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All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Experimental Investigation of Roughness Effects on Transition on Blunt Spherical Capsule Shapes

The present contribution reviews recent experimental results of roughness effects on boundary layer transition on capsule geometries with spherical windward geometries. Experiments in three wind tunnel facilities are considered. The ACE Tunnel of Texas AM University, USA, provided Mach 6 experiments with distributed roughness at relatively low Reynolds numbers, 2.5 · 10(exp 5) < Re(sub d) < 5 · 10(exp 5), with d denoting the capsule diameter. The observed boundary layer transition compared well with correlations based on transient growth theory, even though the roughness heights were in the order of boundary layer thickness. Larger Reynolds numbers, 1 · 10(exp 6) < Re(sub d) < 3·10(exp 6), could be assessed in the hypersonic Ludwieg tube, HLB, of TU Braunschweig, Germany. Transition is observed at rather low, subcritical roughness values in the order of 20 μm for a roughness patch placed about the geometric center of the capsule model. These experiments varied fluctuation levels of the freestream. The authors assume that the observed transitions that occur downstream of the subcritical roughness patch are due to freestream disturbances in the tunnel, which interact with small roughness heights. Additional experiments in the HLB facility with patches of larger roughness height support the relevance of transient growth theory for low-to-medium roughness heights, relative to boundary layer thickness. The effects of Reynolds numbers and total flow enthalpy on transition with isolated roughness were investigated in the HIEST facility of JAXA, Japan. Here, a model insert with roughness elements of varying height for tripping transition to turbulence was employed. The results are compared to known trip effectiveness correlations for isolated roughness. Overall, the transient growth correlation seems to represent roughness-induced transition behavior on the ACE and HLB entry capsule shapes with roughness over the entire capsule surface. These experiment are however for perfect gases. Comparable experiments on roughness induced transition in a high-enthalpy facility are still needed to confirm the validity of transient-growth correlation for vehicle design.

Radespiel, Rolf↗
NASA NTRS2018

ICESat-2 Photon Classification: Finding Signal Photons in the ATL03 Geolocated Photon Data Product

ICESat-2 carries NASA's next-generation laser altimeter, ATLAS, (Advanced Topographic Laser Altimeter System), designed to measure changes in ice sheet height, sea ice freeboard, and vegetation canopy height. ATLAS contains a photon-counting lidar which transmits green (532-nm) pulses at 10kHz. Each pulse is split into 3 pairs of beams (one strong and one weak). Approximately 1014 photons per pulse travel from ATLAS through the atmosphere to reflect off the Earth's surface. Some return back into the ATLAS telescope where they are recorded. Photons from sunlight and instrument noise at the same wavelength are also recorded. The flight software time tags all photons within a 500m to 6 km range window and generates histograms. Using the histograms, it selects a telemetry window which varies from 20m over flat surfaces to hundreds of meters over rougher terrain. ATL03 contains the time, height (relative to the WGS-84 ellipsoid), latitude and longitude of every photon within the telemetry window. The basic challenge is to determine which of these photons were reflected off the surface. We have developed an algorithm that identifies these signal photons and assigns a confidence level (low, medium, or high) to each signal photon based on the signal to noise ratio. We present an overview of the signal identification algorithm and show the results on actual ICESat-2 data over ice sheet, sea ice, vegetated, and water surfaces. Higher level ATLAS products work with aggregations of the photons in order to determine the ellipsoidal height of the Earth, canopy height and structure, and other quantities of geophysical interest.

Remote Sensing↗
NASA NTRS2016

Silicon Emitter Needle and Array Design for Indium Electrospray Arrays for Spacecraft Propulsion

A design for silicon microfabricated emitter arrays was developed for electrospray thrusters for indium propellant in compact architectures with scalable thrust, low mass and volume, high specific impulse and high efficiency operation. The design elements include tip height, height uniformity across the array, tip radii, axial groove depth, tip angle, emitter shank sidewall angle and number of emitters. They were derived from commercial liquid metal ion source designs and modeling, fabrication and test results. The most critical results of the emitter array design analysis suggest that microfabricated silicon emitter array emitters should have a height greater than 280 microns with a height uniformity of +/-10 microns, a tip half angle of 49° for uniform turn-on voltages and current across the array, low beam divergence and high mass utilization efficiency. Elements of the design were fabricated and demonstrated in single emitter and in 400 element emitter arrays to validate the design, fabrication and performance capability. The design height and uniformity of arrays was demonstrated for 85% of the emitters in a prototype array. Required tip and sidewall angles and groove depths have been microfabricated. Single microfabricated silicon emitters demonstrated better performance in current and voltage characteristics than commercially available liquid metal ion sources. Microfabricated emitters and arrays demonstrated the required current and stability performance to enable the MEP thruster development for indium propellant.

