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NASA NTRS1999

Effects on Training Using Illumination in Virtual Environments

Camera based tasks are commonly performed during orbital operations, and orbital lighting conditions, such as high contrast shadowing and glare, are a factor in performance. Computer based training using virtual environments is a common tool used to make and keep CTW members proficient. If computer based training included some of these harsh lighting conditions, would the crew increase their proficiency? The project goal was to determine whether computer based training increases proficiency if one trains for a camera based task using computer generated virtual environments with enhanced lighting conditions such as shadows and glare rather than color shaded computer images normally used in simulators. Previous experiments were conducted using a two degree of freedom docking system. Test subjects had to align a boresight camera using a hand controller with one axis of rotation and one axis of rotation. Two sets of subjects were trained on two computer simulations using computer generated virtual environments, one with lighting, and one without. Results revealed that when subjects were constrained by time and accuracy, those who trained with simulated lighting conditions performed significantly better than those who did not. To reinforce these results for speed and accuracy, the task complexity was increased.

Maida, James C.↗

NASA NTRS2014

Carbon Monitoring System Flux Estimation and Attribution: Impact of ACOS-GOSAT X(CO2) Sampling on the Inference of Terrestrial Biospheric Sources and Sinks

Using an Observing System Simulation Experiment (OSSE), we investigate the impact of JAXA Greenhouse gases Observing SATellite 'IBUKI' (GOSAT) sampling on the estimation of terrestrial biospheric flux with the NASA Carbon Monitoring System Flux (CMS-Flux) estimation and attribution strategy. The simulated observations in the OSSE use the actual column carbon dioxide (X(CO2)) b2.9 retrieval sensitivity and quality control for the year 2010 processed through the Atmospheric CO2 Observations from Space algorithm. CMS-Flux is a variational inversion system that uses the GEOS-Chem forward and adjoint model forced by a suite of observationally constrained fluxes from ocean, land and anthropogenic models. We investigate the impact of GOSAT sampling on flux estimation in two aspects: 1) random error uncertainty reduction and 2) the global and regional bias in posterior flux resulted from the spatiotemporally biased GOSAT sampling. Based on Monte Carlo calculations, we find that global average flux uncertainty reduction ranges from 25% in September to 60% in July. When aggregated to the 11 land regions designated by the phase 3 of the Atmospheric Tracer Transport Model Intercomparison Project, the annual mean uncertainty reduction ranges from 10% over North American boreal to 38% over South American temperate, which is driven by observational coverage and the magnitude of prior flux uncertainty. The uncertainty reduction over the South American tropical region is 30%, even with sparse observation coverage. We show that this reduction results from the large prior flux uncertainty and the impact of non-local observations. Given the assumed prior error statistics, the degree of freedom for signal is approx.1132 for 1-yr of the 74 055 GOSAT X(CO2) observations, which indicates that GOSAT provides approx.1132 independent pieces of information about surface fluxes. We quantify the impact of GOSAT's spatiotemporally sampling on the posterior flux, and find that a 0.7 gigatons of carbon bias in the global annual posterior flux resulted from the seasonally and diurnally biased sampling when using a diagonal prior flux error covariance.

biased sampling↗

NASA NTRS2015

Comparison of Optimal Small Spacecraft Micro Electric Propulsion Technologies for Mission Opportunities

The goal of this paper is to explore the mission opportunities that are uniquely enabled by U-class Solar Electric Propulsion (SEP) technologies. Small SEP thrusters offers significant advantages relative to existing technologies and will revolutionize the class of mission architectures that small spacecraft can accomplish by enabling trajectory maneuvers with significant change in velocity requirements and reaction wheel-free attitude control. This paper aims to develop and apply a common system-level modeling framework to evaluate these thrusters for relevant upcoming mission scenarios, taking into account the mass, power, volume, and operational constraints of small highly-constrained missions. We will identify the optimal technology for broad classes of mission applications for different U-class spacecraft sizes and provide insights into what constrains the system performance to identify technology areas where improvements are needed.

