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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
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NASA NTRS1986

Viscoelastic deformation near active plate boundaries

Model deformations near the active plate boundaries of Western North America using space-based geodetic measurements as constraints are discussed. The first six months of this project were spent gaining familarity with space-based measurements, accessing the Crustal Dynamics Data Information Computer, and building time independent deformation models. The initial goal was to see how well the simplest elastic models can reproduce very long base interferometry (VLBI) baseline data. From the Crustal Dynamics Data Information Service, a total of 18 VLBI baselines are available which have been surveyed on four or more occasions. These data were fed into weighted and unweighted inversions to obtain baseline closure rates. Four of the better quality lines are illustrated. The deformation model assumes that the observed baseline rates result from a combination of rigid plate tectonic motions plus a component resulting from elastic strain build up due to a failure of the plate boundary to slip at the full plate tectonic rate. The elastic deformation resulting from the locked plate boundary is meant to portray interseismic strain accumulation. During and shortly after a large interplate earthquake, these strains are largely released, and points near the fault which were previously retarded suddenly catch up to the positions predicted by rigid plate models. Researchers judge the quality of fit by the sum squares of weighted residuals, termed total variance. The observed baseline closures have a total variance of 99 (cm/y)squared. When the RM2 velocities are assumed to model the data, the total variance increases to 154 (cm/y)squared.

Ward, S. N.↗
DOE OSTI2021

(U) A Theoretical Study of Asay Foil Trajectories (V.02)

We consider the trajectory of a generic Asay foil ejecta momentum diagnostic sensor, for scenarios where ejecta are produced at a planar surface and fly ballistically through a perfect vacuum to the sensor. To do so, we build upon a previously established mathematical formalism derived for the analytic study of stationary sensors (i.e., piezopins). First, we derive the momentum conservation equation for the problem, in a form amenable to accelerating sensors, in terms of a generic ejecta source areal mass function (“source model”). This defines an integro-differential equation (IDE) for the foil trajectory. When ejecta production is instantaneous - as is generally assumed in momentum diagnostic data analyses - the IDE leads to an implicit and easily calculable closed-form solution for the foil trajectory in a perfect system, as long as the ejecta particle velocity distribution is twice-integrable. General properties of the instant-production trajectory solution indicate the existence of a boundary condition the particle velocity distribution must satisfy in order for the analytically predicted foil trajectories to be compatible with certain features commonly observed in foil data. This boundary condition is identical to one derived previously from a consideration of piezopin data. Armed with the analytic solution for instant production, we also consider various techniques used to extract time-dependent cumulative ejecta masses from foil trajectories, and derive an expression for the error imposed by using an approximated equation of motion. This analytic trajectory solution furthermore makes it possible to examine the common practice of presenting inferred cumulative ejecta masses as a function of a normalized implied velocity; we derive conditions under which this methodology is and is not meaningful. We also propose a strategy for extending the instant-production trajectory solution to time-dependent source functions.

42 ENGINEERING↗
DOE OSTI2022

Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Interest in multi-axis additive manufacturing has grown significantly in recent years due to associated benefits that range from improved quality to support for greater geometric complexity. A method of 5-axis Laser Hot-Wire Directed Energy Deposition is developed and demonstrated in this study using an 8-axis industrial robot, comprised of a 6-axis serial link robot and a 2 degree-of-freedom positioner. Coordinated 5-axis motion is used to print Ti-6Al-4V objects predominantly through build plate rotation. Methods of slicing and toolpath generation are presented, including the use of an alternating toolpath direction philosophy and the manipulation of the CAD model surface normal vectors for determining the required build plate tilt angles for maintaining consistent deposition orientations relative to gravity. Another objective of the study was to determine the limits of conventional slicing and layer height control techniques for printing geometries with significant unsupported overhangs. A comparison is made between the behavior of normal and conformal bead alignment in this regard, and the performance of the layer height controller is reported as it relates to process stability and the limits of printing overhang geometries. Unsupported overhangs were successfully printed at 35° without build plate tilt and 45° with build plate tilt. Toolpath velocity and net-shape printing performance are reported as well, with 3D scans of the printed surfaces used for net-shape characterization. In all, the printing of three geometries is presented, including the overhang geometry, a 5-axis toolpath geometry, and a large-scale, multi-bead demonstrator part, which exceeded 500 mm in height and weighed 44 kg (97 lbs).