Marrese-Reading, Colleen M.↗
NASA NTRS2017

Climate Limits Across Space and Time on European Forest Structure

The impact climate has on forests has been extensively studied. However, the large scale effect climate has on forest structures, such as average diameters, heights and basal area are understudied in a spatially explicit manner. The limits, tipping points and thresholds that climate places on forest structures dictate the services a forest may provide, the vulnerability of a forest to mortality and the potential value of the timber there within. The majority of current research either investigates climate impacts on forest pools and fluxes, on a tree physiological scale or on case studies that are used to extrapolate results and potential impacts. A spatially explicit study on how climate affects forest structure over a large region would give valuable information to stakeholders who are more concerned with ecosystem services that cannot be described by pools and fluxes but require spatially explicit information - such as biodiversity, habitat suitability, and market values. In this study, we quantified the limits that climate (maximum, minimum temperature and precipitation) places on 3 forest structures, diameter at breast height, height, and basal area throughout Europe. Our results show clear climatic zones of high and low upper limits for each forest structure variable studied. We also spatially analyzed how climate restricts the potential bio-physical upper limits and creates tipping points of each forest structure variable and which climate factors are most limiting. Further, we demonstrated how the climate change has affected 8 individual forests across Europe and then the continent as a whole. We find that diameter, height and basal area are limited by climate in different ways and that areas may have high upper limits in one structure and low upper limits in another limited by different climate variables. We also found that even though individual forests may have increased their potential upper limit forest structure values, European forests as a whole have lost, on average, 5.0%, 1.7% and 6.5% in potential mean forest diameter, height and basal area, respectively.

Moreno, Adam La Salle↗
NASA NTRS2020

The Evolution of Lidar Networks: A US Perspective

Atmospheric aerosols and clouds play an important role in climate by directly scattering and absorbing sunlight. Aerosol-cloud interactions modify the particle properties causing indirect effects, alter aerosol deposition and rainfall, and contribute substantially to the uncertainties in predicting climate effects. Aerosols also affect air quality and both constituents modulate boundary layer dynamics to a certain extent, in turn impacting aerosol transport and aerosol-cloud interactions. The spatiotemporal distribution of aerosol and cloud layers is thus important, and lidar remains the primary instrument for determining the vertical distribution of aerosols and thin clouds. Lidar still provides important information for opaque cloud layers by determining base heights. Combined lidar and radar data provide a comprehensive coverage of aerosol and cloud vertical distributions, and thus locations where and when they interact. Lidar data provide a means of constraining column aerosol loading observations (e.g. AOD) to vertical extents. In addition, lidar has proven effective at determining a proxy for boundary layer height by examining aerosol gradients and/or cloud base heights in lidar profiles. Polarized lidars provide additional information on particle shape, allowing estimates of cloud phase and separation of dust or smoke from sulfate and sea salt aerosols. Given the importance of lidar observations and a critical maturation in technology and retrieval techniques, several organizations began to build operational lidar networks around 2000. The European Aerosol Research Lidar Network (EARLINET) was started as a research focused network of advanced lidars across Europe. The Asian Dust Lidar Network (ADNET) was also developed as a regional network providing lidar profiles of dust and pollution across Eastern Asia. In the US, the NASA Micro Pulse Lidar Network (MPLNET) was created to provide global lidar profiling at key sites in the NASA Aerosol Robotic Network (AERONET). The Network for the Detection of Atmospheric Composition Change (NDACC) pre-dates these networks and many sites have lidar, but it is not strictly a lidar network and at the time focused less on the lower troposphere. Finally, there were already existing ceilometer networks operated by various meteorological agencies, but in particular here in the US the profile data has not been available. The ceilometer networks were used to provide only clouds base heights and estimates of PBL height. Thus, the distinguishing feature between lidar and ceilometer networks was historically the ability to actually provide profile information (in addition to differences in wavelength, and advanced retrievals such as the raman technique). As time progressed, each lidar network matured and developed more operational capabilities and data sets, coupled with viable data centers providing DAAC services and access to near-real-time (NRT) data. In 2008 under WMO guidance, the Global Atmospheric Watch (GAW) Aerosol Lidar Observation Network (GALION) was formed as a global network made up of the existing lidar networks. The goal was to share information, best practices, and develop frameworks and techniques for quality data. GALION grew to include several other regional lidar networks and this has led to a vast increase in quality lidar sites worldwide.

