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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Establishing and Maintaining the Digital Thread of Additively Manufactured Materials and Applications

Additive Manufacturing (AM) and Integrated Computational Materials Engineering (ICME) are complementary enabling technologies for design and manufacturing of “fit-for-purpose” materials. Both technologies will impact rapid material design, reduction in cost- and time-to-market for new applications, and discovery and implementation of new materials. An ICME approach to design, however, requires experimentally validated material models at multiple length and time scales, an integrated framework that can connect analysis tools with one another to ensure the digital thread of an application is maintained, and the manufacturing (e.g., AM) capability to leverage processing-structure-property-performance (PSPP) relationships to achieve spatially varying material properties where desired. AM enables the implementation of the design of an optimized, spatially varying microstructure through careful selection of the processing parameters used during an additively manufactured build. In order to establish these PSPP relations, a large amount of data is necessary, and that data must be properly captured, analyzed and maintained in an information management system that can establish the required traceability between various aspects of the design process to ensure an application’s digital thread is maintained (from design to end of life). Such an information management system must be able to capture feedstock material pedigree, resulting microstructure from various build parameters, subsequent mechanical properties derived from testing, developed material models, and enable spatial variations in material assignment in an engineering application. Furthermore, the information management system should be easily integrated with traditionally engineered materials in a single, centralized platform to enable an ICME optimization tool to explore both types of manufacturing processes. At NASA GRC, a robust, 21st century materials information management system has been previously developed with a focus towards enabling ICME. In this work, GRC’s ICME schema is extended to accommodate additively manufactured materials, enabling storage of both traditionally and additively manufactured materials in the same construct. The methodology for properly capturing additively manufactured materials across the entire material lifecycle is presented, following the previously established database best practices, as a potential framework for establishing PSPP relationships for additively manufactured materials and applying them to engineering applications.

Data management↗
NASA NTRSDate not supplied

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗
DOE OSTI2021

FVCOM-ICM4.0

FVCOM-ICM is a water quality model that simulates the influence of nutrients and carbon pollution on biogeochemical oceanographic processes such as phytoplankton primary productivity, nutrient consumption, mineralization, decay and settling of particulate organic matter and computes resulting dissolved oxygen (DO) concentrations and pH levels. An “offline” approach of coupling Finite Volume Coastal Ocean Model (FVCOM) hydrodynamic solutions to CE-QUAL-ICM biogeochemical model was used. FVCOM and CE-QUAL-ICM are public domain Fortran Codes that were developed independently by US Army Corps of Engineers and University of Massachusetts. PNNL developed FVCOM-ICM that has the ability to conduct water quality calculations using a previously computed hydrodynamic solution. The biogeochemical calculations using CE-QUAL-ICM kinetics are conducted over the same finite-volume mesh and in the FVCOM framework.

Khangaonkar, Tarang↗
NASA NTRS1993

Enrichment and heating of the intracluster medium by ejection from galaxies

Results of N-body + hydrodynamic simulations designed to model the formation and evolution of clusters of galaxies and intracluster gas are presented. Clusters of galaxies are the largest bound, relaxed objects in the universe. They are strong x-ray emitters; this radiation originates through thermal bremsstrahlung from a diffuse plasma filling the space between cluster galaxies, the intracluster medium or ICM. From observations, one can infer that the mass of the ICM is comparable to or greater than the mass of all the galaxies in the cluster, and that the ratio of mass in hot gas to mass in galaxies, M(sub ICM)/M(sub STARS), increases with the richness of the cluster. Spectroscopic studies of cluster x-ray emission show heavy element emission lines. While M(sub ICM)/M(sub STARS) is greater than or equal to 1 implies that most of the ICM is primordial in nature, the discovery of heavy elements indicates that some of the gas must have been processed through galaxies. Galaxy evolution thus directly impacts cluster evolution.

Metzler, Chris↗
NASA NTRS2003

Spatial Relationship of Signatures of Interplanetary Coronal Mass Ejections

Interplanetary coronal mass ejections (ICMEs) are characterized by a number of signatures. In particular, we examine the relationship between Fe charge states and other signatures during ICMEs in solar cycle 23. Though enhanced Fe charge states characterize many ICMEs, average charge states vary from event to event, are more likely to be enhanced in faster or flare-related ICMEs, and do not appear to depend on whether the ICME is a magnetic cloud.

