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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

XRISM high-resolution X-ray spectroscopy of Cygnus X-1: Orbital and short-term variability of iron absorption

We present the first high-resolution spectroscopy of the black hole high-mass X-ray binary Cygnus X-1 with XRISM, including orbital-phase-resolved analyses and tentative evidence of short-term variability in the Fe K band on second timescales. Using data from the Performance Verification phase in 2024 April, we analyzed spectral variability across orbital phases with the Resolve microcalorimeter and the Xtend CCD imager. The unprecedented resolution of Resolve reveals variability in highly ionized Fe absorption lines. The absorption features show orbital-phase-dependent variability in column density, ionization state, and blueshifted velocity, suggesting structural variations in the focused stellar wind along the line of sight. We also find indications of subtle broadening of the neutral Fe emission profile. In addition, intensity-sorted spectroscopy during dip phases suggests possible variability on timescales of a few seconds in the absorption features, consistent with cooler, denser, and lower-ionized gas clumps. Although the statistical significance is limited, these results hint that the stellar wind and the X-rays from the accretion disk around the black hole may interact on timescales as short as a few seconds. These XRISM results constrain wind-fed accretion in Cyg X-1 and highlight Resolve’s capability to probe plasma environments in high-mass X-ray binaries.

Astronomy and AstroPhysics↗
DOE OSTI2025

Quantifying the Thermodynamic Impacts on the Atmospheric Boundary Layer due to the Sea Breeze in the Coastal Houston Region

The atmospheric boundary layer (ABL) is unique in coastal regions because of kinematic and thermodynamic influences from continental and marine environments. Sea-breeze (SB) circulations act to equilibrate the land–sea temperature gradient through advecting marine air onshore. The strength of the SB varies in terms of stability, temperature, and moisture advection and influences air quality and weather forecasts. The Tracking Aerosol Convection Interactions Experiment (TRACER) collected a wealth of data on coastal boundary layer evolution, including observations from uncrewed aerial systems (UASs). Vertical profiles of temperature, humidity, and winds were collected by the OU CopterSonde UAS from June to September in the coastal region of Houston. These profiles offer 5-m vertical resolution, on average, every 30 min through diurnal transitions, SB events, and nearby deep convection. During the campaign, CopterSonde observations were gathered through 17 SB events, six of which led to convection initiation. The UAS data can resolve the thermodynamic evolution and interactions between the SB and the preexisting convective boundary layer. Results show large variability across observed SBs and their impacts on temperature and moisture. The intensity of thermodynamic changes depends on the time of sea-breeze passage and influence from the Galveston Bay Breeze, a secondary marine circulation commonly observed in this region. In quantifying the spectrum of SB impacts, equivalent potential temperature θ e is used to contextualize its role in convection initiation and evolution. In conclusion, while all SBs tend to increase θ e from moisture advection, the rate and timing of the θ e rise can distinguish convective from nonconvective cases.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Estimating Interplanetary Magnetic Field Conditions at Mercury's Orbit From MESSENGER Magnetosheath Observations Using a Feedforward Neural Network

Abstract Mercury's small magnetosphere is embedded in the dynamic and intense solar wind environment characteristic of the inner heliosphere. Both the magnitude and orientation of the interplanetary magnetic field (IMF) significantly influence the solar wind‐magnetospheric interaction at Mercury, driving phenomena such as magnetic reconnection. The MErcury Surface, Space Environment, Geochemistry and Ranging (MESSENGER) spacecraft provided in‐situ magnetic field measurements of the solar wind, the magnetosheath, and the magnetosphere along each orbit. However, it is a challenge to directly assess the IMF's impact on Mercury's plasma environment due to the temporal separation between observations within the solar wind and the magnetosphere, especially in the absence of an upstream monitor. Here, we present a feedforward neural network (FNN) trained on a subset of magnetosheath observations to estimate the strength and orientation of the IMF upstream of the bow shock. Utilizing magnetosheath magnetic field, cylindrical spatial coordinates, and heliocentric distance measurements, the FNN predicts upstream IMF conditions with an score of 0.70 and mean averaged error of 5.3 nT, thereby greatly decreasing the temporal separation between IMF estimates and magnetospheric measurements throughout the MESSENGER mission. This approach yields IMF estimates for all magnetosheath data measured by MESSENGER, providing a useful tool for future investigations of the IMF impact on Mercury's magnetosphere. This method will be integrable with the dual‐spacecraft BepiColombo magnetosheath measurements, providing useful estimates of upstream IMF conditions particularly during the extended periods in which neither spacecraft sample the solar wind. Our results demonstrate the utility of machine learning techniques on advancing space science research.

