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At least 1,621 records · Page 90

Numerical study of turbulent secondary flows in curved ducts

The pressure driven, fully-developed turbulent flow of an incompressible viscous fluid in curved ducts of square-section is studied numerically by making use of a finite volume method. A nonlinear Kappa - Iota model is used to represent the turbulence. The results for both straight and curved ducts are presented. For the case of fully-developed turbulent flow in straight and curved ducts, the secondary flow is characterized by an eight-vortex structure for which the computed flowfield is shown to be in good agreement with available experimental data. The introduction of moderate curvature is shown to cause a substantial increase in the strength of the secondary flow and to change the secondary flow pattern to either a double-vortex or a four-vortex configuration.

Hur, N.↗

Microbial colonization of a closed growth chamber during hydroponic cultivation of lettuce

The goal of this study was to characterize sessile and planktonic microbiota that developed during two successive hydroponic cultures of lettuce in a closed chamber system. Coupons of polyvinyl chloride (PVC) placed in the nutrient solution lines were removed periodically, as were samples of the nutrient solutions and condensate from the air-handling system. The bacteria and fungi present on the coupons and in fluid samples were enumerated by direct plate counts. Disinfecting the hydroponic system with 0.1% hypochlorite and 0.1 N nitric acid reduced the bacterial densities in biofilm samples from 1 x 10 7 CFU/10 cm 2 to 1 x 10 1 CFU/10 cm 2 and eliminated culturable fungi; Staphylococcus sp., Pseudomonas sp., and Micrococcus sp. survived this procedure. Bacterial and fungal concentrations in all samples returned to predisinfection levels after 2 days of plant growth. Pseudomonas and Acremonium predominated both before and after disinfection. Fungal concentrations never exceeded 7 x 10 2 CFU/10 cm 2 . The coupon microbiota differed from that of the rhizoplane at harvest. Overall, the greatest numbers of species were found on the rhizoplane samples collected during the second crop. The microbial community changed little during individual crops or between successive crops. Diversity indices remained relatively constant for all samples.

Bacteria growth & development↗

Correlative Analysis of Behavioral and Physiological Concomitants of Labor in Pregnant Rats

During parturition, rats exhibit characteristic behavioral expressions of labor. Lordosis contractions, consisting of an elongation of the dams body, are observed beginning several hours prior to neonate births, whereas vertical contractions, repeated rapid lifts of the abdomen, occur immediately preceding the birth of each neonate. We analyzed underlying changes in intrauterine pressure (IUP) using a telemetric sensor that we modified for use in freely-moving rats. This technique enabled us to correlate behavioral expressions of labor contractions with IUP. A small telemetric blood pressure sensor was fitted within a fluid-filled balloon, similar in size to a full term rat fetus. On Gestational day 19 of the rats' 22-day pregnancy, a unit was surgically implanted within the uterus. The dams were simultaneously videotaped, enabling us to directly correlate IUP signals with behavioral expressions of labor contractions. Earlier phases of labor, consisting predominantly of lordosis contractions were characterized by lower pressures relative to later phases during which higher pressures and vertical contractions were frequently observed.

Baer, L. A.↗

Stirling Convertor Technologies Being Developed for a Stirling Radioisotope Generator

The Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and the NASA Glenn Research Center are developing a high-efficiency Stirling Radioisotope Generator (SRG) for NASA space science missions. The SRG is being developed for multimission use, including providing electric power for unmanned Mars rovers and deep space missions. On Mars, rovers with SRGs would be used for missions that might not be able to use photovoltaic power systems, such as exploration at high Martian latitudes and missions of long duration. The projected SRG system efficiency of 23 percent will reduce the required amount of radioisotope by a factor of 4 or more in comparison to currently used Radioisotope Thermoelectric Generators. The Department of Energy recently named Lockheed Martin as the system integration contractor. Lockheed Martin has begun to develop the SRG engineering unit under contract to the Department of Energy, and has contract options to develop the qualification unit and the first flight units. The developers expect the SRG to produce about 114 Wdc at the beginning of mission, using two opposed Stirling convertors and two General Purpose Heat Source modules. STC previously developed the Stirling convertor under contract to the Department of Energy and is now providing further development as a subcontractor to Lockheed Martin. Glenn is conducting an in-house technology project to assist in developing the convertor for space qualification and mission implementation. A key milestone was recently reached with the accumulation of 12 000 hr of long-term aging on two types of neodymium-iron boron permanent magnets. These tests are characterizing any possible aging in the strength or demagnetization resistance of the magnets used in the linear alternator. Preparations are underway for a thermal/vacuum system demonstration and unattended operation during endurance testing of the 55-We Technology Demonstration Convertors. In addition, Glenn is developing a charging system for the convertors to ensure clean fills of the helium working fluid and to monitor levels of any possible contaminants at different test intervals. Possible oxidation effects depend on the level of any oxygen contamination-regenerator materials and displacer radiation shields are now being evaluated for possible oxidation effects.

