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NASA NTRS1992

Automated Weld Characterization Using the Thermoelectric Method

The effective assessment of the integrity of welds is a complicated NDE problem that continues to be a challenge. To be able to completely characterize a weld, detailed knowledge of its tensile strength, ductility, hardness, microstructure, macrostructure, and chemical composition is needed. NDE techniques which can provide information on any of these features are extremely important. In this paper, we examine a seldom used approach based on the thermoelectric (TE) effect for characterizing welds and their associated heat affected zone (HAZ). The thermoelectric method monitors the thermoelectric power which is sensitive to small changes in the kinetics of the conduction electrons near the Fermi surface that can be caused by changes in the local microstructure. The technique has been applied to metal sorting, quality testing, flaw detection, thickness gauging of layers, and microscopic structural analysis. To demonstrate the effectiveness of the technique for characterizing welds, a series of tungsten-inert-gas welded Inconel-718 samples were scanned with a computer controlled TE probe. The samples were then analyzed using a scanning electron microscope and Rockwell hardness tests to characterize the weld and the associated HAZ. We then correlated the results with the TE measurements to provide quantitative information on the size of the HAZ and the degree of hardness of the material in the weld region. This provides potentially valuable information on the strength and fatigue life of the weld. We begin the paper by providing a brief review of the TE technique and then highlight some of the factors that can effect the measurements. Next, we provide an overview of the experimental procedure and discuss the results. Finally, we summarize our findings and consider areas for future research.

Fulton, J. P.↗
NASA NTRS2004

An Overview of MODIS Calibration and Characterization

The MODerate Resolution Imaging Spectroradiometer (MODIS) is one of the key instruments for the NASA s Earth Observing System (EOS). It is currently operating on both EOS Terra and Aqua satellites. The MODIS is a major advance over its heritage sensors in terms of its spectral, spatial, and temporal resolutions with frequent global observations and a broad range of science applications. There are 20 reflective solar bands (RSB) with center wavelengths ranging from 0.41 to 2.l microns and 16 thermal emissive bands (TEB) from 3.7 to 14.4 microns. The absolute radiometric accuracy requirements (lsigma) at the typical spectral radiance levels are plus or minus 2% for the RSB reflectance factors and plus or minus 5% for the RSB radiance products. With few exceptions, the TEB requirements are plus or minus 1%. To verify that the instruments met their specified design requirements both Terra and Aqua MODIS underwent extensive pre-launch calibration and characterization at various levels, including system-level thermal vacuum testing. On-orbit calibration and characterization are performed by the on-board calibrators: a solar diffuser (SD) and a solar diffuser stability monitor (SDSM), a V-groove flat panel blackbody (BB), and a spectro-radiometric calibration assembly (SRCA). In this paper, we present an overview of MODIS calibration and characterization activities, methodologies, and lessons learned from pre-launch testing and on-orbit operations. Key issues to be discussed include our on-orbit efforts of monitoring detectors noise characterization, tracking solar diffuser and optics degradation, and updating sensor s response versus scan-angle. The MODIS experience has provided invaluable lessons that are being used in designing and testing the Visible Infrared Imaging Radiometer Suite (VIIRS), a direct follow-on to the MODIS that will be flown on the National Polar-Orbit Operational Environmental Satellite System (NPOESS) missions.

Xiong, X.↗
NASA NTRS2004

OrbView-3 Initial On-Orbit Characterization

NASA at Stennis Space Center (SSC) established a Space Act Agreement with Orbital Sciences Corporation (OSC) and ORBIMAGE Inc. to collaborate on the characterization of the OrbView-3 system and its imagery products and to develop characterization techniques further. In accordance with the agreement, NASA performed an independent radiometric, spatial, and geopositional accuracy assessment of OrbView-3 imagery acquired before completion of the system's initial on-orbit checkout. OSC acquired OrbView-3 imagery over SSC from July 2003 through January 2004, and NASA collected ground reference information coincident with many of these acquisitions. After evaluating all acquisitions, NASA deemed two multispectral images and five panchromatic images useful for characterization. NASA then performed radiometric, spatial, and geopositional characterizations.

