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At least 1,135 records · Page 63
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Tornadoes in Southeast South America: Mesoscale to Planetary-Scale Environments

Abstract A multiscale analysis of the environment supporting tornadoes in southeast South America (SESA) was conducted based on a self-constructed database of 74 reports. Composites of environmental and convective parameters from ERA5 were generated relative to tornado events. The distribution of the reported tornadoes maximizes over the Argentine plains, while events are rare close to the Andes and south of Sierras de Córdoba. Events are relatively common in all seasons except in winter. Proximity environment evolution shows enhanced instability, deep-layer vertical wind shear, storm-relative helicity, reduced convective inhibition, and a lowered lifting condensation level before or during the development of tornadic storms in SESA. No consistent signal in low-level wind shear is seen during tornado occurrence. However, a curved hodograph with counterclockwise rotation is present. The Significant Tornado Parameter (STP) is also maximized prior to tornadogenesis, most strongly associated with enhanced CAPE. Differences in the convective environment between tornadoes in SESA and the U.S. Great Plains are discussed. On the synoptic scale, tornado events are associated with a strong anomalous trough crossing the southern Andes that triggers lee cyclogenesis, subsequently enhancing the South American low-level jet (SALLJ) that increases moisture advection to support deep convection. This synoptic trough also enhances vertical shear that, along with enhanced instability, sustains organized convection capable of producing tornadic storms. At planetary scales, the tornadic environment is modulated by Rossby wave trains that appear to be forced by convection near northern Australia. Madden–Julian oscillation phase 3 preferentially occurs 1–2 weeks ahead of tornado occurrence. Significance Statement The main goal of this study is to describe what atmospheric conditions (from local to global scales) are present prior to and during tornadic storms impacting southeast South America (SESA). Increasing potential for deep convection, wind shear, and potential for rotating updrafts, as well as reducing convective inhibition and cloud-base height, are predominant a few hours before and during the events in connection to low-level northerly winds enhancing moisture transport to the region. Remote convective activity near northern Australia appears to influence large-scale atmospheric circulation that subsequently triggers convective storms supporting tornadogenesis 1–2 weeks later in SESA. Our findings highlight the importance of accounting for atmospheric processes occurring at different scales to understand and predict tornado occurrences.

Meteorology & Atmospheric Sciences↗
DOE OSTI2021

Challenges and Solutions for Real-Time Phasor Modeling of Large-scale Distribution Network with High PV Penetration

The conversion process of a practical large-scale feeder data from a quasi-static time series (OpenDSS) model into a real-time phasor model (ePHASORSIM in Opal-RT) is discussed in the paper. The process is implemented using an open source Python software. Previous reported implementations for the conversion process lead to several errors when applied to a larger-scale system such as the one considered here. Hence in this work, we describe the common issues in this conversion and propose a customized solution to enhance the efficiency of the conversion and reduce the complexity in the process. A quantitative validation of the enhanced conversion process is presented in this work using an actual high PV penetration feeder model that consists of 2230 buses, and using actual load and PV profile data. After a detailed analysis, this customized conversion software will be made available as an open source tool and is expected to be helpful for researchers who want to pursue a similar conversion. Solutions to various observed issues such as identifying the lines due to islanded network, representation of full impedance model of transformer/lines as sequential models, complexity in the representation of single phase buses/lines as three phase buses/lines to make it compatible with the simulator platform are discussed. Comparison of power flow and time series simulation results obtained from both OpenDSS and ePHASORsim models show very low errors, validating the accuracy of the proposed conversion process.

14 SOLAR ENERGY↗
DOE OSTI2025

Developing ML/AI Methods for High-Throughput Characterization of Multiple-Sensor Streams of Tokamak Dynamics for High-Speed Control (Final Report)

