The calculation of proportional counter energy deposition spectra from experimental data. II - Very small energy losses and high energy delta rays
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Baily, N. A.↗
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A dimensionless number for high-throughput design of multi-principal element alloys in directed energy deposition
The present study demonstrates the development of a dimensionless number to predict the build height in the additive manufacturing technique of directed energy deposition (DED). The build height can also be used to estimate the dendrite arm spacing and, thus, the cooling rate in the fabrication of samples. A baseline sample, 316L stainless steel, was used to fit the build height to the dimensionless number. A range of process parameters, including laser power, laser feed rate, powder flow rate, layer thickness, and hatch spacing, were varied. Based upon dendrite arm spacing, the estimated cooling rate varied between 102 and 104 K/s. Using the fitted relationship for the stainless steel, high-throughput (HT) processing of multi-principal element alloys (MPEAs) was performed. For this study, HT is the ability to fabricate a batch of 25 bulk samples (∼1 cm3) with different compositions within a 5-h period with ±10 at. % accuracy. A range of compositions using in situ alloying of elemental powders in the Fe–Ni–Cr–Mo system were made. The MPEAs' build height followed the same relationship to the dimensionless number as the 316L alloy. The dimensionless number predicts both macro and meso-scale features in HT processing, thus offering a design tool for choosing process parameters in DED additive manufacturing. Also, the ability to control or increase cooling rates can enhance the ability to promote metastability as well as control meso-scale chemical distributions of alloy samples.
Islam, Zahabul (ORCID:0000000169613209)↗
Digital bead modeling for wire-arc directed energy deposition
Prediction of 2D cross-section and full 3D geometry for stacked weld beads is critical for the outcome of wire-arc directed energy deposition (DED) parts; however, most additive path planning software packages model beads as extrusions of a rectangle. Weld beads are not rectangular, and the resulting shape is dependent upon physics effects at the moment of deposition. Physics phenomena such as the geometry of the underlying surface, the heat input of the welding mode, and the direction of gravity contribute to bead shape. Here, this paper presents a novel implicit modeling method that discretizes a 2D area or 3D volume of space into pixels or voxels and constructs fields based on these physics phenomena. The fields are combined using a weighting scheme trained on 3D scan measurements of welds and wire-arc DED prints. Pixels or voxels are added until the known amount of deposited volume has been achieved. Thereby, a strong conservation of mass principle is applied to the process. Utilizing machine learning techniques, the present model can be trained on a database of scans allowing for the representation of a wide variety of prints. Results show that this method can produce predictions with realistic bead morphology and sub-millimeter form error.
Bead geometry modeling↗
Heterogeneous techniques for rescaling energy deposits in the CMS Phase-2 endcap calorimeter
We present the porting to heterogeneous architectures of the algorithm used for applying linear transformations of raw energy deposits in the CMS High Granularity Calorimeter (HGCAL). This is the first heterogeneous algorithm to be fully integrated with HGCAL’s reconstruction chain. After introducing the latter and giving a brief description of the structural components of HGCAL relevant for this work, the role of the linear transformations in the calibration is reviewed. The many ways in which parallelization is achieved are described, and the successful validation of the heterogeneous algorithm is covered. Detailed performance measurements are presented, including throughput and execution time for both CPU and GPU algorithms, therefore establishing the corresponding speedup. We finally discuss the interplay between this work and the porting of other algorithms in the existing reconstruction chain, as well as integrating algorithms previously ported but not yet integrated.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
The 650 °C Tensile Deformation of Graded IN718-René41 Superalloy Fabricated by Laser Blown-Powder Directed Energy Deposition
The microstructure and 650 °C tensile properties of a compositionally graded IN718-René41 (718-R41) superalloy fabricated by laser blown-powder directed energy deposition (DED-LB/M) are investigated to understand structure–property relationships and baseline tensile properties. Digital Image Correlation (DIC), in situ neutron diffraction, and conventional characterization techniques are performed to study the as-built and heat-treated states. The applied heat treatment generates static recrystallization and equiaxed grains in 718-rich compositions, while R41-rich compositions remain partially or un-recrystallized possibly influenced by a higher MC carbide fraction (>0.5%). The yield strengths of the 718 and R41 sections in the heat-treated state are comparable to wrought forms but the graded compositions show weakness due to unoptimized heat treatment. Diffraction elastic constants first decrease and then increase along the 718-R41 composition gradient, while a small difference is observed between the as-built and heat-treated states and γ, γ′ phases. Overall, the compositionally graded region shows a smooth transition in the elastic properties. Grain-level load transfer from the (220) to (200) grains shows compositional dependence, and qualitatively agrees with DIC-measured macroscopic yield strength. Within the (200) grains, the γ/γ′ phases deform elastically until the γ phase yields and afterwards, the γ′ phase takes load from the γ phase.