Ross, Kent↗
NASA NTRS2004

Fabrication of a novel gigabit/second free-space optical interconnect - photodetector characterization and testing and system development

The time when computing power is limited by the copper wire inherent in the computer system and not the speed of the microprocessor is rapidly approaching. With constant advances in computer technology, many researchers believe that in only a few years, optical interconnects will begin to replace copper wires in your Central Processing Unit (CPU). On a more macroscopic scale, the telecommunications industry has already made the switch to optical data transmission as, to date, fiber optic technology is the only reasonable method of reliable, long range data transmission. Within the span of a decade, we will see optical technologies move from the macroscopic world of the telecommunications industry to the microscopic world of the computer chip. Already, the communications industry is marketing commercially available optical links to connect two personal computers, thereby eliminating the need for standard and comparatively slow wired and wireless Ethernet transfers and greatly increasing the distance the computers can be separated. As processing demands continue to increase, the realm of optical communications will continue to move closer to the microprocessor and quite possibly onto the microprocessor itself. A day may come when copper connections are used only to supply power, not transfer data. This summer s work marks some of the beginning stages of a 5 to 10 year, long-term research project to create and study a free-space, 1 Gigabit/sec optical interconnect. The research will result in a novel fabricated, chip-to-chip interconnect consisting of a Vertical Cavity Surface Emitting Laser (VCSEL) Diode linked through free space to a Metal- Semiconductor-Metal (MSM) Photodetector with the possible integration of microlenses for signal focusing and Micro-Electromechanical Systems (MEMS) devices for optical signal steering. The advantages, disadvantages, and practicality of incorporating flip-chip mounting technologies will also be addressed. My work began with the design and construction of a test setup for the experiment and then appropriate characterization of the test system. Specifically, I am involved in the characterization of a commercially available 1550nm wavelength, 5mW diode laser and a study of its modulation bandwidth. Commercially produced photodetectors as well as the incorporation of microwave technology, in the form of RF input and output, are used in the characterization procedure. The next stage involves the use of a probe station and network analyzer to characterize and test a series of photodetectors fabricated on a 2 inch, Indium Gallium Arsenide (InGaAs) wafer in the Branch s microlithography lab. Other project responsibilities include, but are not limited to the incorporation of a transimpedance amplifier to the photodetector circuit; a study of VCSEL technology; bit error rate analysis of an optical interconnect system; and analysis of free space divergence of the VCSEL, optical path length of the interconnect; and any other pertinent optical properties of the one gigabit per second interconnect for fabrication and testing.

Savich, Gregory R.↗
NASA NTRS2004

High-Temperature Probe Station Developed to Characterize Microwave Devices Through 500 C

A photograph and a block diagram of the high-temperature probe station are shown. The system consists of the ceramic heater mounted on a NASA shuttle tile insulator, a direct current power supply, a personal-computer-based data acquisition and temperature controller, microwave probes, a microscope, and a network analyzer. The ability to perform microwave tests at high temperatures is becoming necessary. There is now a need for sensors and communication circuits that can operate at 500 C and above for aircraft engine development and monitoring during flight. To address this need, researchers have fabricated devices using wide bandgap semiconductors such as SiC with targeted operating temperatures of 500 to 600 C. However, the microwave properties of these devices often change drastically with temperature, so any designs that are intended to be used in such an environment must be characterized at high temperatures. For some reliability, lifetime, and direct-current testing, the device under test can be packaged and characterized in an oven. However, for RF and microwave measurements, it is usually not possible to establish a calibrated reference plane at the device terminals within a package. In addition, the characteristics of the package would vary over a 500 C temperature range, and this would have to be accounted for when the data were analyzed. A high temperature probe station allows circuits and devices to be characterized through on wafer measurements across a broad temperature range with known reference plane. The conventional, commercially available thermal wafer-probe stations that are used to evaluate microwave devices across a controlled temperature range have a typical upper limit of 200 C. Standalone thermal heating chucks are available with an extended upper temperature range of 300 to 400 C. To effectively characterize devices at temperatures up to and surpassing 500 C, Glenn researchers developed a custom probe station. In the past, custom probe stations have been developed to test devices under other extreme environments, such as cryogenic temperatures as low as 37 K. Similarly, this custom probe station was specifically modified for high-temperature use. It allows devices to be measured quickly and flexibly, without the use of wire bonds and test fixtures. The probe station is shown making scattering parameter measurements from 1 to 50 GHz with a Hewlett-Packard 8510C Network Analyzer. There is a half-wafer of silicon directly on top of the heater to provide a uniform heated platform for our sample. A quarter wafer of silicon carbide forms the substrate for our test circuit of several transmission lines.

