Publications

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Control of the atomic structure, as measured by the extent of the embrittling B2 chemically ordered phase, is demonstrated in intermetallic alloys through additive manufacturing (AM) and characterized using high fidelity neutron diffraction. As a layer-by-layer rapid solidification process, AM was employed to suppress the extent of chemically ordered B2 phases in a soft ferromagnetic Fe-Co alloy, as a model material system of interest to electromagnetic applications. The extent of atomic ordering was found to be insensitive to the spatial location within specimens and suggests that the thermal conditions within only a few AM layers were most influential in controlling the microstructure, in agreement with the predictions from a thermal model for welding. Analysis of process parameter effects on ordering found that suppression of B2 phase was the result of an increased average cooling rate during processing. AM processing parameters, namely interlayer interval time and build velocity, were used to systematically control the relative fraction of ordered B2 phase in specimens from 0.49 to 0.72. Hardness of AM specimens was more than 150% higher than conventionally processed bulk material. Implications for tailoring microstructures of intermetallic alloys are discussed.

Abstract not provided.

Abstract not provided.

Abstract not provided.

New manufacturing technologies such as additive manufacturing require research and development to minimize the uncertainties in the produced parts. The research involves experimental measurements and large simulations, which result in huge quantities of data to store and analyze. We address this challenge by alleviating the data storage requirements using lossy data compression. We select wavelet bases as the mathematical tool for compression. Unlike images, additive manufacturing data is often represented on irregular geometries and unstructured meshes. Thus, we use Alpert tree-wavelets as bases for our data compression method. We first analyze different basis functions for the wavelets and find the one that results in maximal compression and miminal error in the reconstructed data. We then devise a new adaptive thresholding method that is data-agnostic and allows a priori estimation of the reconstruction error. Finally, we propose metrics to quantify the global and local errors in the reconstructed data. One of the error metrics addresses the preservation of physical constraints in reconstructed data fields, such as divergence-free stress field in structural simulations. While our compression and decompression method is general, we apply it to both experimental and computational data obtained from measurements and thermal/structural modeling of the sintering of a hollow cylinder from metal powders using a Laser Engineered Net Shape process. The results show that monomials achieve optimal compression performance when used as wavelet bases. The new thresholding method results in compression ratios that are two to seven times larger than the ones obtained with commonly used thresholds. Overall, adaptive Alpert tree-wavelets can achieve compression ratios between one and three orders of magnitude depending on the features in the data that are required to preserve. These results show that Alpert tree-wavelet compression is a viable and promising technique to reduce the size of large data structures found in both experiments and simulations.

Abstract not provided.

Abstract not provided.

Abstract not provided.

We investigate the feasibility of additively manufacturing optical components to accomplish task-specific classification in a computational imaging device. We report on the design, fabrication, and characterization of a non-traditional optical element that physically realizes an extremely compressed, optimized sensing matrix. The compression is achieved by designing an optical element that only samples the regions of object space most relevant to the classification algorithms, as determined by machine learning algorithms. The design process for the proposed optical element converts the optimal sensing matrix to a refractive surface composed of a minimized set of non-repeating, unique prisms. The optical elements are 3D printed using a Nanoscribe, which uses two-photon polymerization for high-precision printing. We describe the design of several computational imaging prototype elements. We characterize these components, including surface topography, surface roughness, and angle of prism facets of the as-fabricated elements.

Spatially resolved, line-of-sight measurements of aluminum monoxide emission spectra in laser ablation plasma are used with Abel inversion techniques to extract radial plasma temperatures. Contour mapping of the radially deconvolved signal intensity shows a ring of AlO formation near the plasma boundary with the ambient atmosphere. Simulations of the molecular spectra were coupled with the line profile fitting routines. Temperature results are presented with simultaneous inferences from lateral, asymmetric radial, and symmetric radial AlO spectral intensity profiles. This analysis indicates that shockwave phenomena in the radial profiles, including a temperature drop behind the blast wave created during plasma initiation were measured.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Processing of the low workability Fe-Co-1.5V (Hiperco ® equivalent) alloy is demonstrated using the Laser Engineered Net Shaping (LENS) metals additive manufacturing technique. As an innovative and highly localized solidification process, LENS is shown to overcome workability issues that arise during conventional thermomechanical processing, enabling the production of bulk, near net-shape forms of the Fe-Co alloy. Bulk LENS structures appeared to be ductile with no significant macroscopic defects. Atomic ordering was evaluated and significantly reduced in as-built LENS specimens relative to an annealed condition, tailorable through selection of processing parameters. Fine equiaxed grain structures were observed in as-built specimens following solidification, which then evolved toward a highly heterogeneous bimodal grain structure after annealing. The microstructure evolution in Fe-Co is discussed in the context of classical solidification theory and selective grain boundary pinning processes. Magnetic properties were also assessed and shown to fall within the extremes of conventionally processed Hiperco ® alloys. Hiperco ® is a registered trademark of Carpenter Technologies, Readings, PA.