Richardson, I. G.↗
NASA NTRS2006

Thermodynamic Structure of Collision-Dominated Expanding Plasma: Heating of Interplanetary Coronal Mass Injections

We investigate the thermodynamic structure of interplanetary coronal mass ejections (ICMEs) using combined surveys of the ejecta between 0.3 and 20 AU. ICMEs are shown to have a moderate expansion in the solar wind compared with theoretical predictions. The expansion seems to be governed by a polytrope with gamma approx. 1.3 in this distance range. We find that Coulomb collisions are important contributors to the ion-ion equilibration process in the ICME plasma. The alpha-proton differential speed quickly drops to below 10 km/s due to strong Coulomb collisions. However, the two species of particles are far from thermal equilibrium with a temperature ratio T(sub alpha/T(sub p) = 4-6, suggestive of a preferential heating of alpha particles. The plasma heating rate as a function of heliocentric &stance required for the temperature profile is deduced by taking into account the expansion and energy transfer between protons and alphas via Coulomb collisions. The turbulence dissipation rate is also inferred from the inertial range power spectrum of magnetic fluctuations within ICMEs. Comparison of the turbulence dissipation rate with the required heating rate shows that turbulence dissipation seems sufficient to explain the ICME heating. Sources powering the turbulence are also investigated by examining the instabilities induced by temperature anisotropies and energy deposition by pickup ions.

Liu, Y.↗
NASA NTRS2007

Interplanetary Coronal Mass Ejections During 1996 - 2007

Interplanetary coronal mass ejections, the interplanetary counterparts of coronal mass ejections at the Sun, are the major drivers of interplanetary shocks in the heliosphere, and are associated with modulations of the galactic cosmic ray intensity, both short term (Forbush decreases caused by the passage of the shock, post-shock sheath, and ICME), and possibly with longer term modulation. Using several in-situ signatures of ICMEs, including plasma temperature, and composition, magnetic fields, and cosmic ray modulations, made by near-Earth spacecraft, we have compiled a "comprehensive" list of ICMEs passing the Earth since 1996, encompassing solar cycle 23. We summarize the properties of these ICMEs, such as their occurrence rate, speeds and other parameters, the fraction of ICMEs that are classic magnetic clouds, and their association with solar energetic particle events, halo CMEs, interplanetary shocks, geomagnetic storms, shocks and cosmic ray decreases.

Richardson, I. G.↗
NASA NTRS2007

Solar and Interplanetary Sources of Major Geomagnetic Storms (Dst less than or equal to -100 nT) During 1996 - 2005

We present the results of an investigation of the sequence of events from the Sun to the Earth that ultimately led to the 88 major geomagnetic storms (defined by minimum Dst less than or equal to -100 nT) that occurred during 1996 - 2005. The results are achieved through cooperative efforts that originated at the Living with a Star (LWS) Coordinated Data- Analysis Workshop (CDAW) held at George Mason University in March 2005. Based on careful examination of the complete array of solar and in-situ solar wind observations, we have identified and characterized, for each major geomagnetic storm, the overall solar-interplanetary (solar-IP) source type, the time, velocity and angular width of the source coronal mass ejection (CME), the type and heliographic location of the solar source region, the structure of the transient solar wind flow with the storm-driving component specified, the arrival time of shock/disturbance, and the start and ending times of the corresponding IP CME (ICME). The storm-driving component, which possesses a prolonged and enhanced southward magnetic field (B(sub s)) may be an ICME, the sheath of shocked plasma (SH) upstream of an ICME, a corotating interaction region (CIR), or a combination of these structures. We classify the Solar-IP sources into three broad types: (1) S-type, in which the storm is associated with a single ICME and a single CME at the Sun; (2) M-type, in which the storm is associated with a complex solar wind flow produced by multiple interacting ICMEs arising from multiple halo CMEs launched from the Sun in a short period; (3) C-type, in which the storm is associated with a CIR formed at the leading edge of a high speed stream originating from a solar coronal hole (CH). For the 88 major storms, the S-type, M-type and C-type events number 53 (60%): 24 (27%) and 11 (13%), respectively. For the 85 events for which the surface source regions could be investigated, 54 (63%) of the storms originated in solar active regions, 10 (12%) in quiet Sun regions associated with quiescent filaments or filament channels, and 11 (13%) were associated with coronal holes. Remarkably, 10 (12%) CME-driven events showed no sign of eruptive features on the surface (e.g., no flare, no coronal dimming, and no loop arcade, etc), even though all the available solar observation in a suitable time period were carefully examined. Thus, while it is generally true that a major geomagnetic storm is more likely to be driven by a front-side fast halo CME associated with a major flare, our study indicates a broad distribution of source properties. The implications of the results for space weather forecasting are briefly discussed.