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Large Vehicle Lunar Landing Surface Interaction and In-Situ Resource Based Risk Mitigation: Landing & Launch Pads

A key capability required for the exploration of planetary bodies is the ability to land on the surface. Previous work performed by NASA and other institutions has primarily focused on landing small spacecraft on planetary surfaces and the associated small-to-medium thrusters required for the soft landing. In the case of human exploration—particularly the establishment of long duration exploration and habitation outposts—the ability to land large landers, such as the SpaceX Starship, is necessary. These larger landing systems require the use of more powerful engines, with higher engine exhaust temperatures and higher landing loads. Understanding the excavation of material by the engines, as well as the potential for the landing legs to sink into the subsurface, is key in ensuring reliable and safe landings. A further improvement in landing reliability can be achieved by constructing landing / launch pads, especially with in-situ resources. Some material excavation by the plume is inevitable, leaving at least a portion of the surface scoured and uneven under the lander and ejecting regolith particles and rocks at very high velocities. One possible solution would be to robotically build landing / launch pads (ideally autonomously) at the destination using in-situ materials. In this case, the first one or few landers will need to land on unimproved surfaces at higher risk; however, they would bring the required equipment to build the landing pads with mostly local resources, thus increasing the reliability of safe landing for subsequent larger landers. A number of methods to build in-situ landing and launch pads have already been developed. These methods include no or some addition of required binder additives to the local regolith material, different processing approaches and result in varying landing pad strengths. A sub-scale rocket engine plume, was used to simulate some of the conditions of a landing on the Moon to assess the effectiveness of various materials for an in-situ built landing pad, The GO2/GCH4 rocket engine fired on 1m2 area coupons of representative pad materials. The results will allow continued development towards materials that satisfy the landing pad properties required for the effective risk reduction and increased reliability for landing people and equipment on the lunar surface. This work contained two parts: (1) computer modeling of a large rocket engine plume interacting with regolith on the Moon, using the Granular Gas Flow Solver (GGFS) provided by CFD Research Corporation as well as other computational fluid dynamics codes (CFD) such as Loci/CHEM. (2) Developing landing/launch pad materials that could be used for in-situ construction on the lunar surface in the future, to mitigate the calculated effects of a large vehicle rocket engine landing and launching on the Moon. The resulting computed values of plume impingement surface temperature, stagnation pressure, gas velocity, shear stress and heat flux were then matched as closely as possible in the Earth’s atmosphere in a sub-scale rocket engine GO2/CH4 test which was provided by Masten Space Systems in Mojave, California. The rocket engine was mounted on a test stand with vertical translation capabilities so that the landing operations of a lander could be simulated (Figure 1).The pad materials test coupons were placed at the surface of a large bin containing simulated lunar basalt regolith and subjected to a test firing as shown in Figure 2. The results of this testing will be presented with related findings, analysis and discussion.

Plume Surface Interaction↗
DOE OSTI2020

Baryon-Interacting Dark Matter: heating dark matter and the emergence of galaxy scaling relations