This project evaluated and developed new mathematical and algorithmic techniques capable of handling (in real-time) the growing amounts of data generated by modern fusion research. While existing numerical linear algebra (NLA) methods provide the backbone to classical data analysis and algorithms, these methods fundamentally do not port to distributed architectures nor do they allow low-latency data reduction for control. Motivated by the needs for modern fusion reactors, this project explored and implemented new numerical methods to characterize plasma dynamics, respond in real-time to discharge evolution, and to process massive-scale data accurately and rapidly more fully. This project links expertise in multiple-sensor diagnostics of tokamak plasma dynamics from Columbia University’s Plasma Physics Laboratory with expertise in massive-scale data reduction and extreme data control algorithms at Columbia University’s Data Science Institute. This interdisciplinary project (i) applied machine learning methods, (ii) implemented a properly-trained neural-network for very fast processing of high-speed plasma videography, and (ii) developed the applied mathematical methods, based on randomized-NLA (rNLA) routines, for data analysis, reduction, and real-time control. The Columbia University High Beta Tokamak-Extended Pulse (HBT-EP) facility provided data to test new algorithms and partnership with Columbia University's Data Sciences Institute evaluated the broader use of new algorithms for many challenging control applications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Photovoltaic Deployment Scenarios toward Global Decarbonization: Role of Disruptive Technologies

To totally decarbonize global electrical systems using photovoltaics (PVs) in the 2050–2060 decade, the world would need to install 63.4 TW of PV. This article models and explores how a PV manufacturing ramp‐up trajectory toward this goal can be achieved while assuming that investors continue to make financially rational decisions avoiding stranded production assets and therefore protecting their return on investment. The model effectively exploits experience curve benefits in both the scaling of the manufacturing process and continued progress in product design technologies. The scale‐up challenge is amplified because trajectories that achieve this goal require an unprecedented ramp‐up of production capacity over just two decades, followed by relatively modest demand to maintain the installed base and support continued population growth. It is demonstrated that sustainable ramp‐up of manufacturing is indeed possible and shown that the deployment of the requisite manufacturing capacity can be accelerated and accomplished at lower total capital cost by the introduction of disruptive technologies that have lower capital intensity, embedded energy, or higher efficiency.

14 SOLAR ENERGY↗
DOE OSTI2022

All-atmospheric fabrication of Ag–Cu core–shell nanowire transparent electrodes with Haacke figure of merit >600 × 10–3 Ω−1

Abstract Transparent conducting electrodes (TCEs) are essential components in devices such as touch screens, smart windows, and photovoltaics. Metal nanowire networks are promising next-generation TCEs, but best-performing examples rely on expensive metal catalysts (palladium or platinum), vacuum processing, or transfer processes that cannot be scaled. This work demonstrates a metal nanowire TCE fabrication process that focuses on high performance and simple fabrication. Here we combined direct and plating metallization processes on electrospun nanowires. We first directly metallize silver nanowires using reactive silver ink. The silver catalyzes subsequent copper plating to produce Ag–Cu core–shell nanowires and eliminates nanowire junction resistances. The process allows for tunable transmission and sheet resistance properties by adjusting electrospinning and plating time. We demonstrate state-of-the-art, low-haze TCEs using an all-atmospheric process with sheet resistances of 0.33 Ω sq −1 and visible light transmittances of 86% (including the substrate), leading to a Haacke figure of merit of 652 × 10 –3 Ω −1 . The core–shell nanowire electrode also demonstrates high chemical and bending durability.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Radiative Smoothing in Clouds at Transparent and Absorbing Wavelengths

For absorbing and transparent wavelengths, we discuss the effect of horizontal solar radiative fluxes in clouds on the accuracy of a conventional plane-parallel radiative transfer calculations for a single pixel, known as the Independent Pixel Approximation (IPA). We address the question of correlations between horizontal fluxes, IPA accuracies and radiative smoothing. By smoothing we understand a radiative transfer process whereby radiation does not follow the small-scale fluctuations of cloud structure, producing much smoother radiation fields. The scale eta that characterizes this process is called "radiative smoothing scale." We relate radiative smoothing to the photon's horizontal displacement that characterizes a "spot" of reflected light associated with a point source. We generalize the "spot-size" estimate derived for conservative scattering using the diffusion theory to the case of non-conservative scattering. For reflected light, theoretical results are confirmed with numerical simulations. The radiative smoothing scale eta is a critical value where IPA effectively breaks down; for scales smaller than TI, real radiation field are much smoother than their IPA counterparts for the same cloud structure. In addition to the estimate of il for absorbing wavelengths, we show that: (1) with more absorption, the scale break determined by eta in a log-log plot of wavenumber spectra moves towards smaller scales and (2) the smaller eta the flatter the small-scale slope which means less radiative smoothing, thus more accuracy in the IPA reflection.

