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DOE OSTI2025

High-Fidelity CFD Simulation of Mixed Convection and Forced Convection in a Pebble Bed Test Reactor Core

The Hermes low-power [35-MW(thermal)] reactor will be built and operated by Kairos Power LLC (KP) to demonstrate its fluoride salt-cooled high-temperature reactor (FHR) technology. In the KP FHR, the reactor core is composed of randomly packed pebbles with TRISO fuel particles inside with FLiBe flow upward through the core acting as a coolant. Previous numerical and experimental studies have been limited to either a small-size bed or to a lack of detailed measurements for heat transfer. Here, to address the lack of high-fidelity heat transfer data in a real-size FHR core, in this study, we simulated a pebble bed core with 34 374 pebbles randomly packed, similar to the Hermes reactor's size. The core radius was 14 times that of the pebble diameter, while the core height was 45 times. In this work, we were particularly interested in a mixed convection regime, where buoyancy is important. Therefore, we performed several large-eddy simulations at different Reynolds numbers (160 to 1000) with gravitational force included. The spectral element computational fluid dynamics code NekRS with graphics processing unit acceleration was used for this study. The low-Mach number approximation was applied to address property changes in the FLiBe and to account for buoyancy. A pure hexahedral mesh with 60 million elements was generated by the Voronoi cell method. At the polynomial order of 5, the total degrees of freedom was 7.5 billion. The developed case in this work is the first of its kind in terms of size and complexity. The local numerical data across the domain were obtained and compared with empirical correlations. After examining the data, we found the following conclusions. For pressure drop, the Reger correlation predicted less than a 5% error. On the other hand, for heat transfer, the Wakao correlation outperformed the others. Based on our findings, we recommend the use of the Wakao correlation for the Nusselt number calculation, and for pressure drop, the KTA (Kerntechnischer Ausschuss) correclation, among the available experimental correlations. In conclusion, the Reger direct numerical simulation-driven correlation for pressure drops should also be considered, given its best agreement with our calculations.

Mixed Convection↗

DOE OSTI2026

Towards High-Speed friction stir welding of 25 mm Thick AA2139-T8: tool innovation and process development

Joining thick plates (≥ 12 mm) of aluminum (Al) alloys is challenging due to high tool forces, uneven material flow, and non-uniform heat distribution through the material’s thickness. Recent advancements in tool design and welding parameters for friction stir welding (FSW) in thick plates butt joining have encountered a developmental plateau, highlighting the need for innovative approaches to overcome existing limitations. Here, this study focuses on the systematic development of single-pass and double-pass FSW processes for high-strength aluminum alloy AA2139-T8, to improve joint efficiency and enable high-speed welding capabilities. Experimental evidence is presented for a novel tool design with opposing pin threads, enabling high-speed (178 mm/min) single-pass friction stir butt welding of 25 mm thick AA2139-T8. A series of FSW trials was conducted both in air and with a trailing water spray, using steel backing plates (BPs) to investigate the impact of quenching and cooling rates on process response and joint performance. A joint efficiency of 83% was attained using the novel tool features and effectively controlling process forces and thermal boundary conditions.

AA2139-T8↗

DOE OSTI2021

Long-term shifts in feedbacks among glacier surface change, melt generation and runoff, McMurdo Dry Valleys, Antarctica

Glaciers of the McMurdo dry valleys (MDVs) Antarctica are the main source of streamflow in this polar desert. Because summer air temperatures hover near 0°C small changes in the energy balance strongly affect meltwater generation. In this work, we demonstrate that increased surface roughness, which alters the turbulent transfer of energy between the ice surface and atmosphere, yields a detectable increase in meltwater runoff. At low elevations on the glaciers, basin-like topography became significantly rougher over 13 years between repeat lidar surveys, yielding greater melt. In contrast, the smoother ice at higher elevation exhibited no detectable change in roughness. We pose a conceptual model of the cycle of glacier surface change as a result of climate forcing whereby glacier surfaces transition from being dominated by sublimation to becoming increasingly melt-dominated, which is reversible under prolonged cool periods. This research advances our understanding of warm season effects on polar glaciers.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

