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Young, Zachary

Publications and source records attributed to Young, Zachary.

Revealing melt flow instabilities in laser powder bed fusion additive manufacturing of aluminum alloy via in-situ high-speed X-ray imaging

Laser metal additive manufacturing technologies enable the fabrication of geometrically and compositionally complex parts unachievable by conventional manufacturing methods. However, the certification and qualification of additively manufactured parts are greatly hindered by the stochastic melt flow instabilities intrinsic to the process, which has not been explicitly revealed by direct observation. Here, we report the mechanisms of the melt flow instabilities in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-resolution synchrotron X-ray imaging. Here we identified powder/droplet impact, significant keyhole oscillation, and melting-mode switching as three major mechanisms for causing melt flow instabilities. We demonstrated the detrimental consequences of these instabilities brought to the process, and presented new understanding on the melt flow evolution and keyhole oscillation. This work provides critical insights into process instabilities during laser metal additive manufacturing, which may guide the development of instability mitigation approaches. The results reported here are also important for the development and validation of high-fidelity computational models.

36 MATERIALS SCIENCE↗

Effects of Particle Size Distribution with Efficient Packing on Powder Flowability and Selective Laser Melting Process

The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by a revolution powder analyzer). The effects of PSDs on the selective laser melting (SLM) process are identified by using in-situ high-speed X-ray imaging to observe the melt pool dynamics during the melting process. The results show that the powder beds made of powders with dense packing ratios exhibit larger build height during laser melting. The effects of PSD with efficient packing on powder flowability and selective laser melting process revealed in this work are important for understanding process uncertainties induced by feedstock powders and for designing mitigation approaches.

36 MATERIALS SCIENCE↗

Quantifying EGS Reservoir Complexity with an Integrated Geophysical Approach-Improved Resolution Ambient Seismic Noise Interferometry

The primary goal of the project was met, as improved resolution (from kilometers to tens/hundreds of meters and to a depth of at least 3 km) was added to the seismic interferometry-estimated parameters relative to the work reported in AltaRock Energy Inc. (2014) for the Dixie Valley Geothermal Wellfield. A procedure for initial fault identification, using seismic interferometry, was developed. The project team further improved, and applied a new, cost-effective, and non-invasive exploration method, developed and validated since 2010, during two previous experiments, at Dixie Valley and Soda Lake, Nevada. The method, initially designed for hydrothermal exploration, was adapted to EGS exploration conditions, which require deeper crustal information. Regions of elevated energy for both the 2-7 Hz and 5-15 Hz frequency bands are located above intersections of multiple faults. Thus, an unprecedented, innovative seismic field deployment and ambient seismic noise and signal processing were successfully used to estimate crustal structure and to identify fault locations at depths up to 3 km, at a cost per kilometer of survey that in some cases may be as much as ten times less than the cost of a controlled-source survey. Based on valid and useful seismic data collected and analyzed during Phase I, in Phase II the team has further quantified statistically the advantage of using seismic analysis, in combination with other geological and geophysical techniques, for EGS target identification. A power spectral density analysis of the passive-seismic empirical Green’s functions reveals significantly higher power recorded over the exploration area at the power plant, and in the drilling area, near the BB station 10201, especially on the horizontal components. In this study, the most important relationship observed during the prior report, namely the one between velocity and temperature was explored. The areas that show anomalously high predicted temperature in the geostatistics occur where multiple faults intersect. Not surprisingly, such areas span between the Dixie Valley range front fault and the basin-ward Piedmont faults, in the vicinity of numerous wells. These locations also fall in the area of high EGS favorability from the prior 2014 study. The anomalies also coincide with the high power spectral density values. The result of altering all favorability criteria for the new data reached a maximum of 1/8th of a point and were not large enough to change any favorability value reported in the 2014 study. The new data reinforce the results obtained from the previous 2014 study. The current high-resolution ambient seismic noise project provided excellent results in defining faults in the wellfield. As such the identification of known faults by the project demonstrated the utility of this method for identifying faults at an exploration stage in geothermal development. Such fault identification, while extremely useful in exploration investigation, has not added sufficient new data for the generation of significantly different DVGW favorability maps in the current project. We believe the cost savings of our passive-seismic technique for EGS, over common industry active-source survey techniques, may have a minimum of 30%, and a maximum of 90%. There are many significant non-cost benefits of passive seismic surveys. Our passive-source method provides an environmentally-friendly seismic survey with minimal to negligible impacts. The economic benefit is greater EGS project feasibility.

15 GEOTHERMAL ENERGY↗