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DOE OSTI2025

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗

NASA NTRS2015

4H-SiC JFET Multilayer Integrated Circuit Technologies Tested Up to 1000 K

Testing of semiconductor electronics at temperatures above their designed operating envelope is recognized as vital to qualification and lifetime prediction of circuits. This work describes the high temperature electrical testing of prototype 4H silicon carbide (SiC) junction field effect transistor (JFET) integrated circuits (ICs) technology implemented with multilayer interconnects; these ICs are intended for prolonged operation at temperatures up to 773K (500 C). A 50 mm diameter sapphire wafer was used in place of the standard NASA packaging for this experiment. Testing was carried out between 300K (27 C) and 1150K (877 C) with successful electrical operation of all devices observed up to 1000K (727 C).

JFET↗

DOE OSTI2018

Status of the framework for research in nuclear science and engineering - 25460

The Framework for Research in Nuclear Science and Engineering (FRENSIE) is a collection of packages written in C++ that are designed primarily to aid in methods development. New features are continually being added to the various packages and as a result, the Forward Adjoint Continuous Energy Monte Carlo (FACEMC) tool provided by FRENSIE continues to undergo verification and validation. While FRENSIE is not currently open source, the ultimate goal is for it to be released as such. A few of the more recent developments in FRENSIE include the addition of combinatorial geometry capabilities using ROOT, tet and hex meshing, support for thermal neutron S (α; β) data, photon Doppler broadening, electron interactions using basic analog electron physics models as well as an elastic moment-preserving model, and atomic relaxation. Preliminary verification results for much of the newly added physics models show good agreement between FACEMC and MCNP6. (authors)

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1971

Sounding rocket flight report, MUMP 9 and MUMP 10

The results of the launching of two-Marshall-University of Michigan Probes (MUMP 9 and MUMP 10), Nike-Tomahawk sounding rocket payloads, are summarized. The MUMP is similar to the thermosphere probe, an ejectable instrument package for studying the variability of the earth's atmospheric parameters. The MUMP 9 payload included an omegatron mass analyzer, a molecular fluorescence densitometer, a mini-tilty filter, and a lunar position sensor. This complement of instruments permitted the determination of the molecular nitrogen density and temperature in the altitude range from approximately 143 to 297 km over Wallops Island, Virginia, during January 1971. The MUMP 10 payload included an omegatron mass analyzer, an electron temperature probe, a cryogenic densitometer, and a solar position sensor. These instruments permitted the determination of the molecular nitrogen density and temperature and the charged particle density and temperature in the altitude range from approximately 145 to 290 km over Wallops Island during the afternoon preceding the MUMP 9 launch.

Grassl, H. J.↗

NASA NTRSDate not supplied

Monte Carlo simulations of neutrino and charged lepton propagation in the Earth with nuPyProp

An accurate modeling of neutrino flux attenuation and the distribution of leptons they produce in transit through the Earth is an essential component to determine neutrino flux sensitivities of underground, sub-orbital and space-based detectors. Through neutrino oscillations over cosmic distances, astrophysical neutrino sources are expected to produce nearly equal fluxes of electron, muon and tau neutrinos. Of particular interest are tau neutrinos that interact in the Earth at modest slant depths to produce leptons. Some leptons emerge from the Earth and decay in the atmosphere to produce extensive air showers. Future balloon-borne and satellite-based opticalCherenkov neutrino telescopes will be sensitive to upward air showers from tau neutrino induced lepton decays. We present nuPyProp, a python code that is part of the nuSpaceSim package. nuPyProp generates look-up tables for exit probabilities and energy distributions for (see paper for proper equation) propagation in the Earth. This flexible code runs with either stochastic or continuous electromagnetic energy losses for the lepton transit through the Earth. Current neutrino cross section models and energy loss models are included along with templates for user input of other models. Results from nuPyProp are compared with other recent simulation packages for neutrino and charged lepton propagation. Sources of modeling uncertainties are described and quantified.