The empirical scaling relations observed in disk galaxies remain challenging for models of galaxy formation. The most striking among these is the Mass Discrepancy-Acceleration Relation (MDAR), which encodes both a tight baryonic Tully-Fisher relation (BTFR) and the observed diversity of galaxy rotation curves through the central surface density relation (CSDR). Building on our earlier work [1], we propose here that the MDAR is the result of interactions between baryons and ‘Baryon-Interacting Dark Matter’ (BIDM), which heat up the dark matter. Following a bottom-up, hydrodynamical approach, we find that the MDAR follows if: i) the BIDM equation of state approximates that of an ideal gas; ii) the BIDM relaxation time is order the Jeans time; iii) the heating rate is inversely proportional to the BIDM density. Remarkably, under these assumptions the set of hydrodynamical equations together with Poisson’s equation enjoy an anisotropic scaling symmetry. In the BIDM-dominated regime, this gives rise to an enhanced symmetry which fully captures the low-acceleration limit of the MDAR. We then show that, assuming a cored pseudo-isothermal profile at equilibrium, this set of equations gives rise to parameters reproducing the MDAR. Specifically, in the flat part of the rotation curve the asymptotic rotational velocity matches the parametric dependence of the BTFR. Moreover, in the central region of high-surface brightness galaxies, the profile reproduces the CSDR. Finally, by studying the time-dependent approach to equilibrium, we derive a global combination of the BTFR and CSDR, which matches the expectations in low surface-brightness galaxies. The form of the heating rate also makes model-independent predictions for various cosmological observables. We argue that our scenario satisfies existing observational constraints, and, intriguingly, offers a possible explanation to the EDGES anomaly.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Redshift space power spectrum beyond Einstein-de Sitter kernels

Abstract We develop a framework to compute the redshift space power spectrum (PS), with kernels beyond Einstein-de Sitter (EdS), that can be applied to a wide variety of generalized cosmologies. We build upon a formalism that was recently employed for standard cosmology in Chen, Vlah & White (2020), and utilize an expansion of the density-weighted velocity moment generating function that explicitly separates the magnitude of the k-modes and their angle to the line-of-sight direction dependencies. We compute the PS for matter and biased tracers to 1-loop Perturbation Theory (PT) and show that the expansion has a correct infrared and ultraviolet behavior, free of unwanted divergences. We also add Effective Field Theory (EFT) counterterms, necessary to account for small-scale contributions to PT, and employ an IR-resummation prescription to properly model the smearing of the BAO due to large scale bulk flows within Standard-PT. To demonstrate the applicability of our formalism, we apply it on the ΛCDM and the Hu-Sawicki f(R) models, and compare our numerical results against the elephant suite of N-body simulations, finding very good agreement up to k = 0.27 Mpc -1 h at z = 0.5 for the first three non-vanishing Legendre multipoles of the PS. To our knowledge, the model presented in this work is the most accurate theoretical EFT-PT for modified gravity to date, being the only one that accounts for beyond linear local biasing in redshift-space. Hence, we argue our RSD modeling is a promising tool to construct theoretical templates in order to test deviations from ΛCDM using real data obtained from the next stage of cosmological surveys such as DESI and LSST.

Astronomy & Astrophysics↗
DOE OSTI2026

How to Build an Empirical Speed Distribution for Dark Matter in the Solar Neighborhood

The dark matter flux in a direct detection experiment depends on its local speed distribution. This distribution has been inferred from simulations of Milky Way–like galaxies, but such models serve only as proxies, given that no simulation directly captures the detailed evolution of our own Galaxy. This motivates alternative approaches that obtain this distribution directly from observations. In this work, we utilize 98 Milky Way analogues from the TNG50 simulation to develop and validate a procedure for inferring the dark matter speed distribution using the kinematics of nearby stars. We find that the dark matter that originated from old mergers, plus that from recent nonluminous accretions, is well described by a Maxwell–Boltzmann speed distribution centered at the local standard-of-rest velocity. Meanwhile, recently accreted dark matter from massive mergers has speeds that can be traced from the associated stellar debris of these events. The stellar populations systematically underestimate the velocity dispersion of their dark matter counterparts, but a simple kinematic boost brings the two into good alignment. Using the TNG50 host galaxies, we demonstrate that combining these two contributions provides an accurate reconstruction of the local dark matter speeds. As an application of the procedure to our own Galaxy, we utilize stellar kinematic data from Gaia to quantify how the dark matter remnants from the Milky Way’s last major merger impact its speed distribution in the solar neighborhood.