Thieme, Lanny G.↗

Radial-Electric-Field Piezoelectric Diaphragm Pumps

In a recently invented class of piezoelectric diaphragm pumps, the electrode patterns on the piezoelectric diaphragms are configured so that the electric fields in the diaphragms have symmetrical radial (along-the-surface) components in addition to through-the-thickness components. Previously, it was accepted in the piezoelectric-transducer art that in order to produce the out-of-plane bending displacement of a diaphragm needed for pumping, one must make the electric field asymmetrical through the thickness, typically by means of electrodes placed on only one side of the piezoelectric material. In the present invention, electrodes are placed on both sides and patterned so as to produce substantial radial as well as through-the-thickness components. Moreover, unlike in the prior art, the electric field can be symmetrical through the thickness. Tests have shown in a given diaphragm that an electrode configuration according to this invention produces more displacement than does a conventional one-sided electrode pattern. The invention admits of numerous variations characterized by various degrees of complexity. Figure 1 is a simplified depiction of a basic version. As in other piezoelectric diaphragm pumps of similar basic design, the prime mover is a piezoelectric diaphragm. Application of a suitable voltage to the electrodes on the diaphragm causes it to undergo out-of-plane bending. The bending displacement pushes a fluid out of, or pulls the fluid into, a chamber bounded partly by the diaphragm. Also as in other diaphragm pumps in general, check valves ensure that the fluid flows only in through one port and only out through another port.

Bryant, Robert G.↗

Influence of Population Variation of Physiological Parameters in Computational Models of Space Physiology

The earliest manifestations of Visual Impairment and Intracranial Pressure (VIIP) syndrome become evident after months of spaceflight and include a variety of ophthalmic changes, including posterior globe flattening and distension of the optic nerve sheath. Prevailing evidence links the occurrence of VIIP to the cephalic fluid shift induced by microgravity and the subsequent pressure changes around the optic nerve and eye. Deducing the etiology of VIIP is challenging due to the wide range of physiological parameters that may be influenced by spaceflight and are required to address a realistic spectrum of physiological responses. Here, we report on the application of an efficient approach to interrogating physiological parameter space through computational modeling. Specifically, we assess the influence of uncertainty in input parameters for two models of VIIP syndrome: a lumped-parameter model (LPM) of the cardiovascular and central nervous systems, and a finite-element model (FEM) of the posterior eye, optic nerve head (ONH) and optic nerve sheath. Methods: To investigate the parameter space in each model, we employed Latin hypercube sampling partial rank correlation coefficient (LHSPRCC) strategies. LHS techniques outperform Monte Carlo approaches by enforcing efficient sampling across the entire range of all parameters. The PRCC method estimates the sensitivity of model outputs to these parameters while adjusting for the linear effects of all other inputs. The LPM analysis addressed uncertainties in 42 physiological parameters, such as initial compartmental volume and nominal compartment percentage of total cardiac output in the supine state, while the FEM evaluated the effects on biomechanical strain from uncertainties in 23 material and pressure parameters for the ocular anatomy. Results and Conclusion: The LPM analysis identified several key factors including high sensitivity to the initial fluid distribution. The FEM study found that intraocular pressure and intracranial pressure had dominant impact on the peak strains in the ONH and retro-laminar optic nerve, respectively; optic nerve and lamina cribrosa stiffness were also important. This investigation illustrates the ability of LHSPRCC to identify the most influential physiological parameters, which must therefore be well-characterized to produce the most accurate numerical results.

biomechanics↗

Deep Learning–Assisted Multiobjective Optimization of Geological CO 2 Storage Performance under Geomechanical Risks