Yosui Akaike↗

NASA NTRSDate not supplied

Space Exploration Synthetic Aperture Radar - Lunar Investigations Targeted Experiment (SESAR-LITE)

The SESAR-LITE (Space Exploration Synthetic Aperture Radar - Lunar Investigations Targeted Experiment) instrument is a compact P-band (70 cm wavelength) polarimetric synthetic aperture radar under development at the NASA Goddard Space Flight Center to measure the surface and subsurface of the Moon at full polarimetry and at meter-scale resolution. The radar will use a compact deployable antenna, distributed RF electronics, and multi-channel digital processing system to enable a set of focused mission goals for small payload opportunities. The instrument development is leveraging proven technology advancements recently developed and demonstrated at NASA Goddard Space Flight center for SESAR (Space Exploration Synthetic Aperture Radar), a flagship version of the instrument that was tailored for larger orbital missions. The development of SESAR-LITE addresses accommodation flexibility on multiple launch vehicle families that require small packages while providing unprecedented surface and subsurface imaging of the Moon called for NASA’s Artemis program.

Synthetic Aperture Radar↗

DOE OSTI2019

Half-Metallic Ferromagnetism in V-Doped FmP Binary Monopnictide Compounds: an Ab Initio Calculations

The ab initio calculations of the structural phase stability, magnetic phase stability, and electronic and magnetic properties of the FmP binary monopnictides and the half-metallic ferromagnetic properties of their Fm{sub 1−x}V{sub x}P (for x = 0.25, 0.50, 0.75, and 1)-doped alloys have been assured through the spin-polarized density functional theory (DFT), and they are performed by employing the full-potential linearized augmented plane waves plus local orbitals (FP-L/APW + lo) method that is implemented in the WIEN2k package. The exchange and correlation potential is parameterized by the generated gradient approximation (GGA) of Perdew-Burke-Ernzerhof (PBE) scheme. According to the studies of the magnetic phase stability, the fermium monopnictides (FmP) have a paramagnetic regime, while the ferromagnetic behavior appears when we dope this compound with vanadium. Through the ferromagnetic character of all Fm{sub 1−x}V{sub x}P alloys, the spin-polarized band structures and densities of states exhibit a nearly half-metallic character of Fm{sub 0.75}V{sub 0.25}P alloy, whereas Fm{sub 0.50}V{sub 0.50}P, Fm{sub 0.25}V{sub 0.75}P, and VP compounds showed metallic character. Moreover, the total magnetic moment of the three ternary alloys is mainly contributed by Fm and V elements, where the p-d hybridization reduces the atomic magnetic moment of V element from its free space charge and produces feeble magnetic moments on the nonmagnetic P sites.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1985

Monte Carlo simulation of a new gamma ray telescope

A new Monte Carlo code has been written to simulate the response of the new University of California double scatter gamma ray telescope. This package of modular software routines, written in VAX FORTRAN 77 simulates the detection of 0.1 to 35 MeV gamma rays. The new telescope is flown from high altitude balloons to measure medium energy gamma radiation from astronomical sources. This paper presents (1) the basic physics methods in the code, and (2) the predicted response functions of the telescope. Gamma ray processes include Compton scattering, pair production and photoelectric absorption in plastic scintillator, NaI(Tl) and aluminum. Electron transport processes include ionization energy loss, multiple scattering, production of bremsstrahlung photons and positron annihilation.

Simone, J.↗

NASA NTRS1989

Thermal enclosures for electronically scanned pressure modules operating in cryogenic environments

Specific guidelines to design, construct, and test ESP thermal enclosures for applications at cryogenic temperatures are given. The enclosures maintain the ESP modules at a constant temperature (10 C plus or minus 1 C) to minimize thermal zero and sensitivity shifts, to minimize the frequency of expensive on-line calibrations, and to avoid adverse effects on tunnel and model boundary layers. The enclosures are constructed of a rigid closed-cell foam and are capable of withstanding the stagnation pressures to 932kPa (135 psia) without reduction in thermal insulation properties. This construction procedure has been used to construct several thermal packages which have been successfully used in National Transonic Facility.