Spangelo, Sara↗

NASA NTRS2020

Revisiting the Effectiveness Of HCHO/NO2 Ratios for Inferring Ozone Sensitivity to Its Precursors Using High Resolution Airborne Remote Sensing Observations in A High Ozone Episode During the KORUS-AQ Campaign

The nonlinear chemical processes involved in ozone production (P(O3)) have necessitated using proxy indicators to convey information about the primary dependence of P(O3) on volatile organic compounds (VOCs) or nitrogen oxides (NOx). In particular, the ratio of remotely sensed columns of formaldehyde (HCHO) to nitrogen dioxide (NO2) has been widely used for studying O3 sensitivity. Previous studies found that the errors in retrievals and the incoherent relationship between the column and the near-surface concentrations are a barrier in applying the ratio in a robust way. In addition to these obstacles, we provide calculational-observational evidence, using an ensemble of 0-D photochemical box models constrained by DC-8 aircraft measurements on an ozone event during the Korea-United States Air Quality (KORUS-AQ) campaign over Seoul, to demonstrate the chemical feedback of NO2 on the formation of HCHO is a controlling factor for the transition line between NOx-sensitive and NOx-saturated regimes. A fixed value (~2.7) of the ratio of the chemical loss of NOx (LNOx) to the chemical loss of HO2+RO2 (LROx) perceptibly differentiates the regimes. Following this value, data points with a ratio of HCHO/NO2 less than 1 can be safely classified as NOx-saturated regime, whereas points with ratios between 1 and 4 fall into one or the other regime. We attribute this mainly to the HCHO-NO2 chemical relationship causing the transition line to occur at larger (smaller) HCHO/NO2 ratios in VOC-rich (VOC-poor) environments. We then redefine the transition line to LNOx/LROx~2.7 that accounts for the HCHO-NO2 chemical relationship leading to HCHO = 3.7 × (NO2 – 1.14 × 1016 molec.cm-2). Although the revised formula is locally calibrated (i.e., requires for readjustment for other regions), its mathematical format removes the need for having a wide range of thresholds used in HCHO/NO2 ratios that is a result of the chemical feedback. Therefore, to be able to properly take the chemical feedback into consideration, the use of HCHO = a × (NO2 – b) formula should be preferred to the ratio in future works. We then use the Geostationary Trace gas and Aerosol Sensor Optimization (GeoTASO) airborne instrument to study O3 sensitivity in Seoul. The unprecedented spatial (250 × 250 m2) and temporal (~every 2 h) resolutions of HCHO and NO2 observations form the sensor enhance our understanding of P(O3) in Seoul; rather than providing a crude label for the entire city, more in-depth variabilities in chemical regimes are observed that should be able to inform mitigation strategies correspondingly.

KORUS-AQ; formaldehyde; NOx; VOC; OMI; GeoTASO; oz↗

DOE OSTI2024

Event-Based Energy Impact Tracking and Forecasting with Limited Measurements for Rooftop Units

Packaged air conditioning units and heat pumps, also known as rooftop units (RTUs), are responsible for almost 133 billion kWh of electricity usage annually on site for space cooling U.S. commercial buildings. In addition, the use of heat pumps is a trend we expect to accelerate as buildings transition from fossil fuel-based heating to electricity as a key step for decarbonizing the U.S. commercial buildings sector. However, the operation conditions and energy use of RTUs and heat pumps are usually not well monitored as they are not commonly integrated with building automation systems and lack exposed sensing and control points. To fill this gap, this paper proposes a framework for tracking and forecasting energy impacts resulting from degradation of performance and improved performance for unit servicing using limited data. The proposed framework makes use of a constrained dataset, specifically measurements of the outdoor air temperature and the power demand of individual RTUs, to track and forecast changes in energy use associated with changes in performance over various temporal horizons ranging from days to weeks. Following the detection of an RTU fault, performance degradation, or performance improvement, the framework employs a prediction model to assess the cumulative energy impact. We demonstrate the effectiveness of the method with field-collected data for servicing and degradation examples and compare the predicting accuracy of Gradient Boosting Decision Tree (GBDT) Regression models to Support Vector Regression and Linear Regression models. The results show that GBDT achieved the best accuracy for time-series validation datasets for the servicing and degradation cases, and the prediction model was able to track the cumulative energy impacts of events. The proposed framework can inform building owners of the cumulative change in energy usage of RTUs associated with performance degradation, performance improvement, or a fault.

packaged air conditioners, packaged heat pumps, ro↗

DOE OSTI2025

Active oversight and quality control in standard Bayesian optimization for autonomous experiments

