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At least 1,279 records · Page 71

Dielectrophoresis-Based Particle Sensor Using Nanoelectrode Arrays

A method has been developed for concentrating, or partly separating, particles of a selected species from a liquid or gas containing these particles, and flowing in a channel. An example of this is to promote an accumulation (and thus concentration) of the selected particle (e.g., biological species such as E. coli, salmonella, anthrax, tobacco mosaic virus or herpes simplex, and non-biological materials such as nano- and microparticles, quantum dots, nanowires, nano - tubes, and other inorganic particles) adjacent to the first surface. Additionally, this method can also determine if the particle species is present in the liquid. This is accomplished by providing an insulating material in an interstitial volume between two or more adjacent nanostructure electrodes. It can also be accomplished by providing a functionalizing substance, located on a selected region of the insulating material surface, which promotes attachment of the selected species particles to the functionalized surface, and measuring a selected electrical property such as electrical impedance, conductance, or capacitance. A time-varying electrical field E, having a root-mean-square intensity of E(sup 2) rms, with a non-zero gradient in a direction transverse to the liquid or fluid flow direction, is produced by a nanostructure electrode array with a very high-magnitude gradient near exposed electrode tips. A dielectrophoretic force causes the selected particles to accumulate near the electrode tips, if the medium and selected particles have substantially different dielectric constants. An insulating material surrounds most of the nanostructure electrodes, and a region of the insulating material surface is functionalized to promote attachment of the selected particle species to the surface. An electrical property value Z(meas) is measured at the functionalized surface, and is compared with a reference value Z(ref) to determine if the selected species particles are attached to the functionalized surface. Some advantages of this innovation are that an array of nanostructure electrodes can provide an electric field intensity gradient that is one or more orders of magnitude greater than the corresponding gradient provided by a conventional microelectrode arrangement, and that, as a result of the high-magnitude field intensity gradients, a nanostructure concentrator can trap particles from high-speed microfluidic flows. This is critical for applications where the entire analysis must be performed in a few minutes

Li, Jun↗

Techniques for hot structures testing

Hot structures testing have been going on since the early 1960's beginning with the Mach 6, X-15 airplane. Early hot structures test programs at NASA-Ames-Dryden focused on operational testing required to support the X-15 flight test program, and early hot structures research projects focused on developing lab test techniques to simulate flight thermal profiles. More recent efforts involved numerous large and small hot structures test programs that served to develop test methods and measurement techniques to provide data that promoted the correlation of test data with results from analytical codes. In Nov. 1988 a workshop was sponsored that focused on the correlation of hot structures test data with analysis. Limited material is drawn from the workshop and a more formal documentation is provided of topics that focus on hot structures test techniques used at NASA-Ames-Dryden. Topics covered include the data acquisition and control of testing, the quartz lamp heater systems, current strain and temperature sensors, and hot structures test techniques used to simulate the flight thermal environment in the lab.

Deangelis, V. Michael↗

High-Precision Temperature Control of a Crystal Growth Furnace at 1,500 C

For crystal growth of semiconductor materials a short-term temperature stability of 0.1 C at 1500 C is one of the essential parameters to be addressed for achieving high-quality crystals. Hence, for temperature monitoring and control with high precision in a floating zone furnace two sets of thermo-sensors, type B thermocouples and optical fibre thermometers, have been implemented and successfully operated in the furnace for more than 2000 h. The optical fibre thermometers consist of an optical system made of sapphire (two fibres plus a prism in between for deflection) and transmit the infra-red radiation of the heater to the outside of the hot core of the furnace for pyrometric temperature measurement. A dedicated control algorithm has been set up which controlled the power settings to the individual heaters. Both sensor types showed no degradation after this period and yielded a short-term stability at 1200 C of 0.05 C (optical fibre thermometers), respectively 0.08 C (thermocouples).

Stenzel, Ch.↗

Planned Flight of the Terrestrial HIAD Orbital Reentry (THOR)

The Terrestrial HIAD Orbital Reentry (THOR) is planned for flight in 2016 as a secondary payload on an Orbital Sciences commercial resupply mission to the International Space Station. THOR will launch with its Hypersonic Inflatable Aerodynamic Decelerator (HIAD) stowed as a small cylinder between the second stage motor and the launch vehicle fairing. Once the Cygnus cargo vehicle has separated from the second stage, THOR will likewise separate, autonomously re-orient itself, perform a deorbit burn, then inflate the HIAD to a 3.5m diameter cone before atmospheric interface. THOR is a follow-on mission to the IRVE-3 flight test of 2012. The high energy of orbital reentry will allow THOR to demonstrate the performance of its improved, second-generation inflatable structure and flexible TPS materials, in a more energetic entry environment than previous suborbital test flights.This paper discusses the sequence of events planned to occur as part of the THOR mission. Specific topics will include the THOR mission concept, reentry vehicle design for the expected flight environment, the on-board sensors that will allow quantification of vehicle performance, and how we intend to retrieve the flight data from a reentry vehicle splashing down in international waters.