In geological CO 2 storage, designing the optimal well control strategy for CO 2 injection to maximize CO 2 storage while minimizing the associated geomechanical risks is not trivial. This challenge arises due to pressure buildup, CO 2 plume migration, the highly nonlinear nature of geomechanical responses to rock-fluid interaction, and the high computational cost associated with coupled flow and geomechanics simulations. In this paper, we introduce a novel optimization framework to address these challenges. The optimization problem is formulated as follows: maximize total CO 2 storage while minimizing geomechanical risks by adjusting the injection schedules within bounded constraints. The geomechanical risks are primarily driven by injection-induced pressure build-up, which is characterized by ground displacement and the induced microseismicity. We used the Fourier neural operator (FNO)-based deep learning model to construct surrogate models, replacing the time-consuming coupled flow and geomechanics simulations for evaluating the aforementioned objective functions. The developed surrogate models have been incorporated into a multiobjective optimization framework through a genetic algorithm to reduce the computational burden. The proposed optimization framework reduces the computational cost from approximately 2,400 hours, when using objective function evaluations based on physics-based simulations, to around 20 minutes. A set of Pareto-optimal solutions of the proposed workflow yields nontrivial optimal decisions, reducing the microseismicity potential and the vertical displacement. This Pareto front highlights the optimal trade-offs between CO 2 storage amount, safety, and ground displacement, emphasizing the need for careful optimization and management of injection strategies to achieve a balanced outcome. The novelty of this work is twofold. First, we demonstrate the importance of incorporating the minimization of the geomechanical risks as objective functions into the CO 2 storage optimization workflow to mitigate the potential risk of induced microseismicity and ground displacement. Second, we leverage the FNO-based surrogate models to optimize a real-field CO 2 storage operation.

42 ENGINEERING↗

Collective states and charge density waves in the group IV transition metal trichalcogenides

It has been nearly a century since the original mechanism for charge density wave (CDW) formation was suggested by Peierls. Since then, the term has come to describe several related concepts in condensed matter physics, having their origin in either the electron–phonon or electron–electron interaction. The vast majority of CDW literature deals with systems that are metallic, where discussions of mechanisms related to the Fermi surface are valid. Recently, it has been suggested that semiconducting systems such as TiS 3 and TiSe 2 exhibit behavior related to CDWs. In such cases, the origin of the behavior is more subtle and intimately tied to electron–electron interactions. We introduce the different classifications of CDW systems that have been proposed and discuss work on the group IV transition metal trichalcogenides (TMTs) (ZrTe 3 , HfTe 3 , TiTe 3 , and TiS 3 ), which are an exciting and emergent material system whose members exhibit quasi-one-dimensional properties. TMTs are van der Waals materials and can be readily studied in the few-layer limit, opening new avenues to manipulating collective states. We emphasize the semiconducting compound TiS 3 and suggest how it can be classified based on available data. Although we can conjecture on the origin of the CDW in TiS 3 , further measurements are required to properly characterize it.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Colloidal characterization of ultrafine silicon carbide and silicon nitride powders

The effects of various powder treatment strategies on the colloid chemistry of aqueous dispersions of silicon carbide and silicon nitride are examined using a surface titration methodology. Pretreatments are used to differentiate between the true surface chemistry of the powders and artifacts resulting from exposure history. Silicon nitride powders require more extensive pretreatment to reveal consistent surface chemistry than do silicon carbide powders. As measured by titration, the degree of proton adsorption from the suspending fluid by pretreated silicon nitride and silicon carbide powders can both be made similar to that of silica.

Whitman, Pamela K.↗

Tuning Surface Adhesion Using Grayscale Electron-beam Lithography

Surface texturing of manufactured products tailors their properties, such as friction, adhesion, biocompatibility, or fluid interactions. However, advancements in this area are largely the result of trial-and-effort testing and generally lack a science-guided framework for determining the surface topography that will optimize performance. The present investigation explores grayscale electron-beam lithography as a means to create multiscale surface patterns to control surface performance. Here, we created and characterized a set of surface textures on a silicon wafer; the textures were superpositions of sine waves of varying wavelengths and amplitudes. First, the multiscale topography of the patterned surface was characterized, using profilometry and atomic force microscopy, to understand its fidelity to the designed-in pattern. The results of this analysis demonstrated how grayscale lithography accurately controlled the lateral size of features but was less precise on the vertical height of the surface, and also introduced inherent roughness below the scale of patterning. Second, a micromechanical tester was used to characterize the adhesion of the surfaces with large-scale polished silicon spheres. The results showed that adhesion could be tailored, with significant contribution from all of the designed-in length scales of topography. The strength of adhesion did not correlate with conventional roughness parameters but could be accurately modeled using simple numerical integration. Taken together, this investigation demonstrates the promise and challenges of grayscale e-beam lithography with multiscale patterns as a method for the tailoring of surface performance.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