Welton, Ellsworth J.↗
NASA NTRS2018

Improving Carbon Estimation of Large Tropical Trees by Linking Airborne Lidar Crown Size to Field Inventory

Quantifying tropical aboveground biomass (agb) is an outstanding challenge that requires knowledge on the 3D structure of forests. Recent studies suggest that the uncertainty in estimating agb of large trees is significantly reduced if tree height and crown size are accounted for in addition to the traditional trunk diameter and wood density. Due to the fact that field inventory techniques are not adapted to characterize the 3D forest structure, crown size metrics (e.g. height and radius) are commonly estimated as a function of trunk diameter using allometric models with limitations in explaining crown variability. Airborne lidar techniques have the potential for characterizing tree height and crown size but are not adapted to estimate trunk diameter, which is a strong predictor of agb. Here, we investigate the synergy of field inventory and airborne lidar techniques to characterize the forest structure by assessing the uncertainty introduced by the field-based allometric models in the estimation of agb at the tree-level. We focus in 1454 large individual trees (trunk diameter > 60 cm) located within the La Selva Biological Station for which we dispose of field observations (trunk diameter and wood density) and lidar derived metrics (tree height and crown radius). We show that the field-based allometric models overestimate tree height and underestimate crown radius. As a result, the allometric approach overestimates the tree-level agb in 0.8 Mg when considering the 1454 individuals and the errors can reach more than 50% of the agb of individual trees. These errors on the large trees agb highly impact on the plot-level results and then propagate to the estimation of carbon stocks at the regional and national-levels.

Clark, David↗
NASA NTRS2021

Responses of Florida Scrub Vegetation to Water Additions from a Groundwater Treatment Project and to Hurricane Disturbance

Florida scrub is a fire-maintained shrub vegetation of well-drained, sandy soils; dominant species include several species of Quercus and Serenoa repens. In a remediation project, treated groundwater was distributed through an exfiltration gallery into intact scrub. We established eight permanent line-intercept transects (15 m length) in the site in April 2002, four close to the exfiltration gallery and four more distant from it. We sampled vegetation, < 0.5 m and ≥ 0.5 m, along each transect and measured vegetation height at four points (0, 5, 10, 15 m) annually through 2019. The initial phase of the project operated from October 2002 to early March 2004 (494 days) and distributed 1.74 x 10^8 L of water. The final phase of the project occurred from March 2005 through August 2008 (1251 days) and distributed 1.90 x 10^8 L of water. Pumping raised the water table near the exfiltration gallery. Vegetation height did not differ between the near and far transects initially. Vegetation height increased in the near transects by 2004 with the greatest percent change in 2003 and 2004 as did total cover ≥ 0.5 m. Total cover < 0.5 m and bare ground were similar initially in the near and far transects and declined in the near transects by 2004. Scrub species, particularly the dominant scrub oaks, increased height and cover in response to water additions with no loss of dominant scrub species and no establishment of mesophytes. Hurricane Frances (September 2004) reduced cover ≥ 0.5 m the following year. Hurricane Matthew (October 2016) and Hurricane Irma (September 2017) caused greater damage including breaking limbs as reflected in reduced height and total cover ≥ 0.5 m probably because the older, taller scrub was more vulnerable to wind damage.