From bulk to surface: Structure and dynamics of amorphous alumina from deep potential molecular dynamics

Understanding the atomic-scale structure and dynamics of amorphous oxide surfaces is essential for interpreting their chemical reactivity, mechanical stability, and interfacial behavior, yet direct experimental characterization remains challenging. We employ Deep Potential (DP) molecular dynamics to generate large-scale, ab initio -quality models of amorphous Al 2 O 3 bulk glasses and melt-quenched free surfaces, enabling a quantitative analysis of both structure and relaxation dynamics with statistical confidence inaccessible to direct ab initio simulation. The trained DP model reproduces experimental liquid and glass structure, captures the cooling-rate dependence of the bulk glass transition, and corrects systematic biases in the polyhedral populations predicted by widely used classical force fields. At the free surface, mass density recovers to bulk values over ~10 Å, while local coordination requires a slightly wider subsurface region to fully converge. The outermost layer is oxygen-enriched, exhibits altered polyhedral connectivity with contracted Al–O bonds, and hosts a broad population of under-coordinated motifs (notably AlO 3 and OAl 2 ) whose abundances are governed by glass stability. These under-coordinated surface motifs exhibit distinct vibrational signatures and occur as locally paired Lewis acid and Brønsted base sites consistent with bond-valence compensation, yet remain spatially dispersed rather than aggregating into extended clusters. Despite this pronounced structural heterogeneity, surface relaxation and the glass-transition temperature remain comparable to their bulk counterparts, suggesting that the disordered surface is kinetically stable once formed. Together, these results establish a molecular-level picture of amorphous alumina surfaces and demonstrate the capability of machine-learned potentials to resolve structure–property relationships in disordered oxide interfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Numerical analysis of air dehumidification through electrospray-enhanced vortical flow cyclone separator

The dehumidification of air is a highly energy-intensive process, typically requiring vapor compression systems to cool the air significantly below its dew point temperature. Here, this study numerically investigates air dehumidification achieved by electrostatic and dielectrophoresis forces in a converging duct and centrifugal principles in cyclone separators. An electrospray was employed to energize water droplets, which then captured water vapor via dielectrophoresis. A novelty of the present study is the inclusion of a cyclone separator positioned downstream of the electrospray. This combination increased the dehumidification efficiency and controlled the flow of the condensate. By integrating electrospray technology and applying an electric field, this study examines the impact of particle separation efficiency, pressure drops, and cyclone performance on air dehumidification. The control parameters for air dehumidification were investigated. Three cyclones were modelled for airflow rates of 5 cubic feet per minute [cfm] (0.0024 m 3 /s), 38 cfm (0.0179 m 3 /s), and 200 cfm (0.094 m 3 /s). The results indicated air dehumidification was up to 5.7 % under environmental conditions, similar to those used to validate the CFD model. The degree of air dehumidification was primarily influenced by the electric charge acquired by the water droplets, their flight trajectory, and the vorticity intensity within the cyclone. Air dehumidification could increase by up to 13 % by increasing the number of droplets injected into the air stream, the flight time, and the electrical charge. The breakdown electric field strength threshold near the electrospray was a limiting factor for further enhancing dehumidification performance. This study examines the optimization of an electro-assisted dehumidification system that includes cyclone-based droplet separation through numerical analysis. The results provide insights into the design of energy-efficient air treatment technologies.

42 ENGINEERING↗

DOE OSTI2023

The Effect of Indian Ocean Temperature on the Pacific Trade Winds and ENSO

Abstract A notable shift in the El Niño‐Southern Oscillation (ENSO) has been observed in the early 21st century, characterized by an increased prevalence of Central Pacific (CP) events and strengthened Pacific trade winds. This shift may be attributed to the warming tropical Indian Ocean (TIO). To investigate this, we conduct perturbation experiments using the Insitut Pierre Simon Laplace climate model and nudge TIO surface temperatures to induce warming or cooling effects. Our findings reveal that TIO warming (or cooling) leads to amplified (weakened) mean trade winds and surface warming (cooling) in the Pacific region. Surprisingly, ENSO variability increases in both TIO cooling and warming scenarios. This result is linked to stronger positive feedbacks and a less stable Bjerknes index for either TIO forcing. Additionally, we find that TIO warming leads to more frequent CP events, meridional widening of wind anomalies, and broadening of the ENSO power spectrum toward lower frequencies.