Huang, Shenyan (ORCID:0000000196528114)↗
Processability and Material Behavior of NiTi Shape Memory Alloys Using Wire Laser-Directed Energy Deposition (WL-DED)
Utilizing additive manufacturing (AM) techniques with shape memory alloys (SMAs) like NiTi shows great promise for fabricating highly flexible and functionally superior 3D metallic structures. Compared to methods relying on powder feedstocks, wire-based additive manufacturing processes provide a viable alternative, addressing challenges such as chemical composition instability, material availability, higher feedstock costs, and limitations on part size while simplifying process development. This study presented a novel approach by thoroughly assessing the printability of Ni-rich Ni55.94Ti (Wt. %) SMA using the wire laser-directed energy deposition (WL-DED) technique, addressing the existing knowledge gap regarding the laser wire-feed metal additive manufacturing of NiTi alloys. For the first time, the impact of processing parameters—specifically laser power (400–1000 W) and transverse speed (300–900 mm/min)—on single-track fabrication using NiTi wires in the WL-DED process was examined. An optimal range of process parameters was determined to achieve high-quality prints with minimal defects, such as wire dripping, stubbing, and overfilling. Building upon these findings, we printed five distinct cubes, demonstrating the feasibility of producing nearly porosity-free specimens. Notably, this study investigated the effect of energy density on the printed part density, impurity pick-up, transformation temperature, and hardness of the manufactured NiTi cubes. The results from the cube study demonstrated that varying energy densities (46.66–70 J/mm3) significantly affected the quality of the deposits. Lower to intermediate energy densities achieved high relative densities (>99%) and favorable phase transformation temperatures. In contrast, higher energy densities led to instability in melt pool shape, increased porosity, and discrepancies in phase transformation temperatures. These findings highlighted the critical role of precise parameter control in achieving functional NiTi parts and offer valuable insights for advancing AM techniques in fabricating larger high-quality NiTi components. Additionally, our research highlighted important considerations for civil engineering applications, particularly in the development of seismic dampers for energy dissipation in structures, offering a promising solution for enhancing structural performance and energy management in critical infrastructure.
Dabbaghi, Hediyeh↗
An analysis of energy deposition in a tissue equivalent proportional counter onboard the space shuttle
An improved prediction for space radiations in the lower earth orbits measured by the shuttle TEPC is obtained when energy loss straggling and chord length distribution of the detector are considered. A generalized analytic model is used to describe the energy deposition of direct ion interaction events in a micron-size detector. The transport calculation accounting for the shuttle configuration is accomplished by using a new version of HZETRN that has been extensively verified with laboratory and flight data. The agreement of predicted and measured lineal energy spectra is within 70% for the region above 2 keV/micrometer but within a factor of 2.3 underpredicted for the region below this value. The inclusion of indirect delta ray events in the model is needed before possible causes for the underprediction below 2 keV/micrometer can be assessed.
