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At least 1,243 records · Page 69

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

Portable and Cost-Effective Device for Reliable Detection of Counterfeit and Non-compliant Refrigerants in Diverse Applications

Counterfeit refrigerants pose significant challenges to safety, system reliability, and operational effectiveness due to their harmful contaminants or incompatible chemical compositions. Utilizing these noncompliant products can lead to reduced efficiency, equipment failures, and expensive repairs. Additionally, heightened demand for alternative refrigerants during the industry's transition has created supply gaps, enabling counterfeit products to proliferate. Accurate detection and analysis tools are therefore essential to verify refrigerant authenticity and ensure system integrity in diverse applications. This paper presents the development of a portable device designed for reliable identification and detailed analysis of refrigerant composition. By integrating precision gas sampling, controlled pressure regulation, and automated sensor technology, the device not only detects deviations from standard refrigerant properties but also provides a comprehensive composition breakdown. Pre-calibrated sensors measure the refrigerant gas to identify specific concentrations and contaminants, with an intuitive LED-based indicator system ensuring quick interpretation of results. The user-friendly interface enables operators to select refrigerant types for targeted testing, further enhancing accuracy and usability for field technicians. Comprehensive testing was conducted on mildly flammable A2L refrigerants, showcasing the device’s robustness and adaptability in analyzing composition and detecting discrepancies. The device demonstrated consistent accuracy across a range of refrigerant samples, affirming its reliability in diverse operational environments. Its design minimizes contamination risks during sampling and provides detailed composition results within 90 seconds, ensuring efficient and precise analysis. With a projected price point under $150, the proposed solution delivers affordability alongside its lightweight portability and straightforward operation. Unlike complex and costly alternatives, such as gas chromatography systems, this device provides an accessible option for technicians, customs personnel, and industry operators in need of quick and effective refrigerant verification. Compatible with both current formulations and emerging refrigerant technologies, the device addresses critical counterfeit detection needs across a range of applications. By delivering accurate composition analysis and counterfeit identification, this innovation enhances system performance, safety, and operational reliability in crucial industries.

Cheekatamarla, Praveen [ORNL] (ORCID:0000000248827↗

STRS Radio Service Software for NASA's SCaN Testbed

NASAs Space Communication and Navigation(SCaN) Testbed was launched to the International Space Station in 2012. The objective is to promote new software defined radio technologies and associated software application reuse, enabled by this first flight of NASAs Space Telecommunications Radio System(STRS) architecture standard. Pre-launch testing with the testbeds software defined radios was performed as part of system integration. Radio services for the JPL SDR were developed during system integration to allow the waveform application to operate properly in the space environment, especially considering thermal effects. These services include receiver gain control, frequency offset, IQ modulator balance, and transmit level control. Development, integration, and environmental testing of the radio services will be described. The added software allows the waveform application to operate properly in the space environment, and can be reused by future experimenters testing different waveform applications. Integrating such services with the platform provided STRS operating environment will attract more users, and these services are candidates for interface standardization via STRS.

Mortensen, Dale J.↗

Lessons Learned on the Use of Data Surfaces for Ffowcs Williams-Hawkings Calculations: Airframe Noise Applications

The use of integral solutions to the acoustic analogy-based Ffowcs Williams-Hawkings (FW-H) formulation is the defacto industrial and academic approach for assessing far-field acoustic behavior from airframe noise simulations. The methodology utilizes time-accurate flow variables obtained at arbitrary data surfaces to determine far-field spectra. The solid surface approach, where the time history of pressure is recorded on the surface of the aircraft, is generally preferred. Permeable surfaces, where pressure and velocity are recorded on a user-defined surface enclosing the aircraft, are also used. This paper seeks to share some of the valuable lessons we learned over the past several years on the limitations of the FW-H formulation and best practices for its successful application. We show results for various configurations comprising isolated landing gears, a business jet, a large commercial transport, and a generic low boom supersonic prototype, all at landing conditions. We demonstrate that the solid FW-H approach has significant accuracy limitations for most realistic cases and that the permeable FW-H approach may also fail in specific scenarios, requiring additional costly steps to extract the correct far-field noise spectra. Suggested guidelines for proper FW-H calculations are also given.