Marshak, A.↗
NASA NTRS2001

Icehouse Effect: A Selective Arctic Cooling Trend Current Models are Missing

The icehouse effect is a hypothesized climate feedback mechanism which could result in human-caused surface cooling trends in polar regions. Once understood in detail, it becomes apparent that these trends, which are discernable in the literature, but have been largely dismissed, do not conflict with the consensus assessment of the evidence, which infers century-scale Arctic warming. In fact, confirmation of the hypothesis would substantially strengthen the argument that there is a detectable human influence on today's climate. This apparent enigma is resolved only through careful attention to the detail of the hypothesis and the data supporting it. The posited surface cooling is entirely dependent on the existence of climate warming in layers capping the stable boundary layer. Also, the cooling is not pandemic, but is selective. It is readily revealed in properly sorted data by making use of the principles of micrometeorological similarity. Specifically, the cooling is manifest under a range of favorable turbulence conditions which can develop and disappear locally on time scales of minutes to hours because of the intrinsically intermittent nature of stable boundary layer turbulence. Because of the fine-scale nature of the processes which produce the cooling, modeling it is a difficult proposition. Vertical resolution on the order of 1 meter is required. Adequate models of intermittent surface fluxes coupled with radiation exchange do not currently exist, not as parameterizations for aggregated systems, nor in large eddy simulation (LES) models. This presentation will introduce the theory. An important testable null hypothesis emerges: the icehouse effect produces a unique signature or "fingerprint" which could not be produced by any other known process. The presence of this signature will be demonstrated using nearly all available Arctic temperature observations. Its aggregate effect is clearly found in Arctic monthly surface temperature trends when sorted by climatological stability. Using all available Arctic rawinsonde ascents - about 1.1 million profiles, "frozen moments" of the icehouse processes are captured in various states. Because turbulent time scales are so short in the stable boundary layer. each of these snapshots can be treated as independent -- their chronology is irrelevant. Micrometeorological similarity is invoked to reassemble the soundings into bins of similar stability and it is in a wide, coherent range of these stability bins where the cooling effect is revealed.

Wetzel, Peter J.↗
NASA NTRS2022

The Abundances of F, Cl, and H2O in 4Vesta from Eucrites

The abundance and distribution of magmatic volatiles (i.e., H, C, N, F, S, and Cl) within the silicate portion of a differentiated planetary body has important consequences on its thermochemical evolution. However, the abundances of magmatic volatiles within differentiated bodies are difficult to quantify, and they are often depleted by varying degrees relative to CI chondrites. The mechanisms of depletion are not well constrained and could relate to intrinsic volatile depletion of the building blocks that formed the bodies, high temperature processes that result from accretion, post-accretion loss through parent body geological processes and large-scale impacts, and/or redistribution within a parent body through processes like core formation [1–4]. In the present study, we aim to constrain the abundances of F, Cl, and H2O in eucrites to better understand the magnitude of volatile depletion on 4Vesta. To accomplish this objective, we report electron microprobe analyses of apatite from seven unbrecciated, non-cumulate eucrites (i.e., CMS 04049,GRA 98098, LEW 88010, MAC 02522, MAC 041169,QUE 94484, and QUE 97053) and two monomict, non-cumulate eucrites (i.e., Berthoud and Stannern). In combination with previously published data on eucrite-hosted apatite, we determine Cl/F and H2O/F ratios in bulk rock eucrites through the application of apatite-based melt hygrometry and chlorometry [e.g., 5–7].Additionally, we estimate the bulk rock abundances of F in six non-cumulate eucrites (i.e., GRA 98098, MAC041169, PCA 91078, QUE 97053, Stannern, and Berthoud), which we combine with previously published bulk rock F data on non-cumulate eucrites[8] to constrain the abundances of F, Cl, and H2O in 4Vesta using appropriately paired volatile/refractory element ratios for F, followed by Cl/F and H2O/F ratios for Cl and H2O, respectively.

F M McCubbin↗
NASA NTRS2007

Development and Processing Improvement of Aerospace Aluminum Alloys-Development of AL-Cu-Mg-Ag Alloy (2139)

This final report supplement in presentation format describes a comprehensive multi-tasked contract study to continue the development of the silver bearing alloy now registered as aluminum alloy 2139 by the Aluminum Association. Two commercial scale ingots were processed into nominal plate gauges of two, four and six inches, and were extensively characterized in terms of metallurgical and crystallographic structure, and resulting mechanical properties. This report includes comparisons of the property combinations for this alloy and 2XXX and 7XXX alloys more widely used in high performance applications. Alloy 2139 shows dramatic improvement in all combinations of properties, moreover, the properties of this alloy are retained in all gauge thicknesses, contrary to typical reductions observed in thicker gauges of the other alloys in the comparison. The advancements achieved in this study are expected to result in rapid, widespread use of this alloy in a broad range of ground based, aircraft, and spacecraft applications.

