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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 199 records · Page 11

Calibrating hypersonic turbulence flow models with the HIFiRE-1 experiment using data-driven machine-learned models.

In this paper we study the efficacy of combining machine-learning methods with projection-based model reduction techniques for creating data-driven surrogate models of computationally expensive, high-fidelity physics models. Such surrogate models are essential for many-query applications e.g., engineering design optimization and parameter estimation, where it is necessary to invoke the high-fidelity model sequentially, many times. Surrogate models are usually constructed for individual scalar quantities. However there are scenarios where a spatially varying field needs to be modeled as a function of the model’s input parameters. Here we develop a method to do so, using projections to represent spatial variability while a machine-learned model captures the dependence of the model’s response on the inputs. The method is demonstrated on modeling the heat flux and pressure on the surface of the HIFiRE-1 geometry in a Mach 7.16 turbulent flow. The surrogate model is then used to perform Bayesian estimation of freestream conditions and parameters of the SST (Shear Stress Transport) turbulence model embedded in the high-fidelity (Reynolds-Averaged Navier–Stokes) flow simulator, using shock-tunnel data. The paper provides the first-ever Bayesian calibration of a turbulence model for complex hypersonic turbulent flows. We find that the primary issues in estimating the SST model parameters are the limited information content of the heat flux and pressure measurements and the large model-form error encountered in a certain part of the flow.

42 ENGINEERING↗

The influence of temperature history and flow mixing on the vapor-phase speciation of uranium oxide nanoparticles

The transport of radioactive material following a nuclear event depends heavily on fallout characteristics (e.g., composition, shape, and size), which in turn are controlled by the conditions under which the fallout forms. To this end, we use a novel plasma flow reactor (PFR) to explore how conditions including temperature history and gas mixing influence the chemical speciation and physical characteristics of uranium oxide nanoparticles. The PFR consists of a glass tube attached to an inductively coupled plasma (ICP) torch via an adaptor piece (ring flow injector) located downstream of the plasma-generating RF coil. We increase the gas flow rates from normal ICP operating conditions to higher values both upstream at the RF coil and downstream at the ring flow injector to create four distinct temperature profiles and two distinct gas flow mixing conditions (normal and higher Ar atomic ratios). Ex situ transmission electron microscopy (TEM) analysis is used to determine the crystal structure, morphology, and size distribution of the synthesized particles as a function of temperature and mixing. The particles display a striking dependence on these conditions in terms of the resulting speciation of uranium oxide: lower temperature (higher upstream) and slower cooling (normal downstream with normal Ar atomic ratio mixing) favor the formation of α-UO 3 particles, while faster cooling (higher downstream with higher Ar atomic ratio mixing) and higher temperature (normal upstream) favor the formation of UO 2 particles. The extent of gas mixing dictates particle aggregation: better mixing encourages the particles to aggregate more extensively. Here these results demonstrate the sensitivity of uranium to initial local conditions and can be used to improve our understanding of the kinetics that drive uranium speciation and ultimately inform fallout transport models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Hadronic vacuum polarization using gradient flow

The gradient-flow operator product expansion for QCD current correlators including operators up to mass dimension four is calculated through NNLO. This paves an alternative way for efficient lattice evaluations of hadronic vacuum polarization functions. In addition, flow-time evolution equations for flowed composite operators are derived. Their explicit form for the non-trivial dimension-four operators of QCD is given through order $\alpha_s^3$.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Theoretical modeling of a bottom-raised oscillating surge wave energy converter structural loadings and power performances

Here, this study presents theoretical formulations to evaluate the fundamental parameters and performance characteristics of a bottom-raised oscillating surge wave energy converter (OSWEC) device. Employing a flat plate assumption and potential flow formulation in elliptical coordinates, closed-form equations for the added mass, radiation damping, and excitation forces/torques in the relevant pitch-pitch and surge-pitch directions of motion are developed and used to calculate the system's response amplitude operator and the forces and moments acting on the foundation. The model is benchmarked against numerical simulations using WAMIT and WEC-Sim, showcasing excellent agreement. The sensitivity of plate thickness on the analytical hydrodynamic solutions is investigated over several thickness-to-width ratios ranging from 1:80 to 1:10. The results show that as the thickness of the benchmark OSWEC increases, the deviation of the analytical hydrodynamic coefficients from the numerical solutions grows from 3% to 25%. Differences in the excitation forces and torques, however, are contained within 12%. While the flat plate assumption is a limitation of the proposed analytical model, the error is within a reasonable margin for use in the design space exploration phase before a higher-fidelity (and thus more computationally expensive) model is employed. A parametric study demonstrates the ability of the analytical model to quickly sweep over a domain of OSWEC dimensions, illustrating the analytical model's utility in the early phases of design.