Acoustic propagation, Ffowcs Williams-Hawkings Cal↗

Electronic photography at NASA Langley Research Center

The field of photography began a metamorphosis several years ago which promises to fundamentally change how images are captured, transmitted, and output. At this time the metamorphosis is still in the early stages, but already new processes, hardware, and software are allowing many individuals and organizations to explore the entry of imaging into the information revolution. Exploration at this time is prerequisite to leading expertise in the future, and a number of branches at LaRC have ventured into electronic and digital imaging. Their progress until recently has been limited by two factors: the lack of an integrated approach and the lack of an electronic photographic capability. The purpose of the research conducted was to address these two items. In some respects, the lack of electronic photographs has prevented application of an integrated imaging approach. Since everything could not be electronic, the tendency was to work with hard copy. Over the summer, the Photographics Section has set up an Electronic Photography Laboratory. This laboratory now has the capability to scan film images, process the images, and output the images in a variety of forms. Future plans also include electronic capture capability. The current forms of image processing available include sharpening, noise reduction, dust removal, tone correction, color balancing, image editing, cropping, electronic separations, and halftoning. Output choices include customer specified electronic file formats which can be output on magnetic or optical disks or over the network, 4400 line photographic quality prints and transparencies to 8.5 by 11 inches, and 8000 line film negatives and transparencies to 4 by 5 inches. The problem of integrated imaging involves a number of branches at LaRC including Visual Imaging, Research Printing and Publishing, Data Visualization and Animation, Advanced Computing, and various research groups. These units must work together to develop common approaches to image processing and archiving. The ultimate goal is to be able to search for images using an on-line database and image catalog. These images could then be retrieved over the network as needed, along with information on the acquisition and processing prior to storage. For this goal to be realized, a number of standard processing protocols must be developed to allow the classification of images into categories. Standard series of processing algorithms can then be applied to each category (although many of these may be adaptive between images). Since the archived image files would be standardized, it should also be possible to develop standard output processing protocols for a number of output devices. If LaRC continues the research effort begun this summer, it may be one of the first organizations to develop an integrated approach to imaging. As such, it could serve as a model for other organizations in government and the private sector.

Holm, Jack M.↗

STRS Radio Service Software for NASA's SCaN Testbed

NASA's Space Communication and Navigation(SCaN) Testbed was launched to the International Space Station in 2012. The objective is to promote new software defined radio technologies and associated software application reuse, enabled by this first flight of NASA's Space Telecommunications Radio System (STRS) architecture standard. Pre-launch testing with the testbed's software defined radios was performed as part of system integration. Radio services for the JPL SDR were developed during system integration to allow the waveform application to operate properly in the space environment, especially considering thermal effects. These services include receiver gain control, frequency offset, IQ modulator balance, and transmit level control. Development, integration, and environmental testing of the radio services will be described. The added software allows the waveform application to operate properly in the space environment, and can be reused by future experimenters testing different waveform applications. Integrating such services with the platform provided STRS operating environment will attract more users, and these services are candidates for interface standardization via STRS.

Mortensen, Dale J.↗

The ATLAS multi-user upgrade and potential applications

With the recent integration of the CARIBU-EBIS charge breeder into the ATLAS accelerator system to provide for more pure and efficient charge breeding of radioactive beams, a multi-user upgrade of the ATLAS facility is being proposed to serve multiple users simultaneously. ATLAS was the first superconducting ion linac in the world and is the US DOE low-energy Nuclear Physics National User Facility. The proposed upgrade will take advantage of the continuous-wave nature of ATLAS and the pulsed nature of the EBIS charge breeder in order to simultaneously accelerate two beams with very close mass-to-charge ratios; one stable from the existing ECR ion source and one radioactive from the newly commissioned EBIS charge breeder. In addition to enhancing the nuclear physics program, beam extraction at different points along the linac will open up the opportunity for other potential applications; for instance, material irradiation studies at ~ 1 MeV/u and isotope production at ~ 6 MeV/u or at the full ATLAS energy of ~ 15 MeV/u. Furthermore, the concept and proposed implementation of the ATLAS multi-user upgrade will be presented. Future plans to enhance the flexibility of this upgrade will also be presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Effects of Synchrotron Motion on Nonlinear Integrable Optics

An integrable Rapid-Cycling Synchrotron (iRCS) has been proposed as a replacement for the Fermilab Booster to achieve multi-MW beam power for the Fermilab high-energy neutrino program.* The successful application of nonlinear integrable optics to proton synchrotrons requires careful examination of single-particle longitudinal effects, especially synchrotron motion. For example, synchrobetatron coupling may excite transverse resonances in the ring. We will use the Synergia code to simulate the effects of this synchrobetatron coupling on the iRCS design with nonlinear inserts. Our goal will be to identify new invariants in the presence of this coupling. Assuming the synchrotron tune is sufficiently small, we have identified one or more adiabatic invariants of the motion. These invariants suggest that integrable optics with synchrobetatron coupling retains integrability when averaged over a synchrotron period.