This work proposes a finite element (FE) analysis workflow to simulate directed energy deposition (DED) additive manufacturing at a macroscopic length scale (i.e. part length scale) and to predict thermal conditions during manufacturing, as well as distortions, strength and residual stresses at the completion of manufacturing. The proposed analysis method incorporates a multi-step FE workflow to elucidate the thermal and mechanical responses in laser engineered net shaping (LENS) manufacturing. For each time step, a thermal element activation scheme captures the material deposition process. Then, activated elements and their associated geometry are analyzed first thermally for heat flow due to radiation, convection, and conduction, and then mechanically for the resulting stresses, displacements, and material property evolution. Simulations agree with experimentally measured in situ thermal measurements for simple cylindrical build geometries, as well as general trends of local hardness distribution and plastic strain accumulation (represented by relative distribution of geometrically necessary dislocations).

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Laser welding is a key joining process used extensively in the manufacture and assembly of critical components for several weapons systems. Sandia National Laboratories advances the understanding of the laser welding process through coupled experimentation and modeling. This report summarizes the experimental portion of the research program, which focused on measuring temperatures and thermal history of laser welds on steel plates. To increase confidence in measurement accuracy, researchers utilized multiple complementary techniques to acquire temperatures during laser welding. This data serves as input to and validation of 3D laser welding models aimed at predicting microstructure and the formation of defects and their impact on weld-joint reliability, a crucial step in rapid prototyping of weapons components.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

A 4-color imaging pyrometer was developed to investigate the thermal behavior of laser-based metal processes, specifically laser welding and laser additive manufacturing of stainless steel. The new instrument, coined a 2x pyrometer, consists of four, high-sensitivity silicon CMOS cameras configured as two independent 2-color pyrometers combined in a common hardware assembly. This coupling of pyrometers permitted low and high temperature regions to be targeted within the silicon response curve, thereby broadening the useable temperature range of the instrument. Also, by utilizing the high dynamic range features of the CMOS cameras, the response gap between the two wavelength bands can be bridged. Together these hardware and software enhancements are predicted to expand the real-time (60 fps) temperature response of the 2x pyrometer from 600 °C to 3500 °C. Initial results from a calibrated tungsten lamp confirm this increased response, thus making it attractive for measuring absolute temperatures of steel forming processes.

Abstract not provided.

The human brain (volume=1200cm3) consumes 20W and is capable of performing > 10^16 operations/s. Current supercomputer technology has reached 1015 operations/s, yet it requires 1500m^3 and 3MW, giving the brain a 10^12 advantage in operations/s/W/cm^3. Thus, to reach exascale computation, two achievements are required: 1) improved understanding of computation in biological tissue, and 2) a paradigm shift towards neuromorphic computing where hardware circuits mimic properties of neural tissue. To address 1), we will interrogate corticostriatal networks in mouse brain tissue slices, specifically with regard to their frequency filtering capabilities as a function of input stimulus. To address 2), we will instantiate biological computing characteristics such as multi-bit storage into hardware devices with future computational and memory applications. Resistive memory devices will be modeled, designed, and fabricated in the MESA facility in consultation with our internal and external collaborators.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Recent world events have underscored the need for a satellite based persistent global surveillance capability. To be useful, the satellite must be able to continuously monitor objects the size of a person anywhere on the globe and do so at a low cost. One way to satisfy these requirements involves a constellation of satellites in low earth orbit capable of resolving a spot on the order of 20 cm. To reduce cost of deployment, such a system must be dramatically lighter than a traditional satellite surveillance system with a high spatial resolution. The key to meeting this requirement is a lightweight optics system with a deformable primary and secondary mirrors and an adaptive optic subsystem correction of wavefront distortion. This proposal is concerned with development of MEMS micromirrors for correction of aberrations in the primary mirror and improvement of image quality, thus reducing the optical requirements on the deployable mirrors. To meet this challenge, MEMS micromirrors must meet stringent criteria on their performance in terms of flatness, roughness and resolution of position. Using Sandia's SUMMIT foundry which provides the world's most sophisticated surface MEMS technology as well as novel designs optimized by finite element analysis will meet severe requirements on mirror travel range and accuracy.

The primary goal of this portion of the LDRD is to develop a vertical programmable diffraction grating that can be fabricated with Sandia's Ultra-planar Multi-level MEMS Technology, the SUMMiT V{trademark} process. This grating is targeted for use in a chemical detection system dubbed the Polychromator. A secondary goal is to design diffraction grating structures with additional degrees of freedom (DOF). Gratings with 2.5 microns of vertical stroke have been realized. In addition, rotational DOF grating structures have been successfully actuated, and a structure has been developed that minimizes residual stress effects.

Abstract not provided.

This report outlines our work on the integration of high efficiency photonic lattice structures with MEMS (MicroElectroMechanical Systems). The simplest of these structures were based on 1-D mirror structures. These were integrated into a variety of devices, movable mirrors, switchable cavities and finally into Bragg fiber structures which enable the control of light in at least 2 dimensions. Of these devices, the most complex were the Bragg fibers. Bragg fibers consist of hollow tubes in which light is guided in a low index media (air) and confined by surrounding Bragg mirror stacks. In this work, structures with internal diameters from 5 to 30 microns have been fabricated and much larger structures should also be possible. We have demonstrated the fabrication of these structures with short wavelength band edges ranging from 400 to 1600nm. There may be potential applications for such structures in the fields of integrated optics and BioMEMS. We have also looked at the possibility of waveguiding in 3 dimensions by integrating defects into 3-dimensional photonic lattice structures. Eventually it may be possible to tune such structures by mechanically modulating the defects.