Dillman, Robert↗

Effect of Space Radiation on TES Detectors Performance

The Athena mission and its X-IFU instrument (X-ray Integral Field Unit) will be positioned at the Sun-Earth Lagrangian point L1, where it will be subject to solar wind (low flux plasma of 95% protons and 5% alpha particles) with energy below 0.1 MeV, and to galactic cosmic rays and solar flares (energetic protons, alpha particles, and electrons) with energies up to hundreds of MeV for protons and the GeV for heavier ions. Some of these particles will go through the satellite and hit the focal plane assembly and hence the detectors. These detectors will be TES (Transition-edge sensor) microcalorimeters, flown for the first time in such an environment. In order to ensure the performance of this type of detectors throughout the duration of such mission, it is critical to study the impact of the radiation on their behavior. Indeed, although a lot of reference material exist for semiconductor detectors such as CCDs, little is currently known about the impact of radiation on TES detectors. These energetic events could cause local heating or damage to the detectors and affect their performance. In this work, we describe how we designed a test campaign to assess the impact of L1 radiation on TES detectors for Athena/X-IFU-like missions and present the results of the tests. Analyses includes assessing changes in the pulse shapes and energy resolution of the detectors measured at 55 mK after several radiation dose steps performed at 4 K.

Sophie Beaumont↗

The Athena Mars Rover Science Payload

The Mars Surveyor missions that will be launched in April of 2001 will include a highly capable rover that is a successor to the Mars Pathfinder mission's Sojourner rover. The design goals for this rover are a total traverse distance of at least 10 km and a total lifetime of at least one Earth year. The rover's job will be to explore a site in Mars' ancient terrain, searching for materials likely to preserve a record of ancient martian water, climate, and possibly biology. The rover will collect rock and soil samples, and will store them for return to Earth by a subsequent Mars Surveyor mission in 2005. The Athena Mars rover science payload is the suite of scientific instruments and sample collection tools that will be used to perform this job. The specific science objectives that NASA has identified for the '01 rover payload are to: (1) Provide color stereo imaging of martian surface environments, and remotely-sensed point discrimination of mineralogical composition. (2) Determine the elemental and mineralogical composition of martian surface materials. (3) Determine the fine-scale textural properties of these materials. (4) Collect and store samples. The Athena payload has been designed to meet these objectives. The focus of the design is on field operations: making sure the rover can locate, characterize, and collect scientifically important samples in a dusty, dirty, real-world environment. The topography, morphology, and mineralogy of the scene around the rover will be revealed by Pancam/Mini-TES, an integrated imager and IR spectrometer. Pancam views the surface around the rover in stereo and color. It uses two high-resolution cameras that are identical in most respects to the rover's navigation cameras. The detectors are low-power, low-mass active pixel sensors with on-chip 12-bit analog-to-digital conversion. Filters provide 8-12 color spectral bandpasses over the spectral region from 0.4 to 1.1 micron Narrow-angle optics provide an angular resolution of 0.28 mrad/pixel, nearly a factor of four higher than that of the Mars Pathfinder and Mars Surveyor '98 cameras. Image compression will be performed using a wavelet compression algorithm. The Mini-Thermal Emission Spectrometer (Mini-TES) is a point spectrometer operating in -the thermal IR. It produces high spectral resolution (5 /cm) image cubes with a wavelength range of 5-40 gm, a nominal signal/noise ratio of 500:1, and a maximum angular resolution of 7 mrad (7 cm at a distance of 10 in). The wavelength region over which it operates samples the diagnostic fundamental absorption features of rockforming minerals, and also provides some capability to see through dust coatings that could tend to obscure spectral features. The mineralogical information that Mini-TES provides will be used to select from a distance the rocks and soils that will be investigated in more detail and ultimately sampled. Mini-TES is derived from the MO/MGS TES instrument, but is significantly smaller and simpler. The instrument uses an 8-cm Cassegrain telescope, a Michelson interferometer, and uncooled pyroelectric detectors. Along with its mineralogical capabilities, Mini-TES can provide information on the thermophysical properties of rocks and