13 HYDRO ENERGY↗

Densification of non-radioactive porous siliceous particles loaded with cesium potassium copper hexacyanoferrate by spark plasma sintering

In the development of a conditioning process for cesium-bearing sorbents from the decontamination of aqueous waste streams, the treatment of a granular material composed of (Cs,K) 2 CuFe(CN) 6 loaded onto mesoporous silica particles has been investigated in an additive-free two-step conditioning process involving (i) calcination at 1000 °C to remove volatile species and (ii) densification by spark plasma sintering. A 92.0 % dense pellet was obtained after 10 min sintering at 850 °C under 100 MPa. Density and microstructural measurements indicate that densification is first driven by the viscous flow of a vitreous phase containing Cs, formed during calcination. Additionally, the density of the sample then increases further during sintering by grain boundary diffusion. However, a limited but non negligible part of cesium is lost during densification.

36 MATERIALS SCIENCE↗

Flow Reactor Study of the Soot Precursors of Novel Cycloalkanes as Synthetic Jet Fuel Compounds: Octahydroindene, p -Menthane, and 1,4-Dimethylcyclooctane

Sustainable aviation fuels (SAFs) or Synthetic aviation turbine fuels (SATFs) derived from nonpetroleum sources are essential for energy security and a strong rural and agricultural economy. Airplanes operating on SAF can have lower particle emissions compared to those of conventional jet fuel, reducing air quality impacts near airports. Processing biobased isoprene or wood and agricultural waste can produce cycloalkane-rich fuels with properties meeting ASTM International’s SATF requirements. The unique structures of these cycloalkanes yield lower soot emissions because of their lack of aromatic rings. We measured the soot formation tendency as yield sooting index (YSI) and used laminar flow reactor experiments to evaluate soot precursors formed for isoprene-derived compounds p-menthane and 1,4-dimethylcyclooctane (DMCO), and octahydroindene (OHI)─ produced from woody biomass via catalytic fast pyrolysis. The combustion chemistry of the OHI and DMCO has not been previously studied. Experiments were conducted at 10 bar from 800 to 1200 K, equivalence ratios of 1.0 and 3.0, and residence times of 1.0 and 0.6 s, respectively. Experimentally detected species were used to elucidate the mechanisms of soot precursor formation. OHI exhibited the highest YSI (94.5) and formed a high concentration of benzene primarily by direct dehydrogenation of the six-membered ring. p-Menthane (YSI 92.0) and DMCO (YSI 85.0) oxidation products included fewer aromatic components but higher benzene precursors, including 1,3-butadiene, propyne, and allene. This suggests that the ring-opening pathway is dominant over the dehydrogenation pathway in the benzene formation for these compounds. This experimental speciation provides insight into the influence of the cycloalkane structure on the sooting tendencies of potential SAF blend components, thereby aiding in fuel design processes.

09 BIOMASS FUELS↗

Modeling magnetic confinement of laser-generated plasma in cylindrical geometry leading to disk-shaped structures

Radiation-magnetohydrodynamic simulations were able to reproduce features of the plasma structures observed in recent experiments1, where a laser was used to ablate plasma in a 3 MG magnetic field. The laser ablates the plasma, and localized structures are formed due to the inhibition of heat flow by the magnetic field. The large magnetic pressures cause the plasma to pinch. In an azimuthal fi eld, a disc-shaped plasma is generated. According to simulations, the disc has electron densities that are underdense to the laser, ranging from 10 18 to 10 19 cm -3 , and electron temperatures in the 300 to 1000 eV range during its evolution, similar to experimental data.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Two-dimensional mapping of absolute OH densities in an atmospheric pressure plasma effluent via planar laser-induced fluorescence: effects of He/H 2 O and He/O 2 mixtures in N 2 and air, with and without solid targets