Cho, Alex↗
NASA NTRS2013

Net Shape Spin Formed Cryogenic Aluminum Lithium Cryogenic Tank Domes for Lower Cost Higher Performance Launch Vehicles

With the goal of lower cost (simplified manufacturing and lower part count) and higher performance (higher strength to weight alloys) the NASA Technical Maturation Program in 2006 funded a proposal to investigate spin forming of space launch vehicle cryogenic tank domes. The project funding continued under the NASA Exploration Technology Development Program through completion in FY12. The first phase of the project involved spin forming of eight, 1 meter diameter "path finder" domes. Half of these were processed using a concave spin form process (MT Aerospace, Augsburg Germany) and the other half using a convex process (Spincraft, Boston MA). The convex process has been used to produce the Ares Common Bulkhead and the concave process has been used to produce dome caps for the Space Shuttle light weight external tank and domes for the NASDA H2. Aluminum Lithium material was chosen because of its higher strength to weight ratio than the Aluminum 2219 baseline. Aluminum lithium, in order to obtain the desired temper (T8), requires a cold stretch after the solution heat treatment and quench. This requirement favors the concave spin form process which was selected for scale up. This paper describes the results of processing four, 5.5 meter diameter (upper stage scale) net shaped spin formed Aluminum Lithium domes. In order to allow scalability beyond the limits of foundry and rolling mills (about 12 foot width) the circular blank contained one friction stir weld (heavy lifter scales require a flat blank containing two welds). Mechanical properties data (tensile, fracture toughness, stress corrosion, and simulated service testing) for the parent metal and weld will also be discussed.

Curreri, Peter A.↗
NASA NTRSDate not supplied

Using Controlled Impact Experiments to Understand the Effects of Cohesive Blocks on the Cratering Process

When considering large-scale impact events that occur in the gravity-regime, smallscale target heterogeneities (on order of the projectile diameter) are anticipated to have a minimal effect on the cratering process and are therefore not considered in scaling relations [1-3]. Such heterogeneities and other details of the target's strength and structure, however, become increasingly influential as the magnitude of the impact decreases [4]. At the scale of craters forming mostly in regolith on the Moon (< a few meters), for example, target properties such as cohesive strength, density, porosity, and friction have more leverage than gravity to influence the resultant crater dimensions [5]. Further complications beyond just target properties can manifest in many forms, such as subsurface layers [6]; the presence of random, competent blocks [7]; buried lenses of impact melt; and/or pockets of regolith compacted or indurated to varying degrees by previous impacts. Summing the total effect of target properties and any additional heterogeneities for integration into scaling relations is not straightforward, as each individual parameter will have unequal, and so far, unquantified, effects on the final crater. Even when craters are produced under a best-case scenario of controlled laboratory conditions, understanding the entire relevant parameter space can be a formidable task, and deconvolution of all the contributing factors can be a complex undertaking. To begin the process of quantifying such effects, we are conducting an extensive series of impact experiments to build a framework for the interpretation of craters observed on the characteristically complex surfaces throughout the solar system. Here we present the first, and simplest, configuration to be examined in this multi-year experimental campaign: one in which solitary, cohesive blocks are placed in the path of the projectile’s trajectory at different burial depths in granular, sand targets. Among the variables to be investigated in this configuration are the influence of block size, compressive strength, and burial depth.

impact crater↗
DOE OSTI2024

Granular Temperature Modeling with Large-Scale CFD-DEM Data

The granular temperature is a measure of solids-phase fluctuating kinetic energy in particle-laden gas-solid flows. This report focuses on reduced-order models of granular temperature in triply-periodic cluster induced turbulent flow. The granular temperature data was generated by post-processing large-scale CFD-DEM simulations that were carried out as part of an ALCC awarded study. The algebraic model of Tang et al, originally fit to DNS data, was found to be amenable to the present data. The results of several regression analyses are presented building on the original expression. This work was performed in part through the National Nuclear Security Administration (NNSA) Minority Serving Institutions Internship Program (MSIIP).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Deep Cellular Recurrent Network for Efficient Analysis of Time-Series Data With Spatial Information