Mitchell, Michael↗

NASA NTRS2005

A Hardware and Software Perspective of the Fifth Materials on the International Space Station Experiment (MISSE-5)

Conducting space experiments with small budgets is a fact of life for many design groups with low-visibility science programs. One major consequence is that specialized space grade electronic components are often too costly to incorporate into the design. Radiation mitigation now becomes more complex as a result of being restricted to the use of commercial off-the-shelf (COTS) parts. Unique hardware and software design techniques are required to succeed in producing a viable instrument suited for use in space. This paper highlights some of the design challenges and associated solutions encountered in the production of a highly capable, low cost space experiment package.

Krasowski, Michael↗

NASA NTRS2010

High-Efficiency K-Band Space Traveling-Wave Tube Amplifier for Near-Earth High Data Rate Communications

The RF performance of a new K-Band helix conduction cooled traveling-wave tube amplifier (TWTA) is presented in this paper. A total of three such units were manufactured, tested and delivered. The first unit is currently flying onboard NASA s Lunar Reconnaissance Orbiter (LRO) spacecraft and has flawlessly completed over 2000 orbits around the Moon. The second unit is a proto-flight model. The third unit will fly onboard NASA s International Space Station (ISS) as a very compact and lightweight transmitter package for the Communications, Navigation and Networking Reconfigurable Testbed (CoNNeCT), which is scheduled for launch in 2011. These TWTAs were characterized over the frequencies 25.5 to 25.8 GHz. The saturated RF output power is >40 W and the saturated RF gain is >46 dB. The saturated AM-to- PM conversion is 3.5 /dB and the small signal gain ripple is 0.46 dB peak-to-peak. The overall efficiency of the TWTA, including that of the electronic power conditioner (EPC) is as high as 45 percent.

Simons, Rainee N.↗

DOE OSTI2016

Sandia Advanced MEMS Design Tools v. 3.0

This is a major revision to the Sandia Advanced MEMS Design Tools. It replaces all previous versions. New features in this version: Revised to support AutoCAD 2014 and 2015 This CD contains an integrated set of electronic files that: a) Describe the SUMMiT V fabrication process b) Provide enabling educational information (including pictures, videos, technical information) c) Facilitate the process of designing MEMS with the SUMMiT process (prototype file, Design Rule Checker, Standard Parts Library) d) Facilitate the process of having MEMS fabricated at Sandia National Laboratories e) Facilitate the process of having post-fabrication services performed. While there exists some files on the CD that are used in conjunction with software package AutoCAD, these files are not intended for use independent of the CD. Note that the customer must purchase his/her own copy of AutoCAD to use with these files.

Yarberry, Victor R.↗

DOE OSTI2021

PA-BCI Meteorological dataset 1985-2018

This data package contains a QA/QC-ed meteorological time series dataset from 1985 to 2018, including relative humidity, temperature, solar radiation, rainfall, wind speed, and barometric pressure at Barro Colorado Island (PA-BCI) in Panama. The data were collected at the elevations of 42 m and 48 m at the BCI Lutz station, except for rainfall that was collected at the BCI Clearing station at the elevation of 1 m. Individual time series datasets were collected using electro-mechanical (electronic sensors, data loggers, chart recorders, etc.). The rainfall dataset was collected using the tipping bucket method, and the data could have been underestimated by 13-17% (likely the large values). The data is included as a single CSV file.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2005

