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At least 1,495 records · Page 83

Evaluation of Synthetic Vision Display Concepts for Improved Awareness in Unusual Attitude Recovery Scenarios

A recent study conducted by the Commercial Aviation Safety Team (CAST) determined 40 percent of all fixed-wing fatal accidents, between 2001 and 2011, were caused by Loss-of-Control (LOC) in flight (National Transportation Safety Board, 2015). Based on their findings, CAST recommended manufacturers develop and implement virtual day-visual meteorological conditions (VMC) display systems, such as synthetic vision or equivalent systems (CAST, 2016). In a 2015 simulation study conducted at NASA Langley Research Center (LaRC), researchers gathered to test and evaluate virtual day-VMC displays under realistic flight operation scenarios capable of inducing reduced attention states in pilots. Each display concept was evaluated to determine its efficacy to improve attitude awareness. During the experiment, Evaluation Pilots (EPs) were shown the following three display concepts on the Primary Flight Display (PFD): Baseline, Synthetic Vision (SV) with color gradient, and SV with texture. The baseline configuration was a standard, conventional 'blue over brown' display. Experiment scenarios were simulated over water to evaluate Unusual Attitude (UA) recovery over 'featureless terrain' environments. Thus, the SV with color gradient configuration presented a 'blue over blue' display with a linear blue color progression, to differentiate attitude changes between sky and ocean. The SV with texture configuration presented a 'blue over blue' display with a black checkerboard texture atop a synthetic ocean. These displays were paired with a Background Attitude Indicator (BAI) concept. The BAI was presented across all four Head-Down Displays (HDDs), displaying a wide field-of-view blue-over-blue attitude indicator. The BAI aligned with the PFD and showed through the background of the navigation displays with opaque transparency. Each EP participated in a two-part experiment series with a total seventy-five trial runs: Part I included a set of twenty-five Unusual Attitude Recovery (UAR) scenarios; Part II included a set of fifty Attitude Memory Recall Tasks (AMRT). At the conclusion of each trial, EPs were asked to complete a set post-run questionnaires. Quantitative results showed that there were no significant statistical effects on UA recovery times when utilizing SV with or without the presence of a BAI. Qualitative results show the SV displays (color, texture) with BAI On are most preferred for both UA recognition and recovery when compared with the baseline display. When only comparing SV display concepts, EPs performed better when using the SV with texture, BAI On, than any other display configuration. This is an interesting find considering most EPs noted their preference towards the SV with color gradient when the BAI was on.

Nicholas, Stephanie↗

Synthetic Vision System Commercial Aircraft Flight Deck Display Technologies for Unusual Attitude Recovery

A Commercial Aviation Safety Team (CAST) study of 18 worldwide loss-of-control accidents and incidents determined that the lack of external visual references was associated with a flight crew's loss of attitude awareness or energy state awareness in 17 of these events. Therefore, CAST recommended development and implementation of virtual day-Visual Meteorological Condition (VMC) display systems, such as synthetic vision systems, which can promote flight crew attitude awareness similar to a day-VMC environment. This paper describes the results of a high-fidelity, large transport aircraft simulation experiment that evaluated virtual day-VMC displays and a "background attitude indicator" concept as an aid to pilots in recovery from unusual attitudes. Twelve commercial airline pilots performed multiple unusual attitude recoveries and both quantitative and qualitative dependent measures were collected. Experimental results and future research directions under this CAST initiative and the NASA "Technologies for Airplane State Awareness" research project are described.