Efficient processing of large-scale time series data is an intricate problem in machine learning. Conventional sensor signal processing pipelines with hand engineered feature extraction often involve huge computational cost with high dimensional data. Deep recurrent neural networks have shown promise in automated feature learning for improved time-series processing. However, generic deep recurrent models grow in scale and depth with increased complexity of the data. This is particularly challenging in presence of high dimensional data with temporal and spatial characteristics. Consequently, this work proposes a novel deep cellular recurrent neural network (DCRNN) architecture to efficiently process complex multi-dimensional time series data with spatial information. Here, the cellular recurrent architecture in the proposed model allows for location-aware synchronous processing of time series data from spatially distributed sensor signal sources. Extensive trainable parameter sharing due to cellularity in the proposed architecture ensures efficiency in the use of recurrent processing units with high-dimensional inputs. This study also investigates the versatility of the proposed DCRNN model for classification of multi-class time series data from different application domains. Consequently, the proposed DCRNN architecture is evaluated using two time-series datasets: a multichannel scalp EEG dataset for seizure detection, and a machine fault detection dataset obtained in-house. The results suggest that the proposed architecture achieves state-of-the-art performance while utilizing substantially less trainable parameters when compared to comparable methods in the literature.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Structural Studies of Alloyed and Nanoparticle Transition Metal Dichalcogenides by Selenium-77 Solid-State Nuclear Magnetic Resonance Spectroscopy

Layered transition metal dichalcogenides (TMDCs) such as MoS 2 , MoSe 2 , and WSe 2 are under intense investigation because they are atomically thin semiconductors with photophysical properties that can be tuned by changing their composition or morphology. Mechanochemical processing has been proposed as a method to obtain alloyed TMDCs in the series Mo 1–x W x S y Se 2–y (x = 0–1; y = 0–2). However, elucidating the chemical transformations occurring at the atomic scale following mechanochemical processing can be challenging because the products are often amorphous or microcrystalline. To address this challenge, we probe TMDC mixing and alloying by using a combination of powder X-ray diffraction, Raman spectroscopy, diffuse reflectance spectroscopy, 77 Se solid-state nuclear magnetic resonance (SSNMR) spectroscopy, and planewave density functional theory (DFT) calculations. The nature of the milling material and reaction atmosphere are shown to be essential factors in limiting the formation of undesired oxide byproducts. We demonstrate acquisition of 77 Se SSNMR spectra using different combinations of Carr-Purcell Meiboom-Gill acquisition (CPMG) pulse sequences, magic angle spinning (MAS), and MAS dynamic nuclear polarization. Further, the combination of SSNMR with the other characterization methods clearly demonstrates that high energy impact ball milling induces molecular level alloying of Mo, W and chalcogen atoms in the family Mo 1–x W x S y Se 2–y . Gauge including projector augmented wave DFT calculations yield accurate 77 Se chemical shift (CS) tensor components. 77 Se SSNMR spectroscopy was also applied to study the structure of WSe 2 nanocrystals intercalated with ethylenediamine. The intercalated WSe 2 nanocrystals exhibit a more positive isotropic 77 Se CS as compared to bulk WSe 2 , however, the 77 Se CS anisotropy is the same, confirming the WSe 2 layers have a similar structure as in their bulk counterparts.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Understanding and Mitigating Stickiness in Biochar Produced through Acid Hydrolysis and Dehydration

Levulinic acid is a platform chemical with significant potential for conversion into a wide range of biobased chemicals and fuels. A common process for producing levulinic acid from lignocellulosic feedstocks involves acid hydrolysis and dehydration (AHDH), where hexose polymers are hydrolyzed into monomeric sugars and subsequently dehydrated to levulinic acid and formic acid in the presence of dilute sulfuric acid. However, scaling the AHDH process is challenging because of the formation of byproducts such as sticky biochar, which accumulates in continuous-flow reactors, reducing effective reaction volume and increasing process downtime. This study investigates the effect of a chemical preconditioning step on mitigating sticky biochar formation. Woody biomass was preconditioned at 170 °C with 0.26 wt % sulfuric acid for 30 min, resulting in substantial removal of hemicellulose and acid-soluble lignin. AHDH of these preconditioned solids produced biochar that did not adhere to reactor surfaces. TGA analysis confirmed that the chemical preconditioning step minimized interactions between hemicellulose-derived degradation products and lignin side chains, reducing sticky char formation. Additionally, the study observed a 6% higher yield of organic acids from softwood species compared to hardwoods, with bark content shown to negatively impact yield. These findings suggest that targeted preconditioning of lignocellulosic biomass can enhance reactor operability and improve organic acid production efficiency in AHDH processes.