The fusion of experimental automation and machine learning has catalyzed a new era in materials research, prominently featuring Gaussian Process (GP) Bayesian Optimization (BO) driven autonomous experiments. Here we introduce a Dual-GP approach that enhances traditional GPBO by adding a secondary surrogate model to dynamically constrain the experimental space based on real-time assessments of the raw experimental data. This Dual-GP approach enhances the optimization efficiency of traditional GPBO by isolating more promising space for BO sampling and more valuable experimental data for primary GP training. We also incorporate a flexible, human-in-the-loop intervention method in the Dual-GP workflow to adjust for unanticipated results. We demonstrate the effectiveness of the Dual-GP model with synthetic model data and implement this approach in autonomous pulsed laser deposition experimental data. This Dual-GP approach has broad applicability in diverse GPBO-driven experimental settings, providing a more adaptable and precise framework for refining autonomous experimentation for more efficient optimization.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Constrained optimal ascent-flyback shuttle trajectories.

An optimal Space Shuttle ascent-flyback trajectory shaping capability is presented which is based on the accelerated gradient parameter optimization technique. A typical atmospheric flight branched optimization problem is analyzed which required the determination of 31 parameters. This parameter set includes the description of the vehicle attitude control angles for three branches of Shuttle flight: first stage ascent, second stage ascent, and first stage flyback. The important in-flight inequality constraints required to maintain the integrity of the vehicle are considered. Results indicate that for a launch into a 55 deg inclined ellipse, a 13% increase in payload can be realized by using optimal control in the first-stage ascent rather than the conventional gravity-turn steering.

Kamm, J. L.↗

DOE OSTI2020

Cosmogenic activation of silicon

In the production of 3 H, 7 Be, and 22 Na by interactions of cosmic-ray particles with silicon can produce radioactive backgrounds in detectors used to search for rare events. Through controlled irradiation of silicon CCDs and wafers with a neutron beam that mimics the cosmic-ray neutron spectrum, followed by direct counting, we determined that the production rate from cosmic-ray neutrons at sea level is (112 ± 24) atoms/( kg day ) for 3 H, (8.1 ± 1.9) atoms/( kg day ) for 7 Be, and (43.0 ± 7.2) atoms/( kg day ) for 22 Na . Complementing these results with the current best estimates of activation cross sections for cosmic-ray particles other than neutrons, we obtain a total sea-level cosmic-ray production rate of (124 ± 25) atoms/(kg day) for 3 H, (9.4 ± 2.0) atoms/( kg day ) for 7 Be, and (49.6 ± 7.4) atoms/( kg day ) for 22 Na. These measurements will help constrain background estimates and determine the maximum time that silicon-based detectors can remain unshielded during detector fabrication before cosmogenic backgrounds impact the sensitivity of next-generation rare-event searches.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2026

An end-to-end workflow for executing a classically bootstrapped variational quantum algorithm on an academic quantum computer

Academic quantum computing platforms often face unique challenges in executing quantum workloads due to fragmented software environments and limited engineering support. Unlike commercial ecosystems, academic devices typically evolve without full-stack integration in mind, making it difficult to run complex applications—such as variational quantum algorithms (VQA)—reliably and efficiently. Issues such as incompatible software layers and lack of automated job management significantly increase the overhead of theory-experiment collaboration. To address these challenges, we develop a modular, end-to-end workflow that decouples application-layer code from low-level hardware control, automates circuit submission and result collection, and supports fine-grained circuit-level job scheduling and recovery. The architecture employs a dual-end application programming interface (API) design, enabling robust operation across unstable or resource-constrained hardware backends. For practical use, the framework is lightweight and user-friendly, allowing rapid prototyping of full-stack workflows using basic Python tools. We validate this workflow on a high-fidelity trapped-ion quantum computer by demonstrating a variational quantum eigensolver (VQE) experiment with a classically bootstrapped ansatz initialization technique. The system successfully executed over 60,000 circuits across multiple molecular test cases with minimal human intervention, highlighting the framework’s effectiveness in enabling reproducible, resilient quantum experimentation in academic settings.