43 PARTICLE ACCELERATORS↗

Joining and Integration of Advanced Carbon-Carbon Composites to Metallic Systems for Thermal Management Applications

Recent research and development activities in joining and integration of carbon-carbon (C/C) composites to metals such as Ti and Cu-clad-Mo for thermal management applications are presented with focus on advanced brazing techniques. A wide variety of carbon-carbon composites with CVI and resin-derived matrices were joined to Ti and Cu-clad Mo using a number of active braze alloys. The brazed joints revealed good interfacial bonding, preferential precipitation of active elements (e.g., Ti) at the composite/braze interface. Extensive braze penetration of the inter-fiber channels in the CVI C/C composites was observed. The chemical and thermomechanical compatibility between C/C and metals at elevated temperatures is assessed. The role of residual stresses and thermal conduction in brazed C/C joints is discussed. Theoretical predictions of the effective thermal resistance suggest that composite-to-metal brazed joints may be promising for lightweight thermal management applications.

Singh, M.↗

Elliptic Functions and Integrals with Real Modulus in Fluid Mechanics

Advantage of the elliptic functions and of the more general functions of Schwarz for fluid mechanics. Flows outside and inside polygons. Application to the calculation of an elbow diffuser for a wind tunnel. Properties of the elliptic integrals of the first kind and of the elliptic functions. Properties of the theta functions and decomposition of the elliptic functions into products of theta functions. Properties of the zeta functions. Decomposition of the elliptic functions into sums of zeta functions and calculations of the elliptic integrals. Applications to the calculation of wing profiles, of compressor profiles, and to the study of the vibrations of airplane wings and of compressor vanes. The manuscript of the present paper was checked by Mr. Eichelbrenner who corrected several imperfections and suggested numerous improvements to make reading of the paper easier. However, the limited subject does not permit filling in more than an incomplete knowledge of the properties of analytic functions.

Legendre, Robert↗

Integration of design information

The overall concepts of the integrated programs for aerospace-vehicle design (IPAD) from the user's viewpoint are discussed. Also a top-level view of what the user requires from such a system is provided, and the interactions between the system and user are described. The four major components discussed are design process; data storage, management and manipulation; user interface; and project management. Although an outgrowth of aerospace production experience, the basic concepts discussed, and especially their emphasis on integration, are considered applicable to all problem solving. Thus, these concepts may offer a broad base for exploitation by industry in general. This is the first in a set of three papers, the other two being Future Integrated Design Process, by D. D. Mayer, and Requirements for Company-Wide Management of Engineering Information, by J. W. Southall. In addition to tying the three together, how project management can be handled in a computing environment and also the user interface needs are discussed in detail.

Anderton, G. L.↗

TADPLOT program, version 2.0: User's guide

The TADPLOT Program, Version 2.0 is described. The TADPLOT program is a software package coordinated by a single, easy-to-use interface, enabling the researcher to access several standard file formats, selectively collect specific subsets of data, and create full-featured publication and viewgraph quality plots. The user-interface was designed to be independent from any file format, yet provide capabilities to accommodate highly specialized data queries. Integrated with an applications software network, data can be assessed, collected, and viewed quickly and easily. Since the commands are data independent, subsequent modifications to the file format will be transparent, while additional file formats can be integrated with minimal impact on the user-interface. The graphical capabilities are independent of the method of data collection; thus, the data specification and subsequent plotting can be modified and upgraded as separate functional components. The graphics kernel selected adheres to the full functional specifications of the CORE standard. Both interface and postprocessing capabilities are fully integrated into TADPLOT.