Florida scrub↗
NASA NTRSDate not supplied

Towards Erecting Straighter Lightweight Towers on the Moon Using Deployable Guy Wires

This paper reports our static stability test findings for a simple guy wire system to correct the natural lateral deflections of an 8.5m tall, compact deployable composite tower intended to support exploration of lunar permanently shadowed regions by nearby robotic assets. Deployable composite booms with microgravity flight heritage are currently being investigated at NASA Langley Research Center (LaRC) and Massachusetts Institute of Technology(MIT)’s Space Resources Workshop for their potential to be vertically deployed in the lunar gravity field, in support of NASA’s Artemis campaign. These applications include vertical solar arrays and the provision of elevated lines-of-sight to science or engineering payloads on landers and rovers, in support of nearby or distant crewed or robotic assets exploring scientifically interesting and hard to reach areas. Useful elevated payloads include radio repeaters, remote sensing and imaging, navigation and power beaming systems. However, while these lightweight booms have an excellent height to mass ratio, they typically exhibit slight axial curvature upon deployment resulting in appreciable lateral dead-load deflection of the tip mass relative to the tower base. This static deflection increases with tower height and tip mass, not only constraining the value delivered by the tower but also endangering its integrity. To develop a competitive, lightweight deployable composite boom tower, a capability to correct static deflections during and after deployment may be required. This paper presents a pathfinder deployable guy wire stability system for the MIT / LaRC self-erecting composite boom lunar tower that provides real time measurements, maintains tension passively, and can serve as a reconfigurable platform to test new guy wire components, configurations and control algorithms. Using a validated, calibrated photogrammetry system, the natural lateral deflection of the boom tip relative to the boom base at different deployed heights in Earth’s gravity field was recorded. With real-time tension measurements it was found that guy wires can significantly reduce the tip deflection of a deployable composite boom under dead load. Specifically, we found that (1) control capability is greatest where it is needed most, i.e. for the lever arm closest to being opposite the direction of deflection, and (2) for a tower height of at least 8.5 m and arm length of at least 60 cm, a solution of differential tension in all three arms exists and, in principle, provides sufficient control capability to correct or significantly reduce boom deflections. We also found that natural deflections occur almost entirely out-of-plane of the seams of the boom cross-section, which was expected, and that the natural boom tip lateral deflection under dead load upon deployment was ~5% of boom deployed length, unexpectedly exceeding the manufacturing acceptance specification of 1%.Ongoing and future collaborative work between LaRC and MIT includes the further investigation of the unexpected lateral deflection, testing of alternative guy wire system designs at higher tensions and higher deployed heights, as well as trade studies of costs and benefits of an optimized integrated guywire system compared to other types of static stability solutions.

lunar towers↗
NASA NTRS2024

Direct Ink Write 3D Printing of Fully Dense and Functionally Graded Liquid Metal Elastomer Foams

Liquid metal (LM) elastomer composites offer promising potential in soft robotics, wearable electronics, and human-machine interfaces. Direct ink write (DIW) 3D printing offers a versatile manufacturing technique capable of precise control over LM microstructures, yet challenges such as interfilament void formation in multilayer structures impact material performance. Here, a DIW strategy is introduced to control both LM microstructure and material architecture. Investigating three key process parameters–nozzle height, extrusion rate, and nondimensionalized nozzle velocity–it is found that nozzle height and velocity predominantly influence filament geometry. The nozzle height primarily dictates the aspect ratio of the filament and the formation of voids. A threshold print height based on filament geometry is identified; below the height, significant surface roughness occurs, and above the ink fractures, which facilitates the creation of porous structures with tunable stiffness and programmable LM microstructure. These porous architectures exhibit reduced density and enhanced thermal conductivity compared to cast samples. When used as a dielectric in a soft capacitive sensor, they display high sensitivity (gauge factor = 9.0), as permittivity increases with compressive strain. These results demonstrate the capability to simultaneously manipulate LM microstructure and geometric architecture in LM elastomer composites through precise control of print parameters, while maintaining geometric fidelity in the printed design.

