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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Facet-Dependent Ni Segregation in a Micron-Sized Single-Crystal Li 1.2 Ni 0.2 Mn 0.6 O 2 Cathode

Elemental surface segregation in cathode materials is critical for determining the phase and interfacial reaction between electrode and electrolyte, which consequently affects the electrochemical properties. Single-crystal cathode of Li 1.2 Ni 0.2 Mn 0.6 O 2 and Li 1.2 Ni 0.2 Mn 0.6 O 1.95 F 0.05 with an octahedral morphology of (102) and (003) dominated facets have been manifested to show enhanced electrochemical properties. However, the surface structural features of such single crystals have not been investigated. Herein, using scanning transmission electron microscopy, energy dispersive X-ray spectroscopy, and electron energy loss spectroscopy, we probe the elemental surface segregation characteristics in these single-crystal cathode. We reveal that Ni surface segregation shows dependence on the crystal facet such that it occurs on crystal facets with a mix of cations and anions, but not on the facets with only cations or anions. Furthermore, facet-dependent surface reconstructions are observed, featuring a spinel-like structure at the Ni-rich facet but rock-salt structure at the facet without Ni segregation. The commonly known Mn reduction appears at the single crystal surfaces, more pronounced at the facet without Ni segregation. We further reveal that fluorination leads to the stabilization of surface oxygens. In conclusion, this study provides detailed structural and chemical information about the facet-dependent Ni surface segregation and the resulted phase formation in the rather less explored micron-sized octahedral Li 1.2 Ni 0.2 Mn 0.6 O 2 and Li 1.2 Ni 0.2 Mn 0.6 O 1.95 F 0.05 single crystals, which is key to further exploration of electrochemical properties of cathode in the form of micro-sized single crystal.

25 ENERGY STORAGE↗
DOE OSTI2025

Data for: Climatic Imprint on Interfacially-Controlled Platinum-Palladium Resources

Data package for manuscript "Climatic Imprint on Interfacially-Controlled Platinum-Palladium Resources" by Emily G. Wright, Ivey Wang, Yihang Fang, Elaine D. Flynn, and Jeffrey G. Catalano. This dataset contains adsorption results from experiments designed to investigate the effect of chloride on Pd(II) adsorption to goethite and Pt(II) adsorption to hematite and goethite, including lab experiments, X-ray absorption fine structure spectroscopy, and models of retention within a laterite. See the associated manuscript for full methods information. The file "Wright2025_PtAds_data.csv" contains the target starting Pt concentration (uM), final aqueous Pt and associated error (in uM), calculated adsorbed Pt and associated error (in umol/m2), target and measured aqueous chloride (mM), target aqueous nitrate (mM), final pH, and mineral concentration/loading (g/L). Associated mineral-free controls (mineral loading = 0 g/L) are included; the aqueous Pd error was not calculated and chloride was not measured in every sample. These data appear in Figures 1, S3, S4, S5, S20, and S22 in the associated manuscript. The file "Wright2025_PdAds_data.csv" contains the target starting Pd concentration (uM), final aqueous Pd and associated error (in uM), calculated adsorbed Pd and associated error (in umol/m2), target and measured aqueous chloride (mM), and mineral concentration/loading (g/L). Associated mineral-free controls (mineral loading = 0 g/L) are included; the aqueous Pd error was not calculated and chloride was not measured in every sample. These data appear in Figures 1, S3, S4, S5, and S20 in the associated manuscript. The file "Wright2025_MineralBatches_data.csv" contains the mineral identity and BET specific surface area (m2/g) for every mineral batch synthesized and used in experiments. The annealing time used is listed for hydrothermally annealed goethite. These data appear in Table S2 in the associated manuscript. The file "Wright2025_XRD_data.csv" contains the XRD patterns for every mineral batch synthesized as the counts as a function of two theta (in degrees). See "Wright2025_MineralBatches_data.csv" for more details on specific mineral batches. These data appear in Figure S2 in the associated manuscript. The file "Wright 2025_ZetaPotential_data.csv" contains the measured zeta potentials for samples of goethite (batch G2) at pH 4 the presence of varying amounts of sodium chloride. These data appear in Table S3 in the associated manuscript. The file "Wright2025_XAFSSamples_data.csv" contains the specific mineral batch, measured final aqueous Pd or Pt (uM), measured final aqueous chloride (mM), and estimated adsorbed Pd or Pt (umol/m2) of all XAFS samples. These data appear in Tables S4, S7, S8, and S10 in the associated manuscript. The files "Wright2025_PdXAFS_data.csv" and "Wright2025_PtXAFS_data.csv" contain the normalized spectra of Pd and Pt, respectively, adsorbed to minerals at varying chloride concentrations. See "Wright2025_XAFSSamples_data.csv" for a guide to sample names. Note that "05" in a sample name is equivalent to "0.5". These data appear in Figures 2, S6, S7, S8, S12, S13, and S14 in the associated manuscript. The file "Wright2025_LateriteProfileProfileModelParameters_data.csv" include the ratio of hematite to hematite and goethite in two synthetic, modeled profiles, as well as the modeled surface areas of goethite and hematite as a function of relative depth within the modeled weathering zone. These data were used, in conjunction with equations presented in the paper, to calculate the theoretical concentrations of Pd and Pt (and the resulting Pt/Pd ratio) within the profiles. These data appear in Figure 3 in the associated manuscript. The file "Wright2025_Imagery_data.zip" is a zipped folder containing the TEM and STEM images appear in Figures S18 and S19. Individual files are labeled as either STEM (Fig. S18) or TEM (Fig. S19) with a letter representing the part of the multipart figure.

