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NASA NTRS2021

NASA SpaceCube Edge TPU SmallSat Card for Autonomous Operations and Onboard Science-Data Analysis

Using state-of-the-art artificial intelligence (AI)frameworks onboard spacecraft is challenging because common spacecraft processors cannot provide comparable performance to datacenters with server-grade CPUs and GPUs available for terrestrial applications and advanced deep-learning networks. This limitation makes small, lo w-p o we r AI microchip architectures, such as the Google Coral Edge Tensor Processing Unit (TPU), attractive for space missions where the application-specific design enables both high-performance and power-efficient computing for AI applications. To address these challenging considerations for space deployment, this research introduces the design and capabilities of a CubeSat-sized Edge TPU-based co-processor card, known as the SpaceCube Low-power Ed g e Artificial Intelligence Resilient Node (SC-LEARN). This design conforms to NASA’s CubeSat Card Specification (CS2) for integration into next-generation SmallSat and CubeSat systems. This paper describes the overarching architecture and design of the SC-LEARN, as well as, the supporting test card designed for rapid prototyping and evaluation. The SC-LEARN was developed with three operational modes: (1) a high-performance parallel-processing mode,(2)a fault-tolerant mode for onboard resilience, and (3) a power-saving mode with cold spares. Importantly, this research also elaborates on both training and quantization of Tensor Flow models for the SC-LEARN for use onboard with representative, open-source datasets. Lastly, we describe future research plans, including radiation-beam testing and flight demonstration.

Advanced avionics↗
DOE OSTI2023

Improving Subsurface Stress Characterization for Carbon Dioxide Storage Projects by Incorporating Machine Learning Techniques

The overall objective of this project is to develop a framework for reliable characterization and prediction of the state of stress in the overburden and underburden (including the basement) in CO 2 storage reservoirs using machine learning and integrated geomechanics and geophysical methods. Specifically, we propose to develop workflow encompassing of technologies and/or methods to predict stress and pressure changes due to CO 2 injection in an active tertiary recovery site and their impacts on subtle fault activation, fractures and occurrence of microseismic events and compare responses to field observations. In this project, we anticipate using dataset from the Farnsworth field Unit (FWU) which is operated by Purdure Petroleum. A novel elastic-waveform VSP inversion technique will be used to estimate high-resolution spatial and temporal changes of elastic moduli in CO 2 storage reservoirs, which will be combined with velocity-stress relationship derived from laboratory tests to obtain subsurface pressure and stress. Clustered microseismic data will be jointly inverted for improved focal mechanisms. Least-squares reverse-time migration of microseismic waveform data will be performed to directly image fracture/fault zones. Additionally, a deep neural network machine learning technique with convolutional and recurrent layers will be used for learning the spectro-temporal structures in microseismic waveforms. The results of this geotechnical data analysis will be integrated to develop a high-resolution 3D mechanical earth model extending from the overburden sealing formations to the underburden including the basement. Mechanical properties will be derived through integration of mechanical logs, tests, available results from chemo-mechanical laboratory tests, and elastic inversion of seismic data using a combination of Bayesian and stochastic methods as well as machine learning technique. Failure features (faults/fractures) will be represented and/or modeled based on seismic and core data analysis. A transient hydrodynamic-geomechanical model will be developed through coupling with the calibrated FWU reservoir simulation model. The full physics coupled model will be used to train a reduced order proxy model using machine learning algorithm for estimating stress which will then be used with appropriate constitutive relationships and forward seismological models to simulate pressure changes and induced microseismicity. An advanced optimization framework will be developed to perform a history match to minimize error between field observations and simulated. The history matched proxy model will be verified against the full-physics equivalent. The field observations that will be used in the coupled model calibration process include pressure/stress inverted from VSP, moment magnitude from microseismic analysis, real time downhole pressure measurements, production and injection data. Parameter sensitivity and uncertainty analysis will be performed to characterize the impact of model parameter uncertainty on stress estimates. The proposed project will have significant impact on future field implementation of the proposed technology. Because the project field site is an ongoing CO 2 EOR development, the value of the new technology will be demonstrated in an operational context and evaluated as a viable risk mitigation strategy. Cost/benefit will be evaluated together with the various commercial incentives for CO 2 sequestration available to oil and gas operators. The extensive available dataset and ongoing data acquisition under the SWP Phase III work plan provides flexibility for investigation of multiple approaches and reduces technical risk.