Downey, Alan N.↗
NASA NTRS2003

White Light Used to Enable Enhanced Surface Topography, Geometry, and Wear Characterization of Oil-Free Bearings

A new optically based measuring capability that characterizes surface topography, geometry, and wear has been employed by NASA Glenn Research Center s Tribology and Surface Science Branch. To characterize complex parts in more detail, we are using a three-dimensional, surface structure analyzer-the NewView5000 manufactured by Zygo Corporation (Middlefield, CT). This system provides graphical images and high-resolution numerical analyses to accurately characterize surfaces. Because of the inherent complexity of the various analyzed assemblies, the machine has been pushed to its limits. For example, special hardware fixtures and measuring techniques were developed to characterize Oil- Free thrust bearings specifically. We performed a more detailed wear analysis using scanning white light interferometry to image and measure the bearing structure and topography, enabling a further understanding of bearing failure causes.

Lucero, John M.↗
NASA NTRS2006

Measurement Sets and Sites Commonly Used for High Spatial Resolution Image Product Characterization

Scientists within NASA's Applied Sciences Directorate have developed a well-characterized remote sensing Verification & Validation (V&V) site at the John C. Stennis Space Center (SSC). This site has enabled the in-flight characterization of satellite high spatial resolution remote sensing system products form Space Imaging IKONOS, Digital Globe QuickBird, and ORBIMAGE OrbView, as well as advanced multispectral airborne digital camera products. SSC utilizes engineered geodetic targets, edge targets, radiometric tarps, atmospheric monitoring equipment and their Instrument Validation Laboratory to characterize high spatial resolution remote sensing data products. This presentation describes the SSC characterization capabilities and techniques in the visible through near infrared spectrum and examples of calibration results.

Pagnutti, Mary↗
NASA NTRS2007

System Characterization Results for the QuickBird Sensor

An overall system characterization was performed on several DigitalGlobe' QuickBird image products by the NASA Applied Research & Technology Project Office (formerly the Applied Sciences Directorate) at the John C. Stennis Space Center. This system characterization incorporated geopositional accuracy assessments, a spatial resolution assessment, and a radiometric calibration assessment. Geopositional assessments of standard georeferenced multispectral products were obtained using an array of accurately surveyed geodetic targets evenly spaced throughout a scene. Geopositional accuracy was calculated in terms of circular error. Spatial resolution of QuickBird panchromatic imagery was characterized based on edge response measurements using edge targets and the tilted-edge technique. Relative edge response was estimated as a geometric mean of normalized edge response differences measured in two directions of image pixels at points distanced from the edge by -0.5 and 0.5 of ground sample distance. A reflectance-based vicarious calibration approach, based on ground-based measurements and radiative transfer calculations, was used to estimate at-sensor radiance. These values were compared to those measured by the sensor to determine the sensor's radiometric accuracy. All imagery analyzed was acquired between fall 2005 and spring 2006. These characterization results were compared to previous years' results to identify any temporal drifts or trends.