Geology↗

DOE OSTI2021

Water balance response of permafrost-affected watersheds to changes in air temperatures

Abstract Observations show increases in river discharge to the Arctic Ocean especially in winter over the last decades but the physical mechanisms driving these changes are not yet fully understood. We hypothesize that even in the absence of a precipitation increase, permafrost degradation alone can lead to increased annual river runoff. To test this hypothesis we perform 12 millennium-long simulations over an idealized hypothetical watershed (1 km 2 ) using a distributed, physically based water balance model (Water flow and Balance Simulation Model, WaSiM). The model is forced by both a hypothetical warming defined by an air temperature increase of 7.5 ∘ C over 100 years, and a corresponding cooling scenario. To assess model sensitivity we vary soil saturated hydraulic conductivity and lateral subsurface flow configuration. Under the warming scenario, changes in subsurface water transport due to ground temperature changes result in a 7%–14% increase in annual runoff accompanied by a 6%–20% decrease in evapotranspiration. The increase in runoff is most pronounced in winter. Hence, the simulations demonstrate that changes in permafrost characteristics due to climate warming and associated changes in evapotranspiration provide a plausible mechanism for the observed runoff increases in Arctic watersheds. In addition, our experiments show that when lateral subsurface moisture transport is not included, as commonly done in global-scale Earth System Models, the equilibrium water balance in response to the warming or cooling is similar to the water balance in simulations where lateral subsurface transport is included. However, the transient changes in water balance components prior to reaching equilibrium differ greatly between the two. For example, for high saturated hydraulic conductivity only when lateral subsurface transport is considered, a period of decreased runoff occurs immediately after the warming. This period is characterized by a positive change in soil moisture storage caused by the soil moisture deficit developed during prior cooling.

Debolskiy, Matvey V. (ORCID:0000000296343627)↗

DOE OSTI2022

Electron Cooling Experiment for Proton Beams with Intense Space-Charge in IOTA

Electron cooling as a method of creating intense ion beams has a practical upper limit when it comes to the peak phase space density of ion beams which can be achieved in practice. We describe a new experiment to study electron cooling of 2.5 MeV protons at the intensity limit using the Integrable Optics Test Accelerator (IOTA), which is a storage ring dedicated to beam physics research at Fermilab. This system will enable the study of magnetized electron cooling of a proton beam with transverse incoherent tune shifts approaching -0.5 due to the presence of intense space-charge forces. We present an overview of the hardware design, simulations and specific experiments planned for this project.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

FY23 Status Report on MOOSE-Based Approaches to Modeling Core Bowing in Fast Reactors

Under the U.S. Department of Energy Office of Nuclear Energy’s Advanced Modeling and Simulation (NEAMS) Program, an integrated multiphysics approach is being developed to model the core bowing phenomena important to liquid metal-cooled fast reactors. Core bowing is an important passive safety mechanism whereby increased power (which leads to temperature and flux gradients) influences the core to bow into less reactive configurations when the restraint system is properly designed. The phenomenon includes a complex interplay of radiation transport, duct temperature calculations involving fluid flow and heat transfer, and thermo-mechanical responses to the induced temperature and flux gradients. Structural material properties are also important to determining inelastic response to longer term flux gradients which cause irradiation creep and swelling. While core bowing provides a strong negative reactivity feedback when the restraint system is designed properly, it also results in additional forces between assemblies which increase the loads required to extricate them during refueling or control rod movement. Therefore, the restraint system must be designed with these tradeoffs in mind. The first stage of the work, which commenced in FY21 and continues through FY23, assesses thermo-mechanical modeling tools for producing core bowing predictions consistent with conventional tools. The Multiphysics Object Oriented Simulation Environment (MOOSE) Tensor Mechanics and Contact Modules are employed. This status report describes work on additional thermo-mechanical benchmark verification problems with increased complexity from the examples demonstrated in FY21 and FY22. Several benchmark verification examples were selected from the IAEA verification and validation report with increased number of ducts and more complex contact interaction behavior. These examples involve a full symmetric sector with restraint rings at multiple load pad locations to simulate a limited free-bow restraint system concept, as well as irradiation induced swelling and creep effects in a sector. In addition, improvements to the contact module sideset assignment were assessed and compared with previous MOOSE results to verify the contact behavior. The MOOSE-based results were compared to IAEA benchmark participants’ results. In every case, the MOOSE results agreed with other simulations results for estimating bowing behavior, providing additional verification basis of the tools for this particular physics application. Estimation of contact forces were mostly in agreement, with a few outlier results. A plan was suggested for dealing with the discrepancies with estimating contact force values. In addition, a 1-way coupling demonstration was performed using subchannel analysis code Pronghorn-SC and MOOSE on an ABR-1000-design sodium-cooled fast reactor assembly to evaluate coolant and duct wall temperatures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