Shpigel, Tal [Princeton Univ., NJ (United States)]↗
NASA NTRS1993

The use of computer models to predict temperature and smoke movement in high bay spaces

The Building and Fire Research Laboratory (BFRL) was given the opportunity to make measurements during fire calibration tests of the heat detection system in an aircraft hangar with a nominal 30.4 (100 ft) ceiling height near Dallas, TX. Fire gas temperatures resulting from an approximately 8250 kW isopropyl alcohol pool fire were measured above the fire and along the ceiling. The results of the experiments were then compared to predictions from the computer fire models DETACT-QS, FPETOOL, and LAVENT. In section A of the analysis conducted, DETACT-QS AND FPETOOL significantly underpredicted the gas temperature. LAVENT at the position below the ceiling corresponding to maximum temperature and velocity provided better agreement with the data. For large spaces, hot gas transport time and an improved fire plume dynamics model should be incorporated into the computer fire model activation routines. A computational fluid dynamics (CFD) model, HARWELL FLOW3D, was then used to model the hot gas movement in the space. Reasonable agreement was found between the temperatures predicted from the CFD calculations and the temperatures measured in the aircraft hangar. In section B, an existing NASA high bay space was modeled using the CFD model. The NASA space was a clean room, 27.4 m (90 ft) high with forced horizontal laminar flow. The purpose of this analysis is to determine how the existing fire detection devices would respond to various size fires in the space. The analysis was conducted for 32 MW, 400 kW, and 40 kW fires.

Notarianni, Kathy A.↗
DOE OSTI2021

Classifying Seyfert Galaxies with Deep Learning

The traditional classification for a subclass of the Seyfert galaxies is visual inspection or using a quantity defined as a flux ratio between the Balmer line and forbidden line. One algorithm of deep learning is the convolution neural network (CNN), which has shown successful classification results. We build a one-dimensional CNN model to distinguish Seyfert 1.9 spectra from Seyfert 2 galaxies. We find that our model can recognize Seyfert 1.9 and Seyfert 2 spectra with an accuracy of over 80% and pick out an additional Seyfert 1.9 sample that was missed by visual inspection. We use the new Seyfert 1.9 sample to improve the performance of our model and obtain a 91% precision of Seyfert 1.9. These results indicate that our model can pick out Seyfert 1.9 spectra among Seyfert 2 spectra. We decompose the Hα emission line of our Seyfert 1.9 galaxies by fitting two Gaussian components and derive the line width and flux. We find that the velocity distribution of the broad Hα component of the new Seyfert 1.9 sample has an extending tail toward the higher end, and the luminosity of the new Seyfert 1.9 sample is slightly weaker than the original Seyfert 1.9 sample. This result indicates that our model can pick out the sources that have a relatively weak broad Hα component. In addition, we check the distributions of the host galaxy morphology of our Seyfert 1.9 samples and find that the distribution of the host galaxy morphology is dominated by a large bulge galaxy. In the end, we present an online catalog of 1297 Seyfert 1.9 galaxies with measurements of the Hα emission line.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1993

Collisions of small Spacewatch asteroids with the Earth

The discovery, with the Spacewatch Telescope, of 8 Earth-approaching objects smaller than 100 m in diameter has been reported. I have calculated the probability and velocity of collision with Earth for each of these objects. Using a code we have successfully employed to model the Tunguska and Revelstoke atmospheric explosions, I have simulated the entry of these objects into Earth's atmosphere, assuming iron, stony, carbonaceous, and cometary compositions. The smallest of these objects, with tens to hundreds of kilotons of kinetic energy, pose a substantial threat at the surface only if they are iron objects. An object is taken to 'pose a substantial threat' if it either craters the ground, or explodes in the atmosphere with sufficient energy at low enough altitude to create an overpressure at the surface capable of felling trees or destroying buildings. Larger objects, with energies greater than about a megaton, devastate the surface regardless of whether they are of iron, stony, or carbonaceous composition. Iron objects crater the ground, whereas stony and carbonaceous objects explode in the atmosphere low enough to fell trees and damage buildings over thousands of square kilometers. Spacewatch objects, if presumed to be of carbonaceous composition, are as dangerous as their stony counterparts, as the former objects' lower yield strengths (and hence, higher explosion altitudes) are roughly compensated by their larger masses (as derived from their lower albedos for a given observed magnitude). Although comets are intrinsically less dangerous than asteroids, the 90 m diameter Spacewatch objects would devastate hundreds of square kilometers at the surface, even if cometary.