Hammond, Dana P.↗

A Task Based Approach for Co-Scheduling Ensemble Workloads on Heterogeneous Nodes

Scientific workflows consist of multiple, connected applications, with data and results flowing from one to another in a pipeline. Traditionally, such workflows are executed in sequential order, storing intermediate data in storage disks. Co-scheduling application workflows concurrently on the same compute nodes would greatly reduce the cost of moving data to/from storage and allow real-time analysis of intermediate results. Nevertheless, most parallel programming runtimes do not allow seamless integration of various applications in a scientific workflow, in part due to the complexity of managing data and resources. The situation is even more complicated for heterogeneous systems. In this work we extend the Minos Computing Library (MCL) runtime to accelerate pipe-lined and parallel workloads where multiple applications are running in the same system. MCL’s asynchronous task library and runtime dynamically manages resources to allow co-scheduling of multiple processes sharing heterogeneous resources. In addition, we design a custom ex- tension of the Open Compute Language (OpenCL) to enable multiple processes to share device memory. We enable MCL to coordinate these shared buffers to allow for easy, fast data sharing between applications. Using malleable micro-benchmarks and two application workflows that combine scientific simulation and AI-based analysis, we show that our method outperforms traditional approaches.

Index Terms—Parallel systems, Scheduling and Task ↗

An Open Simulation System Model for Scientific Applications

A model for a generic and open environment for running multi-code or multi-application simulations - called the open Simulation System Model (OSSM) - is proposed and defined. This model attempts to meet the requirements of complex systems like the Numerical Propulsion Simulator System (NPSS). OSSM places no restrictions on the types of applications that can be integrated at any state of its evolution. This includes applications of different disciplines, fidelities, etc. An implementation strategy is proposed that starts with a basic prototype, and evolves over time to accommodate an increasing number of applications. Potential (standard) software is also identified which may aid in the design and implementation of the system.

Williams, Anthony D.↗

Development of Acoustic Model-Based Iterative Reconstruction Technique for Thick-Concrete Imaging

Ultrasound signals have been used extensively for non-destructive evaluation (NDE). However, typical reconstruction techniques, such as the synthetic aperture focusing technique (SAFT), are limited to quasi-homogenous thin media. New ultrasonic systems and reconstruction algorithms are in need for one-sided NDE of non-homogenous thick objects. An application example space is imaging of reinforced concrete structures for commercial nuclear power plants (NPPs). These structures provide important foundation, support, shielding, and containment functions. Identification and management of aging and degradation of concrete structures is fundamental to the proposed long-term operation of NPPs. Another example is geothermal and oil/gas production wells. These multi-layered structures are composed of steel, cement, and several types of soil and rocks. Ultrasound systems with greater penetration range and image quality will allow for better monitoring of the well's health and prediction of high-pressure hydraulic fracturing of the rock. These application challenges need to be addressed with an integrated imaging approach, where the application, hardware, and reconstruction software are highly integrated and optimized. Therefore, we are developing an ultrasonic system with Model-Based Iterative Reconstruction (MBIR) as the image reconstruction backbone. As the first implementation of MBIR for ultrasonic signals, this paper document the first implementation of the algorithm and show reconstruction results for synthetically generated data.

concrete NDE↗

Development of Acoustic Model-Based Iterative Reconstruction Technique for Thick-Concrete Imaging

Ultrasound signals have been used extensively for non-destructive evaluation (NDE). However, typical reconstruction techniques, such as the synthetic aperture focusing technique (SAFT), are limited to quasi-homogenous thin media. New ultrasonic systems and reconstruction algorithms are in need for one-sided NDE of non-homogenous thick objects. An application example space is imaging of reinforced concrete structures for commercial nuclear power plants (NPPs). These structures provide important foundation, support, shielding, and containment functions. Identification and management of aging and degradation of concrete structures is fundamental to the proposed long-term operation of NPPs. Another example is geothermal and oil/gas production wells. These multi-layered structures are composed of steel, cement, and several types of soil and rocks. Ultrasound systems with greater penetration range and image quality will allow for better monitoring of the well s health and prediction of high-pressure hydraulic fracturing of the rock. These application challenges need to be addressed with an integrated imaging approach, where the application, hardware, and reconstruction software are highly integrated and optimized. Therefore, we are developing an ultrasonic system with Model-Based Iterative Reconstruction (MBIR) as the image reconstruction backbone. As the first implementation of MBIR for ultrasonic signals, this paper document the first implementation of the algorithm and show reconstruction results for synthetically generated data.

Almansouri, Hani↗