Bowers, Charles F.↗
DOE OSTI2025

Information theory optimization of signals from small-angle scattering measurements

Small-angle X-ray scattering (SAXS) of particles in solution informs on the conformational states and assemblies of biological macromolecules (bioSAXS) outside of cryo- and solid-state conditions. In bioSAXS, the SAXS measurement under dilute conditions is resolution limited, and through an inverse Fourier transform, the measured SAXS intensities directly relate to the physical space occupied by the particles via the P (r)-distribution. Yet, this inverse transform of SAXS data has been historically cast as an ill-posed, ill-conditioned problem requiring an indirect approach. Here, we show that through the applications of matrix and information theories, the inverse transform of SAXS intensity data is a well-conditioned problem. The so-called ill-conditioning of the inverse problem is directly related to the Shannon number. By exploiting the oversampling enabled by modern detectors, a direct inverse Fourier transform of the SAXS data is possible, provided the recovered information does not exceed the Shannon number. The Shannon limit corresponds to the maximum number of significant singular values that can be recovered in a SAXS experiment, suggesting this relationship is a fundamental property of band-limited inverse integral transform problems. This correspondence reduces the complexity of the inverse problem to the Shannon limit and maximum dimension. We propose a hybrid scoring function using an information theory framework that assesses both the quality of the model-data fit as well as the quality of the recovered P (r)-distribution. The hybrid score utilizes the Akaike information criteria and Durbin-Watson statistic that considers parameter-model complexity, i.e., degrees of freedom, and the randomness of the model-data residuals. The described tests and findings extend the boundaries for bioSAXS by completing the information theory formalism initiated by Peter B. Moore to enable a quantitative measure of resolution in SAXS, robustly determine maximum dimension, and more precisely define the best parameter model appropriately representing the observed scattering data.

Rambo, Robert P. [Science and Technology Facilitie↗
DOE OSTI2025

Bistable random momentum transfer in a linear on-chip resonator

Optical switches and bifurcation rely on the nonlinear response of materials. Here, we demonstrate linear temporal bifurcation responses in a passive multimode microresonator, with strongly coupled chaotic and whispering gallery modes (WGMs). In microdisks, the chaotic modes exhibit broadband transfer within the deformed cavities, but their transient response is less explored and yields a random output of the analog signal distributed uniformly from “0” to “1.” Here, we build chaotic states by perturbing the multimode microring resonators with densely packed silicon nanocrystals on the waveguide surface. In vivo measurements reveal random and “digitized” output that ONLY populates around 0 and 1 intensity levels. The bus waveguide mode couples first to chaotic modes, then either dissipates or tunnels into stable WGMs. This binary pathway generates high-contrast, digitized outputs. In conclusion, the fully passive device enables real-time conversion of periodic clock signals into binary outputs with contrasts exceeding 12.3 dB, data rates of up to 10 7 · bits per second, and 20 dB dynamic range.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