Chyba, C. F.↗
NASA NTRS2002

Controls on Martian Hydrothermal Systems: Application to Valley Network and Magnetic Anomaly Formation

Models of hydrothermal groundwater circulation can quantify limits to the role of hydrothermal activity in Martian crustal processes. We present here the results of numerical simulations of convection in a porous medium due to the presence of a hot intruded magma chamber. The parameter space includes magma chamber depth, volume, aspect ratio, and host rock permeability and porosity. A primary goal of the models is the computation of surface discharge. Discharge increases approximately linearly with chamber volume, decreases weakly with depth (at low geothermal gradients), and is maximized for equant-shaped chambers. Discharge increases linearly with permeability until limited by the energy available from the intrusion. Changes in the average porosity are balanced by changes in flow velocity and therefore have little effect. Water/rock ratios of approximately 0.1, obtained by other workers from models based on the mineralogy of the Shergotty meteorite, imply minimum permeabilities of 10(exp -16) sq m2 during hydrothermal alteration. If substantial vapor volumes are required for soil alteration, the permeability must exceed 10(exp -15) sq m. The principal application of our model is to test the viability of hydrothermal circulation as the primary process responsible for the broad spatial correlation of Martian valley networks with magnetic anomalies. For host rock permeabilities as low as 10(exp -17) sq m and intrusion volumes as low as 50 cu km, the total discharge due to intrusions building that part of the southern highlands crust associated with magnetic anomalies spans a comparable range as the inferred discharge from the overlying valley networks.

Harrison, Keith P.↗
NASA NTRS1995

Recent improvements to and validation of the one dimensional NASA wave rotor model

A numerical model has been developed at the NASA Lewis Research Center which can predict both the unsteady flow quantities within a wave rotor passage and the steady averaged flows in the ports. The model is based on the assumptions of one-dimensional, unsteady, perfect gas flow. The model assesses not only the dominant wave behavior, but the loss effects of finite passage opening time, leakage from the passage ends, viscosity, and heat transfer to and from the passages. The model operates in the rotor reference frame; however, until recently no account was made for the often significant effect of the rotor circumferential velocity component. The present model accounts for this by modifying the passage boundary conditions, allowing the internal computational scheme to remain the rotor reference frame, while quantities such as inlet duct stagnation properties may be specified in the fixed or absolute reference frame. Accurate modeling of this effect is critical to successful wave rotor analysis and design, particularly in off-design predictions where the flows in the inlet ducts are mismatched with the rotor passages and significant turning may take place (i.e., work is done on the gas). The relative simplicity of the model makes it useful for design and optimization, as well as analysis, of wave rotor cycles for many applications. This report, building on several earlier papers, describes the most recent modifications to the model. These include accounting for the relative/absolute transition at the passage boundaries and refinements to the viscous source term correlation which resulted from this accounting. Comparison of model predictions with measured data is then presented and discussed.

Paxson, Daniel E.↗
NASA NTRS1981

A sensitivity model for energy consumption in buildings. Part 1: Effect of exterior environment

A simple analytical model is developed for the simulation of seasonal heating and cooling loads of any class of buildings to complement available computerized techniques which make hourly, daily, and monthly calculations. An expression for the annual energy utilization index, which is a common measure of rating buildings having the same functional utilization, is derived to include about 30 parameters for both building interior and exterior environments. The sensitivity of a general class building to either controlled or uncontrolled weather parameters is examined. A hypothetical office type building, located at the Goldstone Space Communication Complex, Goldstone, California, is selected as an example for the numerical sensitivity evaluations. Several expressions of variations in local outside air temperature, pressure, solar radiation, and wind velocity are presented.