58 GEOSCIENCES↗
NASA NTRS1990

The cleanroom case study in the Software Engineering Laboratory: Project description and early analysis

This case study analyzes the application of the cleanroom software development methodology to the development of production software at the NASA/Goddard Space Flight Center. The cleanroom methodology emphasizes human discipline in program verification to produce reliable software products that are right the first time. Preliminary analysis of the cleanroom case study shows that the method can be applied successfully in the FDD environment and may increase staff productivity and product quality. Compared to typical Software Engineering Laboratory (SEL) activities, there is evidence of lower failure rates, a more complete and consistent set of inline code documentation, a different distribution of phase effort activity, and a different growth profile in terms of lines of code developed. The major goals of the study were to: (1) assess the process used in the SEL cleanroom model with respect to team structure, team activities, and effort distribution; (2) analyze the products of the SEL cleanroom model and determine the impact on measures of interest, including reliability, productivity, overall life-cycle cost, and software quality; and (3) analyze the residual products in the application of the SEL cleanroom model, such as fault distribution, error characteristics, system growth, and computer usage.

Green, Scott↗
NASA NTRS1975

Flight experience with time-of-arrival control for STOL aircraft in the terminal area

A research program on STOL operating systems is underway at the Ames Research Center. One investigation is concerned with design, analysis, and flight test of promising four-dimensional RNAV systems. One promising system generates a capture flight path from the present aircraft position to a waypoint on a selected fixed STOL approach route. It predicts arrival time at the runway and controls time and position along the path. The system was flight tested using a digital avionics system on a Convair 340 and on an experimental powered-lift STOL airplane. Flight tests in the flight director mode show that the pilot can choose and change the desired time of arrival, and meet this time within a few seconds, in spite of navigation errors and varying winds. Initial tests of the automatic mode using a flight simulator and the NASA Augmentor Wing Jet STOL Research Aircraft (AWJSRA) show that good time control was achieved at the cost of excess throttle activity. This fault was later corrected.

Neuman, F.↗
NASA NTRS1992

An analysis of ridge axis gravity roughness and spreading rate

Fast and slow spreading ridges have radically different morphologic and gravimetric characteristics. In this study, altimeter measurements from the Geosat Exact Repeat Mission are used to investigate spreading rate dependence of the ridge axis gravity field. Gravity roughness provides an estimate of the amplitude of the gravity anomaly and is robust to small errors in the location of the ridge axis. Gravity roughness as a weighted root mean square of the vertical deflection at 438 ridge crossings on the mid-ocean ridge system is computed. Ridge axis gravity anomalies show a decrease in amplitude with increasing spreading rate up to an intermediate rate of about 60-80 mm/yr and almost no change at higher rates; overall the roughness decreases by a factor of 10 between the lowest and highest rates. In addition to the amplitude decrease, the range of roughness values observed at a given spreading rate shows a similar order of magnitude decrease with transition between 60 and 80 mm/yr. The transition of ridge axis gravity is most apparent at three relatively unexplored locations on the Southeast Indian Ridge and the Pacific-Antarctic Rise; on these intermediate rate ridges the transition occurs abruptly across transform faults.

Small, Christopher↗
DOE OSTI2021

Salinity Contributions from Geothermal Waters to the Rio Grande and Shallow Aquifer System in the Transboundary Mesilla (United States)/Conejos-Médanos (Mexico) Basin