STRUCTURAL MODELING TO SUPPORT POST-YIELD ACCEPTANCE CRITERIA FOR SPENT NUCLEAR FUEL CLADDING

Spent nuclear fuel (SNF) is evaluated for structural failure during storage and transportation scenarios. The U.S. Department of Energy’s Spent Fuel and Waste Science and Technology (SFWST) program has sponsored significant research in quantifying mechanical loads on SNF during storage and transportation scenarios using experimental and modeling methods. The SFWST program has also performed significant research on measuring the mechanical behavior of irradiated SNF as defueled cladding segments and cladding with fuel pellets to measure composite behavior. This paper considers some of the key material data from the Sibling Pin testing and uses structural modeling and analysis methods that have been informed by testing to consider post-yield acceptance criteria for SNF cladding structural analysis. Test data published by Oak Ridge National Laboratory (ORNL) and Pacific Northwest National Laboratory (PNNL) are the foundation for informing the material behavior of the models developed in this study. In particular, four-point bend (4PB) tests of fueled and defueled cladding segments provide significant information about the bending failure mode of SNF. ORNL’s 4PB test data is on fueled cladding segments, so the composite behavior of SNF is demonstrated. This paper describes PNNL’s coincident beam model that was developed to approximate the composite behavior of SNF. This paper also presents PNNL’s structural dynamic finite element models of a cask tip-over scenario, which is predicted to cause the strongest mechanical loads on SNF of all postulated storage and transportation scenarios. SNF bending loads predicted in the cask tip-over scenario and cladding acceptance criteria beyond yield are considered, with justification based on the Sibling Pin test data. ASME Boiler and Pressure Vessel code stress intensity limits are also considered. The ultimate goal of this work is to aid in the justification of structural acceptance criteria for SNF cladding beyond the cladding’s irradiated yield strength for use in structural analysis of all storage and transportation scenarios.

Klymyshyn, Nicholas A.↗
DOE OSTI2024

Reviews and syntheses: Opportunities for robust use of peak intensities from high-resolution mass spectrometry in organic matter studies

Abstract. Earth's biogeochemical cycles are intimately tied to the biotic and abiotic processing of organic matter (OM). Spatial and temporal variations in OM chemistry are often studied using direct infusion, high-resolution Fourier transform mass spectrometry (FTMS). An increasingly common approach is to use ecological metrics (e.g., within-sample diversity) to summarize high-dimensional FTMS data, notably Fourier transform ion cyclotron resonance mass spectrometry (FT-ICR MS). However, problems can arise when FTMS peak-intensity data are used in a way that is analogous to abundances in ecological analyses (e.g., species abundance distributions). Using peak-intensity data in this way requires the assumption that intensities act as direct proxies for concentrations. Here, we show that comparisons of the same peak across samples (within-peak) may carry information regarding variations in relative concentration, but comparing different peaks (between-peak) within or between samples does not. We further developed a simulation model to study the quantitative implications of using peak intensities to compute ecological metrics (e.g., intensity-weighted mean properties and diversity) that rely on information about both within-peak and between-peak shifts in relative abundance. We found that, despite analytical limitations in linking concentration to intensity, ecological metrics often perform well in terms of providing robust qualitative inferences and sometimes quantitatively accurate estimates of diversity and mean molecular characteristics. We conclude with recommendations for the robust use of peak intensities for natural organic matter studies. A primary recommendation is the use and extension of the simulation model to provide objective guidance on the degree to which conceptual and quantitative inferences can be made for a given analysis of a given dataset. Broad use of this approach can help ensure rigorous scientific outcomes from the use of FTMS peak intensities in environmental applications.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Half-life determination of heavy ions in a storage ring considering feeding and depleting background processes

Heavy-ion storage rings have relatively large momentum acceptance which allows for multiple ion species to circulate at the same time. This needs to be considered in radioactive decay measurements of highly charged ions, where atomic charge exchange reactions can significantly alter the intensities of parent and daughter ions. In this study, we investigate this effect using the decay curves of ion numbers in the recent 205 Tl 81+ bound-state beta decay experiment conducted using the Experimental Storage Ring at GSI Darmstadt. To understand the intricate dynamics of ion numbers, we present a set of differential equations that account for various atomic and nuclear reaction processes—bound state beta decay, atomic electron recombination and capture, and electron ionization. By incorporating appropriate boundary conditions, we develop a set of differential equations that accurately simulate the decay curves of various simultaneously stored ions in the storage ring: 205 Tl 81+ , 205 Pb 81+ , 205 Pb 82+ , 200 Hg 79+ , and 200 Hg 80+ . Through a quantitative comparison between simulations and experimental data, we provide insights into the detailed reaction mechanisms governing stored heavy ions within the storage ring. Our approach effectively models charge-changing processes, reduces the complexity of the experimental setup, and provides a simpler method for measuring the decay half-lives of highly charged ions in storage rings.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Search by the SENSEI Experiment for Millicharged Particles Produced in the NuMI Beam