Planar laser-induced fluorescence (LIF) was employed to measure the absolute density of hydroxyl radicals (OH) in the effluent of the COST Reference Microplasma Jet for two feed gas mixtures: He/H 2 O and He/O 2 . Experiments were conducted with the effluent propagating into air and N 2 environments. For the He/H 2 O case, measurements were also performed with the effluent impinging on a solid target at varying distances from the jet nozzle. Calibration of the OH-LIF signal from the COST-Jet was achieved by comparing it to a reference signal generated by the photofragmentation of H 2 O 2 . Results demonstrated that OH densities were sustained longer when the effluent propagates in a nitrogen environment compared to air, particularly with water added to the feed gas. The broader OH distribution in N 2 suggests slower consumption due to the absence of oxygen, which accelerates OH depletion in air via reactions involving O 2 and HO 2 . Even when water was not added to the feed, as in the He/O 2 case, appreciable OH densities were observed, due to gas impurities and reactive species interactions with atmospheric humidity, forming reaction fronts that delineate the gas flow. Two-dimensional fluid dynamics simulations elucidated the influence of atmospheric gas entrainment and solid targets on the OH distribution. Experimental trends were further compared with a zero-dimensional chemistry model to explore OH production and consumption mechanisms in air and nitrogen environments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Time and space resolved diagnostics for plasma thermal-chemical instability of fuel oxidation in nanosecond plasma discharges

Here, an instability in a nanosecond pulsed dielectric barrier discharge plasma occurring in methane–oxygen–argon mixtures is experimentally observed and measured by 1D time-resolved in situ electric field measurements. This instability, which seems to be created by the positive feedback between plasma kinetics and plasma-assisted low temperature fuel oxidation, is studied using electric field induced second harmonic generation and direct ICCD imaging. The rapid formation of streamers from an originally uniform discharge appears to be caused by the chemical kinetics of plasma-assisted low temperature methane oxidation, which may be resulting in a new type of plasma instability: a thermal-chemical instability. The results also revealed that the occurrence of this possible thermal-chemical instability in a reactive flow drastically changes the plasma properties by forming multiple secondary discharges and possibly leads to micron-sized non-uniform electric distributions. Single shot uncalibrated measurements of the electric field of the micron sized streamers appears to show much greater strengths than the average electric field. Furthermore, one-dimensional data analysis shows the positive feedback loop between the streamers and the low temperature plasma assisted oxidation chemistry in the plasma thermal-chemical instability. The present finding advances the understanding plasma instability growth and provides a new way to control plasma uniformity in plasma-assisted combustion and plasma fuel reforming.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

A Solution Method for the Filtered Lifting Line Theory

The filtered lifting line theory presents a continuous form of the inviscid momentum equations of flow over a lifting device, such as a wing or rotor blade, using body forces without mathematical singularities. This theory is also consistent with an actuator line representation of a lifting device. In this work, we present a reformulation of the equations in terms of the local flow angle along the line, which allows solving the stand-alone equations using multivariate root-finding algorithms. This approach can be used to obtain a fast, computationally inexpensive solution of the loading distribution along a wing without the need to perform computational fluid dynamic simulations. We study the requirements in terms of resolution in the spanwise direction and establish the criteria for spacing and minimum amount of points required along the blade to obtain converged solutions. The solutions are compared to results from large-eddy simulations, and we observed excellent agreement with less than a percent difference in quantities along the blade between the methods.

17 WIND ENERGY↗

In-Cu alloy substrates for low-temperature chemical vapor deposition of Mo2C

Two-dimensional transition metal carbides are promising materials because of their potential for combining the favorable properties of transition metal carbides with the high aspect ratio of two-dimensional materials. Though commonly produced by top-down wet-chemical synthesis methods, synthesis by chemical vapor deposition is being considered because of its ability to achieve large areas, controlled layer thickness, and reduced defect density. Typically, liquid Cu is used as a synthesis substrate, though the high melting temperature of Cu (1085 °C) requires high synthesis temperatures. Thus, alternative substrates have been studied in order to reduce the necessary melting temperature. This work systematically studies the impact of synthesis parameters and substrate composition on the growth of ultrathin Mo2C (∼4–120 nm thick) by chemical vapor deposition on an In-Cu alloy. Mo2C flake size increases, and graphene/Mo2C heterostructures form with an increase in the methane flow rates. Increasing the In composition slightly decreases surface coverage and coalescence but does not appreciably impact the Mo2C flake size. Increasing In content also decreases the alloy substrate melting temperature so that a lower temperature synthesis (800 °C) can be performed. However, the necessary high temperatures for pyrolysis of methane lead to a lower limit for the synthesis temperature, similar to graphene.

