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Li, Mei

Publications and source records attributed to Li, Mei.

10 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

A Gaussian Process-Based extended Goldak heat source model for finite element simulation of laser powder bed fusion additive manufacturing process

In this study, laser powder bed fusion (L-PBF) additive manufacturing (AM) is a key enabling technology to manufacture highly complex and integrated metallic structures. In L-PBF AM process, the melting of the metal powders and the layers underneath can be governed by either “conduction mode” or “keyhole mode”, with the keyhole mode reportedly leading to porosity and decreased strength and ductility by many studies. In part scale simulations, finite element (FE) model is often used to study the temperature distribution during printing and to predict the residual stress, where a volumetric heat flux with a Gaussian or a double ellipsoidal (Goldak) distribution is often applied as the laser heat source. However, the above heat source models can only capture the melt pool shape in the conduction mode, and fail to capture the transition to keyhole melting mode when the process parameters change. To overcome this inaccuracy, an extended Goldak heat source model is proposed by introducing a laser penetration term as a function of laser parameters obtained from a Gaussian-Process (GP) model. The model is validated by “2D pad” AlSi10Mg L-PBF experiments under a wide range of laser power, scan speed, and laser focus offset, and the results show the model successfully captures the measured melt pool shape in all conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Multiscale Modeling of Corrosion and Oxidation Performance and Their Impact on High-temperature Fatigue of Automotive Exhaust Manifold Components

The persistent need to reducing automobile emissions has led to the wide adoption of turbocharger technology and engine downsizing, which results in a substantial raise in exhaust temperature, reaching as high as 950°C. Therefore, the material selection for exhaust manifolds and turbocharger housings becomes significantly challenging. The successful development of the multiscale models on oxidation and corrosion performance, and their impact on high-temperature fatigue will enable the acceleration of new, high-performance, heat-resistant alloy solutions and the reduction of time and cost in achieving a durable design. In this project, we developed and validated multiscale models that can accurately predict the corrosion and oxidation performance and their impact on high-temperature fatigue of high-temperature automotive exhaust manifold components. The capability of accurately predicting the corrosion/oxidation-fatigue damage can significantly reduce the time and cost of achieving a durable design. The models were used to guide the development of new high thermomechanical fatigue (TMF) performance alloys.

Li, Mei↗
DOE OSTI2023

Nonmonotonic effect of chemical heterogeneity on interfacial crack growth at high-angle grain boundaries in Fe-Ni-Cr alloys

Here, an intermittent pattern is observed in the modeling of interfacial cyclic-loading crack growth at high-angle grain boundaries in ternary Fe-Ni-Cr alloys. Different from conventional wisdom of stress-intensity factor, the abrupt crack advances are found driven by extreme value statistics—namely, the aggregation of atoms with most compressive residual stresses. In addition, inherently non-affine atomic stress fluctuations are discovered, and the fluctuations peak at intermediate level of chemical heterogeneity, causing the fastest crack growth. Implications of such nonmonotonic mechanism in regard to the origin of intermediate-temperature embrittlement phenomena are also discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Extend an innovative HPC-Compatible Multiple Temporal-spatial Resolution Concurrent Finite Element Modeling Approach to Guide Laser Powder Bed Fusion Additive

Laser power bed fusing (PBF) additive manufacturing is a key enabling technology to manufacture highly complex and integrated automotive structures. However, the geometric complexity of PBF-AM technique also leads to highly non-uniform heating and cooling rate in the manufactured part, which may cause flaw formation and produce excessive and nonuniform residual stresses, which increase quality uncertainties and manufacture issues, leading to increases in cost and energy consumption in the form of rejected parts. In this research project, we developed an innovative Multi-Spatial-Temporal-Resolution Finite Element (MUST-FE) method and completed the corresponding high performance computation (HPC) platform-based in-house code, which enables high accuracy prediction of temperature and residual stress fields for component-scale PBF-AM manufacture in efficient computation time. The MUST-FE model is calibrated and validated with a “2D pad” AlSi10Mg experiments by matching the melt pool shape and dimension, and with a “XY-cross” AlSi10Mg experiment by matching the thermal distortion and residual stress. The innovative multi-resolution and concurrent modeling approach adopted in this code ensures accuracy and computational efficiency, which will enable energy-efficient and high-yield, low-cost manufacturing of optimized, qualifiable automotive structures and contribute towards reaching technical targets outlined in AMO’s Program Plan to develop additive manufacturing systems that deliver consistently reliable parts with predictable properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cast iron alloy for automotive engine applications with superior high temperature oxidation properties