Prinzel, Lawrence J., III↗

Evaluations of Additively Manufactured Superalloy Lattice Blocks

Cast lattice block structures made up of high-temperature superalloys were previously shown to offer advantages in density, efficiency, and tailored properties. However, inconsistencies in casting die-fill, composition, and microstructure were identified as persistent issues with the casting process path. Three candidate lattice designs were screened through additive manufacturing of a superalloy. Laser powder bed fusion was applied with superalloy powder to produce lattice blocks for three-dimensional octahedral unit-cell designs of three heights. Properties of the structural designs versus additively manufactured lattices were compared, including structural dimensions, densities, defects, grain structures, crystallographic texture, and surface residual stresses. Findings indicate this concept could produce useful superalloy structures for high-temperature-capable static components requiring tailored density, and thermophysical and mechanical properties.

superalloy↗

Half-heusler alloys with enhanced figure of merit and methods of making

Thermoelectric materials and methods of making thermoelectric materials having a nanometer mean grain size less than 1 micron. The method includes combining and arc melting constituent elements of the thermoelectric material to form a liquid alloy of the thermoelectric material and casting the liquid alloy of the thermoelectric material to form a solid casting of the thermoelectric material. The method also includes ball milling the solid casting of the thermoelectric material into nanometer mean size particles and sintering the nanometer size particles to form the thermoelectric material having nanometer scale mean grain size.

36 MATERIALS SCIENCE↗

Method of fabrication of supported liquid membranes

Method for the fabrication of a supported liquid membrane having a dense layer in contact with a porous layer, and a membrane liquid layer within the interconnected pores of the porous layer. The dense layer is comprised of a solidified material having an average pore size less than or equal to about 0.1 nanometer, while the porous layer is comprised of a plurality of interconnected pores and has an average pore size greater than 10 nanometers. The supported liquid membrane is fabricated through the preparation of a casting solution of a membrane liquid and a volatile solvent. A pressure difference is established across the dense layer and porous layer, the casting solution is applied to the porous layer, and the low viscosity casting solution is drawn toward the dense layer. The volatile solvent is evaporated and the membrane liquid precipitates, generating a membrane liquid layer in close proximity to the dense layer.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Fabrication of nanoporous aerogels via freeze substitution of nanowire suspensions

A method of making a nanoporous aerogel includes the steps of providing nanowire suspensions, freeze casting the nanowire suspensions to produce freeze-cast gels, extracting the frozen medium from the freeze-cast gels by freeze-substitution with a solvent to produce wet gels, modifying or functionalizing the wet gels as needed, and drying the wet gels to produce a nanoporous aerogel.

36 MATERIALS SCIENCE↗

Water soluble barrier coatings for washout tooling for a composite layup

A washout tooling for a composite layup is provided. The washout tooling comprises a casting mold having an exterior surface. The casting mold comprises a particulate material and a water-soluble binder. The casting mold is adapted to break down in the presence of an aqueous solution. The washout tooling further comprises a water-soluble coating layer overlying the exterior surface. The water-soluble coating layer is adapted to break down in the presence of an aqueous solution. The washout tooling further comprises a curable composite layer overlying the water-soluble coating layer. The water-soluble coating layer minimizes contact between the particulate material and the curable composite layer.

Saito, Tomonori↗

Evaluating the Impacts of Reactive Gas (Carbon Dioxide and Oxygen) Ingress on Leaching from Cementitious Waste Forms - 17482

Cementitious materials are currently being used as the waste forms for low-activity waste disposal (Saltstone) at the Savannah River Site. In addition, cementitious materials have been selected as the waste form (Cast Stone) for secondary wastes and are being investigated for use for supplemental low-activity waste treatment (Cast Stone) at the Hanford Site. These materials are subjected to numerous aging and degradation phenomena in the disposal environment that potentially impact their long-term durability and performance. One important phenomenon is the ingress of reactive gases (i.e., carbon dioxide and oxygen) that can react with and change the chemistry and pore structure and thus mass transport properties of the waste forms. The reaction of carbon dioxide (i.e., carbonation) reduces the pH of the waste form pore solution impacting the solubility of constituents of potential concern (COPCs). In Cast Stone and Saltstone, the reaction of oxygen (i.e., oxidation) impacts the solubility of redox-sensitive COPCs, notably the technetium-99 (Tc-99) and chromium. The objective of this research is to experimentally characterize the carbonation and oxidation impacts on chemistry and leaching behavior in cementitious waste forms using experimental techniques including United States Environmental Protection Agency (U.S. EPA) Method 1313 and U.S. EPA Method 1315. Results of experimental characterization will be used to parameterize reactive mass transport models to project leaching under a range of field scenarios in future applications. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Spent Nuclear Fuel Package Consolidation using Metallic Void Fillers