CMIP5 Climate Models Overestimate Cooling by Volcanic Aerosols

We compare projections of the observed hemispherical mean surface temperature (HadCRUT4.6.0.0) and the ensemble mean of CMIP5 climate models' simulations on a set of standard regression model forcing variables. We find that the volcanic aerosol regression coefficients of the CMIP5 simulations are consistently significantly larger (by 40–49%) than the volcanic aerosol coefficients of the observed temperature. The probability that the observed differences are caused just by chance is much less than 0.01. The overestimate is due to the climate models' response to volcanic aerosol radiative forcing. The largest overestimate occurs in the winter season of each hemisphere. We hypothesize that the models' parameterization of aerosol-cloud interactions within ice and mixed phase clouds is a likely source of this discrepancy. Furthermore, the models significantly underestimate the effect of solar variability on temperature for both hemispheres.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Benchmark calculations of radiative forcing by greenhouse gases

Changes in concentrations of greenhouse gases lead to changes in radiative fluxes throughout the atmosphere. The value of this change, the instantaneous radiative forcing, varies across climate models, due partly to differences in the distribution of clouds, humidity, and temperature across models, and partly due to errors introduced by approximate treatments of radiative transfer. This paper describes an experiment within the Radiative Forcing Model Intercomparision Project that uses benchmark calculations made with line–by–line models to identify parameterization error in the representation of absorption and emission by greenhouse gases. Clear–sky instantaneous forcing by greenhouse gases is computed using a set of 100 profiles, selected from a re–analysis of present–day conditions, that represent the global annual mean forcing from pre–industrial times to the present–day with sampling errors of less than 0.01 W m –2 . Six contributing line–by–line models agree in their estimate of this forcing to within 0.025 W m –2 while even recently–developed parameterizations have typical errors four or more times larger, suggesting both that the samples reveal true differences among line–by–line models and that parameterization error will be readily identifiable. Agreement among line–by–line models is better in the longwave than in the shortwave where differing treatments of the water vapor vapor continuum affect estimates of forcing by carbon dioxide and methane. The impacts of clouds on instantaneous radiative forcing are estimated from climate model simulations. Here, the adjustment due to stratospheric temperature change by assuming fixed dynamical heating. Adjustments are large only for ozone and for carbon dioxide, for which stratospheric cooling introduces modest non–linearity.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

The impact of stratospheric aerosol intervention on the North Atlantic and Quasi-Biennial Oscillations in the Geoengineering Model Intercomparison Project (GeoMIP) G6sulfur experiment

As part of the Geoengineering Model Intercomparison Project a numerical experiment known as G6sulfur has been designed in which temperatures under a high-forcing future scenario (SSP5-8.5) are reduced to those under a medium-forcing scenario (SSP2-4.5) using the proposed geoengineering technique of stratospheric aerosol intervention (SAI). G6sulfur involves introducing sulfuric acid aerosol into the tropical stratosphere where it reflects incoming sunlight back to space, thus cooling the planet. Here, we compare the results from six Earth-system models that have performed the G6sulfur experiment and examine how SAI affects two important modes of natural variability, the northern wintertime North Atlantic Oscillation (NAO) and the Quasi-Biennial Oscillation (QBO). Although all models show that SAI is successful in reducing global mean temperature as designed, they are also consistent in showing that it forces an increasingly positive phase of the NAO as the injection rate increases over the course of the 21st century, exacerbating precipitation reductions over parts of southern Europe compared with SSP5-8.5. In contrast to the robust result for the NAO, there is less consistency for the impact on the QBO, but the results nevertheless indicate a risk that equatorial SAI could cause the QBO to stall and become locked in a phase with permanent westerly winds in the lower stratosphere.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Roles of the atmosphere and ocean in the projected north atlantic warming hole