soils. Viewing upward, it can also provide temperature profiles through the martian atmospheric boundary layer. Elemental and Mineralogical Composition: Once promising samples have been identified from a distance using Pancam/Mini-TES, they will be studied in detail using up to three compositional sensors that can be placed directly against them by an Instrument Arm. The two compositional sensors, presently on the payload are an Alpha-Proton-X-Ray Spectrometer (APXS), and a Mossbauer Spectrometer. The APXS is derived closely from the instrument that flew on Mars Pathfinder. Radioactive alpha sources and three detection modes (alpha, proton, and x-ray) provide elemental abundances of rocks and soils to complement and constrain mineralogical data. The Athena APXS will have a revised mechanical design that will cut down significantly on backscattering of alpha particles from martian atmospheric carbon. It will also include a target of known elemental composition that will be used for calibration purposes. The Athena Mossbauer Spectrometer is a diagnostic instrument for the mineralogy and oxidation state of Fe-bearing phases, which are particularly important on Mars. The instrument measures the resonant absorption of gamma rays produced by a Co-57 source to determine splitting of nuclear energy levels in Fe atoms that is related to the electronic environment surrounding them. It has been under development for space flight for many years at the Technical University of Darmstadt. The Mossbauer Spectrometer (and the other arm instruments) will be able to view a small permanent magnet array that will attract magnetic particles in the martian soil. The payload may also include a Raman Spectrometer. If included, the Raman Spectrometer will provide precise identification of major and minor mineral phases. It requires no sample preparation, and is also sensitive to organics. Fine-Scale Texture: The Instrument Arm a also carries a Microscopic Imager that will obtain high-resolution monochromatic images of the same materials for which compositional data will be obtained. Its spatial resolution is 20 micron/pixel over a 1 cm depth of field, and 40 micron/pixel over a 1-cm depth of field. Like Pancam, it uses the same active pixel sensor detectors and electronics as the rover's navigation cameras. The Instrument Arm is a three degree-of-freedom arm that uses designs and components from the Mars Pathfinder and Mars Surveyor '98 projects. Its primary function is instrument positioning. Along with the instruments noted above, it also carries a brush that can be used to remove dust and other loose coatings from rocks. Sample Collection and Storage: Martian rock and soil samples will be collected using a low-power rotary coring drill called the Mini-Corer. An important characteristic of this device is that it can obtain intact samples of rock from up to 5 cm within strong boulders and bedrock, Nominal core dimensions are 8xl7 mm. The Mini-Corer drills a core to the commanded depth in a rock, shears it off, retains it, and extracts it. It can also acquire samples of loose soil, using soil sample cups that are pressed downward into loose material. The Mini-Corer can drill at angles from vertical to 45' off vertical. It has six interchangeable bits for long life. Mechanical damage to the sample during drilling is minimal, and heating is negligible. After acquisition, the sample may be viewed by the arm instruments, and/or placed in one of 104 compartments in the Sample Container. A subset of the acquired samples may be replaced with other samples obtained later if desired. The Sample Container has no moving parts, and is mounted external to the rover for easy removal by the Mars Surveyor 2005 flight system. Operation of the rover will make extensive use of automated onboard navigation and hazard avoidance capabilities. Otherwise, use of onboard autonomy is minimal. Data downlink capability is about 40 Mbit/sol, and the use of the Mars Surveyor '01 orbiter for data relay imposes a limit of at most two command cycles per sol. Because of the significant amount of time available between command cycles, all payload elements will be operated sequentially, rather than in parallel.; this approach also significantly simplifies operations and minimizes peak power usage. The landing site for the '01 rover has not been selected yet. Site selection will make as full use as possible of Mars Global Surveyor data, and will involve substantial input from the broad Mars science community. Summary: The following table describes the mass, power, providers, and key scientific objectives of all the major elements of the Athena payload. Additional Athena payload information may be found at: http://astrosun.tn.cornell.edu/athena/index.html. Additional information contained in the original.