This study introduces the idea of a consolidated spent nuclear fuel (SNF) package, formed by casting a metal into a SNF canister to fill any accessible void spaces. It is well known that castings experience shrinkage during cooling resulting in air gaps between the filler and its boundaries. For a consolidated SNF package, the air gap formed between the metallic filler and package components would have a negative impact on the thermal effusivity benefit offered by the filler. Here we present one solution to this challenge based on thermodynamic/solidification and metallic bonding principles. The key idea here is to pre-coat the package components with a low melting point metal, and to oxidize the coating instead of the components during the pre-heating step of the casting process. This allows for wetting of the boundary with the filler metal without the use of a flux that wouldn't survive the preheat temperature and could also contaminate the boundary with corrosive compounds. Potential benefits of successfully adopting this idea are twofold. First, improved heat diffusion inside the package due to the absence of the gap, which is significant for conceptual SNF with higher decay heat and high peak to average ratio. Second, improved proliferation resistance by making the fissile material recovery process more complex. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Wire Arc Additive Manufacturing of Multi-material Parts Using H-13 Tool Steel

H-13 tools steel’s relative hardness, resistance to thermal fatigue, and high tolerance of thermal shock, make it very desirable for use in forging, pressing, casting, and extrusion processes[1]. H-13 is however typically quite expensive when compared to many other steel compositions. It is therefore desirable to encase a lower cost steel composition with H-13. This configuration allows for the benefits of H-13 tooling to be realized, at a considerably reduced cost. To demonstrate the viability of this concept, a casting tool was fabricated using a Wire Arc Additive Manufacturing (WAAM) process. Initial materials testing was conducted on a multi-material wall which consisted of one section of H-13 tool steel, and one section of 410NiNmo. These tests included scanning electron microscopy, energy dispersive X-ray spectroscopy, and hardness testing. This testing generated favorable results and subsequently a casting tool was fabricated for evaluation. Utilization of a Multi-Material WAAM process to fabricate large tooling in this manner could yield significant improvements in material cost, manufacturing agility, and supply chain complexity.

Lambert, Nathan [ORNL] (ORCID:0009000324134206)↗

Prediction and Measurement of the Kinetics of Isothermal Crystallization and Devitrification of Mold Powder Slags

The rate and extent of formation of crystalline phases in the slag film that develops between the mold and the strand in steel continuous casting determine heat transfer and lubrication between them and therefore play crucial roles in shell integrity. In this work, a commercial mold powder for casting medium carbon (MC) thin steel slabs is selected for carrying out detailed comparisons between predicted and experimental results of the rates of isothermal crystallization and devitrification of liquid and glassy slag, respectively. Predictions are obtained with a kinetic model that combines the induction period (of Šimon and Kolman) and the Kissinger methods to evaluate time–temperature–transformation (TTT) diagrams for the devitrification and crystallization reactions associated with the peaks appearing in non-isothermal thermo-analysis traces. To obtain experimental validation of the diagram, a high-temperature confocal laser scanning microscope (HT-CLSM) is used to rapidly heat or cool a sample, ~ 140 mg, of glassy powder or liquid slag, respectively, to selected isothermal conditions, where it is held for a prescribed length of time before quenching. Identification and quantification of the phases present in the quenched samples are done by a quantitative X-ray powder diffraction analysis (QXRPDA) method that uses a PONKCS (partial or not known crystal structure) procedure based on Le Bail and Rietveld strategies for refinement of diffraction patterns. The many experimental results indicate that the predicted TTT diagrams for devitrification and crystallization of the mold slag give a good estimation of the rate of the transformations that take place at different temperatures and reveal the differences in the reactions that occur along both paths.