58 GEOSCIENCES↗
NASA NTRS1992

Influence of convection on microstructure

The primary motivation for this research has been to determine the cause for space processing altering the microstructure of some eutectics, especially the MnBi-Bi eutectic. Prior experimental research at Grumman and here showed that the microstructure of MnBi-Bi eutectic is twice as fine when solidified in space or in a magnetic field, is uninfluenced by interfacial temperature gradient, adjusts very quickly to changes in freezing rate, and becomes coarser when spin-up/spin-down (accelerated crucible rotation technique) is used during solidification. Theoretical work at Clarkson predicted that buoyancy driven convection on earth could not account for the two fold change in fiber spacing caused by solidification in space. However, a lamellar structure with a planar interface was assumed, and the Soret effect was not included in the analysis. Experimental work at Clarkson showed that the interface is not planar, and that MnBi fibers project out in front of the Bi matrix on the order of one fiber diameter. Originally four primary hypotheses were to be tested under this current grant: (1) a fibrous microstructure is much more sensitive to convection than a lamellar microstructure, which was assumed in our prior theoretical treatment; (2) an interface with one phase projecting out into the melt is much more sensitive to convection than a planar interface, which was assumed in our prior theoretical treatment; (3) the Soret effect is much more important in the absence of convection and has a sufficiently large influence on microstructure that its action can explain the flight results; and (4) the microstructure is much more sensitive to convection when the composition of the bulk melt is off eutectic. As reported previously, we have learned that while a fibrous microstructure and a non-planar interface are more sensitive to convection than a lamellar microstructure with a planar interface, the influence of convection remains too small to explain the flight and magnetic field results. Similarly addition of the Soret effect does not explain the flight and magnetic field results.

Wilcox, William R.↗
NASA NTRS1999

Experimental Studies of the Interaction Between a Parallel Shear Flow and a Directionally-Solidifying Front