Squyes, S. W.↗

Collaboration of the NASA Glenn Research Center and Rolls-Royce Developed Thin Film Multilayered Dielectrics for Harsh Environments

The use of thin films to electrically insulate thin film sensors on engine components minimizes the intrusiveness of the sensors and allows a more accurate measurement of the environment. A variety of insulating films were investigated for preventing electrical shorting caused by insulator failure between the sensor and the component. By alternating layers of sputtered high-temperature ceramics, a sequence of insulating layers was devised that (1) prevents pinholes from forming completely through the insulator and (2) maintains high electrical resistivity at high temperatures. The total thickness is only a fraction of that needed for conventional insulating techniques. The Sensors and Electronics Technology Branch of the NASA Glenn Research Center has an in-house effort to develop thin film sensors for surface measurement in propulsion system research. Thin film sensors do not require special machining of the components on which they are mounted, and they are considerably thinner (less than 10 mm thick) than wire or foil sensors. The thin film sensors are thus much less disturbing to the operating environment and have a minimal impact on the physical characteristics of the supporting component. To further this research, NASA Glenn and Rolls-Royce (Derby, UK), with assistance from the Ohio Aerospace Institute (OAI) and the Akima Corporation, pursued a joint investigation using multilayered thin film dielectrics as a reliable insulator in harsh environments. The use of a multilayered scheme is thought to be promising for the fabrication of electrically insulating thin films. A major cause of conduction in thin film dielectrics is the presence of defects, such as pinholes, that propagate through the film to the underlying substrate surface. By alternating the insulating material, each new growth pattern would deviate from the previous one, eliminating direct pathways for conduction to the substrate. The film depositions and testing were conducted in the Instrument Research Laboratory at Glenn. The multilayered insulator test samples were made from alumina and stainless steel shims that were first covered with a sputtered underlayer of either yttria-stabilized zirconia or chromium carbide, and then overcoated with a sputtered top layer of alumina. An example of a test sample is shown in the following photograph. Each multilayered insulator sample was 5 mm thick, at least an order of magnitude thinner than conventional insulators. The insulating properties of the samples were tested in a high-temperature air oven to determine their suitability. The multilayer insulators tested showed a stabilized film at temperatures in excess of 800 C (1472 F). The underlying materials in these multilayers allow thermal expansion stresses produced during the heating to be graded. The chromium carbide-alumina multilayer had the best adhesion at high temperatures, presumably from the induced chemical bonding between the substrate and the chromium carbide underlayer. However, the zirconia-alumina multilayer proved to have slightly better insulating properties when adhering. The application of the zirconia-alumina insulator has been demonstrated on a nickel-alloy fan blade, as shown. The insulators using thin film sensors still need to be tested in a relevant high-temperature combustion environment.

Wrbanek, John D.↗

Superlattice Long-Wavelength Infrared Sensors

Superlattice of LaN and Si detects at wavelengths up to 12 micrometers. If LaN grown epitaxially on silicon, sensitivity of silicon-based photodetectors extended farther into infrared wavelength region with high quantum detection efficiency by use of LaN/Si superlattices. In principle, by appropriate choice of thicknesses of layers, effective band-gap energy of superlattice structure set to any desired value between band gaps of two materials.

Fathauer, Robert W.↗

Single Ball Bearing Lubricant and Material Evaluator

A test apparatus provides an applied load to a monoball through a trolley which moves along a loading axis. While applying the load to the monoball, the torque meter is in communication with the spherical monoball, and a load cell senses the application of applied force to the monoball. Meanwhile, a rotary actuary imports rotary oscillating motion to the monoball which is sensed by a position sensor and a torque meter. Accordingly, a processor can determine the coefficient of friction in substantially real time along with a cycles per second rate.

Philip B Hall↗

Remote Raman Sensor System for Testing of Rocks and Minerals

Recent and future explorations of Mars and lunar surfaces through rovers and landers have spawned great interest in developing an instrument that can perform in-situ analysis of minerals on planetary surfaces. Several research groups have anticipated that for such analysis, Raman spectroscopy is the best suited technique because it can unambiguously provide the composition and structure of a material. A remote pulsed Raman spectroscopy system for analyzing minerals was demonstrated at NASA Langley Research Center in collaboration with the University of Hawaii. This system utilizes a 532 nm pulsed laser as an excitation wavelength, and a telescope with a 4-inch aperture for collecting backscattered radiation. A spectrograph equipped with a super notch filter for attenuating Rayleigh scattering is used to analyze the scattered signal. To form the Raman spectrum, the spectrograph utilizes a holographic transmission grating that simultaneously disperses two spectral tracks on the detector for increased spectral range. The spectrum is recorded on an intensified charge-coupled device (ICCD) camera system, which provides high gain to allow detection of inherently weak Stokes lines. To evaluate the performance of the system, Raman standards such as calcite and naphthalene are analyzed. Several sets of rock and gemstone samples obtained from Ward s Natural Science are tested using the Raman spectroscopy system. In addition, Raman spectra of combustible substances such acetone and isopropanol are also obtained. Results obtained from those samples and combustible substances are presented.