Flight Experiment↗
Production of mechanically-generated 316L stainless steel feedstock and its performance in directed energy deposition processing as compared to gas-atomized powder
The objective of this work is to study the feasibility of mechanically-generated feedstock for use in directed energy deposition (DED) processing. Mechanically-generated powder was created by machining 316L stainless steel bar stock followed by comminution of the resulting chips through oscillation ball milling. This methodology's production yield and processing time for the specifications of a commercially available DED system are presented along with resulting powder morphology. Performance of the mechanically-generated feedstock was compared to gas-atomized powder and evaluated based on the following figures of merit: flowability, printed part height, printed part density, and chemical compositional stability throughout processing. Mechanically-generated feedstock was created to meet deposition system requirements. Compared with gas-atomized powder, mechanically-generated powder did not flow as well through the powder-delivery system. Parts printed from mechanically-generated feedstock were generally taller than their counterparts from gas-atomized feedstock, but their densities were less predictable. As a result, chemical composition of prints using both feedstocks was within standard nominal compositions for 316L stainless steel.
36 MATERIALS SCIENCE↗
Energy deposition model in STREAM with photon transport
Recent efforts have been taken to implement a photon transport module for the neutron transport analysis code STREAM, considering the explicit photon energy distribution in the problem instead of using the locally deposition assumption as employed in previous STREAM versions. The current energy release model in STREAM based on the On-the-fly energy released per fission model is modified accordingly to account for the photon energy deposition computed explicitly by this module. The impacts of the modified energy release model with photon transport in STREAM on the power distribution, fuel temperature and other core parameters during depletion with feedback calculations are studied on several problems from the VERA benchmark suit. Overall, the photon transport provides a better power map for depletion and feedback calculations, especially when strong gamma emitters are present. The fuel temperature, in general, is decreased when the photon transport is employed because fission gammas have been transported out of their birthplace. The new energy deposition model in STREAM with photon transport indicates that gamma energy accounts for about 9.7% of the total energy released in a fresh VERA5 2D core and rises to 10.5% at the End of Cycle. Around 2.5% of the total energy released will be deposited in the coolant in this 2D core. (authors)
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
GRCop-42: Comparison between laser powder bed fusion and laser powder direct energy deposition
This study involves a comparative analysis of additively manufactured GRCop-42 specimens produced using two processes: laser-powder bed fusion (L-PBF) and laser powder direct energy deposition (LP-DED). The investigation characterizes a range of material attributes, including surface topography, internal defects, microstructural features, quasi-static mechanical properties, and fractographic characteristics. The findings demonstrate that, despite the specimens being fabricated with the same base material, the resulting material properties vary significantly between the two additive manufacturing processes. As such, material properties cannot be presumed to be uniform across different manufacturing methods. Consequently, material characterization must be conducted for individual manufacturing processes based on specific parameters.
36 MATERIALS SCIENCE↗
Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods
For standard Additive Manufacturing (AM) processes, traditional path planning typically relies on a 2.5-dimensional approach. In wire-arc directed energy deposition (DED), commonly referred to as wire-arc additive manufacturing (WAAM), this 2.5D approach inherently limits final near net shape due to the stair-step effect and restricts the maximum overhang angle achievable without part degradation. To achieve better near net shape and part quality, a 3D planning approach that modulates the tool tip position and angle without process changes is demonstrated in components containing up to 105° of unsupported overhang. The experimental methods are validated with half and fully enclosed cylinder sections containing 90° of overhang. The non-gravity aligned methods are then applied to a commercial WAAM system for a composite tool mold demonstrator part. As a result, the methods developed in this paper enable expansion of WAAM system capabilities to parts containing large overhangs without compromising the net shape or material structure of the resulting parts and without the need for a part positioner.
Additive manufacturing↗
Wire directed energy deposition of steel-aluminum structures using cold metal transfer process
In this study, a sharp transition from 316L stainless steel to 4043 aluminum alloy was fabricated using wire directed energy deposition (DED) via the cold metal transfer (CMT) process. The CMT process with its inherently low heat input, led to a significant reduction in intermetallic thickness at the bi-metallic interface compared to blown powder DED technique reported in the literature resulting in superior properties when compared to those of dissimilar steel-aluminum welds. Thermo-kinetic modeling confirmed that the intermetallic formation is through a classical nucleation and growth mechanism, and the fraction and thickness can be controlled by adjusting CMT process parameters to kinetically arrest or minimize the intermetallic formation. These findings underscore the efficacy of CMT-based wire DED for fabrication of steel-aluminum bi-metallic structures.