Holekamp, Kara↗
NASA NTRS2006

NASA Radiometric Characterization

This viewgraph presentation reviews the characterization of radiometric data by NASA. The objective was to perform radiometric vicarious calibrations of imagery and compare with vendor-provided calibration coefficients. The approach was to use multiple, well-characterized sites. These sites are widely used by the NASA science community for radiometric characterization of airborne and space borne sensors. Using the data from these sites, the investigators performed independent characterizations with independent teams. Each team has slightly different measurement techniques and data processing methods.

Holekamp, Kara↗
NASA NTRS2007

Detector Noise Characterization and Performance of MODIS Thermal Emissive Bands

MODIS has 16 thermal emissive bands, a total of 160 individual detectors (10 for each spectral bands), located on the two cold focal plane assemblies (CFPA). MODIS TEB detectors were fully characterized pre-launch in a thermal vacuum (TV) environment using a NIST traceable blackbody calibration source (BCS) with temperatures ranging from 170 to 340K. On-orbit the TEB detectors are calibrated using an on-board blackbody (BB) on a scan-by-scan basis. For nominal on-orbit operation, the on-board BB temperature is typically controlled at 285K for Aqua MODIS and 290K for Terra MODIS. For the MODIS TEB calibration, each detector's noise equivalent temperature difference (NEdT) is often used to assess its performance and this parameter is a major contributor to the calibration uncertainty. Because of its impact on sensor calibration and data product quality, each MODIS TEB detector's NEdT is monitored on a daily basis at a fixed BB temperature and completely characterized on a regular basis at a number of BB temperatures. In this paper, we describe MODIS on-orbit TEB NEdT characterization activities, approaches, and results. We compare both pre-launch and on-orbit performance with sensor design specification and examine detector noise characterization impact on the calibration uncertainty. To date, 135 TEB detectors (out of a total of 160 detectors) in Terra MODIS (launched in December 1999) and 158 in Aqua MODIS (launched in May 2002) continue to perform with their NEdT below (or better than) their design specifications. A complete summary of all TEB noisy detectors, identified both pre-launch and on-orbit, is provided.

Xiong, X.↗
NASA NTRS2009

XPS Protocol for the Characterization of Pristine and Functionalized Single Wall Carbon Nanotubes

Recent interest in developing new applications for carbon nanotubes (CNT) has fueled the need to use accurate macroscopic and nanoscopic techniques to characterize and understand their chemistry. X-ray photoelectron spectroscopy (XPS) has proved to be a useful analytical tool for nanoscale surface characterization of materials including carbon nanotubes. Recent nanotechnology research at NASA Johnson Space Center (NASA-JSC) helped to establish a characterization protocol for quality assessment for single wall carbon nanotubes (SWCNTs). Here, a review of some of the major factors of the XPS technique that can influence the quality of analytical data, suggestions for methods to maximize the quality of data obtained by XPS, and the development of a protocol for XPS characterization as a complementary technique for analyzing the purity and surface characteristics of SWCNTs is presented. The XPS protocol is then applied to a number of experiments including impurity analysis and the study of chemical modifications for SWCNTs.

Sosa, E. D.↗
NASA NTRS2010

Characterizing the Space Debris Environment with a Variety of SSA Sensors

Damaging space debris spans a wide range of sizes and altitudes. Therefore no single method or sensor can fully characterize the space debris environment. Space debris researchers use a variety of radars and optical telescopes to characterize the space debris environment in terms of number, altitude, and inclination distributions. Some sensors, such as phased array radars, are designed to search a large volume of the sky and can be instrumental in detecting new breakups and cataloging and precise tracking of relatively large debris. For smaller debris sizes more sensitivity is needed which can be provided, in part, by large antenna gains. Larger antenna gains, however, produce smaller fields of view. Statistical measurements of the debris environment with less precise orbital parameters result. At higher altitudes, optical telescopes become the more sensitive instrument and present their own measurement difficulties. Space Situational Awareness, or SSA, is concerned with more than the number and orbits of satellites. SSA also seeks to understand such parameters as the function, shape, and composition of operational satellites. Similarly, debris researchers are seeking to characterize similar parameters for space debris to improve our knowledge of the risks debris poses to operational satellites as well as determine sources of debris for future mitigation. This paper will discuss different sensor and sensor types and the role that each plays in fully characterizing the space debris environment.