36 MATERIALS SCIENCE↗

Nonisothermal Crystallization Kinetics of Glassy Mold Fluxes

Crystallization of the solid glassy mold flux film occurring in the gap between the initial shell and mold wall is important, as it determines the in-mold heat transfer and mold lubrication during the process of continuous casting. In order to study the nonisothermal crystallization behavior of the glassy mold flux film in the continuous casting mold, the continuous heating transformation diagram, crystallization mechanism, and precipitate phases were investigated using the single hot thermocouple technique, kinetic models, a scanning electron microscope, and an energy-dispersive spectrometer (EDS). The results show that the initial crystallization temperature for CaO-SiO{sub 2} based flux A ranges from [1086 K to 1147 K (813 °C to 874 °C)], which is lower than the case of CaO-Al{sub 2}O{sub 3} based flux B ranging from [1205 K to 1245 K (932 °C to 972 °C)]. The crystallization kinetics for flux A are constant nucleation rate, two-dimensional growth, and control by diffusion. For flux B, they are constant nucleation rate, three-dimensional growth, and control by interface reaction. Besides, the EDS results indicate that the precipitate crystals in fluxes A and B are CaSiO{sub 3} and Ca{sub 2}AlSiO{sub 4}, respectively.

36 MATERIALS SCIENCE↗

The effect of scandium addition on microstructure and mechanical properties of Al–Si–Mg alloy: A multi-refinement modifier

Effect of scandium (Sc) additions on the microstructure, mechanical properties and fracture behavior of Al–Si–Mg casting alloy (F357) were systematically investigated. It was found that Sc addition caused a multi-refining efficiency on the microstructure of as-cast F357 alloy, including refinement of grains and secondary dendrite arm spacing (SDAS), modification of eutectic Si and harmless disposal of β-Al{sub 5}FeSi phase. Subsequent T6 heat treatment had further induced the complete spheroidization of eutectic Si and precipitation of fine secondary Al{sub 3}Sc dispersoids in the Sc modified alloys. Thus the mechanical properties, especially the ductility, were significantly enhanced by the addition of Sc combined with the heat treatment. The highest ultimate tensile strength, yield strength and elongation were achieved in 0.8 wt.% Sc modified F357 alloy combined with T6 heat treatment. Furthermore, fractographic examinations indicated that the ductile fracture mechanism served as a dominate role in the modified alloys due to the formation of fine, deep and uniformly distributed dimples. - Highlights: • Detailed characterization of the multi-refining microstructure of Sc modified F357 alloy was performed. • The multi-refinement was proposed to refine grain and SDAS, modify eutectic Si and β-phase. • Sc modifier combined with T6 treatment is effective in improving tensile properties. • Modification of eutectic Si in F357 alloy with Sc is consistent with the IIT mechanism.

36 MATERIALS SCIENCE↗

Development of mechanical properties in a CaO added AZ31 magnesium alloy processed by equal-channel angular pressing