36 MATERIALS SCIENCE↗
Energy deposition rates by charged particles
A summary of measurements of the precipitation of electrons and positive ions (in the keV-MeV range) detected aboard eight rockets launched within the Energy Budget Campaign from Northern Scandinavia is given, together with corresponding satellite data. In some cases strong temporal variations of the downgoing integral fluxes were observed. The fluxes provide the background for the calculated ion production rates and altitude profiles of the energy deposition into the atmosphere at different levels of geomagnetic disturbance and cosmic noise absorption. The derived ion production rates by eneretic particles are compared to other night-time ionisation sources.
Torkar, K. M.↗
High-throughput, in situ imaging of multi-layer powder-blown directed energy deposition with angled nozzle
Laser metal additive manufacturing (AM) has become an increasingly popular technology due to its flexibility in geometry and materials. As one of the commercialized additive processes, powder-blown directed energy deposition (DED) has been used in multiple industries such as aerospace, automotive, medical device, etc. However, a lack of fundamental understanding remains for this process, and many opportunities for alloy development and implementation can be identified. A high-throughput, in situ DED system capable of multi-layer builds that can address these issues is presented here. In this work, implications of layer heights and energy density are investigated through an extensive process parameter sweep, showcasing the power of a high-throughput setup while also discussing multi-layer interactions.
47 OTHER INSTRUMENTATION↗
Implementation of disruptive designs for gas turbine components using direct energy deposition additive manufacturing
This research aims to develop a framework for establishing the correlation between in-situ monitoring data, process parameters, and microstructure evolution in blown-powder laser-directed energy deposition (DED) additive manufacturing (AM). To achieve this, a comprehensive manufacturing framework has been developed, spanning from in-situ data acquisition, melt-pool simulation, microstructure modeling, and statistical microstructure quantification. A machine learning-based surrogate model is constructed to predict melt pool geometry directly from in-situ coaxial camera data. The surrogate model is trained using outputs from a high-fidelity melt pool simulation, which provides accurate melt pool dimension data under varying process conditions. The predicted melt pool geometry is then used as input to a microstructure model to predict microstructural features. To rigorously compare and analyze microstructures, the project introduces statistical metrics that quantify differences based on key features such as morphology and texture. Microstructures are represented using advanced statistical descriptors including angular chord length distribution, two-point spatial statistics, orientation distribution function, and global spherical harmonic. These representations are used to compute four distinct “dissimilarity scores” that quantitatively capture differences in texture and morphology. This framework is demonstrated to enable automated calibration of simulation parameters by minimizing discrepancies between simulated and target microstructures. The technology developed in this project enables direct correlation between in-situ monitoring data and resulting microstructure, paving the way for adaptive microstructure control in metal AM. This capability strengthens the connection between process parameters and final material properties, facilitating more precise and reliable material design.
36 MATERIALS SCIENCE↗
Comparison of Energy Deposition in the Auroral Oval and Cap Regions for Cases Where Transpolar Structures Exist
For several cases where the full auroral zone is imaged and transpolar structures exist, we compare the total energy input to the auroral oval with the total energy input in the polar cap. This comparison is made for cases where auroral intensification near local midnight is and is not observed. Temporal evolution of the energy balance between the energy deposited in the oval and polar cap can be used to understand the mechanism that triggers substorms.
Spann, J. F., Jr.↗
Global atmospheric energy deposition by energetic electrons - Quantitative spatial and temporal characteristics inferred from the Atmospheric X-ray Imaging Spectrometer (PEM/AXIS) on UARS
The primary purpose of PEM/AXIS is to provide a global monitor of the energy input to the upper atmosphere due to energetic electrons. The design, development, and calibration of AXIS are described and an assessment of its excellent on-orbit performance is presented. The unique capabilities of X-ray imaging spectrometers to monitor the global patterns of electron energy deposition in the atmosphere are shown through an analysis of some specific cases during the first year of the UARS mission.