Stansbery, Eugene G.↗
NASA NTRS2012

Microbial Characterization Space Solid Wastes Treated with a Heat Melt Compactor

The on going purpose of the project efforts was to characterize and determine the fate of microorganisms in space-generated solid wastes before and after processing by candidate solid waste processing. For FY 11, the candidate technology that was assessed was the Heat Melt Compactor (HMC). The scope included five HMC. product disks produced at ARC from either simulated space-generated trash or from actual space trash, Volume F compartment wet waste, returned on STS 130. This project used conventional microbiological methods to detect and enumerate microorganisms in heat melt compaction (HMC) product disks as well as surface swab samples of the HMC hardware before and after operation. In addition, biological indicators were added to the STS trash prior to compaction in order to determine if these spore-forming bacteria could survive the HMC processing conditions, i.e., high temperature (160 C) over a long duration (3 hrs). To ensure that surface dwelling microbes did not contaminate HMC product disk interiors, the disk surfaces were sanitized with 70% alcohol. Microbiological assays were run before and after sanitization and found that sanitization greatly reduced the number of identified isolates but did not totally eliminate them. To characterize the interior of the disks, ten 1.25 cm diameter core samples were aseptically obtained for each disk. These were run through the microbial characterization analyses. Low counts of bacteria, on the order of 5 to 50 per core, were found, indicating that the HMC operating conditions might not be sufficient for waste sterilization. However, the direct counts were 6 to 8 orders of magnitude greater, indicating that the vast majority of microbes present in the wastes were dead or non-cultivable. An additional indication that the HMC was sterilizing the wastes was the results from the added commercial spore test strips to the wastes prior to HMC operation. Nearly all could be recovered from the HMC disks post-operation and all were showed negative growth when run through the manufacturer's protocol, meaning that the 106 or so spores impregnated into the strips were dead. Control test strips, i.e., not exposed to the HMC conditions were all strongly positive. One area of concern is that the identities of isolates from the cultivable counts included several human pathogens, namely Staphylococcus aureus. The project reported here provides microbial characterization support to the Waste Management Systems element of the Life Support and Habitation Systems program.

Strayer, Richard F.↗
NASA NTRS2012

Characterization of Material Response During Arc-Jet Testing with Optical Methods Status and Perspectives

The characterization of ablation and recession of heat shield materials during arc jet testing is an important step towards understanding the governing processes during these tests and therefore for a successful extrapolation of ground test data to flight. The behavior of ablative heat shield materials in a ground-based arc jet facility is usually monitored through measurement of temperature distributions (across the surface and in-depth), and through measurement of the final surface recession. These measurements are then used to calibrate/validate materials thermal response codes, which have mathematical models with reasonably good fidelity to the physics and chemistry of ablation, and codes thus calibrated are used for predicting material behavior in flight environments. However, these thermal measurements only indirectly characterize the pyrolysis processes within an ablative material pyrolysis is the main effect during ablation. Quantification of pyrolysis chemistry would therefore provide more definitive and useful data for validation of the material response codes. Information of the chemical products of ablation, to various levels of detail, can be obtained using optical methods. Suitable optical methods to measure the shape and composition of these layers (with emphasis on the blowing layer) during arc jet testing are: 1) optical emission spectroscopy (OES) 2) filtered imaging 3) laser induced fluorescence (LIF) and 4) absorption spectroscopy. Several attempts have been made to optically measure the material response of ablative materials during arc-jet testing. Most recently, NH and OH have been identified in the boundary layer of a PICA ablator. These species are suitable candidates for a detection through PLIF which would enable a spatially-resolved characterization of the blowing layer in terms of both its shape and composition. The recent emission spectroscopy data will be presented and future experiments for a qualitative and quantitative characterization of the material response of ablative materials during arc-jet testing will be discussed.