From gas to stars in energetic environments: dense gas clumps in the 30 Doradus region within the Large Magellanic Cloud

We present parsec-scale interferometric maps of HCN(1-0) and HCO{sup +}(1-0) emission from dense gas in the star-forming region 30 Doradus, obtained using the Australia Telescope Compact Array. This extreme star-forming region, located in the Large Magellanic Cloud (LMC), is characterized by a very intense ultraviolet ionizing radiation field and sub-solar metallicity, both of which are expected to impact molecular cloud structure. We detect 13 bright, dense clumps within the 30 Doradus-10 giant molecular cloud. Some of the clumps are aligned along a filamentary structure with a characteristic spacing that is consistent with formation via varicose fluid instability. Our analysis shows that the filament is gravitationally unstable and collapsing to form stars. There is a good correlation between HCO{sup +} emission in the filament and signatures of recent star formation activity including H{sub 2}O masers and young stellar objects (YSOs). YSOs seem to continue along the same direction of the filament toward the massive compact star cluster R136 in the southwest. We present detailed comparisons of clump properties (masses, linewidths, and sizes) in 30Dor-10 to those in other star forming regions of the LMC (N159, N113, N105, and N44). Our analysis shows that the 30Dor-10 clumps have similar masses but wider linewidths and similar HCN/HCO{sup +} (1-0) line ratios as clumps detected in other LMC star-forming regions. Our results suggest that the dense molecular gas clumps in the interior of 30Dor-10 are well shielded against the intense ionizing field that is present in the 30 Doradus region.

79 ASTRONOMY AND ASTROPHYSICS↗

Multi-dimensional modeling of a thermal energy storage canister

The Solar Dynamic Power Module being developed for Space Station Freedom uses a eutectic mixture of LiF-CaF2 phase change material (PCM) contained in toroidal canisters for thermal energy storage. Presented are the results from heat transfer analyses of a PCM containment canister. One and two dimensional finite difference computer models are developed to analyze heat transfer in the canister walls, PCM, void, and heat engine working fluid coolant. The modes of heat transfer considered include conduction in canister walls and solid PCM, conduction and pseudo-free convection in liquid PCM, conduction and radiation across PCM vapor filled void regions, and forced convection in the heat engine working fluid. Void shape, location, growth or shrinkage (due to density difference between the solid and liquid PCM phases) are prescribed based on engineering judgment. The PCM phase change process is analyzed using the enthalpy method. The discussion of the results focuses on how canister thermal performance is affected by free convection in the liquid PCM and void heat transfer. Characterizing these effects is important for interpreting the relationship between ground-based canister performance (in 1-g) and expected on-orbit performance (in micro-g). Void regions accentuate canister hot spots and temperature gradients due to their large thermal resistance. Free convection reduces the extent of PCM superheating and lowers canister temperatures during a portion of the PCM thermal charge period. Surprisingly small differences in canister thermal performance result from operation on the ground and operation on-orbit. This lack of a strong gravity dependency is attributed to the large contribution of container walls in overall canister energy redistribution by conduction.

Kerslake, Thomas W.↗

Investigation of Drop Formation by a Vortex Ring in Microgravity

An investigation of drop formation by a vortex ring propagating through one or more fluid interfaces in microgravity is described. The main goal of the research is to determine the dynamics of drop formation by vortical flows in the capillary limit with large density change across the intel-face. Dimensional analysis shows that in microgravity experiments the capillary limit can be studied using a relatively large vortex ring diameter to facilitate experimental characterization of the interaction. Results obtained in density matched systems are reviewed to illustrate the complex nature of these interactions.

Bernal, Luis P.↗

Numerical Calibration of Mass Flow Plug for Inlet Testing

A simple control volume model has been developed to calculate the discharge coefficient through a mass flow plug (MFP) and validated with a calibration experiment. The maximum error of the model within the operating region of the MFP is 0.54%. The control volume analysis developed work is comprised of a sequence of flow calculations through the MFP. The model uses the MFP geometry and operating pressure and temperature to couple continuity, momentum, energy, an equation of state, and wall shear. The discharge coefficient calculation also includes the effects of boundary layer growth, including the reduction in cross-sectional flow area as characterized by the boundary layer displacement thickness. The last calculation in the sequence uses an integral method to calculate the growth of the boundary layer, from which the displacement thickness is then determined. The result of these successive calculations is an accurate one-dimension model of the velocity, pressure, and temperature through the MFP. For comparison, a computational fluid dynamic (CFD) calibration is shown, which when compared to the presented numerical model, had a lower accuracy with a maximum error of 1.35% in addition to being slower by a factor of 100."