Garcia, Christopher S.↗

Single ball bearing lubricant and material evaluator

A test apparatus provides an applied load to a monoball through a trolley which moves along a loading axis. While applying the load to the monoball, the torque meter is in communication with the spherical monoball, and a load cell senses the application of applied force to the monoball. Meanwhile, a rotary actuary imports rotary oscillating motion to the monoball which is sensed by a position sensor and a torque meter. Accordingly, a processor can determine the coefficient of friction in substantially real time along with a cycles per second rate.

Hall, Philip B.↗

Applications of thermal remote sensing to detailed ground water studies

Three possible applications of thermal (8-14 microns) remote sensing to detailed hydrogeologic studies are discussed in this paper: (1) the direct detection of seeps and springs, (2) the indirect evaluation of shallow ground water flow through its thermal effects on the land surface, and (3) the indirect location of small volumes of ground water inflow into surface water bodies. An investigation carried out with this purpose in an area containing a complex shallow ground water flow system indicates that the interpretation of the thermal imageries is complicated by many factors, among which the most important are: (1) altitude, angle of view, and thermal-spatial resolution of the sensor; (2) vegetation type, density, and vigor; (3) topography; (4) climatological and micrometeorological effects; (5) variation in soil type and soil moisture; (6) variation in volume and temperature of ground water inflow; (7) the hydraulic characteristics of the receiving water body, and (8) the presence of decaying organic material.

Souto-Maior, J.↗

Thermal coupling apparatus for electroexplosive devices

This paper describes the equipment for nondestructive testing of electroexplosive devices using a thermal coupling technique. The technique utilizes a self-balancing bridge to apply a nominal amount of power to the bridge wire of the device. The bridge wire behaving as a thermal sensor detects heat flow into the device when heat is preferentially directed down the center of the explosive column toward the bridge wire. Thermal equilibrium is upset and the change in power from the self-balancing bridge is measured directly in watts. Faults such as omissions, incorrect materials, contamination, and so on, can be detected by observing the rate of heat flow to the bridge wire. The response is indicative of the thermal resistance and diffusivity of the system. The paper also presents data on electroexplosive devices loaded with inert and explosive materials.

Menichelli, V. J.↗

A solid-state digital temperature recorder for space use

A solid-state, digital, temperature recorder has been developed for use in space experiments. The recorder is completely self-contained and includes a temperature sensor; all necessary electronics for signal conditioning, processing, storing, control and timing; and a battery power supply. No electrical interfacing with the particular spacecraft on which the unit is used is required. The recorder is small, light, and sturdy, and has no moving parts. It uses only biocompatible materials and has passed vibration and shock spaceflight qualification tests. The unit is capable of storing 2048, -10 to +45 C, 8-bit temperature measurements taken at intervals selectable by factors of 2 from 1.875 to 240 min; data can be retained for at least 6 months. The basic recorder can be simplified to accommodate a variety of applications by adding memory to allow more data to be recorded, by changing the front end to permit measurements other than temperature to be made, and by using different batteries to realize various operating periods. Stored flight data are read out from the recorder by means of a ground read-out unit.

Westbrook, R. M.↗

Lightweight Lidar Telescopes for Space Applications

NASA is intent on exploiting the unique perspective of space-based remote optical instruments to observe and study large-scale environmental processes. Emphasis on smaller and more affordable missions continues to force the remote sensing instruments to find innovative ways to reduce the size, weight, and cost of the sensor package. This is a challenge because many of the proposed instruments incorporate a high quality meter-class telescope that can be a significant driver of total instrument costs. While various methods for telescope weight reduction have been achieved, many of the current approaches rely on exotic materials and specialized manufacturing techniques that limit availability or substantially increase costs. A competitive lightweight telescope technology that is especially well suited to space-based coherent Doppler wind lidar has been developed through a collaborative effort involving NASA Marshall Space Flight Center (MSFC) through the Global Hydrology and Climate Center (GHCC) and the University of Alabama in Huntsville (UAH) at the Center for Applied Optics (CAO). The new lightweight optics using metal alloy shells and surfaces (LOMASS) fabrication approach is suitable for high quality metal mirrors and meter-class telescopes. Compared to alternative materials and fabrication methods the new approach promises to reduce the areal density of a meter-class telescope to less than 15-kg/sq m; deliver a minimum VIO-RMS surface optical quality; while using commercial materials and equipment to lower procurement costs. The final optical figure and finish is put into the mirrors through conventional diamond turning and polishing techniques. This approach is especially advantageous for a coherent lidar instrument because the reduced telescope weight permits the rotation of the telescope to scan the beam without requiring heavy wedges or additional large mirrors. Ongoing investigations and preliminary results show promise for the LOMASS approach to be successful in demonstrating a novel alternative approach to fabricating lightweight mirrors with performance parameters comparable with the Space Readiness Coherent Lidar Experiment (SPARCLE). Development and process characterization is continuing with the design and fabrication of mirrors for a 25-cm telescope suitable for a lidar instrument.