Freshwater scarcity has raised concerns about the long-term availability of the water supplies within the transboundary Mesilla (United States)/Conejos-Médanos (Mexico) Basin in Texas, New Mexico, and Chihuahua. Analysis of legacy temperature data and groundwater flux estimates indicates that the region’s known geothermal systems may contribute more than 45,000 tons of dissolved solids per year to the shallow aquifer system, with around 8500 tons of dissolved solids being delivered from localized groundwater upflow zones within those geothermal systems. If this salinity flux is steady and eventually flows into the Rio Grande, it could account for 22% of the typical average annual cumulative Rio Grande salinity that leaves the basin each year—this salinity proportion could be much greater in times of low streamflow. Regional water level mapping indicates upwelling brackish waters flow towards the Rio Grande and the southern part of the Mesilla portion of the basin with some water intercepted by wells in Las Cruces and northern Chihuahua. Upwelling waters ascend from depths greater than 1 km with focused flow along fault zones, uplifted bedrock, and/or fractured igneous intrusions. Overall, this work demonstrates the utility of using heat as a groundwater tracer to identify salinity sources and further informs stakeholders on the presence of several brackish upflow zones that could notably degrade the quality of international water supplies in this developed drought-stricken region.

Pepin, Jeff D. (ORCID:0000000274109979)↗
NASA NTRS1986

Performance Evaluation Tests for Environmental Research (PETER): evaluation of 114 measures

The goal of the Performance Evaluation Tests for Environmental Research (PETER) Program was to identify a set of measures of human capabilities for use in the study of environmental and other time-course effects. 114 measures studied in the PETER Program were evaluated and categorized into four groups based upon task stability and task definition. The Recommended category contained 30 measures that clearly obtained total stabilization and had an acceptable level of reliability efficiency. The Acceptable-But-Redundant category contained 15 measures. The 37 measures in the Marginal category, which included an inordinate number of slope and other derived measures, usually had desirable features which were outweighed by faults. The 32 measures in the Unacceptable category had either differential instability or weak reliability efficiency. It is our opinion that the 30 measures in the Recommended category should be given first consideration for environmental research applications. Further, it is recommended that information pertaining to preexperimental practice requirements and stabilized reliabilities should be utilized in repeated-measures environmental studies.

NASA Program Space Medicine↗
NASA NTRS2005

Non-Intrusive Techniques of Inspections During the Pre-Launch Phase of Space Vehicle

This paper addresses a method of non-intrusive local inspection of surface and sub-surface conditions, interfaces, laminations and seals in both space vehicle and ground operations with an integrated suite of imaging sensors during pre-launch operations. It employs an advanced Raman spectrophotometer with additional spectrophotometers and lidar mounted on a flying robot to constantly monitor the space hardware as well as inner surface of the vehicle and ground operations hardware. This paper addresses a team of micro flying robots with necessary sensors and photometers to monitor the entire space vehicle internally and externally. The micro flying robots can reach altitude with least amount of energy, where astronauts have difficulty in reaching and monitoring the materials and subsurface faults. The micro flying robot has an embedded fault detection system which acts as an advisory system and in many cases micro flying robots act as a Supervisor to fix the problems. As missions expand to a sustainable presence in the Moon, and extend for durations longer than one year in lunar outpost, the effectiveness of the instrumentation and hardware has to be revolutionized if NASA is to meet high levels of mission safety, reliability, and overall success. The micro flying robot uses contra-rotating propellers powered by an ultra-thin, ultrasonic motor with currently the world's highest power weight ratio, and is balanced in mid-air by means of the world's first stabilizing mechanism using a linear actuator. The essence of micromechatronics has been brought together in high-density mounting technology to minimize the size and weight. The robot can take suitable payloads of photometers, embedded chips for image analysis and micro pumps for sealing cracks or fixing other material problems. This paper also highlights advantages that this type of non-intrusive techniques offer over costly and monolithic traditional techniques.