Clifford↗

DOE OSTI2025

Modified gravity constraints from the full shape modeling of clustering measurements from DESI 2024

We present cosmological constraints on deviations from general relativity (GR) from the first-year of clustering observations from the Dark Energy Spectroscopic Instrument (DESI) in combination with other available datasets including the CMB data from Planck with CMB-lensing from Planck and ACT, BBN constraints on the physical baryon density, the galaxy weak lensing and clustering from DESY3 and supernova data from DESY5. We first consider the μ(a,k)–Σ(a,k) modified gravity (MG) parameterization (as well as η(a,k)) in a ΛCDM and a w 0 w a CDM cosmological backgrounds. Using a functional form for time-only evolution gives μ 0 = 0.11 +0.44 -0.54 from DESI(FS+BAO)+BBN and a wide prior on n s . Using DESI(FS+BAO)+CMB+DESY3+DESY5-SN, we obtain μ 0 = 0.05 ± 0.22 and Σ 0 = 0.008 ± 0.045 and similarly μ 0 = 0.02 +0.19 -0.24 and η 0 = 0.09 +0.36 -0.60 , in an ΛCDM background. In w 0 w a CDM we obtain μ 0 = -0.24 +0.32 -0.28 and Σ 0 = 0.006 ± 0.043, consistent with GR, and we still find a preference of the data for a dynamical dark energy with w 0 > -1 and w a < 0. Using functional dependencies in both time and scale gives μ 0 and Σ 0 with a same level of precision as above but other scale MG parameters remain hard to constrain. We then move to binned parameterizations in a ΛCDM background starting with two bins in redshift and obtain, μ 1 = 1.02 ± 0.13, μ 2 = 1.04 ± 0.11, Σ 1 = 1.021 ± 0.029 and Σ 2 = 1.022 +0.027 -0.023 , all consistent with the unity value of GR in the binning formalism. We then extend the analysis to combine two bins in redshift and two in scale giving 8 MG parameters that we find all consistent with GR. We note that we find here that the tension reported in previous studies about Σ 0 being inconsistent with GR when using Planck PR3 data goes away when we use the recent LoLLiPoP+HiLLiPoP likelihoods. As noted in previous studies, this seems to indicate that the tension is indeed related to the CMB lensing anomaly in PR3 which is also resolved when using the recent likelihoods. We then constrain the class of Horndeski theory in the effective field theory of dark energy approach. We consider both EFT-basis and α-basis in the analysis. Assuming a power law parameterization for the EFT function Ω, which controls non-minimal coupling, we obtain Ω 0 = 0.012 +0.001 -0.012 and s 0 = 0.996 +0.54 -0.20 from the combination of DESI(FS+BAO)+DESY5SN+CMB in a ΛCDM background, which are consistent with GR. Similar results are obtained when using the α-basis and assuming no-braiding (α B = 0) giving c M < 1.14 at 95% CL in a ΛCDM background, also in agreement with GR. However, we see a mild yet consistent indication for c B > 0 when α B is allowed to vary which will require further study to determine whether this is due to systematics or new physics.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Enhanced pedestal transport driven by edge collisionality on Alcator C-Mod and its role in regulating H-mode pedestal gradients

Experimental measurements of plasma and neutral profiles across the pedestal are used in conjunction with 2D edge modeling to examine pedestal stiffness in Alcator C-Mod H-mode plasmas. Enhanced D α experiments on Alcator C-Mod observed pedestal degradation and loss in confinement below a critical value of net power crossing the separatrix, P net = $P^{crit}_{net}$ ≈ 2.3 MW, in the absence of any external fueling. New analysis of ionization and particle flux profiles reveal saturation of the pedestal electron density, $n^{ped}_{e}$, despite continuous increases in ionization throughout the pedestal, inversely related to P net . A limi to the pedestal $\nabla$n e emerges as the particle flux, Γ D , continues to grow, implying increases in the effective particle diffusivity, D eff . This is well-correlated with the separatrix collisionality, $v^*_{sep}$ and a turbulence control parameter, α t , implying a possible transition in type of turbulence. The transition is well correlated with the experimentally observed value of $P^{crit}_{net}$. SOLPS-ITER modeling is performed for select discharges from the power scan, constrained with experimental electron and neutral densities, measured at the outer midpane. The modeling confirms general growth in D eff , consistent with experimental findings, and additionally suggests even larger growth in Χ e at the same $P^{crit}_{net}$.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1992

Interplanetary Program to Optimize Simulated Trajectories (IPOST). Volume 1: User's guide

IPOST is intended to support many analysis phases, from early interplanetary feasibility studies through spacecraft development and operations. The IPOST output provides information for sizing and understanding mission impacts related to propulsion, guidance, communications, sensor/actuators, payload, and other dynamic and geometric environments. IPOST models three degree of freedom trajectory events, such as launch/ascent, orbital coast, propulsive maneuvering (impulsive and finite burn), gravity assist, and atmospheric entry. Trajectory propagation is performed using a choice of Cowell, Encke, Multiconic, Onestep, or Conic methods. The user identifies a desired sequence fo trajectory events, and selects which parameters are independent (controls) and dependent (targets), as well as other constraints and the coat function. Targeting and optimization is performed using the Stanford NPSOL algorithm. IPOST structure allows sub-problems within a master optimization problem to aid in the general constrained parameter optimization solution. An alternate optimization method uses implicit simulation and collocation techniques.

