possibly years after, someone inadvertently stepped on the wiring harness. With the pressure and motion of unintended contact, some of the Kapton insulation rubbed off against the burred screw head. The SIAT suspected the wire damage was pre-existing and was caused 4 or 5 years prior to the flight. Finally, the intense vibrations during the launch sequence allowed contact between the exposed conductor and exposed metal area on the burred screw head, resulting in the arcing and shorting of the wire. Due to the quick turnaround times of Space Shuttle Orbiters, wiring issues caused from multiple maintenance events were often overlooked. Additionally, failing to incorporate thorough and early inclusion of human systems integration (HSI) applications as a crucial part of the decision process can result in these types of misshaps. In order to reduce human error associated with integrated manufacturing, maintenance, refurbishment and flight preparations, wire inspection criteria should be refined and standardized, visual inspection processes should be quantified, and technicians should be certified by specially trained instructors. This case, among many others, unveils why human error management and development of safety metrics is a vital piece in the development of complex systems, and why it should be supported aggressively and implemented program wide.

Human Systems Integration↗

NASA NTRS2018

Zero Launch Mass Three Dimensional Print Head

NASA's strategic goal is to put humans on Mars in the 2030s. The NASA Human Spaceflight Architecture Team (HAT) and NASA Mars Design Reference Architecture (DRA) 5.0 has determined that in-situ resource utilization (ISRU) is an essential technology to accomplish this mission. Additive construction technology using in-situ materials from planetary surfaces will reduce launch mass, allow structures to be three dimensionally (3D) printed on demand, and will allow building designs to be transmitted digitally from Earth and printed in space. This will ultimately lead to elimination of reliance on structural materials launched from Earth (zero launch mass of construction consumables). The zero launch mass (ZLM) 3D print head project addressed this need by developing a system that 3D prints using a mixture of in-situ regolith and polymer as feedstock, determining the optimum mixture ratio and regolith particle size distribution, developing software to convert g-code into motion instructions for a FANUC robotic arm, printing test samples, performing materials testing, and printing a reduced scale habitable structure concept. This paper will focus on the ZLM 3D Print Head design, materials selection, software development, and lessons learned from operating the system in the NASA KSC Swamp Works Granular Mechanics & Regolith Operations (GMRO) Laboratory.

Regolith↗

NASA NTRS2020

Bioinspired multilayered cellular composites with enhanced energy absorption and shape recovery

Inspired by the multiscale configuration of the microstructure of cork, the paper describes the design, 3D printing, and evaluation of a new type of multilayered cellular composite (MCC) structure composed of hard brittle and soft flexible phases. The mechanical behavior of 3D printed MCC structures have been investigated both experimentally and numerically. The experiments show that the MCC structure absorbs four times the amount of energy of a conventional cellular configuration under compressive strains up to 70%. Finite element simulations and 2D digital image correlation (DIC) also show that the multilayered architecture provides a more uniform strain distribution and higher stress transfer efficiency, with a resulting progressive failure mode rather than a catastrophic one. Cyclic loading tests demonstrate that the MCC structure also possesses exceptional shape recoverability under compressive deformations up to 40%. These remarkable performance characteristics result from synergies between the properties of the two constituent materials and the chosen multilayered cellular microstructure. The soft phase, in particular, plays a pivotal role in absorbing elastic energy during loading and then releasing the stored energy while unloading. The volume fraction of the soft phase is also essential to control energy absorption and the transition of failure modes. The deformation mechanisms demonstrated here are robust and applicable to other architected cellular materials across multiple length scales and suggest new ways to design lightweight and high-resilience structural materials.

bioinspired composites↗

NASA NTRS1996

Detection of Delamination in Composite Beams Using Broadband Acoustic Emission Signatures

Delamination in composite structure may be caused by imperfections introduced during the manufacturing process or by impact loads by foreign objects during the operational life. There are some nondestructive evaluation methods to detect delamination in composite structures such as x-radiography, ultrasonic testing, and thermal/infrared inspection. These methods are expensive and hard to use for on line detection. Acoustic emission testing can monitor the material under test even under the presence of noise generated under load. It has been used extensively in proof-testing of fiberglass pressure vessels and beams. In the present work, experimental studies are conducted to investigate the use of broadband acoustic emission signatures to detect delaminations in composite beams. Glass/epoxy beam specimens with full width, prescribed delamination sizes of 2 inches and 4 inches are investigated. The prescribed delamination is produced by inserting Teflon film between laminae during the fabrication of composite laminate. The objectives of this research is to develop a method for predicting delamination size and location in laminated composite beams by combining smart materials concept and broadband AE analysis techniques. More specifically, a piezoceramic (PZT) patch is bonded on the surface of composite beams and used as a pulser. The piezoceramic patch simulates the AE wave source as a 3 cycles, 50KHz, burst sine wave. One broadband AE sensor is fixed near the PZT patch to measure the AE wave near the AE source. A second broadband AE sensor, which is used as a receiver, is scanned along the composite beams at 0.25 inch step to measure propagation of AE wave along the composite beams. The acquired AE waveform is digitized and processed. Signal strength, signal energy, cross-correlation of AE waveforms, and tracking of specific cycle of AE waveforms are used to detect delamination size and location.