A cast iron alloy is provided with a composition in weight percent (wt. %) of carbon between 2.6 to 3.4 wt. %, silicon between 2.4 to 3.2 wt. %, manganese between 0.3 to 0.6 wt. %, molybdenum between 0.4 to 1.2 wt. %, nickel between 0.6 to 1.75 wt. %, magnesium between 0.01 to 0.075 wt. %, aluminum between 1.8 to 3.5 wt. %, sulfur between 0.003 to 0.025 wt. %, zirconium between 0.001 to 0.02 wt. %, cerium between 0.001 to 0.03 wt. %, lanthanum between 0.0005 to 0.02 wt. %, and a balance of iron and unavoidable trace elements. A part formed from the cast iron alloy is also provided and the part has an Ac1 temperature equal to or greater than 895° C. and a thermo-mechanical fatigue lifetime of at least 10,000 cycles when cycled between 400° C. to 800° C. with a total cyclic strain equal to 0.001 m/m.

Godlewski, Larry Alan↗
DOE OSTI2023

Effect of Cr and Ni concentrations on resilience of cast Nb- alloyed heat resistant austenitic steels at extreme high temperatures

Austenitic Cr–Ni alloyed heat resistant steels with Nb additions are used for intensively thermo-mechanically loaded cast components working in extreme high temperature oxidizing environment. Their performance during static oxidation and transient thermo-mechanical loading was investigated to recommend an optimal cost-effective Cr/Ni composition of Nb-alloyed austenitic class steels. Here, the static oxidation and transient thermo-mechanical behavior of three austenitic steels with different Cr/Ni alloying levels were investigated and compared for variety of working conditions. Static oxidation was performed between 900 °C and 1000 °C in air for 400 h. The critical temperature which increases spallation during static oxidation was determined for each of the steel alloying levels. In addition, thermal cycling of a constrained specimen was done with varying upper cycling temperatures between 850 °C and 1000 °C. SEM and TEM analyses were supported by thermodynamic simulation of the phases precipitated in the metal matrix and the structure of formed oxide layers. These studies were used to determine the mechanisms of degradation of thermo-mechanically loaded Cr/Ni austenitic steels at extreme high temperatures. A recommendation for a cost-effective Cr/Ni alloying level for different working conditions was determined.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Hybrid Al Casting + AM Components for Automotive Applications

Although casting Aluminum (Al) alloys is widely used for automotive application, the conventional casting process is showing limitations for modern vehicle production. A hybrid manufacturing method that is capable of fabricating automotive structures with tailored functionality and tuned attributes at a high production rate is proposed in this project, utilizing the merits of conventional casting methods and additive manufacturing (AM) methods. Ford is interested in supplementing conventional casting processes (e.g., shape casting, high pressure die casting) with local modifications to geometry and microstructure using additive manufacturing techniques. Two additive manufacturing methods, wire-arc and laser hot-wire directed energy deposition AM process, were evaluated by deposition of 4043 filler wire onto high-pressure die cast and permanent mold cast Al-Si alloys. The feasibility of this hybrid manufacturing method was determined through trial deposition and evaluation of defects, microstructure, and mechanical properties. Laser hot-wire deposition was found to be beneficial for this application with low porosity, a refined microstructure, and mechanical properties similar to those reported in the literature for 4043. The mechanical properties of the interface between the A356 casting and deposited 4043 were found to be controlled by the weaker deposit material.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Prostaglandin E2 Increased Rat Cortical Bone Mass When Administered Immediately Following Ovariectomy