Young, Katherine T. (ORCID:0000000285845576)↗

Resilient U.S. Land Ports of Entry

The continued operation of Land Ports of Entry (LPOE), managed by the Customs and Border Protection (CBP) and General Services Administration% is vital to the U.S. economy and security. Border faculties are included in the Department of Homeland Security (DHS) Government Facilities Sector2, one of the 16 critical infrastructures "whose assets, systems, and networks, whether physical or virtual, are considered so vital to the United States that their incapacitation or destruction would have a debilitating effect on security, national economic security, national public health or safety, or any combination thereof.'" Specifically, disruptions to the flow of border crossing traffic, in the form of closures or increased border crossing wait times, impact the economy and security of all countries involved. This paper describes a process for analyzing and improving the resilience of U.S. Land Ports of Entry. For LPOE, the team believes that energy resilience is the primary objective due to the complete reliance on the e-manifest system and the increasing use of Multi-Energy Portals (MEPs). Emanifests are part of CPB's Automated Commercial Environment (ACE). They document several key pieces of information about cargo vehicles wishing to cross the border into the United States and are submitted before arriving at the port. Vehicles can be flagged for more invasive inspection based on the content of the e-manifest. MEPs are a non-intrusive inspection (NII) technology used to scan the contents of the cargo. Together MEPs and ACE serve an important role in aiding CBP with their mission to protect "the public from dangerous people and materials", and "enabling legitimate trade and travel.'" To analyze resilience of a port, the team would need to understand the port's current energy usage, which systems depend on energy and what backup systems exist, and any emergency operation plans that dictate how systems are operated in the event of a power outage. The team would also need to determine the design basis threats (DBTs) for the LPOE which could include natural disasters, manmade events, and accidents. The magnitudes of the DBTs are calculated and are then translated to expected impacts on the infrastructure and systems at the port. With this information gathered, existing LPOE models developed here at Sandia National Laboratories could be extended to support decisions about resilience. Current models are implemented in FlexSim, a 3rd party discrete event simulator. FlexSim provides 3-D visuals of physical layout that can reveal valuable insights, allows input to be variable (e.g. time it takes to interact with the CBP officer at primary inspection can vary) so that a whole range of possibilities can be captured in the results, and can be used to collect user-defined output metrics. Current LPOE models focus on cargo vehicle traffic, and process changes caused by the installation of new drive-through MEPs. Extending them to address resilience questions would require the addition of key pieces of information learned during the resilience analysis including critical systems, failure rates, and process changes for when failures occur. The primary output metric for current models is border crossing wait time. Additional metrics would also be added to the model to gain a more complete understanding of impacts related to resilience, for example, MEP scan rate. Once complete, the model could be used to analyze the effectiveness of mitigation strategies representing some future state.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

High-dimensional Data-driven Energy optimization for Multi-Modal Transit Agencies (HD-EMMA) (Final Technical Report)