Okafor, A. C.↗

NASA NTRS2018

Vision 2040: A Roadmap for Integrated, Multiscale Modeling and Simulation of Materials and Systems

Over the last few decades, advances in high-performance computing, new materials characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) and additive manufacturing have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. While these advances have driven significant progress in the development of aerospace components and systems, that progress has been limited by persistent technology and infrastructure challenges that must be overcome to realize the full potential of integrated materials and systems design and simulation modeling throughout the supply chain. As a result, NASA's Transformational Tools and Technology (TTT) Project sponsored a study (performed by a diverse team led by Pratt & Whitney) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. This report describes the findings of this 2040 Vision study (e.g., the 2040 vision state; the required interdependent core technical work areas, Key Element (KE); identified gaps and actions to close those gaps; and major recommendations) which constitutes a community consensus document as it is a result of over 450 professionals input obtain via: 1) four society workshops (AIAA, NAFEMS, and two TMS), 2) community-wide survey, and 3) the establishment of 9 expert panels (one per KE) consisting on average of 10 non-team members from academia, government and industry to review, update content, and prioritize gaps and actions. The study envisions the development of a cyber-physical-social ecosystem comprised of experimentally verified and validated computational models, tools, and techniques, along with the associated digital tapestry, that impacts the entire supply chain to enable cost-effective, rapid, and revolutionary design of fit-for-purpose materials, components, and systems. Although the vision focused on aeronautics and space applications, it is believed that other engineering communities (e.g., automotive, biomedical, etc.) can benefit as well from the proposed framework with only minor modifications. Finally, it is TTT's hope and desire that this vision provides the strategic guidance to both public and private research and development decision makers to make the proposed 2040 vision state a reality and thereby provide a significant advancement in the United States global competitiveness.

multi-scale modeling↗

DOE OSTI2023

A Case Study of Tunable White LED Lighting with Networked Lighting Controls (Emory University Cognitive Empowerment Program)

Emory University and Georgia Institute of Technology (Georgia Tech) partnered to create the Charlie and Harriet Schaffer Cognitive Empowerment Program (CEP) facility in northeast Atlanta. Together with the funders they are building a program to help individuals experiencing mild cognitive impairment (MCI) to maintain their physical and cognitive health, and independence as long as possible. In addition to applying effective strategies and therapies, the two research groups are investigating the responses of the MCI members to treatments that involve acoustical conditions, exercise and movement, and lighting changes that may support retention or relearning of skills. Care partners and family members receive support and instruction to improve home and work life, promoting joy, purpose, and wellness in the family groups. The lighting system uses tunable-white LEDs, employing luminaires with both warm and cool-color emitters that can be dimmed separately to produce any white correlated color temperature (CCT) between 2700 K and 6500 K. All luminaires were dimmable to achieve subdued or lively surroundings for different treatments, time-of-day, and mood. A central networked digital control system was employed to allow tuning of multiple spaces together (for example, bright, cool morning light could be programmed for extra stimulation, or lighting in all spaces at the end of the day could be reduced in both light output and CCT to promote relaxation and not interfere with the melatonin cycle of occupants). Almost all spaces were equipped with individual room control of dimming and color temperature with touch screens to allow users to tune the lighting as desired, but each room’s controls could also be specially programmed through the server in case the research staff were investigating lighting settings on learning, for example. The server incorporates a timeclock, and it is able to send signals to switch off all lighting after occupancy hours, or enable occupancy sensors to control the lighting. The bulk of the construction work was completed in January 2020. It was clear from an initial walk-through that although the lighting system produced the expected high light level with low-glare qualities of light, that there were issues and inconsistencies to be resolved. These were noted in an initial punchlist visit and expected to be resolved when the tech representatives from the agency visited with the electrical contractor in the following few weeks. What followed was 2.5 years of identifying unexpected lighting performance in terms of light output, color, scheduling, and occupancy. This report documents the issues encountered in the effort to get the lighting and controls systems to operate as intended. It concludes with guidance for design professionals and manufacturers to help avoid problematic complexity in future projects.

42 ENGINEERING↗

DOE OSTI2026

Accelerating laser ray tracing in high fidelity physics simulations of laser melting using squeeze U-net

Laser melting is a core component of the ongoing industrial revolution, dubbed Industry 4.0, as lasers facilitate fast and precise melting and fusion in advanced manufacturing. There is a strong need to optimize the laser process using simulations. However, this has proven challenging as high fidelity simulations are needed for predictive modeling and this is currently prohibitively expensive even when run on hundreds of processors on high performance computers. The challenge is capturing complex physics of laser material interaction, fluid dynamics, thermal physics and material phase transformations at various length and time scales. To close this technological gap, we modified a squeeze U-net to accelerate the laser ray tracing component of such high fidelity models by ~4x–40x while preserving the core physics principle of conservation of energy with 97% accuracy. This approach enables the accurate modeling of global laser energy absorption as a function of local surface temperatures and complex surface topologies, which govern the reflection directions and energy losses of laser rays upon interacting with the material surface.

Computer science↗

DOE OSTI2020

Understanding effects of printhead geometry in aerosol jet printing

Aerosol jet printing offers a versatile, high-resolution digital patterning capability broadly relevant to flexible and printed electronic systems. Despite its promise and numerous demonstrations, the theoretical principles driving process outputs have not been thoroughly explored. In this study, a custom-built, modular printing system is developed to provide a head-to-head comparison of two print nozzle geometries to better understand the technology. Print resolution data from a range of process parameters are analyzed using a support vector machine framework. The linear deposition rate is identified as a key variable, which can confound careful studies of printing performance. Taking this into account, a clear difference is observed between the printheads, corresponding to a difference in resolution of 57% ± 11% under typical conditions. Models to understand differences in aerodynamic and mass transport effects identify enhanced drying within the NanoJet printhead as a likely cause of this difference. Overall, this study provides improved understanding of the aerosol jet printing process, including valuable insight to inform process optimization, robust data analysis, ink formulation, and printer geometric design.

42 ENGINEERING↗