Spencer Pak↗
NASA NTRSDate not supplied

Improving Boundary Layer Data Assimilation Using Observation Data from Multiple Observing Systems in the NASA GEOS System

The Planetary Boundary Layer (PBL) is a complex interface that mediates energy and moisture exchanges between the Earth’s surface and atmosphere. Accurate simulation and observation of PBL characteristics, such as PBL height and thermodynamic structure, have proven to be a challenge. In our latest efforts, we have focused on improving PBL thermodynamic structure using data from multiple observing systems in the Goddard Earth Observing System (GEOS), developed by the NASA Global Modeling and Assimilation Office (GMAO). We present strategies and results from assimilating PBL height data derived from radiosondes, GNSS radio occultation, space-based lidar (CALIPSO, CATS, IceSat-2), ground-based lidar (MPLNET), and radar wind profilers, including a novel global PBL height analysis dataset. We also discuss the impacts of better representing capping inversions by using PBL height data together with other observations in GEOS through adjustments to the background error covariance. Long-term statistics of the impact of assimilating and utilizing PBL height data in GEOS are presented. In addition, we explore an innovative approach to assimilate GNSS-RO refractivity data in the lower troposphere.

Eun-Gyeong Yang↗
NASA NTRS2024

Vertical Structure of Gas and Dust in Four Debris Disks

We present high-spectral-resolution M-band spectra from iSHELL on NASA’s Infrared Telescope Facility along the line of sight to the debris disk host star HD 32297. We also present a Gemini Planet Imager H-band polarimetric image of the HD 131488 debris disk. We search for fundamental CO absorption lines in the iSHELL spectra of HD 32297, but do not detect any. We place an upper limit on the CO column density of ∼6×1015cm−2. By combining the column density upper limit, the CO mass measured with the Atacama Large Millimeter/submillimeter Array (ALMA), and the geometrical properties of the disk, we estimate the scale height of the CO to be 2au across the radial extent of the disk (∼80–120au). We use the same method to estimate the CO scale height of three other edge-on, CO-rich debris disks that all have CO observed in absorption with the Hubble Space Telescope as well as in emission with ALMA: β Pictoris, HD 110058, and HD 131488. We compare our estimated CO scale heights of these four systems to the millimeter dust scale heights and find that, under the assumption of hydrostatic equilibrium, there is a potential correlation between the CO and millimeter dust scale heights. There are multiple factors that affect the gas vertical structure such as turbulence, photodissociation with weak vertical mixing, as well as where the gas originates. One possible explanation for the potential correlation could be that the gas and dust are of a similar secondary origin in these four systems.

Kadin Worthen↗
DOE OSTI2023

Calibration technique of wall shear stress sensors using oscillating plate

Disclosed are a system and methods for calibrating wall shear stress sensors. The system includes an oscillating plate coupled to an actuator and mounted on a rolling elements, and one or more sensors coupled to a height adjusting device. The system can further comprise a height control rod coupled to a height control base and a sensor holder configured to house the one or more sensors and supported on a connector, the connector configured to be rotatably disposed about the height control rod. The system can be calibrated by causing the actuator to oscillate the oscillating plate at a frequency, sensing, using the one or more sensors, shear stress at a wall, the shear stress at the wall being associated with a velocity field, and determining a theoretical wall shear stress based on fluid properties, the frequency, and the height of the one or more sensors above the oscillating plate.

Freidkes, Brett R.↗
DOE OSTI2024

Autonomous thermal tracking reveals spatiotemporal patterns of seabird activity relevant to interactions with floating offshore wind facilities

Planning is underway for placement of infrastructure needed to begin offshore wind (OSW) energy generation along the West Coast of the United States and elsewhere in the Pacific Ocean. In contrast to the primarily nearshore windfarms currently in the North Atlantic, the seabird communities inhabiting Pacific Wind Energy Areas (WEAs) include significant populations of species that fly by dynamic soaring, a behavior dependent on wind and in which flight height increases steeply with wind speed. Therefore, a more precise and detailed assessment of their 3D airspace use is needed to better understand the potential collision risks that OSW turbines may present to these seabirds. Toward this end, a novel technology called the ThermalTracker-3D (TT3D), which uses thermal imaging and stereo vision, was developed to render high-resolution (on average within ±5 m) flight tracks and related behavior of seabirds. The technology was developed and deployed on a wind-profiling LiDAR buoy in the Humboldt WEA, located 34 to 57 km off California’s coast. During the at-sea deployment between 24 May and 13 August 2021, the TT3D successfully tracked birds moving between 10 and 500 m from the device, around the clock, and in all weather conditions; a total of 1407 detections and their corresponding 3D flight trajectories were recorded. Mean altitudes of detections ranged 6-295 m above sea level (asl). Considering the degree of overlap with anticipated rotor swept zones (RSZ), which extend 25-260 m asl, 79% of detected birds (per m 3 of airspace) moved below the RSZ, 21% moved at heights overlapping the RSZ, and another 0.04% occurred at heights exceeding the RSZ. The high-resolution tracks provided valuable insight into seabird space use, especially at heights that make them vulnerable to collision during various environmental conditions (e.g., darkness, strong winds). Observations made by the TT3D will be useful in filling critical knowledge gaps related to estimating collision and avoidance between seabirds and OSW facilities in the Pacific and elsewhere. Future research will focus on enhancing the TT3D’s identification capabilities to the lowest taxon through validation studies and artificial intelligence, further contributing to seabird conservation efforts associated with OSW.