Millicharged particles appear in several extensions of the standard model, but have not yet been detected. These hypothetical particles could be produced by an intense proton beam striking a fixed target. We use data collected in 2020 by the SENSEI experiment in the MINOS cavern at the Fermi National Accelerator Laboratory to search for ultrarelativistic millicharged particles produced in collisions of protons in the NuMI beam with a fixed graphite target. The absence of any ionization events with 3 to 6 electrons in the SENSEI data allow us to place world-leading constraints on millicharged particles for masses between 30 to 380 MeV. This work also demonstrates the potential of utilizing low-threshold detectors to investigate new particles in beam-dump experiments, and motivates a future experiment designed specifically for this purpose. Published by the American Physical Society 2024

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Strategies for community-sourced biocuration in bioinformatics: a case study on MIBiG 4.0

Biocuration is essential to transform molecular sequence data into standardized, machine-readable resources. Such curated datasets enable comparative analysis, predictive modeling, and data integration across bioinformatics platforms. While professional biocuration is resource-intensive and usually limited to institutional settings, community-driven approaches can mobilize large-scale annotation of specialized datasets and are more resilient to disruptions in scientific funding. Here, we present a model for community-powered curation applied to the Minimum Information about a Biosynthetic Gene Cluster (MIBiG) repository. Through a framework of workflows for metadata capture, annotation validation, and contributor coordination, the MIBiG 4.0 initiative recruited 267 scientists across 178 institutions from 33 countries, volunteering an estimated 4000 h of work. These efforts expanded the MIBiG repository by 22% and enhanced its usability in downstream molecular data analyses in comparative genomic analyses, natural product discovery, and machine learning applications. We provide strategies and actionable lessons for adopting this model, supporting the sustainability of curated bioinformatics resources central to nucleic acid research and related fields.

biocuration↗
DOE OSTI2026

Substitution or Shared Utilization? Intrahousehold Vehicle Use in Mixed-Powertrain Households

While previous research has focused heavily on understanding the factors deriving alternative fuel vehicle adoption rates, there remains a significant gap in understanding how households distribute mileage across different powertrains. This study utilizes data from the 2022 Next Generation National Household Travel Survey to investigate vehicle miles traveled within a sample of 150 plug-in electric vehicle (PEV)-owning households (in which at least one battery electric vehicle is present), characterizing how different powertrains are integrated into daily mobility. Leveraging a Seemingly Unrelated Regression (SUR) framework the study jointly models the utilization of PEVs, hybrid electric vehicles (HEV), and internal combustion engine vehicles (ICEVs) while accounting for household-level substitution effects. The results provide evidence of an asymmetric substitution effect. In households with mixed-powertrain configurations, the ICEV captures a substantially higher share of household miles (compared with the PEV), acting as a utility sponge. Conversely, the model identifies specific socioeconomic and geographic cohorts that prioritize PEV as the primary household workhorse, indicating a systematic sorting effect. Although the sample size limits broader generalizability, these findings suggest that PEVs are used for frequent, specific routine-intensive roles, whereas the ICEV remains a specialized utility vehicle. These insights highlight distinct intrahousehold vehicle use behaviors that are often obscured by aggregate fleetwide statistics.

25 ENERGY STORAGE↗
DOE OSTI2026

Desmearing Bonse–Hart USANS data using Bayesian Gaussian process regression

Ultra-small-angle neutron scattering (USANS) enables access to micrometer-scale structures but is intrinsically affected by strong, anisotropic resolution smearing arising from slit-geometry optics. As a result, recovery of the intrinsic scattering intensity constitutes an ill-posed inverse problem, and commonly used iterative desmearing methods lack rigorous uncertainty quantification. We present a Bayesian desmearing framework for slit-geometry USANS based on Gaussian process regression. In this approach, the scattering intensity is modeled as a smooth random function, and the instrumental point spread function is incorporated explicitly as a forward operator. The resulting formulation yields a closed-form maximum a posteriori solution with well-defined credibility intervals. Computational benchmarks and experimental validation using combined USANS and small-angle neutron scattering (SANS) measurements demonstrate that the framework enables stable desmearing, suppresses experimental noise, and preserves physically meaningful structural features under realistic conditions.