Zhang, J.↗
NASA NTRS2010

Interplanetary Circumstances of Quasi-Perpendicular Interplanetary Shocks in 1996-2005

The angle (theta(sub Bn)) between the normal to an interplanetary shock front and the upstream magnetic field direction, though often thought of as a property "of the shock," is also determined by the configuration of the magnetic field immediately upstream of the shock. We investigate the interplanetary circumstances of 105 near-Earth quasi-perpendicular shocks during 1996-2005 identified by theta(sub Bn) greater than or equal to 80 degrees and/or by evidence of shock drift particle acceleration. Around 87% of these shocks were driven by interplanetary coronal mass ejections (ICMEs); the remainder were probably the forward shocks of corotating interaction regions. For around half of the shocks, the upstream field was approximately perpendicular to the radial direction, either east-west or west-east or highly inclined to the ecliptic. Such field directions will give quasi-perpendicular configurations for radially propagating shocks. Around 30% of the shocks were propagating through, or closely followed, ICMEs at the time of observation. Another quarter were propagating through the heliospheric plasma sheet (HPS), and a further quarter occurred in slow solar wind that did not have characteristics of the HPS. Around 11% were observed in high-speed streams, and 7% in the sheaths following other shocks. The fraction of shocks found in high-speed streams is around a third of that expected based on the fraction of the time when such streams were observed at Earth. Quasi-perpendicular shocks are found traveling through ICMEs around 2-3 times more frequently than expected. In addition, shocks propagating through ICMEs are more likely to have larger values of theta(sub Bn) than shocks outside ICMEs.

Richardson, I. G.↗
NASA NTRS2011

Galactic Cosmic Ray Intensity Response to Interplanetary Coronal Mass Ejections/Magnetic Clouds in 1995-2009

We summarize the response of the galactic cosmic ray (CGR) intensity to the passage of the more than 300 interplanetary coronal mass ejections (ICMEs) and their associated shocks that passed the Earth during 1995-2009, a period that encompasses the whole of Solar Cycle 23. In approx.80% of cases, the GCR intensity decreased during the passage of these structures, i.e., a "Forbush decrease" occurred, while in approx.10% there was no significant change. In the remaining cases, the GCR intensity increased. Where there was an intensity decrease, minimum intensity was observed inside the ICME in approx.90% of these events. The observations confirm the role of both post-shock regions and ICMEs in the generation of these decreases, consistent with many previous studies, but contrary to the conclusion of Reames, Kahler, and Tylka (Astrophys. 1. Lett. 700, L199, 2009) who, from examining a subset of ICMEs with flux-rope-like magnetic fields (magnetic clouds) argued that these are "open structures" that allow free access of particles including GCRs to their interior. In fact, we find that magnetic clouds are more likely to participate in the deepest GCR decreases than ICMEs that are not magnetic clouds.