Peters, Bruce R.↗

Repair and Utilization of the Kratos XSAM 800 X-Ray Photoelectron Spectrometer (XPS)

The objectives for this summer faculty fellowship were first to repair the Kratos XSAM 800 X-ray Photoelectron Spectrometer (XPS) and then to utilize the instrument to participate in ongoing research projects at KSC and in the researcher's own laboratory at UCF. The first 6 weeks were used in repairing the instrument. Working both alone and with the Kratos service engineer, a number of hardware problems, largely associated with the sample stage control system, were corrected. Defective parts were identified and fixed in the computer driver boards, the stage power supply, and the driver interface. The power supply was completely replaced. After four weeks of work, the instrument was functional. This occurred on a Wednesday. The following Friday the instrument had to be completely shut down because the power to the O & C Building was to be turned off. The instrument was properly secured. On Monday, the instrument was powered up and the original problems returned. After another 2 weeks of work, a software problem was identified. This problem caused the computer to use a defective port for the sample stage control. It was circumvented by rewriting the startup routine. The final 3 weeks of the fellowship were spent using the XPS to analyze samples being studied in the Langley materials project (Martha Williams) and a catalyst project (Dr. Orlando Melendez). During this time, several sample analysis requests from other groups at KSC also came in and those samples were run as well. The summer faculty fellowship also allowed many contacts to be made. After meeting with the sensors group, two projects were identified for collaboration and white papers are being prepared. One project aims to develop small, very sensitive hydrogen detectors and the other to develop a broad area, easily monitored, zero power consumption hydrogen detector. In addition to the work mentioned above, the XPS was utilized in a study underway in Dr. Hampton's laboratory at UCF.

Hampton, Michael D.↗

Development and Application of Wide Bandwidth Magneto-Resistive Sensor Based Eddy Current Probe

The integration of magneto-resistive sensors into eddy current probes can significantly expand the capabilities of conventional eddy current nondestructive evaluation techniques. The room temperature solid-state sensors have typical bandwidths in the megahertz range and resolutions of tens of microgauss. The low frequency sensitivity of magneto-resistive sensors has been capitalized upon in previous research to fabricate very low frequency eddy current sensors for deep flaw detection in multilayer conductors. In this work a modified probe design is presented to expand the capabilities of the device. The new probe design incorporates a dual induction source enabling operation from low frequency deep flaw detection to high frequency high resolution near surface material characterization. Applications of the probe for the detection of localized near surface conductivity anomalies are presented. Finite element modeling of the probe is shown to be in good agreement with experimental measurements.

Wincheski, Russell A.↗

The Additive Manufacturing Moment Measure (AM3) Approach to Predictions of Solid Cooling Rate and Time Above Melt

Qualification of a laser powder bed fusion additive manufacturing (LPBF-AM) process requires knowledge of the multi-scale material physics during the process, per part. As the LPBF-AM build occurs, each moment is influenced by the process history. Knowledge of the build sequence can be used to generate a discretized time-space-condition point field that when coupled with a nearest neighbors’ calculation results in a generalized and fully parallel process model computation. This GPU accelerated approach was developed for part-scale analysis of build files along with in-situ process monitoring sensor data and is termed the “Additive Manufacturing Moment Measure” (AM3). The AM3 approach will be presented and then used to evaluate an AM Bench relevant geometry with synchronized in-situ process data, ex-situ nondestructive evaluation, and optical microscopy observations. These comparisons permit a better understanding of how the process actions can affect the LPBF-AM build quality and the signals generated during in-situ process monitoring.

Additive Manufacturing↗