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A High-Throughput Method to Define Additive Manufacturing Process Parameters: Application to Haynes 282

This paper demonstrates how an analytical and experimental method can be used to rapidly define the 45 additive manufacturing settings for a new alloy where the process parameters were previously unknown. A nickel-based superalloy, Haynes 282, was chosen for the analysis. An experimental matrix of focused processing parameters was predicted with a dimensionless number and 100 samples were printed using the Selective Laser Melting technique. High-throughput measurements validated the predicted process conditions needed to achieve desired density and hardness. The whole process was completed in 16 hours. The new technique was confirmed with analytical processing maps adopted by the metal additive manufacturing community. With the predicted set of process parameters, microstructural characterizations and tensile testing were used to confirm the predictions. The resultant as-fabricated microstructures have refined length scales of both microsegregation and secondary phase distributions. As a result, the mechanical properties were comparable within the predicted processing window and exhibited high strength and high ductility.

Laser Material Processing↗

Thick target neutron yields from Beryllium, Carbon, Tungsten, and Lead targets irradiated by 26.7 MeV/nucleon 4 H e ions

The angular and energy distributions of secondary neutrons produced from 26.7 MeV/nucleon 4 He ions, stopping in thick Be, C, W and Pb targets are measured by the time of flight method. The GEANT4, PHITS, and FLUKA Monte Carlo simulation codes with different physics models are employed to simulate the neutron yields and the results are compared with the experimental data. For the thick Be and C targets, GEANT4 with INCL++ reproduces the experimental data reasonably well. Whereas PHITS with JQMD-2.0 overestimates the neutron yields at intermediate energies and FLUKA with PEANUT underestimated the neutron yields at intermediate energies. For W and Pb targets, FLUKA with PEANUT physics model agree with experimental data best. PHITS with JQMD-2.0 overestimates the neutron yield at intermediate energies at 0°, and GEANT4 with INCL++ underestimates the neutron yield at intermediate energies at three angles.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Surface-mediated spontaneous emulsification of the acylated peptide, semaglutide

Acylated peptides composed of glucagon-like peptide-1 receptor agonists modified with a fatty acid side chain are an important class of therapeutics for type 2 diabetes and obesity but are susceptible to an unusual physical instability in the presence of hydrophobic surfaces, i.e., spontaneous emulsification, also known as ouzo formation in practice. In this work, light scattering, small-angle X-ray scattering, and circular dichroism measurements are used to characterize the physical properties of the semaglutide colloidal phase, including size distribution, shape, secondary structure, internal structure, and internal composition, as a function of solution physico-chemical conditions. The existence and size of the colloids formed are successfully predicted by a classical Rayleigh model, which identifies the parameters controlling their size and formation. Colloid formation is found to be catalyzed by hydrophobic surfaces, and formation rates are modeled as an autocatalytic reaction, enabling the formation of a master curve for various surfaces that elucidates the mechanism. Surfaces differ due to differences in surface wettability, which can be correlated with Hansen solubility parameters. This work provides insights into this unusual colloidal phenomenon and guides the peptide synthesis process and drug product formulation in the pharmaceutical industry.

59 BASIC BIOLOGICAL SCIENCES↗

Influence of Powder Characteristics and Processing Methods on Creep Performance of Powder Metallurgy Hot Isostatic Pressed SS316