Flow Measurement↗

Wind Tunnel Test of A Scale Model of A Venus Probe to Determine Aeroacoustics Environment

The Zephyr probe for NASA’s DAVINCI project is being designed to fly to Venus and collect measurements to characterize the Venusian atmosphere while it descends towards the surface. Despite a slow descent speed as the probe approaches the surface, the very dense atmosphere means the vibro-acoustic environment that the probe must withstand could be very harsh. A wind tunnel test campaign was conducted to characterize the surface-pressure fluctuations (acoustics) on the external surface of the probe during the descent. The goal was to provide forcing functions for vibro-acoustic analysis of all instruments inside the probe. A 25% scale-model of the Zephyr probe was manufactured, instrumented with 18 microphones, and tested in two wind tunnels located in the Fluid Mechanics Lab at NASA Ames Research Center at velocities ranging from 13 m/s to 48 m/s. Trip strips were added to the model to ensure a turbulent boundary layer on the model. Microphones were located appropriately to provide spectra of pressure fluctuations in regions with different flow characteristics as well as for calculating various two-point statistics. The acoustic spectra measured in the wind tunnel tests were scaled up to flight-scale using the estimated flight trajectory information. Besides fluctuating surface-pressure measurements, hot-film velocity measurements as well as smoke-laser flow visualization were conducted to better understand the flow around the probe. Lastly, several different geometry configurations were tested to see whether any reduction in acoustic levels could be achieved, but none of the configurations that were tested offered significant improvements. The flow visualization showed 3 primary flow regimes on the model: an attached turbulent boundary layer on the front of the model, a region of separated flow upstream of the flared lip, and a large, separated wake at the rear of the model. The acoustic spectra generally show three different shapes corresponding to these flow regions, with the highest levels seen at the rear of the model, and directly in front of the drag plate. The scaled overall levels of pressure fluctuations were found to be high: in the range of 130dB to 155dB.

planetary probe↗

Transitional regimes of natural convection in a differentially heated cubical cavity under the effects of wall and molecular gas radiation

The transition to unsteadiness and the dynamics of weakly turbulent natural convection, coupled to wall or gas radiation in a differentially heated cubical cavity with adiabatic lateral walls, are studied numerically. The working fluid is air with small contents of water vapor and carbon dioxide whose infrared spectral radiative properties are modelled by the absorption distribution function model. A pseudo spectral Chebyshev collocation method is used to solve the flow field equations and is coupled to a direct ray tracing method for radiation transport. Flow structures are identified by means of either the proper orthogonal decomposition or the dynamic mode decomposition methods. We first retrieve the classical mechanism of transition to unsteadiness without radiation, characterized by counter-rotating streamwise-oriented vortices generated at the exit of the vertical boundary layers. Wall radiation through a transparent medium leads to a homogenization of lateral wall temperatures and the resulting transition mechanism is similar to that obtained with perfectly conducting lateral walls. The transition is due to an unstable stratification upstream the vertical boundary layers and is characterized by periodically oscillating transverse rolls of axis perpendicular to the main flow. When molecular gas radiation is accounted for, no periodic solution is found and the transition to unsteadiness displays complex structures with chimneys-like rolls whose axes are again parallel to the main flow. The origin of this instability is probably due to centrifugal forces, as suggested previously for the case without radiation. Above the transition to unsteadiness, at Ra = 3 × 10{sup 8}, it is shown that both wall and gas radiation significantly intensify turbulent fluctuations, decrease the thermal stratification in the core of the cavity, and increase the global circulation.