Tung, Chi-Huan [Oak Ridge National Laboratory (ORN↗
DOE OSTI2025

Fungal Spore Seasons Advanced Across the US Over Two Decades of Climate Change

Abstract Phenological shifts due to climate change have been extensively studied in plants and animals. Yet, the responses of fungal spores—organisms important to ecosystems and major airborne allergens—remain understudied. This knowledge gap limits our understanding of their ecological and public health implications. To address this, we analyzed a long‐term (2003–2022), large‐scale (the continental US) data set of airborne fungal spores collected by the US National Allergy Bureau. We first pre‐processed the spore data by gap‐filling and smoothing. Afterward, we extracted 10 metrics describing the phenology (e.g., start and end of season) and intensity (e.g., peak concentration and integral) of fungal spore seasons. These metrics were derived using two complementary but not mutually exclusive approaches—ecological and public health approaches, defined as percentiles of total spore concentration and allergenic thresholds of spore concentration, respectively. Using linear mixed‐effects models, we quantified annual shifts in these metrics across the continental US. We revealed a significant advancement in the onset of the spore seasons defined in both ecological (11 days, 95% confidence interval: 0.4–23 days) and public health (22 days, 6–38 days) approaches over two decades. Meanwhile, total spore concentrations in an annual cycle and in a spore allergy season tended to decrease over time. The earlier start of the spore season was significantly correlated with climatic variables, such as warmer temperatures and altered precipitations. Overall, our findings suggest possible climate‐driven advanced fungal spore seasons, highlighting the importance of climate change mitigation and adaptation in public health decision‐making.

Environmental Sciences & Ecology↗
DOE OSTI2026

Knowledge-guided learning with curated prior genetic biomarkers for robust model interpretation

Abstract Motivation Knowledge-guided learning offers effective and robust model training strategies in data-scarce settings by incorporating established domain knowledge, thereby enhancing generalization, robustness, and interpretability. By contrast, conventional deep learning approaches rely purely on data-driven learning, which can limit robust model interpretability, particularly in high-dimensional settings with limited size samples. In computational biology, knowledge-guided learning has primarily leveraged network- and structural-based knowledge, leading to biologically interpretable representations and enhanced predictive performance compared to conventional approaches. However, curated biomarkers, one of the most accessible forms of biological knowledge, remain largely unexplored within knowledge-guided paradigms. Results In this study, we propose a model-agnostic training paradigm, Biomarker-driven Explainable Prior-guided Learning (BioExPL), that can be applied to any neural networks that incorporates curated prior knowledge. BioExPL enforces neural networks to reflect curated biomarker priors in their latent representations through a novel knowledge-alignment loss. BioExPL consistently demonstrated significantly improved predictive performance and enhanced model interpretability with minimized computational overhead in simulation studies and intensive experiments on multiple cancer datasets. BioExPL not only integrates prior curated knowledge into the model but also accurately identifies unknown associated signals additionally. BioExPL is model-agnostic and domain-independent, enabling its integration into diverse neural network architectures. Availability and implementation The open-source is publicly available at: https://github.com/datax-lab/BioExPL.

Baek, Beomsu [Department of Computer Science, Univ↗
DOE OSTI2025

Optimization of Scrap Melting Using an Electric Arc in Steel Manufacturing

Steel industry is crucial to the national economy and security. Around 67% of crude steel in the U.S is produced in electric arc furnaces (EAF), which is energy intensive. Around 140 EAFs operate in the U.S., consuming about 8.6x10 7 MMBtu/year of electricity. One of major challenges for EAFs includes maximizing the efficiency of the electrical energy provided in the form of electric arcs to melt various scrap mixes. To address this issue, a computational fluid dynamics (CFD) methodology is chosen to analyze scrap melting using the electric arc. Due to complex furnace phenomena and the wide variety of potential scenarios, high performance computing (HPC) is essential to yield comprehensive and detailed CFD analyses and systematic parametric studies for optimized EAF operation. The objectives are to 1) simulate scrap melting using electric arc, 2) evaluate electrode/arc position for optimum scrap melting and 3) establish reduced order model for CFD data-base for fast model calculation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Distinguishing isotropic and anisotropic signals for X-ray total scattering using machine learning