The U.S. nuclear energy expansion goals are driving the demand for manufacturing routes that can rapidly produce large, complex, near net shape components. Powder metallurgy hot isostatic pressing (PM HIP) is an advanced manufacturing technique that can be economically scaled-up, while alleviating the supply chain challenges that forging and casting face in terms of cost and lead time constraints. This makes PM-HIP a viable technology to aid and accelerate large-scale part manufacturing for nuclear applications. However, large-scale qualification and deployment of this technology require a thorough understanding of the influence of powder feedstock quality, powder handling history, hot isostatic pressing (HIP) parameters, and subsequent heat treatment on microstructural evolution and elevated temperature mechanical performance. The present work focusses on 316 austenitic stainless steel (SS316) which is most commonly used in high temperature environments for nuclear applications Results from this study show that PM HIPed SS316 meets ASME tensile requirements at room temperature and at elevated temperature. However, creep performance of PM-HIPed SS316 remains inferior to its wrought counterpart, demonstrating that tensile performance alone is not a reliable metric for long duration high temperature integrity. Further, this report delineates powder derived microstructural features that govern creep damage, with key evidences pointing to “microstructural inheritance” from gas atomized powder feedstocks. Commercial SS316 powders of varying chemical compositions and recycling histories were studies, and the results showed large differences in elemental segregation, oxide surface layers and secondary phase distributions. Multi-scale characterization revealed segregation of chromium, molybdenum, manganese and silicon at the boundaries and the precipitation of manganese-, silicon-, and molybdenum-oxides. During HIP consolidation, these surface oxides transform into decorated prior particle boundaries (PPBs) and grain boundary inclusions that persist through conventional post-HIP solution annealing treatment. The retained oxides in post-HIP microstructures were found to influence grain growth, precipitation behavior, and ultimately creep cavitation and fracture. Such post-HIP heat treatments are therefore limited by a complex trade-off between grain growth, and oxide coarsening which aggravate creep damage by acting as nucleation sites for cavities. The objective of this work is to establish an integrated processing–structure–property framework for PM-HIP 316 stainless steel by investigating the influence of powder feedstock characteristics in pre- and post-HIP processing as well as to understand the significance of post-HIP heat treatment on microstructural evolution and creep properties. The results from this report emphasize the significance of powder feedstock integrity in improving creep performance of PM-HIPed SS316, by highlight the effect of rapid solidification, elemental segregation, oxide formation and powder recycling on microstructural defect inheritance following HIP consolidation. Rather than considering HIP processing, solution annealing, and mechanical performance independently, this report treats powder production, HIP consolidation, post-HIP thermal processing, and creep deformation as interconnected stages within a continuous metallurgical process. The resulting framework will provide a scientific basis for developing feedstock engineering strategies capable of improving long-term reliability of PM-HIP stainless steels and accelerating their qualification for advanced nuclear applications.

Ajjarapu, Pavan [Oak Ridge National Laboratory (OR↗

Spectrophotometry of beta Lyrae

Two hundred and fourteen scans over the wavelength region 1100 A to 1800 A with 10 A resolution were obtained by OAO spacecraft for the eclipsing binary Beta Lyrae between JD 2440889.5 and JD 2440904.5. Preliminary results indicate that: (1) The intensity at primary minimum is almost exactly one-half that at maximum and that the primary eclipse is less deep than that in the visual or longer ultraviolet wavelengths; (2) except for the 1100 to 1200 A region, the depth of the primary eclipse appears independent of wavelength; (3) the energy distribution at secondary minimum is similar to that at primary; (4) the two most prominent emission lines match well both with Si IV and C IV emission observed in gamma Vel and imply an exciting source of high temperature; (5) the emission lines do not show variation with phase.

Houck, T. E.↗

The definition of cross polarization.

Consideration of three alternate definitions of cross-polarization known to the author. The three definitions are expressed precisely in terms of the same antenna pattern coordinate system, and the relative merits of the various definitions are discussed. One of the definitions is shown to be the proper choice for describing source current polarizations, another is suitable for relating source current distributions to secondary patterns, and the third is the best choice for describing antenna patterns.