A Design of a Modular GPHS-Stirling Power System for a Lunar Habitation Module

Lunar habitation modules need electricity and potentially heat to operate. Because of the low amounts of radiation emitted by General Purpose Heat Source (GPHS) modules, power plants incorporating these as heat sources could be placed in close proximity to habitation modules. A design concept is discussed for a high efficiency power plant based on a GPHS assembly integrated with a Stirling convertor. This system could provide both electrical power and heat, if required, for a lunar habitation module. The conceptual GPHS/Stirling system is modular in nature and made up of a basic 5.5 KWe Stirling convertor/GPHS module assembly, convertor controller/PMAD electronics, waste heat radiators, and associated thermal insulation. For the specific lunar application under investigation eight modules are employed to deliver 40 KWe to the habitation module. This design looks at three levels of Stirling convertor technology and addresses the issues of integrating the Stirling convertors with the GPHS heat sources assembly using proven technology whenever possible. In addition, issues related to the high-temperature heat transport system, power management, convertor control, vibration isolation, and potential system packaging configurations to ensure safe operation during all phases of deployment will be discussed.

Schmitz, Paul C.↗

NASA NTRS2010

Scanning Mechanism of the FY-3 Microwave Humidity Sounder

Astrium GmbH Germany, developed the scanning equipment for the instrument package of the MicroWave Humidity Sounder (MWHS) flying on the FY-3 meteorological satellite (FY means Feng Yun, Wind and Cloud) in a sun-synchronized orbit of 850-km altitude and at an inclination of 98.8 . The scanning mechanism rotates at variable velocity comprising several acceleration / deceleration phases during each revolution. The Scanning Mechanism contains two output shafts, each rotating a parabolic offset Antenna Reflector. The mechanism is operated in closed loop by means of redundant control electronics. MWHS is a sounding radiometer for measurement of global atmospheric water vapour profiles. An Engineering Qualification Model was developed and qualified and a first Flight Model was launched early 2008. The system is now working for more than two years successful in orbit. A second Flight Model of the Antenna Scanning Mechanism and of its associated control electronics was built and delivered to the customer for application on the follow-on spacecraft that will be launched by the end of 2010.

Schmid, Manfred↗

NASA NTRS2011

Scatterometer-Calibrated Stability Verification Method

The requirement for scatterometer-combined transmit-receive gain variation knowledge is typically addressed by sampling a portion of the transmit signal, attenuating it with a known-stable attenuation, and coupling it into the receiver chain. This way, the gain variations of the transmit and receive chains are represented by this loop-back calibration signal, and can be subtracted from the received remote radar echo. Certain challenges are presented by this process, such as transmit and receive components that are outside of this loop-back path and are not included in this calibration, as well as the impracticality for measuring the transmit and receive chains stability and post fabrication separately, without the resulting measurement errors from the test set up exceeding the requirement for the flight instrument. To cover the RF stability design challenge, the portions of the scatterometer that are not calibrated by the loop-back, (e.g., attenuators, switches, diplexers, couplers, and coaxial cables) are tightly thermally controlled, and have been characterized over temperature to contribute less than 0.05 dB of calibration error over worst-case thermal variation. To address the verification challenge, including the components that are not calibrated by the loop-back, a stable fiber optic delay line (FODL) was used to delay the transmitted pulse, and to route it into the receiver. In this way, the internal loopback signal amplitude variations can be compared to the full transmit/receive external path, while the flight hardware is in the worst-case thermal environment. The practical delay for implementing the FODL is 100 s. The scatterometer pulse width is 1 ms so a test mode was incorporated early in the design phase to scale the 1 ms pulse at 100-Hz pulse repetition interval (PRI), by a factor of 18, to be a 55 s pulse with 556 s PRI. This scaling maintains the duty cycle, thus maintaining a representative thermal state for the RF components. The FODL consists of an RF-modulated fiber-optic transmitter, 20 km SMF- 28 standard single-mode fiber, and a photodetector. Thermoelectric cooling and insulating packaging are used to achieve high thermal stability of the FODL components. The chassis was insulated with 1-in. (.2.5-cm) thermal isolation foam. Nylon rods support the Micarta plate, onto which are mounted four 5-km fiber spool boxes. A copper plate heat sink was mounted on top of the fiber boxes (with thermal grease layer) and screwed onto the thermoelectric cooler plate. Another thermal isolation layer in the middle separates the fiberoptics chamber from the RF electronics components, which are also mounted on a copper plate that is screwed onto another thermoelectric cooler. The scatterometer subsystem fs overall stability was successfully verified to be calibratable to within 0.1 dB error in thermal vacuum (TVAC) testing with the fiber-optic delay line, while the scatterometer temperature was ramped from 10 to 30 C, which is a much larger temperature range than the worst-case expected seasonal variations.