It has long been recognized that flow in the melt can have a profound influence on the dynamics of a solidifying interface and hence the quality of the solid material. In particular, flow affects the heat and mass transfer, and causes spatial and temporal variations in the flow and melt composition. This results in a crystal with nonuniform physical properties. Flow can be generated by buoyancy, expansion or contraction upon phase change, and thermo-soluto capillary effects. In general, these flows can not be avoided and can have an adverse effect on the stability of the crystal structures. This motivates crystal growth experiments in a microgravity environment, where buoyancy-driven convection is significantly suppressed. However, transient accelerations (g-jitter) caused by the acceleration of the spacecraft can affect the melt, while convection generated from the effects other than buoyancy remain important. Rather than bemoan the presence of convection as a source of interfacial instability, Hurle in the 1960s suggested that flow in the melt, either forced or natural convection, might be used to stabilize the interface. Delves considered the imposition of both a parabolic velocity profile and a Blasius boundary layer flow over the interface. He concluded that fast stirring could stabilize the interface to perturbations whose wave vector is in the direction of the fluid velocity. Forth and Wheeler considered the effect of the asymptotic suction boundary layer profile. They showed that the effect of the shear flow was to generate travelling waves parallel to the flow with a speed proportional to the Reynolds number. There have been few quantitative, experimental works reporting on the coupling effect of fluid flow and morphological instabilities. Huang studied plane Couette flow over cells and dendrites. It was found that this flow could greatly enhance the planar stability and even induce the cell-planar transition. A rotating impeller was buried inside the sample cell, driven by an outside rotating magnet, in order to generate the flow. However, it appears that this was not a well-controlled flow and may also have been unsteady. In the present experimental study, we want to study how a forced parallel shear flow in a Hele-Shaw cell interacts with the directionally solidifying crystal interface. The comparison of experimental data show that the parallel shear flow in a Hele-Shaw cell has a strong stabilizing effect on the planar interface by damping the existing initial perturbations. The flow also shows a stabilizing effect on the cellular interface by slightly reducing the exponential growth rate of cells. The left-right symmetry of cells is broken by the flow with cells tilting toward the incoming flow direction. The tilting angle increases with the velocity ratio. The experimental results are explained through the parallel flow effect on lateral solute transport. The phenomenon of cells tilting against the flow is consistent with the numerical result of Dantzig and Chao.

Zhang, Meng↗
NASA NTRS1996

Nucleation and Crystallization of Globular Proteins: What we Know and What is Missing

Recently. much progress has been made in understanding the nucleation and crystallization of globular proteins, including the formation of compositional and structural crystal defects, Insight into the interactions of (screened) protein macro-ions in solution, obtained from light scattering, small angle X-ray scattering and osmotic pressure studies. can guide the search for crystallization conditions. These studies show that the nucleation of globular proteins is governed by the same principles as that of small molecules. However, failure to account for direct and indirect (hydrodynamic) protein interactions in the solutions results in unrealistic aggregation scenarios. Microscopic studies of numerous proteins reveal that crystals grow by the attachment of growth units through the same layer-spreading mechanisms as inorganic crystals. Investigations of the growth kinetics of hen-egg-white lysozyme (HEWL) reveal non-steady behavior under steady external conditions. Long-term variations in growth rates are due to changes in step-originating dislocation groups. Fluctuations on a shorter timescale reflect the non-linear dynamics of layer growth that results from the interplay between interfacial kinetics and bulk transport. Systematic gel electrophoretic analyses suggest that most HEWL crystallization studies have been performed with material containing other proteins at percent levels. Yet, sub-percent levels of protein impurities impede growth step propagation and play a role in the formation of structural/compositional inhomogeneities. In crystal growth from highly purified HEWL solutions, however, such inhomogeneities are much weaker and form only in response to unusually large changes in growth conditions. Equally important for connecting growth conditions to crystal perfection and diffraction resolution are recent advances in structural characterization through high-resolution Bragg reflection profiling and X-ray topography.

Rosenberger, F.↗
DOE OSTI2017

Tuning Block Polymer Structure, Properties, and Processability for the Design of Efficient Nanostructured Materials Systems

Block polymers (BPs) are ideal building blocks for nanoporous membranes, microelectronics templates, energy storage devices, and other technologies. For these systems, precise control over morphology, properties, and processability are essential to optimize performance. The Epps group has used a multidisciplinary approach to control BP nanostructure ordering and orientations, order-disorder and glass transition temperatures, and mechanical and transport properties through the informed manipulation of BP effective segregation strengths and interfacial energetics. For example, alterations in macromolecular interactions between BP chains were achieved through the introduction of composition gradients between copolymer blocks or by adding dopants. In thin films, high-throughput approaches were designed to modify and characterize substrate-polymer interactions, and solvent annealing techniques were developed to facilitate nanoscale alignment and ordering. Finally, by manipulating BP interfacial energetics to gain exquisite tunability of nanostructures and materials' properties, the group is accelerating the development of next-generation BPs that will be harnessed to fabricate inexpensive, efficient, and high-performance devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Impacts to FeRAM design arising from interfacial dielectric layers and wake up modulation in ferroelectric hafnium zirconium oxide