Lansing, F. L.↗
NASA NTRS2011

Micrometeoroid and Orbital Debris Threat Assessment: Mars Sample Return Earth Entry Vehicle

This report provides results of a Micrometeoroid and Orbital Debris (MMOD) risk assessment of the Mars Sample Return Earth Entry Vehicle (MSR EEV). The assessment was performed using standard risk assessment methodology illustrated in Figure 1-1. Central to the process is the Bumper risk assessment code (Figure 1-2), which calculates the critical penetration risk based on geometry, shielding configurations and flight parameters. The assessment process begins by building a finite element model (FEM) of the spacecraft, which defines the size and shape of the spacecraft as well as the locations of the various shielding configurations. This model is built using the NX I-deas software package from Siemens PLM Software. The FEM is constructed using triangular and quadrilateral elements that define the outer shell of the spacecraft. Bumper-II uses the model file to determine the geometry of the spacecraft for the analysis. The next step of the process is to identify the ballistic limit characteristics for the various shield types. These ballistic limits define the critical size particle that will penetrate a shield at a given impact angle and impact velocity. When the finite element model is built, each individual element is assigned a property identifier (PID) to act as an index for its shielding properties. Using the ballistic limit equations (BLEs) built into the Bumper-II code, the shield characteristics are defined for each and every PID in the model. The final stage of the analysis is to determine the probability of no penetration (PNP) on the spacecraft. This is done using the micrometeoroid and orbital debris environment definitions that are built into the Bumper-II code. These engineering models take into account orbit inclination, altitude, attitude and analysis date in order to predict an impacting particle flux on the spacecraft. Using the geometry and shielding characteristics previously defined for the spacecraft and combining that information with the environment model calculations, the Bumper-II code calculates a probability of no penetration for the spacecraft.

Christiansen, Eric L.↗
NASA NTRS2001

Simplified Analysis of Pulse Detonation Rocket Engine B1owdown Gasdynamics and Performance

Pulsed detonation rocket engines (PDREs) have generated considerable research interest in recent years as a chemical propulsion system potentially offering improved performance and reduced complexity compared to conventional rocket engines. The detonative mode of combustion employed by these devices offers a thermodynamic advantage over the constant-pressure deflagrative combustion mode used in conventional rocket engines and gas turbines. However, while this theoretical advantage has spurred a great deal of interest in building PDRE devices, the unsteady blowdown process intrinsic to the PDRE has made realistic estimates of the actual propulsive performance problematic. The recent review article by Kailasanath highlights some of the difficulties in comparing the available experimental measurements with numerical models. The goal of this paper is to improve understanding of PDRE blowdown gasdynamics and performance issues through use of a simplified model that captures the essential features of the unsteady blowdown process, and yet remains computationally inexpensive. The PDRE system studied here is highly idealized, consisting of a constant-area detonation tube with one end closed and the other end open to the environment. The tube is prefilled with a gaseous propellant mixture with no initial velocity or outflow to the environment. The detonation is initiated instantaneously at the closed end of the device. Chapman-Jouguet (C-J) post-detonation gas conditions are calculated using the CET89 version of the NASA thermochemical code. The I-D, unsteady method of characteristics is used to calculate the flowfield following the detonation front. See the compressible flow texts by Thompson and Zucrow and Hoffman for details of this method. Parametric studies of the effect of mixture stoichiometry, fill temperature, and blowdown pressure ratio on performance are reported. A comparison of the performance of an idealized straight-tube PDRE with a conventional steady-state rocket engine is provided. The effect of constant-gamma and equilibrium chemistry assumptions is also examined. Additionally, in order to form an assessment of the accuracy of the model, the flowfield time history is compared to experimental data from Stanford University.

Morris, Christopher I.↗
DOE OSTI2025

Design and Analysis of an Integrated Additively Manufactured Test Article for Plasma-Facing Components