There exists a warming deficit in sea surface temperatures (SST) over the subpolar North Atlantic in response to quadrupled CO 2 , referred to as the projected North Atlantic warming hole (WH). This study employs a partial coupling technique to accurately verify the relative roles of oceanic and atmospheric processes in the formation of the projected WH within an atmosphere-ocean coupled framework. By decomposing the SST anomalies in the subpolar North Atlantic into two components: those induced by atmospheric processes (i.e., the atmosphere-forced component) and those driven by changes in ocean circulation (i.e., the ocean-driven component), we find that the projected WH is primarily driven by changes in ocean circulation, with almost no contribution from atmospheric processes. Specifically, the slowdown of the Atlantic Meridional Overturning Circulation (AMOC) results in a cooling of SST in the WH region due to reduced northward ocean heat transport into this region. This study further quantifies the influence of a positive coupled feedback through surface heat flux (SHF) on the AMOC response under greenhouse gas forcing within this self-consistent framework. It is found that the AMOC slowdown leads to a negative SST anomaly in the subpolar North Atlantic and subsequently a positive ocean-driven SHF anomaly, which in turn further weakens the AMOC. In conclusion, this positive feedback through the SHF contributes about 50% to the total AMOC slowdown in response to quadrupled CO 2 .

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Top Loading Helium Cryostat Integrated with High-Pressure Cell with Fast Remote Pressure Control (Final Report for SBIR Phase 1)

A large number of physical phenomena, such as superconductivity and quantum critical phenomena, often appear only at very low temperatures below 5 K. There is an immense interest to investigate these phenomena at high pressure as a means of tuning interatomic distances, and thus the interaction parameters controlling these phenomena, in a continuous and controlled fashion. The current P-T condition for neutron scattering experiments are limited to either relatively low pressures of about 2 GPa at temperatures below 5 K, or to relatively high temperatures at pressures or tens of GPa. The purpose of this research is to develop neutron sample environment instrumentation for reaching 10-20 GPa at 1-2K with rapid and reliable online pressure and temperature control (i.e. without having to interrupt the experiment). The ultimate goal of the project is to design an integrated fast-cooling low-temperature sample environment cryogenic system compatible with state of the art neutron diamond anvil cells suitable for single-crystal neutron scattering experiments for temperatures down to 2K and pressures of several tens of GPa. The integrated system will consist of top-loading Helium flow cryostat with in-situ sample alignment mechanisms, large-volume diamond anvil cells (DAC) made from novel superalloy Pascalloy and optimized for fast cooling and heating, and a compact remote pressure control mechanism for the DAC based on a novel concept of inflatable bellows integrated with a lever-arm based force amplifier. In Phase I, we have designed, manufactured, and tested prototypes of the novel compact force-amplified pneumatic pressure control mechanism for Neutron Diamond Anvil Cell (nDAC), which allows to use pneumatic bellows system for smooth remote pressure control in the nDAC inside a top-loading cryostat with bore size of 70 mm or larger. This allows significant minimum temperature decrease in remotely controlled nDAC from 5-10 K down to 2 K. We also studied mechanical properties of a novel non-magnetic superalloy Pascalloy with different heat-treatment conditions and preliminary results indicate that up to date this is probably the strongest and most suitable material for making more compact and lightweight cryogenic nDACs for neuron scattering experiments at extreme conditions, allowing much faster cooling and heating. Potential applications: The new developments will allow to create a wide range of compact Diamond Anvil Cells for neutron diffraction which can reach several tens of GPA pressure at 2-4 K while preserving accurate remote pressure control capabilities. The new concepts can be used for developing sample environment instrumentation outside the neutron scattering field. The new development have very strong potential for expanding experimental capabilities in materials sciences and have high commercialization potential. The proposed new cryogenic high-pressure system or any of its individual components will be in high demand not only in neutron scattering facilities, but also at synchrotron beamlines and other high-pressure research facilities around the world.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Global and regional hydrological impacts of global forest expansion