Hong, P. E.↗

NASA NTRSDate not supplied

Battery Relevant Cell Side Wall Rupture Characterization

The propensity for a cell design to experience can side wall rupture (SWR) during thermal runaway is highly influenced by how a battery design mechanically constrains its cells. Testing cells while unsupported has been found to yield false negative results that don't represent this risk in a battery configuration. This talk addresses how to verify the adequacy of battery design measures used to control SWR and how to get results relevant, accurate, and statistically defendable for a proposed battery design.

thermal runaway↗

NASA NTRS2025

Countermeasures for Mitigation of Sensorimotor Decrements Following Head-Down Tilt Bed Rest

BACKGROUND Astronauts experience postflight disturbances in postural and locomotor control due to sensorimotor adaptations during spaceflight. These alterations may have adverse consequences if a rapid egress is required after landing. Although exercise is partially effective for mitigating cardiovascular and muscular deconditioning, additional countermeasures are needed to further preserve sensorimotor function. Proprioception training and electrical muscle stimulation (EMS) are two promising in-flight countermeasures. Since prolonged head down tilt bed rest (HDTBR) is a spaceflight analog for body unloading and causes postural and locomotor control decrements that parallel those observed after spaceflight, it can be used to facilitate the development of these countermeasures. METHODS This study will determine the effects of proprioception training and EMS on functional task performance and sensorimotor function following 60 days of 6° HDTBR. Subjects will be randomly assigned to one of four groups: 1) an EMS arm, 2) a proprioception training arm, 3) an exercise plus proprioceptive training arm, and 4) a control arm. The EMS countermeasure will include daily bilateral stimulation of selected bilateral lower extremity muscles (30 minutes per session). Proprioception training will be performed three days per week (25 minutes per session) consisting of body-loaded postural tasks in the horizontal position on an air bearing sled. Exercise training will mimic current protocols used on the International Space Station, but treadmill aerobic exercise will be replaced with additional cycling aerobic exercise. Primary outcome measures will include pre- and post- HDTBR functional tests that require high demand for dynamic control of postural stability. Secondary measures will be used to explore key physiological changes that underlie countermeasure benefits. All HDTBR and data collection activities will be completed by the German Aerospace Center (DLR) at the :envihab facility. Given the constrained samples size, a Bayesian modelling approach will be used to quantify the probability that there is an effect of a given magnitude. HARDWARE AND PROTOCOL DEVELOPMENT Final hardware modifications and protocol developments were completed in preparation for Campaign 1, which began in September 2024. These included shipment, setup, and operator training for the transportable gravity bed, horizontal squat device, foam obstacle course, EMS devices, leg dexterity system, foot sole skin sensitivity system, and Radiofrequency Echographic Multi Spectrometry (REMS) ultrasound device. In addition, specialized protocols were developed for data collection using DLR’s equipment, including muscle morphology magnetic resonance imaging (MRI), optical coherence tomography, venous blood flow MRI and ultrasound, muscle ultrasound and impedance, and skin blood flow ultrasound. We will present early data from the first campaign, which concluded in November, 2024. These will be compared with previous data from the recent 30-day HDTBR campaigns (Spaceflight associated neuro-ocular syndrome countermeasures (SANS-CM)) conducted at DLR. RELEVANCE The deliverable from this project will be proof-of-concept sensorimotor countermeasure designs for functional task performance with full assessment of efficacy in a spaceflight analog. If one or more countermeasures are effective, they will be translated for validation with the suite of operationally implemented in-flight countermeasures.