Thirumalainambi, Rejkumar↗
DOE OSTI2023

Determining circuit model parameters from operation data for PV system degradation analysis: $\mathrm{PVPRO}$

Physics-based circuit parameters like series and shunt resistance are essential to provide insights into the degradation status of photovoltaic (PV) arrays. However, calculating these parameters typically requires a full current-voltage characteristic (I-V curve), the acquisition of which involves specific measurement devices and costly methods. Thus, I-V curves of the PV system level are often not available. Here this paper proposes a methodology (PVPRO) to estimate these I-V curve parameters using only operation (string-level DC voltage and current) and weather data (irradiance and temperature). PVPRO first performs multi-stage data pre-processing to remove noisy data. Next, the time-series DC data are used to fit an equivalent circuit single-diode model (SDM) to estimate the circuit parameters by minimizing the differences between the measured and estimated values. In this way, the time evolutions of the SDM parameters are obtained. We evaluate PVPRO on synthetic datasets and find an excellent estimation of both SDM and the key I-V parameters (e.g., open-circuit voltage, short-circuit current, maximum power, etc.) with an average relative error of 0.55%. The performance, especially the extracted degradation rate of parameters, is robust to various measurement noises and the presence of faults. In addition, PVPRO is applied to a 271 kW PV field system. The relative error between the real and estimated operation voltage and current is less than 1%, suggesting that degradation trends are well captured. PVPRO represents a promising open-source tool to extract the time-series degradation trends of key PV parameters from routine operation data.

14 SOLAR ENERGY↗
NASA NTRS1999

Work on Planetary Atmospheres and Planetary Atmosphere Probes

A major objective of the grant was to complete the fabrication, test, and evaluation of the atmosphere structure experiment on the Galileo Probe, and to receive, analyze, and interpret data received from the spacecraft. The grantee was competitively selected to be Principal Investigator of Jupiter's atmosphere structure on the Galileo Probe. His primary motivation was to learn as much as possible about Jupiter's atmosphere by means of a successful atmosphere structure experiment, and to support the needs and schedule of the Galileo Project. After a number of launch delays, the Flight instrument was shipped to Kennedy Space Center 2 years after the start of this collaboration, on April 14, 1989, at which time it was determined from System level tests of the ASI on the Probe that the instrument was in good working order and ready for flight. The spacecraft was launched on October 18, 1989. Data analysis of test and calibration data taken over a period of years of instrument testing was continued in preparation for the encounter. The initial instrument checkout in space was performed on October 26, 1989. The data set received by telemetry was thoroughly analyzed, and a report of the findings was transmitted to the Probe Operations Office on Feb. 28, 1990. Key findings reported were that the accelerometer biases had shifted by less than 1 mg through launch and since calibration at Bell Aerospace in 1983; accelerometer scale factors, evaluated by means of calibration currents, fell on lines of variation with temperature established in laboratory calibrations; pressure sensor offsets, correlated as a function of temperature, fell generally within the limits of several years of ground test data; atmospheric and engineering temperature sensor data were internally consistent within a few tenths of a degree; and the instrument electronics performed all expected functions without any observable fault. Altogether, this checkout was highly encouraging of the prospects of instrument performance, although performed greater than 5 years prior to Jupiter encounter. Capability of decoding the science data from the Experiment Data Record to be provided at encounter was developed and exercised using the tape recording of the first Cruise Checkout data. A team effort was organized to program the selection and combination of data words defining pressure, temperature, acceleration, turbulence, and engineering quantities; to apply decalibration algorithms to convert readings from digital numbers to physical quantities; and to organize the data into a suitable printout. A paper on the Galileo Atmosphere Structure Instrument was written and submitted for publication in a special issue of Space Science Reviews. At the Journal editor's request, the grantee reviewed other Probe instrument papers submitted for this special issue. Calibration data were carefully taken for all experiment sensors and accumulated over a period of 10 years. The data were analyzed, fitted with algorithms, and summarized in a calibration report for use in analyzing and interpreting data returned from Jupiter's atmosphere. The sensors included were the primary science pressure, temperature, and acceleration sensors, and the supporting engineering temperature sensors. This report was distributed to experiment coinvestigators and the Probe Project Office.