As ferroelectric hafnium zirconium oxide (HZO) becomes more widely utilized in ferroelectric microelectronics, integration impacts of intentional and non-intentional dielectric interfaces and their effects upon the ferroelectric film wake up and circuit parameters become important to understand. In this work, the effect of the addition of a linear dielectric aluminum oxide, Al 2 O 3 , below a ferroelectric Hf 0.58 Zr 0.42 O 2 film in a capacitor structure for FeRAM applications with NbN electrodes was measured. Depolarization fields resulting from the linear dielectric is observed to induce a reduction of the remanent polarization of the ferroelectric. Addition of the aluminum oxide also impacts the wake up of the HZO with respect to the cycling voltage applied. Intricately linked to the design of a FeRAM 1C/1T cell, the metal-ferroelectric-insulator-metal (MFIM) devices are observed to significantly shift charge related to the read states based on aluminum oxide thickness and wake up cycling voltage. As a result, a 33% reduction in the separation of read states is measured, which complicates how a memory cell is designed and illustrates the importance of clean interfaces in devices.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Assessing the interfacial corrosion mechanism of Inconel 617 in chloride molten salt corrosion using multi-modal advanced characterization techniques

The United States Department of Energy (DOE) has committed to expanding the domestic clean energy portfolio in response to the rising challenges of energy security in the wake of climate change. Accordingly, the construction of a series of Generation IV reactor technologies are being demonstrated, including sodium-cooled, small modular, and molten chloride fast reactors (MCFRs). To date, there are no fully qualified structural materials for constructing MCFRs. A number of commercial structural alloys have been considered for the construction of MCFRs, including alloys from the Inconel and Hastelloy series. Informed qualification of structural materials for the construction of MCFRs in the future can only be ensured by expanding the current fundamental knowledgebase of information pertaining to material performance under environmental stressors relevant to operation of the reactor, including corrosion susceptibility. The purpose of this investigation is to illustrate how a correlative multi-modal electron microscopy characterization approach, including the novel application of focused-ion beam 3D reconstruction capabilities, can elucidate the corrosion mechanism of a candidate structural material Inconel 617 for MCFR in NaCl-MgCl 2 eutectic salt at 700°C for 1,000 h. Evidence of intergranular corrosion, Ni and Fe dealloying, and Cr-O enrichment along the grain boundary, which most likely corresponds to Cr 2 O 3 , is a phenomenon that has been documented in other Ni-based superalloys exposed to chloride molten salt systems. Additional corrosion products, including the formation of insoluble MgAl 2 O 4 , within the porous network produced by the salt attack is a novel observation. In addition, Mo 3 Si 5 and τ 2 precipitates are detected in the alloy bulk and are dissolved by the salt. Furthermore, the lack of detection of design γ' precipitates in Inconel 617 after 1,000 h could indicate that the molten salt corrosion mechanism has indirectly induced a phase transformation of Al 2 TiNi (τ 2 ) and Ni 3 (Al,Ti) (γ’) phase. This investigation provides a comprehensive understanding of molten salt corrosion mechanisms in a complex material system such as a commercial structural alloy for applications in MCFRs.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Effect of Ionizing Radiation on the Mechanical and Structural Properties of Graphite Fiber Reinforced Composites

Graphite/epoxy (T300/5208) and graphite/polyimide composites (C6000/PMR 15) were exposed to various levels of 0.5 MeV electron radiation with the maximum dose being 10,000 Mrad. A three point bending test was used to evaluate the ultimate stress and modulus of the composites. In all composites except transverse samples of C6000/PMR 15 ultimate stress values remained approximately constant or increased slightly. The modulus values remained approximately constant for all composite types regardless of the radiation level. Interfacial aspects of composites were studied. Interlaminar shear tests were performed on T300/5208 and C6000/PMR 15 composites irradiated to 10,000 Mrad. There was an initial increase in interlaminar shear strength (up to 1,000 Mrad) followed by a sharp decrease with further radiation exposure. Using scanning electron microscopy no visual differences in the mode of fracture could be detected between ruptured control samples and those exposed to various levels of radiation. Electron spectroscopy for chemical analysis (ESCA) revealed little change in the surface elements present in control and highly irradiated T300/5208 composite samples.