17 WIND ENERGY↗
NASA NTRS2015

Airborne Lidar-Based Estimates of Tropical Forest Structure in Complex Terrain: Opportunities and Trade-Offs for REDD+

Background: Carbon stocks and fluxes in tropical forests remain large sources of uncertainty in the global carbon budget. Airborne lidar remote sensing is a powerful tool for estimating aboveground biomass, provided that lidar measurements penetrate dense forest vegetation to generate accurate estimates of surface topography and canopy heights. Tropical forest areas with complex topography present a challenge for lidar remote sensing. Results: We compared digital terrain models (DTM) derived from airborne lidar data from a mountainous region of the Atlantic Forest in Brazil to 35 ground control points measured with survey grade GNSS receivers. The terrain model generated from full-density (approx. 20 returns/sq m) data was highly accurate (mean signed error of 0.19 +/-0.97 m), while those derived from reduced-density datasets (8/sq m, 4/sq m, 2/sq m and 1/sq m) were increasingly less accurate. Canopy heights calculated from reduced-density lidar data declined as data density decreased due to the inability to accurately model the terrain surface. For lidar return densities below 4/sq m, the bias in height estimates translated into errors of 80-125 Mg/ha in predicted aboveground biomass. Conclusions: Given the growing emphasis on the use of airborne lidar for forest management, carbon monitoring, and conservation efforts, the results of this study highlight the importance of careful survey planning and consistent sampling for accurate quantification of aboveground biomass stocks and dynamics. Approaches that rely primarily on canopy height to estimate aboveground biomass are sensitive to DTM errors from variability in lidar sampling density.

Airborne lidar↗
DOE OSTI2023

Duke Forest FACE (FACTS-I): Plant and Soil Response Data

This dataset describing the responses of plant and soil pools and fluxes to elevated atmospheric CO2 concentration and increased nitrogen supply was collected from Duke Forest Free Air CO2 Enrichment (FACE) – Forest-Atmosphere Carbon Transfer and Storage (FACTS-I) experiment from 1996 to 2012. The dataset includes data files for allometry (diameter at breast height, tree height, and height to live crown base), leaf area index, biomass (stem, branch, foliage, and root biomass, tree density, and basal area), net primary productivity (stem, branch, foliage, reproductive, and coarse root NPP), sap flux density, soil CO2 efflux, and stem temperature. Data files were formatted as .csv (Microsoft Excel or other spreadsheet programs can be used to read the format) and file descriptions, including variable name, unit, and data range, can be found in ‘FileDescription_[data_name].txt’ files. The Duke FACE experiment was in a loblolly pine (Pinus taeda L.) plantation established in 1983. Naturally regenerated broadleaved species including sweetgum (Liquidambar styraciflua L.) and tulip poplar (Liriodendron tulipifera L.), mostly in the overstory, and winged elm (Ulmus alata Michx.) and red maple (Acer rubrum L.) were common in the understory. The FACE experiment commenced with two plots (plots 7-8) in 1994 (Oren et al. 2001), with six additional plots (plots 1-6) coming online on 27 August 1996. CO2 enrichment was terminated on 31 October 2010 and post-enrichment data collection continued through 2012. Complete fertilization was applied annually to half of plots 7-8 from 1998 to 2004. The nutrient addition experiment expanded to half of plots 1-6 with a common protocol of N-fertilization in 2005 and continued until 2012. The levels of treatment in this dataset were expressed as ambient CO2 (AMB) or elevated CO2 (ELE) for CO2 treatment and control soil (CONT) or fertilized soil (FERT) for N treatment, respectively.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Additive manufacturing of complexly shaped SiC with high density via extrusion-based technique – Effects of slurry thixotropic behavior and 3D printing parameters