Processing through the application of equal-channel angular pressing (ECAP) is recognized as one of the attractive severe plastic deformation techniques where the processed bulk metals generally achieve ultrafine-grained microstructure leading to improved physical characteristics and mechanical properties. Magnesium has received much attention to date for its lightweight, high strength and excellent elasticity. Mg alloys with addition of CaO is reported to provide the successful casting procedure without usage of greenhouse gas, SF{sub 6}, whereas it is generally used for preventing the oxidation of Mg during casting. In the present investigation, a CaO added AZ31 (AZ31-CaO) magnesium alloy was processed by ECAP at elevated temepratures with a few steps of reduction which result in significant grain refinement to ~ 1.5 μm after 6 passes. Compression testing at room temperature demonstrated the AZ31-CaO alloy after ECAP showed enhanced yield strength more than the as-processed commercial AZ31 alloy while both alloys maintained ductility in spite of significant reduction in grain size. The improved strength in the AZ31-CaO alloy was attributed to the formation of fine Al{sub 2}Ca precipitates which experience breaking-up through ECAP and accelerate the microstructural refinement. Moreover, the preservation of ductility was attributed to the enhancement of strain hardening capability in the AZ31 alloy at room temperature. This study discusses the feasibility of using ECAP to improve both strength and ductility on magnesium alloys by applying the diagram describing the paradox of strength and ductility. - Highlights: • AZ31 and AZ31-CaO magnesium alloys were processed by ECAP up to 6 passes. • AZ31-CaO alloy after ECAP showed improved yield strength without losing ductility. • CaO in AZ31 forms fine Al{sub 2}Ca accelerating microstructural refinement during ECAP. • Feasibility of using ECAP was shown to improve both strength and ductility in Mg.

36 MATERIALS SCIENCE↗

Microscopic insight into the origin of enhanced glass-forming ability of metallic melts on micro-alloying

Extensive efforts have been made to develop metallic-glasses with large casting diameter. Such efforts were hindered by the poor understanding of glass formation mechanisms and the origin of the glass-forming ability (GFA) in metallic glass-forming systems. In this work, we have investigated relaxation dynamics of a model bulk glass-forming alloy system that shows the enhanced at first and then diminished GFA on increasing the percentage of micro-alloying. The micro-alloying did not have any significant impact on the thermodynamic properties. The GFA increasing on micro-alloying in this system cannot be explained by the present theoretical knowledge. Our results indicate that atomic caging is the primary factor that influences the GFA. The composition dependence of the atomic caging time or residence time is found to be well correlated with GFA of the system.

36 MATERIALS SCIENCE↗

Energy Reductions Using Next-Generation Remanufacturing Techniques

The goal of this project was to develop a radically new surface coating approach that greatly enhances the performance of thermal spray coatings. Rather than relying on a roughened grit blasted substrate surface for developing a mechanical bond between the coating and substrate, which is the normal practice with conventional thermal spraying, a hybrid approach of combining a focused laser beam to thermally treat the substrate surface in the vicinity of the rapidly approaching thermally-sprayed powder particles was developed. This new surface coating process is targeted primarily at enabling remanufacturing of components used in engines, drive trains and undercarriage systems; thereby providing a substantial global opportunity for increasing the magnitude and breadth of parts that are remanufactured through their life cycle, as opposed to simply being replaced by new components. The projected benefits of a new remanufacturing process that increases the quantity of components that are salvaged and reused compared to being fabricated from raw materials will clearly vary based on the specific industry and range of candidate components that are considered. At the outset of this project two different metal processing routes were considered, castings and forgings, and the prototypical components for each process were liners and crankshafts, respectively. The quantities of parts used in the analysis are based on our internal production of approximately 158,000 diesel engines in 2007. This leads to roughly 1,000,000 liners (assuming a mixture of 6- and 8-cylinder engines) and 158,000 crankshafts. Using energy intensity factors for casting and forgings, respectively, of 4450 and 5970 Btu-hr/lb along with the energy-induced CO 2 generation factor of 0.00038 lbs CO 2 /Btu, energy savings of over 17 trillion BTUs and CO 2 reductions of over 6.5 million lbs could potentially be realized by remanufacturing the above mentioned quantities of crankshafts and liners. This project supported the Industrial Technologies Program's initiative titled 'Industrial Energy Efficiency Grand Challenge.' To contribute to this Grand Challenge, we. pursued an innovative processing approach for the next generation of thermal spray coatings to capture substantial energy savings and green house gas emission reductions through the remanufacturing of steel and aluminum-based components. The primary goal was to develop a new thermal spray coating process that yields significantly enhanced bond strength. To reach the goal of higher coating bond strength, a laser was coupled with a traditional twin-wire arc (TWA) spray gun to treat the component surface (i.e., heat or partially melt) during deposition. Both ferrous and aluminum-based substrates and coating alloys were examined to determine what materials are more suitable for the laser-assisted twin-wire arc coating technique. Coating adhesion was measured by static tensile and dynamic fatigue techniques, and the results helped to guide the identification of appropriate remanufacturing opportunities that will now be viable due to the increased bond strength of the laser-assisted twin-wire arc coatings. The feasibility of the laser-assisted TWA (LATWA) process was successfully demonstrated in this current effort. Critical processing parameters were identified, and when these were properly controlled, a strong, diffusion bond was developed between the substrate and the deposited coating. Consequently, bond strengths were nearly doubled over those typically obtained using conventional grit-blast TWA coatings. Note, however, that successful LATWA processing was limited to ferrous substrates coated with steel coatings (e.g., 1020 and 1080 steel). With Al-based substrates, it was not possible to avoid melting a thin layer of the substrate during spraying, and this layer re-solidified to form a band of intermetallic phases at the substrate/coating interface, which significantly diminished the coating adhesion. The capability to significantly increase the bond strength with ferrous substrates and coatings may open new remanufacturing opportunities that were previously not considered due to concerns with the limits of the mechanical bonding of conventional TWA coatings. However, the limited results obtained within this one-year program are not sufficient to move the LATWA into a production environment. Additional work will be needed engineer the process to coat components with more complex geometries than the flat specimens studied in this work. In addition part-specific bench testing and relevant field tests will be required to fully establish the necessary confidence for introducing the LATWA process. These are typical constraints and requirements for most any new production process, and it is quite possible this new process will continue to be a viable approach for extending the usage of remanufacturing, and in turn capturing the resulting energy savings and green house gas emission reductions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Multiphase Nano-Composite Coatings for Achieving Energy Optimization