Public bus transit services in the U.S. are responsible for at least 19.7 million metric tons of CO 2 emission annually. Electric vehicles (EVs) can have a much lower environmental impact than comparable internal combustion engine vehicles (ICEVs), especially in urban areas. Unfortunately, EVs are also much more expensive than ICEVs. As a result, many public transit agencies can afford only mixed fleets of transit vehicles, consisting of EVs, hybrids (HEVs), and ICEVs. Transit agencies that operate such mixed fleets of vehicles face a challenging optimization problem: these agencies need to decide which vehicles are assigned to serving which transit trips. Since the advantage of EVs over ICEVs varies depending on the route and time of day (e.g., the benefit of EVs is higher in slower traffic with frequent stops and lower on highways), the assignment can have a significant effect on energy use and, hence, environmental impact. Through this project, we have developed reference data about energy collections and constructed a set of machine learning models that can accurately predict the energy consumption for the whole fleet at the level of each trip. We have used these models to develop a scheduling and assignment strategy that can rotate the different vehicle types across the transit agencies’ routes. The optimization algorithm ensures that the vehicles are matched to trips considering weather patterns, expected congestion, and road gradients to minimize the overall energy usage. We list the key observations from our project for other practitioners below. Details are available in the report, and the list of source code and our publications are included in the appendix. 1. We have demonstrated the feasibility of collecting, merging and analyzing large volumes of high-resolution real-world telemetry data from a mixed vehicle fleet. To mitigate the inherent noise of the recorded GPS points, the team developed an algorithm that filters data and maps the points onto a street. The algorithm considers previous and subsequent location measurements and different characteristics of nearby streets to determine how likely the vehicle travels on them. Then, the team segmented the time series into disjoint contiguous samples based on adjacent road segments and repeated the outlier detection and removal. For each data point, the team added features corresponding to elevation changes within the samples, weather features, such as temperature, and traffic data, such as speed ratio between actual speed and free-flow speed. 2. We have developed two forms of machine learning models that be used to understand and analyze the energy operations of a mixed vehicle transit fleet. The micro prediction model provides estimates of instantaneous energy prediction for all types of buses (diesel, hybrid, and electric). Such a model is important in evaluating the energy impacts of real-time bus operation strategies, but it is challenging due to diversified driving cycles of transit buses. The model can help the drivers understand the impact of their driving behaviors and short-term congestions. The macro prediction models estimate average energy consumption across the whole trip considering the features: distance traveled, various road-type features, elevation change, day of the week, time of day, various weather features (temperature, humidity, etc.), and traffic features (speed ratio and jam factor). 3. We have demonstrated that it is possible to transfer the machine learning models we have developed in this project to other teams and cities by using inductive transfer learning. We also showed that the performance of the macro energy prediction models can be improved using a multi-task learning approach where the learning parameters are shared between the models being developed for different vehicle types. The advantage of this approach is improved learning performance as the models can exploit common spatio-temporal and environmental characteristics. 4. Finally, we have developed trip and vehicle assignment and scheduling algorithms that use the energy prediction models and develop a trip to vehicle type (diesel, electric, hybrid) assignment for the whole operation to reduce overall emissions and cost. We have shown through simulations that the proposed algorithms can save $\$$ 48,910 in energy costs and 175 metric tons of CO 2 emission annually for CARTA.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Effect of Lateral Conduction in a Rectangular Fuel Plate and Optimum Stripe Widths for the OPAL Reactor

The impetus for this work is the Proliferation Resistance Optimization (PRO-X) program, which was created by the National Nuclear Security Administration (NNSA) of the US Department of Energy (DOE) to provide a framework for developing reactor designs that minimize the production of special nuclear materials while maximizing performance for peaceful uses. The Argentine company INVAP and Argonne National Laboratory collaborated to share knowledge and expertise regarding the thermal analysis of research reactors. Working together, they designed a series of test problems based on the Open Pool Australian Light Water (OPAL) reactor, whose fuel is in the form of flat plates cooled by water flowing through narrow rectangular channels. ANL used their PLTEMP/ANL code. INVAP used their TERMIC code (and its new multi-plate version, TERMIC-MP). Then, INVAP and ANL compared the two sets of results. 1-D models were used during the collaboration since for research reactor analysis, largely 1-D thermal-hydraulics models are commonly used because they are simple to apply and technically defendable. The collaboration between the two organizations aims for improvements in thermal-hydraulic models. Improvements to methods and models can reduce modeling uncertainties and excessive conservatism, allowing greater reactor performance without reducing predicted safety margins. Therefore, these improvements potentially expand the design space, making additional designs feasible, which, in turn, may achieve better fuel utilization and proliferation resistance in the designs. This report provides justification for the lateral node size (stripe width) chosen for the 1-D computer models during the collaboration. The lateral heat conduction in OPAL fuel plates is evaluated using the two-dimensional conduction capability of PLTEMP/ANL to determine a representative hot-stripe width that can be conservatively used for one-dimensional steady-state thermal-hydraulic analysis. Basically, a representative hot-stripe width needs to be selected so that the actual heat flux averaged over this stripe width is greater than or equal to the maximum heat flux obtained by the two-dimensional analysis. Detailed results in this report show that a hot-stripe width of 8.125 mm can be conservatively used for the one-dimensional thermal-hydraulics analysis of all plates. Therefore, eight equal stripes (8.125 mm each) are recommended to be modeled in the MCNP and PLTEMP/ANL full core models of the OPAL reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Rapid CFD Using Machine Learning Algorithms (CRADA Final Report)