Richardson, I. G.↗
NASA NTRS2012

Using Statistical Multivariable Models to Understand the Relationship Between Interplanetary Coronal Mass Ejecta and Magnetic Flux Ropes

In-situ measurements of interplanetary coronal mass ejections (ICMEs) display a wide range of properties. A distinct subset, "magnetic clouds" (MCs), are readily identifiable by a smooth rotation in an enhanced magnetic field, together with an unusually low solar wind proton temperature. In this study, we analyze Ulysses spacecraft measurements to systematically investigate five possible explanations for why some ICMEs are observed to be MCs and others are not: i) An observational selection effect; that is, all ICMEs do in fact contain MCs, but the trajectory of the spacecraft through the ICME determines whether the MC is actually encountered; ii) interactions of an erupting flux rope (PR) with itself or between neighboring FRs, which produce complex structures in which the coherent magnetic structure has been destroyed; iii) an evolutionary process, such as relaxation to a low plasma-beta state that leads to the formation of an MC; iv) the existence of two (or more) intrinsic initiation mechanisms, some of which produce MCs and some that do not; or v) MCs are just an easily identifiable limit in an otherwise corntinuous spectrum of structures. We apply quantitative statistical models to assess these ideas. In particular, we use the Akaike information criterion (AIC) to rank the candidate models and a Gaussian mixture model (GMM) to uncover any intrinsic clustering of the data. Using a logistic regression, we find that plasma-beta, CME width, and the ratio O(sup 7) / O(sup 6) are the most significant predictor variables for the presence of an MC. Moreover, the propensity for an event to be identified as an MC decreases with heliocentric distance. These results tend to refute ideas ii) and iii). GMM clustering analysis further identifies three distinct groups of ICMEs; two of which match (at the 86% level) with events independently identified as MCs, and a third that matches with non-MCs (68 % overlap), Thus, idea v) is not supported. Choosing between ideas i) and iv) is more challenging, since they may effectively be indistinguishable from one another by a single in-situ spacecraft. We offer some suggestions on how future studies may address this.

Riley, P.↗
NASA NTRS2013

The Solar Connection of Enhanced Heavy Ion Charge States in the Interplanetary Medium: Implications for the Flux-Rope Structure of CMEs

We investigated a set of 54 interplanetary coronal mass ejection (ICME) events whose solar sources are very close to the disk center (within +/- 15deg from the central meridian). The ICMEs consisted of 23 magnetic-cloud (MC) events and 31 non-MC events. Our analyses suggest that the MC and non-MC ICMEs have more or less the same eruption characteristics at the Sun in terms of soft X-ray flares and CMEs. Both types have significant enhancements in ion charge states, although the non-MC structures have slightly lower levels of enhancement. The overall duration of charge-state enhancement is also considerably smaller than that in MCs as derived from solar wind plasma and magnetic signatures. We find very good correlation between the Fe and O charge-state measurements and the flare properties such as soft X-ray flare intensity and flare temperature for both MCs and non-MCs. These observations suggest that both MC and non-MC ICMEs are likely to have a flux-rope structure and the unfavorable observational geometry may be responsible for the appearance of non-MC structures at 1 AU. We do not find any evidence for an active region expansion resulting in ICMEs lacking a flux-rope structure because the mechanism of producing high charge states and the flux-rope structure at the Sun is the same for MC and non-MC events.

flux rope↗
NASA NTRS2017

A Sun-to-Earth Analysis of Magnetic Helicity of the 2013 March 17-18 Interplanetary Coronal Mass Ejection

We compare the magnetic helicity in the 2013 March 17-18 interplanetary coronal mass ejection (ICME) flux rope at 1 au and in its solar counterpart. The progenitor coronal mass ejection (CME) erupted on 2013 March 15 from NOAA active region 11692 and is associated with an M1.1 flare. We derive the source region reconnection flux using the post-eruption arcade (PEA) method that uses the photospheric magnetogram and the area under the PEA. The geometrical properties of the near-Sun flux rope is obtained by forward-modeling of white-light CME observations. Combining the geometrical properties and the reconnection flux, we extract the magnetic properties of the CME flux rope. We derive the magnetic helicity of the flux rope using its magnetic and geometric properties obtained near the Sun and at 1 au. We use a constant-α force-free cylindrical flux rope model fit to the in situ observations in order to derive the magnetic and geometric information of the 1 au ICME. We find a good correspondence in both amplitude and sign of the helicity between the ICME and the CME, assuming a semicircular (half torus) ICME flux rope with a length of π au. We find that about 83% of the total flux rope helicity at 1 au is injected by the magnetic reconnection in the low corona. We discuss the effect of assuming flux rope length in the derived value of the magnetic helicity. This study connecting the helicity of magnetic flux ropes through the Sun-Earth system has important implications for the origin of helicity in the interplanetary medium and the topology of ICME flux ropes at 1 au and hence their space weather consequences.