Ludwig, A. C.↗

Heating of the ambient ionosphere by an artificially injected electron beam

An electrostatic analyzer on the electron accelerator of the Electron Echo 2 experiment showed that the electrons of the background plasma were heated to 10,000 K or more within 8 ms of the start of gun pulses. The degree of heating was dependent on the orientation of the rocket with respect to the magnetic field but was not measurably dependent on ambient electron density, neutral atmosphere density, or on the pitch angle at which the 40-keV electron beam was injected. This heating was also accompanied by an increase of plasma density. No evidence was found for an ion-free region around the rocket during gun pulses. These observations show that significant amounts of ionization are taking place around the rocket. During part of the flight a two-temperature electron distribution was found. It is believed that the high-temperature part of these distributions represents secondaries produced by the beam.

Cartwright, D. G.↗

Stable dielectric charge distributions from field enhancement of secondary mission

The emission of secondary electrons from dielectrics subject to numerous effects of electric field which are experimentally difficult to control is discussed. Measurements are reported using pulse techniques such that local fields do not build to significant levels, but measurements with fields present are also of interest. A specific series of measurements under controlled conditions are described and their implications in terms of fields, magnitude and angle, near the dielectric surface were examined. The measurements were made for a charged fluorinated-ethylene-propylene surface near a grounded aluminum half-round resting on the surface. The geometry produced a stable surface-charge gradient being controlled by a strongly enhanced secondary emission for which a model is constructed. Observations of surface flashovers under various conditions confirm the predictions of some scaling exercises.

Robinson, J. W.↗

Systems study for an Integrated Digital-Electric Aircraft (IDEA)

The results of the Integrated Digital/Electric Aircraft (IDEA) Study are presented. Airplanes with advanced systems were, defined and evaluated, as a means of identifying potential high payoff research tasks. A baseline airplane was defined for comparison, typical of a 1990's airplane with advanced active controls, propulsion, aerodynamics, and structures technology. Trade studies led to definition of an IDEA airplane, with extensive digital systems and electric secondary power distribution. This airplane showed an improvement of 3% in fuel use and 1.8% in DOC relative to the baseline configuration. An alternate configuration, an advanced technology turboprop, was also evaluated, with greater improvement supported by digital electric systems. Recommended research programs were defined for high risk, high payoff areas appropriate for implementation under NASA leadership.

Tagge, G. E.↗

Studies of the aurorally-induced ultraviolet emissions on the nightside of Venus

The effect of a monoenergetic flux of electrons on a model atmosphere of the nightside thermosphere of Venus was examined. The neutral model chosen is that of Hedin for high solar activity and l65 degrees solar zenith angle. The model is based on measurements made by the Pioneer Venus Orbiter Neutral Mass Spectrometer. Four species were included in the calculation: CO2, O, CO, and N2. The numerical method that was chosen for energy deposition of the primary electrons is the continuous slowing down approximation. The secondary electron distribution was computed using the empirically determined shape of the differential cross section.

Fox, J. L.↗

Statistical Analysis For Nucleus/Nucleus Collisions

Report describes use of several statistical techniques to charactertize angular distributions of secondary particles emitted in collisions of atomic nuclei in energy range of 24 to 61 GeV per nucleon. Purpose of statistical analysis to determine correlations between intensities of emitted particles and angles comfirming existence of quark/gluon plasma.

Mcguire, Stephen C.↗

Hydrodynamic behavior and electrochemical impedance of the Hanging Meniscus Rotating Disk (HMRD) electrode. I - Meniscus shape under rotation. II - I-BIEM calculations of frequency dispersion and minimization

The shape equations for an HMRD in static and rotating configurations are developed and solved numerically. A rationale for the applicability of the standard Levich equations to the rotating case is given. The region of stability of the HMRD is examined, and the observed small negative intercept for a Levich plot is explained. The iterative boundary integral equation method is applied to the problem of frequency dispersion at an HMRD electrode. It is shown that a range of disk sizes and heights can be chosen to give almost uniform primary and secondary current distribution and minimal frequency disperison.