Seiff, Alvin↗
NASA NTRS2011

Recommendations for Enabling Manual Component Level Electronic Repair for Future Space Missions

Long duration missions to the Moon and Mars pose a number of challenges to mission designers, controllers, and the crews. Among these challenges are planning for corrective maintenance actions which often require a repair. Current repair strategies on the International Space Station (ISS) rely primarily on the use of Orbital Replacement Units (ORUs), where a faulty unit is replaced with a spare, and the faulty unit typically returns to Earth for analysis and possible repair. The strategy of replace to repair has posed challenges even for the ISS program. Repairing faulty hardware at lower levels such as the component level can help maintain system availability in situations where no spares exist and potentially reduce logistic resupply mass.This report provides recommendations to help enable manual replacement of electronics at the component-level for future manned space missions. The recommendations include hardware, tools, containment options, and crew training. The recommendations are based on the work of the Component Level Electronics Assembly Repair (CLEAR) task of the Exploration Technology Development Program from 2006 to 2009. The recommendations are derived based on the experience of two experiments conducted by the CLEAR team aboard the International Space Station as well as a group of experienced Miniature/Microminiature (2M) electronics repair technicians and instructors from the U.S. Navy 2M Project Office. The emphasis of the recommendations is the physical repair. Fault diagnostics and post-repair functional test are discussed in other CLEAR reports.

Struk, Peter M.↗
NASA NTRS2001

Potential Evaporite Biomarkers from the Dead Sea

The Dead Sea is located on the northern branch of the African-Levant Rift systems. The rift system, according to one model, was formed by a series of strike slip faults, initially forming approximately two million years ago. The Dead Sea is an evaporite basin that receives freshwater from springs and from the Jordan River. The Dead Sea is different from other evaporite basins, such as the Great Salt Lake, in that it possesses high concentrations of magnesium and has an average pH of 6.1. The dominant cation in the Great Salt Lake is sodium, and the pH is 7.7. Calcium concentrations are also higher in the Dead Sea than in the Great Salt Lake. Both basins are similar in that the dominant anion is chlorine and the salinity levels are approximately 20 %. Other common cations that have been identified from the waters of the Dead Sea and the Great Salt Lake include sodium and potassium. A variety of Archea, Bacteria, and a single genus of a green algal, Dunaliella, has been described from the Dead Sea. Earlier studies concentrated on microbial identification and analysis of their unique physiology that allows them to survive in this type of extreme environment. Potential microbial fossilization processes, microbial fossils, and the metallic ions associated with fossilization have not been studied thoroughly. The present study is restricted to identifying probable microbial morphologies and associated metallic ions. XRD (X Ray Diffraction) analysis indicates the presence of halite, quartz, and orthoclase feldspar. In addition to these minerals, other workers have reported potassium chloride, magnesium bromide, magnesium chloride, calcium chloride, and calcium sulfate. Halite, calcium sulfate, and orthoclase were examined in this report for the presence of microbes, microbially induced deposits or microbial alteration. Neither the gypsum nor the orthoclase surfaces possesses any obvious indications of microbial life or fossilization. The sand-sized orthoclase particles are weathered with 122 extensive fan-shaped mineral deposits. The gypsum deposits are associated with halite minerals and also exhibit extensive weathering. Halite minerals represent the only substrates that have probable rod-shaped microbial structures with long, filamentous, apical extensions. EDS (energy dispersive x-ray) analysis of the putative microbes indicates elevated calcium levels that are enriched with magnesium. The rod-shaped structures exhibit possible fossilization stages. Rhombohedralshaped minerals of magnesium-enriched calcium carbonate are deposited on the microbial surfaces, and eventually coat the entire microbial surface. The sodium chloride continues to crystallize on nearby halite surface and even crystallizes on the fossilized microbial remains. The putative fossils are found exclusively on halite surfaces, and all contained elevated levels of calcium magnesium cations. Both of these metallic cations are associated with microbial activity and fossilization. Their morphological diversity is low in comparison with the reported living Dead Sea microbial population. If we examine the fossil record for multicellular organisms, fossilization rates are lower for soft-bodied organisms than for those possessing hard parts, i.e. shells, bones. For example, smaller, single celled organisms would have a smaller chance of fossilization; their fossilized shapes could be mistaken for abiotic products. Another consideration is that dead organisms in the water column are probably utilized as a food source by other microbes before fossilization processes are completed. This may be an important consideration as we attempt to model and interpret ancient microbial environments either on Earth or on Mars.