Pal, Sanchita↗
NASA NTRS2018

Kinetic Properties of an Interplanetary Shock Propagating Inside a Coronal Mass Ejection

We investigate the kinetic properties of a typical fast-mode shock inside an interplanetary coronal mass ejection (ICME) observed on 1998 August 6 at 1 au, including particle distributions and wave analysis with the in situ measurements from Wind. Key results are obtained concerning the shock and the shock-ICME interaction at kinetic scales: (1) gyrating ions, which may provide energy dissipation at the shock in addition to wave-particle interactions, are observed around the shock ramp; (2) despite the enhanced proton temperature anisotropy of the shocked plasma, the low plasma beta inside the ICME constrains the shocked plasma under the thresholds of the ion cyclotron and mirror-mode instabilities; (3) whistler heat flux instabilities, which can pitch-angle scatter halo electrons through a cyclotron resonance, are observed around the shock, and can explain the disappearance of bi-directional electrons (BDEs) inside the ICME together with normal betatron acceleration; (4) whistler waves near the shock are likely associated with the whistler heat flux instabilities excited at the shock ramp, which is consistent with the result that the waves may originate from the shock ramp; (5) the whistlers share a similar characteristic with the shocklet whistlers observed by Wilson et al., providing possible evidence that the shock is decaying because of the strong magnetic field inside the ICME.

Liu, Mingzhe↗
NASA NTRS2022

Effect of an Interplanetary Coronal Mass Ejection on Saturn’s Radio Emission

The Saturn Kilometric Radiation (SKR) was observed for the first time during the flyby of Saturn by the Voyager spacecraft in 1980. These radio emissions, in the range of a few kHz to 1 MHz, are emitted by electrons travelling around auroral magnetic field lines. Their study is useful to understand the variability of a magnetosphere and its coupling with the solar wind. Previous studies have shown a strong correlation between the solar wind dynamic pressure and the SKR intensity. However, up to now, the effect of an Interplanetary Coronal Mass Ejection (ICME) has never been examined in detail, due to the lack of SKR observations at the time when an ICME can be tracked and its different parts be clearly identified. In this study, we take advantage of a large ICME that reached Saturn mid-November 2014 (Witasse et al., J. Geophys. Res. Space Physics, 2017, 122, 7865–7890). At that time, the Cassini spacecraft was fortunately travelling within the solar wind for a few days, and provided a very accurate timing of the ICME structure. A survey of the Cassini data for the same period indicated a significant increase in the SKR emissions, showing a good correlation after the passage of the ICME shock with a delay of ∼13 h and after the magnetic cloud passage with a delay of 25–42 h.

B. Cecconi↗
NASA NTRS2022

On the Importance of Investigating CME Complexity Evolution During Interplanetary Propagation

This perspective paper brings to light the need for comprehensive studies on the evolution of interplanetary coronal mass ejection (ICME) complexity during propagation. To date, few studies of ICME complexity exist. Here, we define ICME complexity and associated changes in complexity, describe recent works and their limitations, and outline key science questions that need to be tackled. Fundamental research on ICME complexity changes from the solar corona to 1 AU and beyond is critical to our physical understanding of the evolution and interaction of transients in the inner heliosphere. Furthermore, a comprehensive understanding of such changes is required to understand the space weather impact of ICMEs at different heliospheric locations and to improve on predictive space weather models.

CME↗
DOE OSTI2025

The bulk motion of gas in the core of the Centaurus galaxy cluster

Galaxy clusters contain vast amounts of hot ionized gas known as the intracluster medium (ICM). In relaxed cluster cores, the radiative cooling time of the ICM is shorter than the age of the cluster. However, the absence of line emission associated with cooling suggests heating mechanisms that offset the cooling, with feedback from active galactic nuclei (AGNs) being the most likely source. Turbulence and bulk motions, such as the oscillating (‘sloshing’) motion of the core gas in the cluster potential well, have also been proposed as mechanisms for heat distribution from the outside of the core. Here we present X-ray spectroscopic observations of the Centaurus galaxy cluster with the X-Ray Imaging and Spectroscopy Mission satellite. We find that the hot gas flows along the line of sight relative to the central galaxy, with velocities from 130 km s −1 to 310 km s −1 within about 30 kpc of the centre. This indicates bulk flow consistent with core gas sloshing. Although the bulk flow may prevent excessive accumulation of cooled gas at the centre, it could distribute the heat injected by the AGN and bring in thermal energy from the surrounding ICM. The velocity dispersion of the gas is found to be only ≲120 km s −1 in the core, even within about 10 kpc of the AGN. This suggests that the influence of the AGN on the surrounding ICM motion is limited in the cluster.