Understanding structure–property relationships is essential for advancing technologies based on thin films. X-ray pair distribution function (PDF) analysis can access relevant atomic structure details spanning local-, mid- and long-range structure. While X-ray PDF has been adapted for thin films on amorphous substrates, measurements on single-crystal substrates are necessary to accurately determine structure origins for some thin film materials, especially those for which the substrate changes the accessible structure and properties. However, when measuring films on single-crystal substrates, high-intensity anisotropic Bragg spots saturate 2D detector images, overshadowing the thin films' isotropic scattering signal. This renders previous data processing methods for films on amorphous substrates unsuitable for films on single-crystal substrates. To address this measurement need, we developed IsoDAT2D, an innovative data processing approach using unsupervised machine learning algorithms. The program combines dimensionality reduction and clustering algorithms to separate thin film and single-crystal substrate X-ray scattering signals. We use SimDAT2D , a program we developed to generate simulated thin film data, to validate IsoDAT2D . Here we also use IsoDAT2D to isolate X-ray total scattering signal from a thin film on a single-crystal substrate. The resulting PDF data are compared with similar data processed using previous methods, especially substrate subtraction for single-crystal and amorphous substrates. PDF data from IsoDAT2D -identified X-ray total scattering data are significantly better than from single-crystal substrate subtraction, but not as reliable as PDF data from amorphous substrate subtraction. With IsoDAT2D , there are new opportunities to expand PDF to a wider variety of thin films, including those on single-crystal substrates, with which new structure–property relationships can be elucidated to enable fundamental understanding and technological advances.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Energy Emissions Accounting Methods Can Determine Whether Direct Air Capture with Storage Achieves Net Removal

The voluntary carbon market within the United States has expanded rapidly in recent years and enabled private companies and other organizations to provide revenue streams to carbon dioxide removal (CDR) technologies. For a CDR technology to participate in the voluntary carbon market (VCM), the emissions associated with constructing and operating the technology must be less than the CO 2 captured from the atmosphere. Assessing the extent to which this is true for direct air capture with storage (DACS), a relatively energy-intensive CDR technology, strongly depends on the accounting method used to assess the emissions intensity of purchased energy. We simulate the hourly weather-dependent operation of sorbent- and solvent-based DACS in California, Louisiana, Texas, and Wyoming, representing a wide range of local weather and electric and natural gas grid compositions. In all cases, the single most important emissions accounting decision is the method used to estimate the emissions intensity of purchased grid electricity, which varies the calculated net removal by −1049% to +108%. All other factors influencing net removal introduce a variation of at most ±14%. No electricity emissions accounting method is universally conservative across all scenarios, and none is objectively more accurate. High-spatiotemporal-resolution, high-quality, publicly available data sets and models for electricity emissions accounting do not currently exist and are urgently needed to enable standardization of emissions accounting methods to more accurately determine the true emissions impacts of DACS and other energy-intensive facilities.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Understanding the Thermal Physics and Metallurgy of Metal Big Area Additive Manufacturing

The research goal of this EPSCoR-DOE partnership is to mitigate defects in parts made using a new type of additive manufacturing (AM) process called metal Big Area Additive Manufacturing (m-BAAM). To realize this goal, the PIs will detect and correct defects in the part as it is being printed by combining fundamental knowledge of the thermal physics and metallurgy of m-BAAM with in-process sensor data. Developed at the DOE-funded Manufacturing Demonstration Facility at Oak Ridge National Laboratory, the m-BAAM process involves one or more robots working together to produce a part by fusing metal wire layer-by-layer using arc welding. The process can print large metal parts such as turbine blades, which is not possible using other AM processes. In addition, m-BAAM production rates are more than ten times faster than other AM processes while requiring one-tenth of the material cost. Despite their potential to become a critical force multiplier in the energy generation industry, m-BAAM parts may fail to print accurately due to retention of heat and uneven cooling. Overheating and anomalous cooling rates in turn can cause inconsistencies in the microstructure, leading to sudden failure when used in safety-critical applications. In other words, flaw formation in m-BAAM parts is governed by the thermal history – intensity and spatial distribution of heat inside the part during printing. The thermal history is a complex function of the part shape and process settings such as welding energy, path taken by the welding torch for deposition (tool path), wire feed rate, among others.

36 MATERIALS SCIENCE↗