Cahan, Boris D.↗

Space Station Freedom secondary power wiring requirements

Secondary power is produced by DDCU's (direct current to direct current converter units) and routed to and through secondary power distribution assemblies (SPDA's) to loads or tertiary distribution assemblies. This presentation outlines requirements of Space Station Freedom (SSF) EEE (electrical, electronic, and electromechanical) parts wire and the approved electrical wire and cable. The SSF PDRD (Program Definition and Requirements Document) language problems and resolution are reviewed. The cable routing to and from the SPDA's is presented as diagrams and the wire recommendations and characteristics are given.

Sawyer, C. R.↗

Electron transport and energy degradation in the ionosphere: Evaluation of the numerical solution, comparison with laboratory experiments and auroral observations

Auroral electron transport calculations are a critical part of auroral models. We evaluate a numerical solution to the transport and energy degradation problem. The numerical solution is verified by reproducing simplified problems to which analytic solutions exist, internal self-consistency tests, comparison with laboratory experiments of electron beams penetrating a collision chamber, and by comparison with auroral observations, particularly the emission ratio of the N2 second positive to N2(+) first negative emissions. Our numerical solutions agree with range measurements in collision chambers. The calculated N(2)2P to N2(+)1N emission ratio is independent of the spectral characteristics of the incident electrons, and agrees with the value observed in aurora. Using different sets of energy loss cross sections and different functions to describe the energy distribution of secondary electrons that emerge from ionization collisions, we discuss the uncertainties of the solutions to the electron transport equation resulting from the uncertainties of these input parameters.

Lummerzheim, D.↗

Light ion components of the galactic cosmic rays: Nuclear interactions and transport theory

Light nuclei are present in the primary galactic cosmic rays (GCR) and are produced in thick targets due to projectile or target fragmentation from both nucleon and heavy induced reactions. In the primary GCR, He-4 is the most abundant nucleus after H-1. However, there are also a substantial fluxes of H-2 and He-3. In this paper we describe theoretical models based on quantum multiple scattering theory for the description of light ion nuclear interactions. The energy dependence of the light ion fragmentation cross section is considered with comparisons of inclusive yields and secondary momentum distributions to experiments described. We also analyze the importance of a fast component of lights ions from proton and neutron induced target fragementation. These theoretical models have been incorporated into the cosmic ray transport code HZETRN and will be used to analyze the role of shielding materials in modulating the production and the energy spectrum of light ions.

Cucinotta, F. A.↗

On Measuring Cosmic Ray Energy Spectra with the Rapidity Distributions

An important goal of cosmic ray research is to measure the elemental energy spectra of galactic cosmic rays up to 10(exp 16) eV. This goal cannot be achieved with an ionization calorimeter because the required instrument is too massive for space flight. An alternate method will be presented. This method is based on measuring the primary particle energy by determining the angular distribution of secondaries produced in a target layer. The proposed technique can be used over a wide range of energies (10 (exp 11) -10 (exp 16) eV) and gives an energy resolution of 60% or better. Based on this technique, a conceptual design for a new instrument (KLEM) will be presented. Due to its light weight, this instrument can have a large aperture enabling the direct measurement of cosmic rays to 1016 eV.

Bashindzhagyan, G.↗

An Instrument to Measure Elemental Energy Spectra of Cosmic Ray Nuclei Up to 10(exp 16) eV

A longstanding goal of cosmic ray research is to measure the elemental energy spectra of cosmic rays up to and through the "knee" (approx. equal to 3 x 10 (exp 15) eV. It is not currently feasible to achieve this goal with an ionization calorimeter because the mass required to be deployed in Earth orbit is very large (at least 50 tonnes). An alternative method will be presented. This is based on measuring the primary particle energy by determining the angular distribution of secondaries produced in a target layer using silicon microstrip detector technology. The proposed technique can be used over a wide range of energies (10 (exp 11)- 10 (exp 16) eV) and gives an energy resolution of 60% or better. Based on this technique, a design for a new lightweight instrument with a large aperture (KLEM) will be described.

Adams, J.↗