McWatters, Dalia A.↗

DOE OSTI2016

Sandia MEMS Visualization Tools v. 3.0

This is a revision to the Sandia MEMS Visualization Tools. It replaces all previous versions. New features in this version: Support for AutoCAD 2014 and 2015 . This CD contains an integrated set of electronic files that: a) Provides a 2D Process Visualizer that generates cross-section images of devices constructed using the SUMMiT V fabrication process. b) Provides a 3D Visualizer that generates 3D images of devices constructed using the SUMMiT V fabrication process. c) Provides a MEMS 3D Model generator that creates 3D solid models of devices constructed using the SUMMiT V fabrication process. While there exists some files on the CD that are used in conjunction with software package AutoCAD , these files are not intended for use independent of the CD. Note that the customer must purchase his/her own copy of AutoCAD to use with these files.

Yarberry, Victor↗

NASA NTRS2000

The Spacecraft Materials Selector: An Artificial Intelligence System for Preliminary Design Trade Studies, Materials Assessments, and Estimates of Environments Present

Institutions need ways to retain valuable information even as experienced individuals leave an organization. Modern electronic systems have enough capacity to retain large quantities of information that can mitigate the loss of experience. Performance information for long-term space applications is relatively scarce and specific information (typically held by a few individuals within a single project) is often rather narrowly distributed. Spacecraft operate under severe conditions and the consequences of hardware and/or system failures, in terms of cost, loss of information, and time required to replace the loss, are extreme. These risk factors place a premium on appropriate choice of materials and components for space applications. An expert system is a very cost-effective method for sharing valuable and scarce information about spacecraft performance. Boeing has an artificial intelligence software package, called the Boeing Expert System Tool (BEST), to construct and operate knowledge bases to selectively recall and distribute information about specific subjects. A specific knowledge base to evaluate the on-orbit performance of selected materials on spacecraft has been developed under contract to the NASA SEE program. The performance capabilities of the Spacecraft Materials Selector (SMS) knowledge base are described. The knowledge base is a backward-chaining, rule-based system. The user answers a sequence of questions, and the expert system provides estimates of optical and mechanical performance of selected materials under specific environmental conditions. The initial operating capability of the system will include data for Kapton, silverized Teflon, selected paints, silicone-based materials, and certain metals. For situations where a mission profile (launch date, orbital parameters, mission duration, spacecraft orientation) is not precisely defined, the knowledge base still attempts to provide qualitative observations about materials performance and likely exposures. Prior to the NASA contract, a knowledge base, the Spacecraft Environments Assistant (SEA,) was initially developed by Boeing to estimate the environmental factors important for a specific spacecraft mission profile. The NASA SEE program has funded specific enhancements to the capability of this knowledge base. The SEA qualitatively identifies over 25 environmental factors that may influence the performance of a spacecraft during its operational lifetime. For cases where sufficiently detailed answers are provided to questions asked by the knowledge base, atomic oxygen fluence levels, proton and/or electron fluence and dose levels, and solar exposure hours are calculated. The SMS knowledge base incorporates the previously developed SEA knowledge base. A case history for previous flight experiment will be shown as an example, and capabilities and limitations of the system will be discussed.

Pippin, H. G.↗