This is a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (“LLNL”) and Guardian Glass, LLC ("Guardian Glass") to develop a fast-running emulator of the reactive Computational Fluid Dynamics (“CFD”) simulations needed to understand the complex reactions and flows in the glass melting, fining, and forming subprocesses. This CRADA project is sponsored under the High-Performance Computing for Manufacturing (“HPC4Mfg”) Program of the Department of Energy’s Advanced Manufacturing Office (“AMO”) within the Energy Efficiency and Renewable Energy (“EERE”) Office.

36 MATERIALS SCIENCE↗

Kinetic corrections to heat-flow and Nernst advection for laser heated plasmas

Reduced models for approximating the impact of kinetic electron behavior on the transport of thermal energy and magnetic field are investigated. The thermal flux limiter has improved agreement with Vlasov–Fokker–Planck data when a harmonic form is used that adjusts the electron mean free path to account for electron–electron collisions; these results apply to both unmagnetized and magnetized plasmas. Once a magnetic field is incorporated, the mean free path should also be modified using the electron gyroradius. A flux limiter on Nernst advection of magnetic fields is also required; a form that limits Nernst by the same fraction as the thermal heat-flow best reproduces kinetic simulations. A flux limiter form for the cross terms (Righi–Leduc and cross-gradient-Nernst) is also suggested. Hohlraum simulations relevant to fusion experiments on the National Ignition Facility are found to be sensitive to all of these details.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Characterization of flowing liquid films as a regenerating plasma mirror for high repetition-rate laser contrast enhancement

In this paper, we characterize a high repetition-rate regenerating plasma mirror produced by the thin film of liquid formed when two laminar streams collide. The use of a flowing liquid film is inexpensive and the interaction surface refreshes automatically, avoiding buildup of on-target debris. The composition of the liquid material and the relative angle of the film-generating nozzles was optimized for this application. Spectra measured in reflection from a water-based plasma mirror showed a blue shift but an optical reflectivity of up to 30%. The thickness of the film was found to be of the order of 2 μm, and the stability of the reflected spot was ≈1 mrad. The reflected beam profile was highly distorted but stable. Further optimization of the nozzles to affect the fluid flow should enable significant improvements in control of the fluid films and increase in the reflectivity of these mirrors.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Operando synchrotron X-ray analysis of melt pool dynamics in an Al-Sn immiscible alloy

The melt flow in an Al-50vol.% Sn immiscible alloy, produced by single-track laser melting of Al and Sn elemental powders, was studied in real time. High-speed synchrotron X-ray imaging was used to track Al and Sn liquids’ movements, and also to examine elemental distributions in the laser tracks, complimented by electron microscopy after solidification. Key aspects, including melt pool geometry, keyhole instability, and flow dynamics (flow pattern and velocity), were examined using digital image analysis. Relatively deeper melt pools formed at 400 W and 300 mm/s exhibited greater stability, with smooth surfaces, consistent outward flow, and minor vortices near the keyhole. In contrast, shallower pools produced at higher scanning speeds (>500 mm/s) demonstrated greater instability with increased surface waviness, and stronger velocity fluctuations, leading to numerous micro-vortices and increased Al-Sn heterogeneity. Velocity scale estimations, supported by experimental observations, examined the roles of vapour pressure, Marangoni effect, buoyancy, inertial, and surface tension forces in the flow. The results revealed that vapour pressure and mechanical waves dominated at high scanning speeds (shallow pools), while Marangoni forces were equally significant in deep pools at lower speeds (300 mm/s). Buoyancy was found to have minimal impact in both cases. Furthermore, the interaction between inertial and surface tension forces played a critical role in determining the degree of waviness of the pools’ surfaces. These findings offer valuable insights into melt pool dynamics during laser processing of immiscible alloys and other metallic systems using elemental powders, and provide guidance for developing high-fidelity computational fluid dynamics models.

immiscible alloys↗