Abstract. Large-scale reforestation, afforestation, and forest restoration schemes have gained global support as climate change mitigation strategies due to their significant carbon dioxide removal (CDR) potential. However, there has been limited research into the unintended consequences of forestation from a biophysical perspective. In the Community Earth System Model version 2 (CESM2), we apply a global forestation scenario, within a Paris Agreement-compatible warming scenario, to investigate the land surface and hydroclimate response. Compared to a control scenario where land use is fixed to present-day levels, the forestation scenario is up to 2 °C cooler at low latitudes by 2100, driven by a 10 % increase in evaporative cooling in forested areas. However, afforested areas where grassland or shrubland are replaced lead to a doubling of plant water demand in some tropical regions, causing significant decreases in soil moisture (∼ 5 % globally, 5 %–10 % regionally) and water availability (∼ 10 % globally, 10 %–15 % regionally) in regions with increased forest cover. While there are some increases in low cloud and seasonal precipitation over the expanded tropical forests, with enhanced negative cloud radiative forcing, the impacts on large-scale precipitation and atmospheric circulation are limited. This contrasts with the precipitation response to simulated large-scale deforestation found in previous studies. The forestation scenario demonstrates local cooling benefits without major disruption to global hydrodynamics beyond those already projected to result from climate change, in addition to the cooling associated with CDR. However, the water demands of extensive forestation, especially afforestation, have implications for its viability, given the uncertainty in future precipitation changes.

Environmental Sciences & Ecology↗

DOE OSTI2020

Warm Arctic, Cold Siberia Pattern: Role of Full Arctic Amplification Versus Sea Ice Loss Alone

The effect of future Arctic amplification (AA) on the extratropical atmospheric circulation remains unclear in modeling studies. Using a collection of coordinated atmospheric and coupled global climate model perturbation experiments, we find an emergent relationship between the high-latitude 1,000–500 hPa thickness response and an enhancement of the Siberian High in winter. This wave number-1-like sea level pressure anomaly pattern is linked to an equatorward shift of the eddy-driven jet and a dynamical cooling response in eastern Asia. Additional simulations, where AA is imposed directly into the model domain by nudging, demonstrate how the sea ice forcing is insufficient by itself to capture the vertical extent of the warming and by extension the amplitude of the response in the Siberian High. Additionally, this study demonstrates the importance of the vertical extent of the tropospheric warming over the polar cap in revealing the “warm Arctic, cold Siberia” anomaly pattern in future projections.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Microgravity effects on nonequilibrium melt processing of neodymium titanate: thermophysical properties, atomic structure, glass formation and crystallization

The relationships between materials processing and structure can vary between terrestrial and reduced gravity environments. As one case study, we compare the nonequilibrium melt processing of a rare-earth titanate, nominally 83TiO 2 -17Nd 2 O 3 , and the structure of its glassy and crystalline products. Density and thermal expansion for the liquid, supercooled liquid, and glass are measured over 300–1850 °C using the Electrostatic Levitation Furnace (ELF) in microgravity, and two replicate density measurements were reproducible to within 0.4%. Cooling rates in ELF are 40–110 °C s -1 lower than those in a terrestrial aerodynamic levitator due to the absence of forced convection. X-ray/neutron total scattering and Raman spectroscopy indicate that glasses processed on Earth and in microgravity exhibit similar atomic structures, with only subtle differences that are consistent with compositional variations of ~2 mol. % Nd 2 O 3 . The glass atomic network contains a mixture of corner- and edge-sharing Ti-O polyhedra, and the fraction of edge-sharing arrangements decreases with increasing Nd 2 O 3 content. X-ray tomography and electron microscopy of crystalline products reveal substantial differences in microstructure, grain size, and crystalline phases, which arise from differences in the melt processes.

36 MATERIALS SCIENCE↗

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↗