Current plasma-facing components (PFCs) used in helium-cooled divertor modules are complex structures with tungsten tile, steel sleeve components, and cartridges, all assembled in a helium-cooled multiple jet (HEMJ) structure. The goal of this project is to simplify the complex PFC design using additive manufacturing techniques to create a single integrated tungsten test article. Apart from the flexibility this opens up in exploring a wide array of geometries for the article, having a single integrated article significantly reduces the number of joints and parts in the article, thus reducing chances of leaks. A process called electron beam melting has shown to produce very high-density samples and unique geometries, enabling HEMJ or similar designs. To validate and optimize this novel design, the model underwent a series of computational fluid dynamics and finite element analysis simulations to replicate steady-state heat flux in the divertors. The simulations presented in this study consider a steady-state base heat flux of 5 MW/m 2 , with water serving as the coolant. Future research will explore the use of helium as a coolant, simulate edge-localized-mode conditions, and include experimental validation. Since 3D-printed tungsten is anisotropic, the build direction versus build plane of the article are taken into consideration for the test article strength. Because of the high operating temperatures and low ductility of tungsten, thermal creep and brittle fracture are important failure mechanisms to consider. In conclusion, the cap is evaluated with various flow velocities and nozzle diameters, and an optimal design choice is made for which this cap will survive the divertor conditions with a conservative safety margin.

Divertor↗
DOE OSTI2025

Multi-physics melt pool modeling and process optimization for laser direct energy deposition of Nb-based refractory C103: Defect formation, geometric precision, and process mapping

Recent developments in additive manufacturing (AM) technology have reignited interest in the fabrication of the Nb-based refractory C103 alloy offering solutions to the challenges posed by traditional manufacturing methods. However, the limited numerical and experimental studies on laser direct energy deposition (DED) of C103 have hindered the understanding of the relationships between process parameters and build quality. This has made it challenging to consistently produce parts with the desired quality and microstructure suitable for critical applications. In this study, we focus on optimizing the laser DED process for C103 by employing a hybrid approach that combines experimental techniques and computational fluid dynamics (CFD). This approach facilitates the development of process maps for defect detection and geometric precision. To achieve this, multi-layer C103 samples were fabricated using laser DED under various process parameters, enabling the creation of a process map for defect detection. Additionally, a multi-physics, multiphase simulation framework was developed within a high-performance computing (HPC) environment to establish process maps for geometric precision. Using these process maps, printability windows were identified for achieving both the desired geometric accuracy and defect-free prints. It was observed that prints with a power-to-velocity (P/V) ratio close to unity resulted in defect-free outcomes. This study provides a foundation for reducing design lead time and rejected parts, ultimately optimizing the laser DED process for C103.

Defect formation and geometric precision↗
NASA NTRS1993

The physical mechanism of comet outbursts: An experiment

During a series of impact experiments into regolith-like powders at the NASA Ames Research Center Vertical Gun Facility in 1976, I observed and filmed a unique anomalous event that may illuminate outburst mechanisms in comets. During one test, a new batch of basalt powder (half the mass in particles less than 800 microns in diameter) retained some air pressure while the vacuum chamber was being evacuated. As a result, the projectile impacted into gas-charged regolith. Instead of ejecting the normal, relatively negligible amount of debris, the disturbance triggered a major eruption that lasted at least 18 seconds. The experimental results have been recently re-analyzed with reference to cometary phenomena. A series of frames from this eruption experiment are shown. The ejecta velocities of 150 to 300 cm/s would have been sufficient to drive debris into the coma of a comet nucleus smaller than a few kilometers diameter. The event suggests a mechanism for comet outbursts, discussed briefly by Hartmann et al.: the pore space in a layer of regolith, possibly with weak effective tensile strength, becomes gas charged as ice slowly sublimates. Once the effective tensile strength is exceeded by the gas pressure, the surface fails locally, triggering an eruption such as photographed here. This model is consistent with the emerging view of regolith materials on comets and is closest to the recent model of Rickman et al. The earlier models generally picture a more uniform flow of debris off the comet, not outbursts. Rickman et al. allow gas pressure to build until it matches the overburden pressure, followed by 'instantaneous blow-off'. They note that as soon as the mantle is found to be unstable, we consider it to be instantaneously swept away by the gas pressure. The main new points made here are that the experiment gives a more realistic view of the blow-off process after surface failure occurs, and the present model gives a recharge mechanism that can explain recurrent outbursts on comets such as P/Schwassmann-Wachmann 1 and 2060 Chiron. In fact, the resulting jets resemble distinct jet structures in high-resolution comet comae.

Hartmann, William K.↗