To investigate the effects of ovariectomy and the simultaneous administration of prostaglandin E2 (PGE2) on rat tibial shaft cortical bone histomorphometry, thirty-five 3 month-old female Sprague-Dawley rats were either ovariectomized (OVX), or sham ovariectomy (sham-OVX). The OVX rats were divided into three groups and treated with 0, 1 and 6 mg PGE2/kg/day for 90 days. The double fluorescent labeled undecalcified tibial shaft cross sections (proximal to the tibiofibular junction) of all the subjects were used for histomorphometry analysis. No differences in cross-sectional area and cortical bone area were found between sham-OVX and OVX controls, but OVX increased marrow area, intracortical porosity area and endocortical eroded perimeter. Periosteal and endocortical bone formation rates decreased with aging yet OVX prevented these changes. These OVX-induced increases in marrow area and endocortical eroded perimeter were prevented by 1 mg PGE2/kg/day treatment and added bone to periosteal and endocortical surfaces and to the marrow cavity. At the 6 mg/kg/day dose level, PGE2-treated OVX rats increased total tissue area, cortical bone area, marrow trabmular bone area, minimal cortical width and intracortical porosity area, and decreased marrow area compared to basal, sham-OVX and OVX controls. In addition, periosteal bone formation was elevated in the 6 mg PGE2/kg/day-treated OVX rats compared to OVX controls. Endocortical eroded perimeter increased from basal and sham-OVX control levels, but decreased from OVX control levels in the 6 mg PGE2/kg/day-treated OVX rats. Our study confirmed that ovariectomy does not cause osteopenia in tibial shaft cortical bone in rats, but it does stimulate endocortical bone resorption and enlarges marrow area. The new findings from the present study demonstrate that PGE2 prevents the OVX-induced increases in endocortical bone resorption and marrow area and adds additional bone to periosteal and endocortical surfaces and to marrow cavity to increase total bone mass in the tibial shaft of OVX rats when given immediately following ovafiectomy.

Ke, Hua Zhu↗
NASA NTRS1992

Prostaglandin E2 Prevents Ovariectomy-Induced Cancellous Bone Loss in Rats

The object of this study was to determine whether prostaglandin E2, (PGE2) can prevent ovariectomy induced cancellous bone loss. Thirty-five 3-month-old female Sprague-Dawley rats were divided into two groups. The rats in the first group were ovariectomized (OVX) while the others received sham operation (sham-OVX). The OVX group was further divided into three treatment groups. The daily doses for the three groups were 0,1 and 6 mg PGE2/kg for 90 days. Bone histomorphometric analyses were performed on double-fluorescent-labeled undecalcified proximal tibial metaphysis (PTM). We confirmed that OVX induces massive cancellous bone loss (-80%) and a higher bone turnover (+143%). The new findings from the present study demonstrate that bone loss due to ovarian hormone deficiency can be prevented by a low-dose (1 mg) daily administration of PGE2. Furthermore, a higher-dose (6 mg) daily administration of PGE2 not only prevents bone loss but also adds extra bone to the proximal tibial metaphyses. PGE, at the 1-mg dose level significantly increased trabecular bone area, trabecular width, trabecular node density, density of node to node, ratio of node to free end, and thus significantly decreased trabecular separation from OVX controls. At this dose level, these same parameters did not differ significantly from sham-OVX controls. However, at the 6-mg dose level PGE2, there were significant increases in trabecular bone area, trabecular width, trabecular node density, density of node to node, and ratio of node to free end, while there was significant decrease in trabecular separation from both OVX and sham-operated controls. The changes in indices of trabecular bone microanatomical structure indicated that PGE2 prevented bone loss as well as the disconnection of existing trabeculae. In summary, PGE2, administration to OVX rats decreased bone turnover and increased bone formation parameters resulting in a positive bone balance that prevented bone loss (in both lower and higher doses) and added extra bone to metaphyses of OVX rats (in higher dose). These findings support the strategy of the use of bone stimulation agents in the prevention of estrogen depletion bone loss (postmenopausal osteoporosis).

Ke, Hua Zhu↗