42 ENGINEERING↗

Analysis of gas storage and transport in Eagle Ford shale using pressure pulse decay measurements with He, Kr and CO 2

Detailed characterization of gas transport and storage in low-permeability and organic-rich shales is associated with an array of challenges due to the complex morphology of the pore space, representing a broad range of pore sizes, combined with the heterogeneous fabric of the shale matrix. These factors, and their interplay during gas transport and sorption, complicate a) the analysis of shale samples at the laboratory scale (~ up to a ft. In length), and b) the prediction of natural gas production and carbon sequestration potential at larger scales. Here, in this work, tandem experiments with inert (helium – He) and adsorbing (krypton - Kr and carbon dioxide - CO 2 ) gases were performed and analyzed to develop an efficient workflow for characterizing and modeling transport and sorption at the laboratory scale. In particular, pressure pulse-decay (PPD) measurements were conducted on an Eagle Ford shale core sample at room temperature using He, Kr, and CO 2 . PPD measurements with He (a non-sorbing gas) were employed to probe the overall porosity, including natural fractures, microcracks, mesopores, and micropores. A triple-porosity model (TPM) was adopted to interpret the gas transport in the shale sample: The pore space is represented by three interacting continua, including macropores (larger fractures), mesopores (including microcracks), and micropores. To facilitate the application of the TPM, a modified analytical approach is introduced to extract effective transport parameters (in terms of the characteristic time for transport at relevant porosity levels) directly from the PPD measurements with He. To validate the modeling approach, model parameters extracted from two He PPD measurements are demonstrated to provide excellent agreement with a 3rd He PPD measurement performed at a higher pressure. The effective transport parameters, extracted from the He experiments, were subsequently converted for application to the Kr and CO 2 PPD experiments, by accounting for relevant transport modes and differences in fluid properties. Excess adsorption isotherms were extracted from the equilibrium pressures of the Kr and CO 2 PPD experiments using the He pore volume as a baseline. These adsorption isotherms were then integrated into the TPM to predict combined gas transport and sorption for Kr and CO 2 , with transport coefficients translated from the He measurements. The predictions for Kr and CO 2 are demonstrated to be in excellent agreement with the experimental observations. This, in turn, demonstrates that the proposed analytical approach provides for an effective characterization of mass transfer rates in shales, that can be applied directly in a TPM representation of mass transfer and sorption.

58 GEOSCIENCES↗

A Simulated Evaluation of Powder Flowability Through a Partially Obstructed Consumable in Blown Powder Directed Energy Deposition Systems

Abstract In the interest of continued industrialization of metal additive manufacturing in modern production environments, cost is often referenced as a primary deterrent to new adopters. Conventional economic models for additive systems, processes, and supply chains often focus on specific process applications with little generalizability, or they neglect significant costs associated with production such as machine maintenance and consumable part replacement. Compounding the latter issue are substantial knowledge gaps in consumable part wear characterization for additive and other convergent manufacturing systems. In coaxial blown powder directed energy deposition systems, gas atomized metal powder is wasted during material deposition at a rate that is partly dependent on present wear phenomena in a consumable nozzle housed in the cladding head assembly. The price and lead time required to replace the nozzle incentivizes its reuse even when visibly worn. Often this initiates a process quality decline in the form of underbuilt geometry and internal defects due to losses in powder catchment efficiency. While depositing H13 steel using a hybrid manufacturing machine tool equipped with such a deposition system, a unique partial clog with a bridge-like structure formed at the consumable nozzle exit when supporting argon gas flows failed mid-process. To further understand coaxial multi-phase powder flow in the event of support gas failure, a computational fluid dynamics simulation is tailored to relevant process parameters, H13 powder material profile, and machine operator observations collected after the incident. The resulting differences in powder flow compared to control gas flow parameters is presented and discussed. The powder flowability and performance of the clogged nozzle is then assessed by using an optical profilometer to extract the profile of the clog and recreate the clog geometry within the simulation environment. In past work this simulation has been experimentally validated for a 316L steel powder material profile and used specifically for analyzing powder stream geometry and catchment efficiency. After the initial powder flow characterization, the clog is removed, and the nozzle is reprofiled. After removing the obstructing clog, the newly unobstructed nozzle geometry, the original off the shelf nozzle geometry, and additional nozzle profiles exploring different consumable refurbishment strategies are reevaluated in the simulation. Powder catchment efficiency for all variant nozzle geometries and relevant flow variables are compared and discussed, along with potential mitigation strategies for optimizing powder flowability with worn consumables. This work expands on the known morphology of blown powder obstructions and wear defects present in consumable coaxial nozzles while discussing pragmatic simulation driven responses to unanticipated subsystem failure in hybrid manufacturing machining platforms.

DeWitte, Lisa↗