Wolf, Kay Woodroof↗
DOE OSTI2018

Exchange Kinetics for a Single Block Copolymer in Micelles of Two Different Sizes

The effect of micellar size on the chain exchange kinetics in spherical micelles consisting of poly(methyl methacrylate)-block-poly(n-butyl methacrylate) (PMMA-b- PnBMA) in a mixture of ionic liquids (1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, [EMIM][TFSI], and 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)- imide, [BMIM][TFSI]) was investigated using time-resolved small-angle neutron scattering (TR-SANS). Two spherical micelles with different core sizes were prepared from a single block copolymer by using different protocols. In one case the micelles were formed in the presence of a cosolvent, while in the other a polymer thin film was directly dissolved in the ionic liquid. Interestingly, the micelle core size prepared from the latter method is ~30% larger than that obtained in the former case. TR-SANS experiments reveal that the rate of single chain exchange in the micelles with a larger core size is slowed down by ~3 times compared to the smaller core radius. We surmise this can be possibly attributed to the smaller interfacial area per chain, and larger corona density, for micelles with a larger core dimension. These geometrical factors can potentially lead to changes in both the attempt time and activation barrier for chain expulsion during the unimer exchange process. Our results clearly suggest that, in addition to the molecular characteristics of the block copolymer and solvent, the geometrical structure of the micelle plays an important role in the unimer dynamic exchange processes in block copolymer micelles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Towards efficient time-resolved X-ray absorption studies of electron dynamics at photocatalytic interfaces

We present a picosecond time-resolved X-ray absorption spectroscopy (tr-XAS) setup designed for synchrotron-based studies of interfacial photochemical dynamics. The apparatus combines a high power, variable repetition rate picosecond laser system with a time-resolved X-ray fluorescence yield detection technique. Time-tagging of the detected fluorescence signals enables the parallel acquisition of X-ray absorption spectra at a variety of pump–probe delays employing the well-defined time structure of the X-ray pulse trains. The viability of the setup is demonstrated by resolving dynamic changes in the fine structure near the O1s X-ray absorption edge of cuprous oxide (Cu 2 O) after photo-excitation with a 355 nm laser pulse. Two distinct responses are detected. A pronounced, quasi-static, reversible change of the Cu 2 O O1s X-ray absorption spectrum by up to ~30% compared to its static line shape corresponds to a redshift of the absorption edge by ~1 eV. This value is small compared to the 2.2 eV band gap of Cu 2 O but in agreement with previously published results. Here, the lifetime of this effect exceeds the laser pulse-to-pulse period of 8 μs, resulting in a quasi-static spectral change that persists as long as the sample is exposed to the laser light, and completely vanishes once the laser is blocked. Additionally, a short-lived response corresponding to a laser-induced shift of the main absorption line by ~2 eV to lower energies appears within <200 ps and decays with a characteristic timescale of 43 ± 5 ns. Both the picosecond rise and nanosecond decay of this X-ray response are simultaneously captured by making use of a time-tagging approach – highlighting the prospects of the experimental setup for efficient probing of the electronic and structural dynamics in photocatalytic systems on multiple timescales.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Solid-liquid work of adhesion of coarse-grained models of n-hexane on graphene layers derived from the conditional reversible work method

We address the question of how reducing the number of degrees of freedom modifies the interfacial thermodynamic properties of heterogeneous solid-liquid systems. We consider the example of n-hexane interacting with multi-layer graphene which we model both with fully atomistic and coarse-grained (CG) models. The CG models are obtained by means of the conditional reversible work (CRW) method. The interfacial thermodynamics of these models is characterized by the solid-liquid work of adhesion W{sub SL} calculated by means of the dry-surface methodology through molecular dynamics simulations. We find that the CRW potentials lead to values of W{sub SL} that are larger than the atomistic ones. Clear understanding of the relationship between the structure of n-hexane in the vicinity of the surface and W{sub SL} is elucidated through a detailed study of the energy and entropy components of W{sub SL}. We highlight the crucial role played by the solid-liquid energy fluctuations. Our approach suggests that CG potentials should be designed in such a way that they preserve the range of solid-liquid interaction energies, but also their fluctuations in order to preserve the reference atomistic value of W{sub SL}. Our study thus opens perspectives into deriving CG interaction potentials that preserve the thermodynamics of solid-liquid contacts and will find application in studies that intend to address materials driven by interfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Effects of surface charge and cluster size on the electrochemical dissolution of platinum nanoparticles using COMB3 and continuum electrolyte models