Winter, Michael↗
NASA NTRS2012

Wideband Single-Crystal Transducer for Bone Characterization

The microgravity conditions of space travel result in unique physiological demands on the human body. In particular, the absence of the continual mechanical stresses on the skeletal system that are present on Earth cause the bones to decalcify. Trabecular structure decreases in thickness and increases in spacing, resulting in decreased bone strength and increased risk of injury. Thus, monitoring bone health is a high priority for long-term space travel. A single probe covering all frequency bands of interest would be ideal for such measurements, and this would also minimize storage space and eliminate the complexity of integrating multiple probes. This invention is an ultrasound transducer for the structural characterization of bone. Such characterization measures features of reflected and transmitted ultrasound signals, and correlates these signals with bone structure metrics such as bone mineral density, trabecular spacing, and thickness, etc. The techniques used to determine these various metrics require measurements over a broad range of ultrasound frequencies, and therefore, complete characterization requires the use of several narrowband transducers. This is a single transducer capable of making these measurements in all the required frequency bands. The device achieves this capability through a unique combination of a broadband piezoelectric material; a design incorporating multiple resonator sizes with distinct, overlapping frequency spectra; and a micromachining process for producing the multiple-resonator pattern with common electrode surfaces between the resonators. This device consists of a pattern of resonator bars with common electrodes that is wrapped around a central mandrel such that the radiating faces of the resonators are coplanar and can be simultaneously applied to the sample to be measured. The device operates as both a source and receiver of acoustic energy. It is operated by connection to an electronic system capable of both providing an excitation signal to the transducer and amplifying the signal received from the transducer. The excitation signal may be either a wide-bandwidth signal to excite the transducer across its entire operational spectrum, or a narrow-bandwidth signal optimized for a particular measurement technique. The transducer face is applied to the skin covering the bone to be characterized, and may be operated in through-transmission mode using two transducers, or in pulse-echo mode. The transducer is a unique combination of material, design, and fabrication technique. It is based on single-crystal lead magnesium niobate lead titanate (PMN-PT) piezoelectric material. As compared to the commonly used piezoceramics, this piezocrystal has superior piezoelectric and elastic properties, which results in devices with superior bandwidth, source level, and power requirements. This design necessitates a single resonant frequency. However, by operating in a transverse length-extensional mode, with the electric field applied orthogonally to the extensional direction, resonators of different sizes can share common electrodes, resulting in a multiply-resonant structure. With carefully sized resonators, and the superior bandwidth of piezocrystal, the resonances can be made to overlap to form a smooth, wide-bandwidth characteristic.

Liang, Yu↗
NASA NTRS2012

Wideband Single-Crystal Transducer for Bone Characterization

The microgravity conditions of space travel result in unique physiological demands on the human body. In particular, the absence of the continual mechanical stresses on the skeletal system that are present on Earth cause the bones to decalcify. Trabecular structure decreases in thickness and increases in spacing, resulting in decreased bone strength and increased risk of injury. Thus, monitoring bone health is a high priority for long-term space travel. A single probe covering all frequency bands of interest would be ideal for such measurements, and this would also minimize storage space and eliminate the complexity of integrating multiple probes. This invention is an ultrasound transducer for the structural characterization of bone. Such characterization measures features of reflected and transmitted ultrasound signals, and correlates these signals with bone structure metrics such as bone mineral density, trabecular spacing, and thickness, etc. The techniques used to determine these various metrics require measurements over a broad range of ultrasound frequencies, and therefore, complete characterization requires the use of several narrowband transducers. This is a single transducer capable of making these measurements in all the required frequency bands. The device achieves this capability through a unique combination of a broadband piezoelectric material; a design incorporating multiple resonator sizes with distinct, overlapping frequency spectra; and a micromachining process for producing the multiple-resonator pattern with common electrode surfaces between the resonators. This device consists of a pattern of resonator bars with common electrodes that is wrapped around a central mandrel such that the radiating faces of the resonators are coplanar and can be simultaneously applied to the sample to be measured. The device operates as both a source and receiver of acoustic energy. It is operated by connection to an electronic system capable of both providing an excitation signal to the transducer and amplifying the signal received from the transducer. The excitation signal may be either a wide-bandwidth signal to excite the transducer across its entire operational spectrum, or a narrow-bandwidth signal optimized for a particular measurement technique. The transducer face is applied to the skin covering the bone to be characterized, and may be operated in through transmission mode using two transducers, or in pulse-echo mode.