Chenette, D. L.↗
Laser Powder Directed Energy Deposition of Steels for Nuclear Applications
This comprehensive investigation examines the structure–property relationships in two nuclear alloy systems—Alloy 709 (A709) austenitic stainless steel and Grade 92 (G-92) ferritic/martensitic (F/M) steel—manufactured via directed energy deposition (DED) for sodium-cooled fast reactor applications. This study establishes the fundamental mechanisms for controlling microstructures for optimizing the mechanical performance of additively manufactured nuclear materials through systematic heat treatment optimization and multiscale characterization. As-deposited A709 steel develops a complex multiscale strengthening architecture consisting of a fine cellular solidification structure with diameter of 2-3 µm within10–50 µm grains, elevated dislocation densities from rapid thermal cycling, and grain boundary precipitates that activate concurrent Hall–Petch, dislocation, and precipitation hardening mechanisms to achieve exceptional properties [yield strength (YS): 603 MPa, ultimate tensile strength (UTS): 844 MPa, Vickers hardness: 220 HV] that achieve a 44% superior strength compared to that of the wrought material. Heat treatments produce different results. Solution annealing (SA) dissolves the cellular structure and reduces the hardness to 190 HV. Precipitation treatment (PT) keeps the cellular structure but adds carbides, allowing the hardness to reach 205 HV. The best approach combines both treatments (SA+PT) and creates uniform precipitate distributions with M 23 C 6 carbides at the grain boundaries and MX carbonitrides in the matrix, achieving a hardness of 195 HV. However, directional differences persist, with a 12%–15% strength variation between orientations due to the inherited layered microstructural architecture that survives aggressive heat treatment. While tensile testing at 550°C demonstrates 40%–50% thermal softening with dynamic strain aging, DED A709 steel still maintains a 71% higher YS than that of the wrought material. Ion irradiation studies (100–400 dpa) of DED A709 steel reveal progressive radiation damage with increasing void density and radiation-induced segregation causing nickel enrichment and chromium depletion, which will ultimately compromise mechanical properties. As-deposited G-92 exhibits exceptional strength (UTS: 1650–1700 MPa, 430 HV) through a complex microstructure containing both ferrite and martensite phases, a high geometrically necessary dislocation (GND) density (17.04×10 14 /m 2 ), and fine carbides. Heat treatments create distinct changes. Normalizing produces fresh martensite with the highest hardness (460 HV) and an increased GND density (20.23×10 14 /m 2 ). Tempering develops dual precipitation systems and reduces the hardness to 290 HV. The optimal approach uses sequential normalizing plus tempering, achieving balanced properties with the lowest hardness (250 HV) and a reduced GND density (11.01×10 14 /m 2 ). A processing-dependent anisotropy is observed: horizontal specimens achieve superior ductile behavior, while vertical specimens exhibit brittle failure. A tempering heat treatment successfully mitigates this anisotropic behavior by transforming the hard martensitic as-deposited structure into tempered martensite enabling both horizontal and vertical specimens to exhibit similar stress–strain characteristics with visible necking behavior. Remarkably, testing at 550°C reveals a reversal in the anisotropy, where as-deposited specimens achieve near isotropy with superior thermal stability (a 15%–20% strength reduction), while tempered specimens develop an orientation dependence with a 25%–30% strength reduction. Both alloy systems demonstrate that DED processing creates specimens with a superior strength through refined microstructural features, though with distinct strengthening mechanisms—austenitic through cellular structures and precipitates versus F/M through phase transformations and precipitates. Heat treatment optimization requires alloy-specific approaches, with A709 benefiting from controlled precipitation while G-92 requires careful phase transformation control. The results show that DED manufacturing can produce nuclear materials with exceptional performance, but directional effects and temperature-dependent behavior must be carefully considered for reactor component design and qualification.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