Morris, Penny A.↗
NASA NTRS2012

Soldering in a Reduced Gravity Environment (SoRGE)

Future long-duration human exploration missions will be challenged by constraints on mass and volume allocations available for spare parts. Addressing this challenge will be critical to the success of these missions. As a result, it is necessary to consider new approaches to spacecraft maintenance and repair that reduce the need for large replacement components. Currently, crew members on the International Space Station (ISS) recover from faults by removing and replacing, using backup systems, or living without the function of Orbital Replacement Units (ORUs). These ORUs are returned to a depot where the root cause of the failure is determined and the ORU is repaired. The crew has some limited repair capability with the Modulation/DeModulation (MDM) ORU, where circuit cards are removed and replace in faulty units. The next step to reducing the size of the items being replaced would be to implement component-level repair. This mode of repair has been implemented by the U.S. Navy in an operational environment and is now part of their standard approach for maintenance. It is appropriate to consider whether this approach can be adapted for future spaceflight operations. To this end, the Soldering in a Reduced Gravity Environment (SoRGE) experiment studied the effect of gravity on the formation of solder joints on electronic circuit boards. This document describes the SoRGE experiment, the analysis methods, and results to date. This document will also contain comments from the crew regarding their experience conducting the SoRGE experiment as well as recommendations for future improvements. Finally, this document will discuss the plans for the SoRGE samples which remain on ISS.

Easton, John W.↗
NASA NTRS2021

System Validation on the Europa Clipper mission in Early Implementation Phase

NASA’s next flag-ship mission - Europa Clipper, will embark on a journey to Jupiter’s icy moon Europa in 2024 to assess its environment and habitability with a highly capable spacecraft. Post Jupiter-Orbit-Insertion, the spacecraft will be commanded to perform intricate, yet meticulously planned Europa flybys to perform science investigations using a suite of instruments, while withstanding Jupiter’s harsh radiation environment. The success of this mission is dependent on a well-coordinated project and its elements such as the flight hardware and software, the ground support and mission operations teams, procedures and other cross-cutting elements. The Europa Clipper project needs to ensure that these elements are realized at a reasonable confidence level prior to launch and other mission critical events. System Validation test and analysis activities exercise and confirm the integrity of the system of all project elements in the expected flight environment with reasonable stressing conditions. These activities go beyond system design requirements verification and are driven by validation objectives that describe the end-to-end functional and operational capabilities required during nominal and off-nominal flight-like scenarios and critical events. The challenges associated with validating that the Europa Clipper project as a whole can function and perform correctly to meet the intended mission objectives with the as-delivered capabilities of all of its elements are daunting. This paper discusses the systematic methodology established in the early implementation phase of the Europa Clipper project for developing System Validation activities and their validation objectives, and addressing any validation-related challenges on the project. Approaches include decomposition of mission objectives using activity timelines in the Mission Design plan for developing nominal scenarios, use of fault trees for exploring off-nominal cases and system boundaries, and use of Model-based Systems Engineering (MBSE) tools for planning and prioritizing these activities.

Wang, Xu↗
NASA NTRSDate not supplied

Vibration Anomaly Detection by Clustering in Unmanned Aerial Vehicles.

One of the critical factors affecting flight safety of unmanned aerial vehicles (UAVs) is the amount of vibration they are exposed to during a flight. On one hand, external causes such as wind gusts and turbulences or internal vehicle-centric faults such as incorrect sensor mounting or propeller imbalances can cause high vibrations in UAVs. On the other hand, high vibration itself may induce noise in the onboard miniature sensors of the UAV such as its accelerometers, gyroscopes and GPS that can lead to uncertain state estimation causing the multi-rotor to drift from its desired position or even result in loss-of-control. Hence, it is important to monitor the vibration levels during a UAV flight. This paper specifically looks into vibrations recorded by the autopilot system of a multi-rotor in presence of varying magnitudes of wind. Using data from experimental flights conducted at two separate flight test regions under varying wind conditions, we aim to classify between a nominal and anomalous vibration level for small UAV systems. Further, we analyse other parameters of interest that affect vibrations in UAVs such as UAV air speed and any propeller imbalance signatures. Analysis results from experimental flights demonstrate the effect of wind on vibration magnitude in unmanned aircrafts.