Liang, Yu↗
NASA NTRS2013

DebriSat - A Planned Laboratory-Based Satellite Impact Experiment for Breakup Fragment Characterizations

The goal of the DebriSat project is to characterize fragments generated by a hypervelocity collision involving a modern satellite in low Earth orbit (LEO). The DebriSat project will update and expand upon the information obtained in the 1992 Satellite Orbital Debris Characterization Impact Test (SOCIT), which characterized the breakup of a 1960 s US Navy Transit satellite. There are three phases to this project: the design and fabrication of DebriSat - an engineering model representing a modern, 60-cm/50-kg class LEO satellite; conduction of a laboratory-based hypervelocity impact to catastrophically break up the satellite; and characterization of the properties of breakup fragments down to 2 mm in size. The data obtained, including fragment size, area-to-mass ratio, density, shape, material composition, optical properties, and radar cross-section distributions, will be used to supplement the DoD s and NASA s satellite breakup models to better describe the breakup outcome of a modern satellite.

Liou, Jer-Chyi↗
NASA NTRS2013

Neutron Characterization for Additive Manufacturing

Oak Ridge National Laboratory (ORNL) is leveraging decades of experience in neutron characterization of advanced materials together with resources such as the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) shown in Fig. 1 to solve challenging problems in additive manufacturing (AM). Additive manufacturing, or three-dimensional (3-D) printing, is a rapidly maturing technology wherein components are built by selectively adding feedstock material at locations specified by a computer model. The majority of these technologies use thermally driven phase change mechanisms to convert the feedstock into functioning material. As the molten material cools and solidifies, the component is subjected to significant thermal gradients, generating significant internal stresses throughout the part (Fig. 2). As layers are added, inherent residual stresses cause warping and distortions that lead to geometrical differences between the final part and the original computer generated design. This effect also limits geometries that can be fabricated using AM, such as thin-walled, high-aspect- ratio, and overhanging structures. Distortion may be minimized by intelligent toolpath planning or strategic placement of support structures, but these approaches are not well understood and often "Edisonian" in nature. Residual stresses can also impact component performance during operation. For example, in a thermally cycled environment such as a high-pressure turbine engine, residual stresses can cause components to distort unpredictably. Different thermal treatments on as-fabricated AM components have been used to minimize residual stress, but components still retain a nonhomogeneous stress state and/or demonstrate a relaxation-derived geometric distortion. Industry, federal laboratory, and university collaboration is needed to address these challenges and enable the U.S. to compete in the global market. Work is currently being conducted on AM technologies at the ORNL Manufacturing Demonstration Facility (MDF) sponsored by the DOE's Advanced Manufacturing Office. The MDF is focusing on R&D of both metal and polymer AM pertaining to in-situ process monitoring and closed-loop controls; implementation of advanced materials in AM technologies; and demonstration, characterization, and optimization of next-generation technologies. ORNL is working directly with industry partners to leverage world-leading facilities in fields such as high performance computing, advanced materials characterization, and neutron sciences to solve fundamental challenges in advanced manufacturing. Specifically, MDF is leveraging two of the world's most advanced neutron facilities, the HFIR and SNS, to characterize additive manufactured components.

Watkins, Thomas↗