T R Macaulay↗

DOE OSTI2025

Dynamic Low-Rank Training with Spectral Regularization: Achieving Robustness in Compressed Representations

Deployment of neural networks on resource-constrained devices demands models that are both compact and robust to adversarial inputs. However, compression and adversarial robustness often conflict. In this work, we introduce a dynamical low-rank training scheme enhanced with a novel spectral regularizer that controls the condition number of the low-rank core in each layer. This approach mitigates the sensitivity of compressed models to adversarial perturbations without sacrificing clean accuracy. The method is model- and data-agnostic, computationally efficient, and supports rank adaptivity to automatically compress the network at hand. Extensive experiments across standard architectures, datasets, and adversarial attacks show the regularized networks can achieve over 94\% compression while recovering or improving adversarial accuracy relative to uncompressed baselines.

Schotthoefer, Steffen [ORNL] (ORCID:00000002156965↗

DOE OSTI2025

Dynamical Low-Rank Compression of Neural Networks with Robustness under Adversarial Attacks

Deployment of neural networks on resource-constrained devices demands models that are both compact and robust to adversarial inputs. However, compression and adversarial robustness often conflict. In this work, we introduce a dynamical low-rank training scheme enhanced with a novel spectral regularizer that controls the condition number of the low-rank core in each layer. This approach mitigates the sensitivity of compressed models to adversarial perturbations without sacrificing clean accuracy. The method is model- and data-agnostic, computationally efficient, and supports rank adaptivity to automatically compress the network at hand. Extensive experiments across standard architectures, datasets, and adversarial attacks show the regularized networks can achieve over 94 compression while recovering or improving adversarial accuracy relative to uncompressed baselines.

Schotthoefer, Steffen [ORNL] (ORCID:00000002156965↗

NASA NTRS2014

Exploration of the Theoretical Physical Capacity of the John F. Kennedy International Airport Runway System

A design study was completed to explore the theoretical physical capacity (TPC) of the John F. Kennedy International Airport (KJFK) runway system for a northflow configuration assuming impedance-free (to throughput) air traffic control functionality. Individual runways were modeled using an agent-based, airspace simulation tool, the Airspace Concept Evaluation System (ACES), with all runways conducting both departures and arrivals on a first-come first-served (FCFS) scheduling basis. A realistic future flight schedule was expanded to 3.5 times the traffic level of a selected baseline day, September 26, 2006, to provide a steady overdemand state for KJFK runways. Rules constraining departure and arrival operations were defined to reflect physical limits beyond which safe operations could no longer be assumed. Safety buffers to account for all sources of operational variability were not included in the TPC estimate. Visual approaches were assumed for all arrivals to minimize inter-arrival spacing. Parallel runway operations were assumed to be independent based on lateral spacing distances. Resulting time intervals between successive airport operations were primarily constrained by same-runway and then by intersecting-runway spacing requirements. The resulting physical runway capacity approximates a theoretical limit that cannot be exceeded without modifying runway interaction assumptions. Comparison with current KJFK operational limits for a north-flow runway configuration indicates a substantial throughput gap of approximately 48%. This gap may be further analyzed to determine which part may be feasibly bridged through the deployment of advanced systems and procedures, and which part cannot, because it is either impossible or not cost-effective to control. Advanced systems for bridging the throughput gap may be conceptualized and simulated using this same experimental setup to estimate the level of gap closure achieved.

Neitzke, Kurt W.↗

DOE OSTI2020

Single-Step Shear-Based Deformation Processing of Electrical Conductor Wires

Commercial electrical conductor wires are currently produced from aluminum alloys by multi-step deformation processing involving rolling and drawing. These processes typically require 10 to 20 steps of deformation, since the plastic strain or reduction that can be imposed in a single step is limited by material workability and process mechanics. Here, we demonstrate a fundamentally different, single-step approach to produce flat wire aluminum products using machining-based deformation that also ensures adequate material workability in the formed product. Two process routes are proposed: (1) chip formation by free-machining (FM), with a post-machining, light drawing reduction (<20%) to achieve desired finish and (2) constrained chip formation by large strain extrusion machining (LSEM). Using commercially pure aluminum conductor alloys (Al 1100 and EC1350) as representative material systems, we demonstrate key features of the machining-based processing, including (a) single-step processing to achieve flat wire geometries, (b) surface finish (Ra = 0.2 to 1.0 μm) comparable to that of commercial wire products made by drawing/rolling, (c) deformation control independent of wire size, and (d) hardness increases of 50–150% over that of annealed wires, while retaining high electrical conductivity (>56% IACS). Here, the wire microstructure, which can also be varied via the large-strain deformation parameters, is correlated with mechanical and electrical properties. Implications for commercial manufacture of flat wire products are discussed.

36 MATERIALS SCIENCE↗