biopolymers↗
NASA NTRSDate not supplied

Evaluating Subgrid-Scale Properties of Low Clouds over the Beaufort Sea in Arctic System Reanalysis using ARISE Airborne In Situ Observations

Arctic low clouds influence the evolution of the Arctic system through their effects on radiative fluxes, boundary layer mixing, stability, turbulence, humidity, and precipitation. Unfortunately, atmospheric models and retrospective analysis (reanalysis) products struggle to accurately simulate the occurrence and properties of low clouds in the Arctic. To better understand the magnitude and possible causes of this problem, we analyze the disagreements between the Arctic System Reanalysis version 2 (ASR) and data taken during the September 2014 Arctic Radiation-IceBridge Sea and Ice Experiment (ARISE) airborne campaign conducted over the Beaufort Sea. Previous analysis of grid scale-averaged meteorological variables revealed a lack of cloud water produced in ASR, related to warm/dry biases, a failure to produce sufficient cloud water in conditions that are observed to be favorable for large cloud water values, and sampling issues with the ARISE flight paths. However, ARISE collected meteorological observations at one second intervals, offering spatial data resolution comparable to the subgrid scale of ASR. Subgrid scale properties and processes must be parameterized in conventional atmospheric models and reanalyses such as ASR, and often rely on assumed distributions of meteorological variables about the grid box mean state. To enable an examination of the realism of ASR’s subgrid scale properties, we use high resolution data from ARISE determine the “subgrid scale” distributions of cloud water and thermodynamic variables in the real atmosphere. Preliminary results show that the subgrid scale distribution of thermodynamic variables about the grid scale mean resembles the triangular distribution assumed in many bulk microphysical parameterization schemes, but also with tails resembling Gaussian distributions. The main goal is to understand the partitioning of the total available atmospheric water into water vapor and cloud water. Models typically covert some percentage of total water in a grid box to cloud water based on the estimated amount of supersaturation from the assumed vapor distribution. The ARISE measurements can reveal the relationship between subgrid scale supersaturation and the partition between cloud water and water vapor.

Jason Brant Dodson↗
NASA NTRS2015

A Decision-Support Model for Selecting Additive Manufacturing Versus Subtractive Manufacturing Based on Energy Consumption

This paper presents a simple computational model for determining whether additive manufacturing or subtractive manufacturing is more energy efficient for production of a given metallic part. The key discriminating variable is the fraction of the bounding envelope that contains material – i.e. the volume fraction of solid material. For both the additive process and the subtractive process, the total energy associated with the production of a part is defined in terms of the volume fraction of that part. The critical volume fraction is that for which the energy consumed by subtractive manufacturing equals the energy consumed by additive manufacturing. For volume fractions less than the critical value, additive manufacturing is more energy efficient. For volume fractions greater than the critical value, subtractive manufacturing is more efficient. The model considers the entire manufacturing lifecycle – from production and transport of feedstock material through processing to return of post-production scrap for recycling. Energy consumed by processing equipment while idle is also accounted for in the model. Although the individual energy components in the model are identified and accounted for in the expressions for additive and subtractive manufacturing, values for many of these components may not be currently available. Energy values for some materials’ production and subtractive and additive manufacturing processes can be found in the literature. However, since many of these data are reported for a very specific application, it may be difficult, if not impossible, to reliably apply these data to new process-material manufacturing scenarios since, very often, insufficient information is provided to enable extrapolation to broader use. Consequently, this paper also highlights the need to develop improved knowledge of the energy embodied in each phase of the manufacturing process. To be most valuable, users of the model should determine the energy consumed by their manufacturing process equipment on the basis of energy-per-unit-volume of production for each material of interest – considering both alloy composition and form. Energy consumed during machine idle per unit time should also be determined by the user then scaled to specific processing scenarios. Energy required to generate feedstock material (billet, plate, bar, wire, powder) must be obtained from suppliers.

J K Watson↗
NASA NTRSDate not supplied

Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.

Laser Powder Bed Fusion↗