galaxies and clusters↗
DOE OSTI2022

AI-Enabled Discovery and Physics-Based Optimization of Energy Efficient Processing Strategies for Advanced Turbine Alloys (Final Technical Report)

In this project, the multi-organizational team of academic and industrial researchers from the University of Kentucky an aerospace and energy generation OEM partner has leveraged novel Digital Process Twin (DPT) models of process/structure interactions (i.e., process-induced surface integrity) to advance a paradigm of fully integrated computational materials engineering (ICME). Using efficient process models as the core of a digital process simulator for a reinforcement learning algorithm, the team has integrated industrial data and metrics of structure/performance/energy relationships and manufacturing-related energy metrics to optimize dynamic processing parameters for significantly improved life-cycle energy efficiency of advanced γ-TiAl low-pressure turbine (LPT) alloys, as indicated by a set of design relevant parameters (e.g., residual stresses and scrap rate). The key objective and anticipated outcome of the project was at least a 10% reduction in life-cycle embodied energy for a recently developed, γ-TiAl low-pressure turbine (LPT) alloy and nickel-based superalloy Inconel 718, through the adoption of the proposed AI-enabled process optimization approach. The final project outcomes significantly exceeded this original target, realizing manufacturing-related energy efficiency improvements of more than 130% for TiAl and up to 80% for Inconel 718. Rather than following the prevailing and highly inefficient empirical paradigm, the proposed study demonstrated the feasibility of adopting a digital, physics-based process design and optimization paradigm. The recurring need for manual intervention, rework, reinspection causes significant production bottlenecks and unnecessary expense associated with delivering the requisite component quality. The OEM partner, and turbine industry in general, expect to reap significant cost and resource savings if an AI-optimized set of parameters can be applied to specific machining operations. The technical scope of the proposed project involved the paving of a realistic path towards model-based and AI-enabled Integrated Computational Materials Engineering (ICME), and away from inefficient empirical process optimization and legacy manufacturing practices, which are no longer able to efficiently process novel high-performance turbine alloy materials. The project team will address the fundamental knowledge gap that currently exists within the ICME paradigm with respect to the process/structure/performance/energy impacts of finishing processes. While significant resources have been devoted to the ‘early stages’ of manufacturing, such as alloy design, primary and secondary processing, finishing processes have not been adequately integrated within ICME. To provide an actionable path towards model-based finishing process design (e.g., machining, burnishing, grinding, polishing), we will employ a novel AI-enabled process optimization paradigm, based on a computationally efficient, physics-based process simulator. Through limited experimental work to calibrate and validate our process simulator model via an advanced in-situ characterization technique and process optimization via reinforcement learning, the project will seek to demonstrate a viable alternative to the inefficient ‘legacy’ processing strategies, empirical testing and broad scope machining learning approaches, all of which fail to adequately consider complex process physics. The project team has identified an intermetallic γ-TiAl LPT alloy, which is currently being used as part of the OEM partner’s advanced gas turbine designs. This particular alloy poses significant manufacturing challenges during finishing operations, which limit the degree to which the current turbine design can be manufactured in an energy- and cost-efficient manner. Empirical testing and numerical modeling efforts to optimize processing parameters for γ-TiAl have not been able to resolve these manufacturing challenges, so the proposed physics-based AI-enabled optimization technology would offer a truly novel and transformative capability. The multi-organizational team of academic and industry experts from the UKY and the OEM partner will work together closely to demonstrate the analytical and experimental critical function and characteristic proof of concept of this novel approach.

20 FOSSIL-FUELED POWER PLANTS↗