unmanned aviation↗
DOE OSTI2025

Assessment of thermally driven local structural phase changes in 1⁢𝑇′−MoTe 2

The role of layer disorder is important in establishing the topological phases of MoTe 2 . A rich tapestry of atomic ordering influences the structural phase transitions (SPTs), but there is little understanding of the mechanistic details of the phase transition. An atomistic level study was conducted to investigate the local structure of the 1⁢𝑇′ and 𝑇 𝑑 phases of MoTe 2 by using the pair distribution function (PDF) technique. While the average structure exhibits an SPT and coexistence of phases as a function of temperature, the local structure showed the suppression of SPT. The sample retained its monoclinic structure at all temperatures in short-range order. A sharp PDF peak observed at short distances indicated a strong atom-atom correlation between the Mo and Te atoms within the Mo octahedra. In addition, a large-box modeling of the PDF data indicated a preferential motion of Te atoms towards 𝑐 axis at all temperatures. Structural defects, such as stacking faults, likely result in the coexistence of phases in the average structure and suppress the local SPT of MoTe 2 . These results are stepping stones to understand the long-debated origins of structural, vibrational, and electronic properties of MoTe 2 and similar transition metal dichalcogenides.

2-dimensional systems↗
DOE OSTI2023

Localized keyhole pore prediction during laser powder bed fusion via multimodal process monitoring and X-ray radiography

Systematic fault detection and control during laser powder bed fusion (L-PBF) has been a long-standing objective for system manufacturers and researchers in the additive manufacturing (AM) industry. This manuscript investigates a data fusion approach for detection of keyhole porosity formation during laser irradiation of Ti-6Al-4V substrates by concurrent recording of thermally induced optical emission measured using both off-axis and coaxial photodiode sensors, and acoustic emission. Subsurface defect formation was monitored via high-speed synchrotron X-ray imaging at 20,000 frames per second, enabling temporal registration of keyhole pore formation events to the monitoring signals at a resolution of 50 µs. We developed data fusion machine learning (ML) models for localized prediction of keyhole pore formation at various time scales ranging from 0.5 ms to 2 ms. The signal segments were featurized using two independent approaches: (1) power spectral density (PSD) and (2) highly comparative time series analysis (HCTSA) framework. The extracted features from different sensor modalities were fused together to construct a multimodal feature space and sequential feature selection was used to determine the most informative features for training the ML models. The predictive performance was evaluated for three classifying algorithms: Support Vector Machine (SVM), K-Nearest Neighbor (KNN), and Gaussian Naive Bayes (GNB). As a result, pore formation events were predicted with up to 0.95 F1-score, 1.0 recall and 0.94 accuracy. The most heavily weighted features indicate that model performance is chiefly governed by the acoustic monitoring signal, with a secondary contribution from the optical emission sensors.

36 MATERIALS SCIENCE↗
NASA NTRS2003

TF41 Engine Fan Disk Seeded Fault Crack Propagation Test

Uncontained engine failures, although rare in occurrence, can have a catastrophic effect on aircraft performance and safety. Engine disk cracks can eventually lead to these type of failures. A number of techniques to detect engine disk cracks have been developed in recent years. However, these technologies have only been validated by disk spin pit tests, not actual engine tests. Due to this, a project was established to perform seeded fault engine tests on a TF41 engine disk fan. A defect was machined in the first stage fan disk of a TF41 engine. The disk was run in a spin pit to initiate a crack. Once initiated, the disk was run in an actual engine test facility. The engine was cycled by a number of start and stops with the goal of propagating the crack to disk burst through low cycle fatigue. Various crack detection techniques were installed on the engine and run real-time during the test to validate their abilities to detect disk cracks. These techniques were based on methods such as change in mass imbalance using vibration or shaft displacement, change in blade position, acoustic emission, and torsional resonance. At the completion of 4474 test cycles, the crack in the TF41 disk was determined to have grown approximately 0.025 inches. This was far less the predicted crack growth based on a fracture mechanics analysis and finite element stress analysis.

Lewicki, David G.↗