Here, additive manufacturing of dense SiC parts was achieved via an extrusion-based process followed by electrical-field assisted pressure-less sintering. The aim of this research was to study the effect of the rheological behavior of SiC slurry on the printing process and quality, as well as the influence of 3D printing parameters on the dimensions of the extruded filament, which are directly related to the printing precision and quality. Different solid contents and dispersant- Darvan 821A concentrations were studied to optimize the viscosity, thixotropy and sedimentation rate of the slurry. The optimal slurry was composed of 77.5 wt% SiC, Y 2 O 3 and Al 2 O 3 powders, 0.25 wt% dispersant and 0.01 wt% defoamer. The printing parameters studied included extrusion pressure, nozzle size, layer height and printing speed; the one that had the most prominent effect on filament width and height was indicated as layer height. The nozzle inner diameter of 1.04 mm, speed of 350 mm/min, layer height of 0.7 mm and extrusion air pressure of 0.31 MPa were the optimal printing parameters. Furthermore, the relationship between the printing parameters and the filament dimensions was successfully predicted by using machine learning and grey system theory. Finally, the relative density of the printed SiC parts sintered at 1900 oC reached 94.7±1.5%.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A process optimization framework for laser direct energy deposition: Densification, microstructure, and mechanical properties of an Fe-Cr alloy

Laser Direct Energy Deposition (DED) is a metal additive manufacturing technique with the ability to fabricate large and complex parts through deposition of metal powders. However, achieving high-density parts and targeted build heights using DED can be challenging due to the large number of highly sensitive process variables. This work proposes a robust fabrication parameter optimization framework to generate process maps for primary parameters in DED, including laser power, scan speed, mass flow rate, hatch spacing, and layer height. Simple single-track experiments were utilized to map out the parameter space, and a combination of geometric criteria for hatch spacing and layer height were proposed to determine parameter sets that achieve both targeted build heights and mitigate porosity formation. Using this framework, specimens with >99 % density and consistent mechanical properties were successfully fabricated over a wide range of process parameters for an Fe-9wt.%Cr (Fe9Cr) alloy, a surrogate for radiation damage-resistant reduced activation ferritic/martensitic (RAFM) steels. Processing these materials using DED is of particular interest in the development of plasma facing components for nuclear fusion applications. The microstructure and mechanical properties of as-printed Fe9Cr were characterized using optical and electron microscopy, X-ray diffraction, and uniaxial tensile tests. As-printed Fe9Cr displayed ~25 % elongation and ultimate tensile strengths of up to 475 MPa which is comparable to similar wrought alloys. Finally, the proposed framework will allow for accelerated DED parameter optimization for novel alloy systems, as well as open the possibility for local microstructure control while simultaneously mitigating defect formation.

42 ENGINEERING↗
DOE OSTI2021

Development and validation of a gamma-ray detection response model for neutron-diagnosed subcritical experiments

In a neutron-diagnosed subcritical experiment, a highly sensitive and fast detector is required to accurately determine the true fission γ-ray emission rate from an object composed of special nuclear material under interrogation, in addition to a proper detector response model for use in forward modeling. We present the development of a detector response model that is based in GEANT4 and uses post-processing techniques to include photomultiplier tube time and pulse height response effects. We also define a set of detector performance evaluation metrics that emphasized our experimental objectives. A suite of time and pulse height response measurements for several diverse detector assemblies are described. These assemblies were simulated with this response model and benchmarked against the laboratory measurements. This response model reproduces the pulse height curve shapes and performance hierarchy of the measured detectors well. Additionally, the simulated time response curves exhibit reasonable agreement with counterpart measurements. These measurements and simulation results together suggest that a large volume EJ-299-49 plastic scintillator that is mated to an ultraviolet transmitting plastic light guide and relies on total internal reflection for light transport to the photocathode will provide significantly faster timing, increase pulse height by a factor of 3, and require 25% less γ rays to meet experimental needs, compared to the candidate detector design developed prior to the availability of this response model. Application of this response model and associated performance metrics in the context of large-scale design sensitivity studies is also discussed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