UES Inc. and ANL teamed in this work to develop novel coating systems for the protection of surfaces from thermal degradation mainly in two applications; Machining and Die casting. These coatings were specifically designed for the purpose by incorporating required material phases and the overall architecture, which led to reduce the energy usage and increase efficiency of the operations. Following the UES/ANL's feasibility work, the coatings were developed utilizing High power impulse magnetron sputtering (HiPMS) and Large area filtered arc deposition (LAFAD) techniques. Toughness, hardness and oxidation resistance: contrasting qualities have been mixed in the right proportion to attain the suitable material characteristic for the cause. Hafnium diboride (HfB 2 ) based materials provided such a system and its properties were tamed to attain the right combination of toughness and hardness by working on the microstructure and architecture of coatings. An effective interfacing material (graded concentrations of topcoat) was also achieved in this work to provide the required adhesion between the substrate and the coating. Combination of an appropriate bond coat and a functional top coat provided the present thermal degradation resistant coating for cutting tools and die-casting applications. Laboratory level performance tests and industrial level application tests by partner companies (Beta Site Testing) were used for the development of these coatings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Energy-Saving Melting and Revert Reduction (E-SMARRT): Energy Efficiency Instrumentation

As with any manufacturing operation, the metalcasting processes have several sources of variation. Additionally, the metalcasting industry routinely produces a wide variety of complex shaped components, which often exacerbates the problem of determining the source of variation. The goals of this project were to develop better tools and strategies to collect and manage process and product information. Based on industry feedback, five areas were selected based on the amount of variation caused by this source or the potential for improvement in terms of energy, emissions and competitiveness. These five areas were: 1. Heat Treatment Control Strategies 2. Semi-Automated Grinding 3. Surface Mapping Software 4. Study of Impact of Repairs via Weld Gouges 5. Rapid Pattern Making Machine. This project collectively looked at areas of the steel casting production process which could help reduce the rework, scrap and energy consumption required. Through these efforts, casting producers are better equipped to control their processes and specify processes that better meet their customers’ needs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