We study the site-dependent dissolution of platinum nanoparticles under electrochemical conditions to assess their thermodynamic stability as a function of shape and size using empirical molecular dynamics and electronic-structure models. The third-generation charge optimized many-body potential is employed to determine the validity of uniform spherical representations of the nanoparticles in predicting dissolution potentials (the Kelvin model). To understand the early stages of catalyst dissolution, implicit solvation techniques based on the self-consistent continuum solvation method are applied. It is demonstrated that interfacial charge and polarization can shift the dissolution energies by amounts on the order of 0.74 eV depending on the surface site and nanoparticle shape, leading to the unexpected preferential removal of platinum cations from highly coordinated sites in some cases.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Mechanisms for long carrier lifetime in Cd(Se)Te double heterostructures

II–VI semiconductors are used in numerous electro-optical applications. For example, CdTe-based solar technology is cost competitive with other electricity generation sources, yet there is still significant room to improve. Carrier lifetime has historically been well below the radiative recombination limit. Lifetimes reaching beyond 100 ns can significantly enhance performance and enable novel device structures. Here, double heterostructures (DHs) with passivated interfaces demonstrate lifetimes exceeding 1 µs, yet this appears only for CdSeTe and not for CdTe DHs. We compare the passivation mechanisms in CdTe and CdSeTe DHs. CdSeTe lifetimes on the order of 1 µs correspond to a combination of superior intragrain lifetime, extremely low grain boundary recombination and greater Te4+ interfacial presence compared to CdTe.

36 MATERIALS SCIENCE↗
NASA NTRS1987

Ginzburg-Landau theory for the solid-liquid interface of bcc elements

Consideration is given to a simple order-parameter theory for the interfacial tension of body-centered-cubic solids in which the principal order parameter is the amplitude of the density wave at the smallest nonzero reciprocal-lattice vector of the solid. The parameters included in the theory are fitted to the measured heat of fusion, melting temperature, and solid-liquid density difference, and to the liquid structure factor and its temperature derivative at freezing. Good agreement is found with experiment for Na and Fe and the calculated anisotropy of the surface tension among different crystal faces is of the order of 2 percent. On the basis of various assumptions about the universal behavior of bcc crystals at melting, the formalism predicts that the surface tension is proportional to the heat of fusion per surface atom.

Shih, W. H.↗
DOE OSTI2025

Nanoscale interfacial melting enables bonding during high velocity microparticle impacts

Melting during high-velocity particle impact has been understood to be typically detrimental to bonding by lowering the strength at the interface and promoting rebound before solidification can occur. Here we establish a possible remedy to this challenge: by dramatically restricting the volume of molten material, its resolidification is accelerated, effectively forming a nanoscale, braze-type joint during impact. In-situ single particle impact imaging is combined with post-mortem structural and chemical analyses to reveal a regime where adhesion is governed not by extensive plastic deformation, but by the kinetics of melt layer resolidification. Furthermore, these findings redefine the role of melting in impact-based processes, establishing transient melting and rapid solidification as a viable strategy for engineering successful adhesion events.

Additive manufacturing↗
DOE OSTI2023

Modeling the interfacial failure and resulting mechanical properties of z-pinned additively manufactured composites

The mechanical properties of Fused Filament Fabrication (FFF) parts are limited in the build direction, albeit advantages such as design flexibility and in-house customization. Here, in this paper, a novel z-pinning approach that enhances mechanical properties in the build direction by depositing material across multiple layers within the part was investigated through numerical simulations and validated experimentally. A finite element model for z-pinned composite structures was developed by assigning fiber-orientation dependent material properties obtained using a micromechanics approach to beads and pins. The bead-to-bead and pin-to-pin adhesions within the z-pinned structures were modeled using a cohesive traction separation law. The properties of cohesive elements for carbon fiber-reinforced polylactic acid (CF-PLA) z-pinned composites were calibrated using tensile experiments. The elastic modulus and tensile strength of CF-PLA z-pinned composites in the build direction were predicted with the developed numerical model. The numerical investigation on various geometrical parameters revealed that the largest pin volume increases the stiffness and tensile strength by 40% and thus, has the greatest influence on the mechanical properties of the z-pinned composites. The effect of z-pin geometrical parameters on the mechanical properties was summarized to aid in the design of z-pinned additively manufactured composite structures.

36 MATERIALS SCIENCE↗

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