SEARCH · Search NASA

Results for “Particle Size Distribution Control”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 199 records · Page 11

All sources NASA NTRS DOE OSTI

DOE OSTI2024

A Comprehensive Northern Hemisphere Particle Microphysics Data Set From the Precipitation Imaging Package

Microphysical observations of precipitating particles are critical data sources for numerical weather prediction models and remote sensing retrieval algorithms. However, obtaining coherent data sets of particle microphysics is challenging as they are often unindexed, distributed across disparate institutions, and have not undergone a uniform quality control process. This work introduces a unified, comprehensive Northern Hemisphere particle microphysical data set from the National Aeronautics and Space Administration precipitation imaging package (PIP), accessible in a standardized data format and stored in a centralized, public repository. Data is collected from 10 measurement sites spanning 34° latitude (37°N–71°N) over 10 years (2014–2023), which comprise a set of 1,070,000 precipitating minutes. The provided data set includes measurements of a suite of microphysical attributes for both rain and snow, including distributions of particle size, vertical velocity, and effective density, along with higher-order products including an approximation of volume-weighted equivalent particle densities, liquid equivalent snowfall, and rainfall rate estimates. The data underwent a rigorous standardization and quality assurance process to filter out erroneous observations to produce a self-describing, scalable, and achievable data set. Case study analyses demonstrate the capabilities of the data set in identifying physical processes like precipitation phase-changes at high temporal resolution. Bulk precipitation characteristics from a multi-site intercomparison also highlight distinct microphysical properties unique to each location. This curated PIP data set is a robust database of high-quality particle microphysical observations for constraining future precipitation retrieval algorithms, and offers new insights toward better understanding regional and seasonal differences in bulk precipitation characteristics.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1988

A TEOM (tm) particulate monitor for comet dust, near Earth space, and planetary atmospheres

Scientific missions to comets, near earth space, and planetary atmospheres require particulate and mass accumulation instrumentation for both scientific and navigation purposes. The Rupprecht & Patashnick tapered element oscillating microbalance can accurately measure both mass flux and mass distribution of particulates over a wide range of particle sizes and loadings. Individual particles of milligram size down to a few picograms can be resolved and counted, and the accumulation of smaller particles or molecular deposition can be accurately measured using the sensors perfected and toughened under this contract. No other sensor has the dynamic range or sensitivity attained by these picogram direct mass measurement sensors. The purpose of this contract was to develop and implement reliable and repeatable manufacturing methods; build and test prototype sensors; and outline a quality control program. A dust 'thrower' was to be designed and built, and used to verify performance. Characterization and improvement of the optical motion detection system and drive feedback circuitry was to be undertaken, with emphasis on reliability, low noise, and low power consumption. All the goals of the contract were met or exceeded. An automated glass puller was built and used to make repeatable tapered elements. Materials and assembly methods were standardized, and controllers and calibrated fixtures were developed and used in all phases of preparing, coating and assembling the sensors. Quality control and reliability resulted from the use of calibrated manufacturing equipment with measurable working parameters. Thermal and vibration testing of completed prototypes showed low temperature sensitivity and high vibration tolerance. An electrostatic dust thrower was used in vacuum to throw particles from 2 x 10(exp 6) g to 7 x 10(exp -12) g in size. Using long averaging times, particles as small as 0.7 to 4 x 10(exp 11) g were weighted to resolutions in the 5 to 9 x 10(exp -13) g range. The drive circuit and optics systems were developed beyond what was anticipated in the contract, and are now virtually flight prototypes. There is already commercial interest in the developed capability of measuring picogram mass losses and gains. One area is contamination and outgassing research, both measuring picogram losses from samples and collecting products of outgassing.

Source record↗

NASA NTRS2016

New Satellite Project Aerosol-UA: Remote Sensing of Aerosols in the Terrestrial Atmosphere

We discuss the development of the Ukrainian space project Aerosol-UA which has the following three main objectives: (1) to monitor the spatial distribution of key characteristics of terrestrial tropospheric and stratospheric aerosols; (2) to provide a comprehensive observational database enabling accurate quantitative estimates of the aerosol contribution to the energy budget of the climate system; and (3) quantify the contribution of anthropogenic aerosols to climate and ecological processes. The remote sensing concept of the project is based on precise orbital measurements of the intensity and polarization of sunlight scattered by the atmosphere and the surface with a scanning polarimeter accompanied by a wide-angle multispectral imager-polarimeter. Preparations have already been made for the development of the instrument suite for the Aerosol-UA project, in particular, of the multi-channel scanning polarimeter (ScanPol) designed for remote sensing studies of the global distribution of aerosol and cloud properties (such as particle size, morphology, and composition) in the terrestrial atmosphere by polarimetric and spectrophotometric measurements of the scattered sunlight in a wide range of wavelengths and viewing directions from which a scene location is observed. ScanPol is accompanied by multispectral wide-angle imager-polarimeter (MSIP) that serves to collect information on cloud conditions and Earths surface image. Various components of the polarimeter ScanPol have been prototyped, including the opto-mechanical and electronic assemblies and the scanning mirror controller. Preliminary synthetic data simulations for the retrieval of aerosol parameters over land surfaces have been performed using the Generalized Retrieval of Aerosol and Surface Properties (GRASP) algorithm. Methods for the validation of satellite data using ground-based observations of aerosol properties are also discussed. We assume that designing, building, and launching into orbit a multi-functional high-precision scanning polarimeter and an imager-polarimeter should make a significant contribution to the study of natural and anthropogenic aerosols and their climatic and ecological effects.

remote sensing↗

DOE OSTI2024

Electrochemical Imaging of Precisely‐Defined Redox and Reactive Interfaces

Abstract Understanding the diverse electrochemical reactions occurring at electrode‐electrolyte interfaces (EEIs) is a critical challenge to developing more efficient energy conversion and storage technologies. Establishing a predictive molecular‐level understanding of solid electrolyte interphases (SEIs) is challenging due to the presence of multiple intertwined chemical and electrochemical processes occurring at battery electrodes. Similarly, chemical conversions in reactive electrochemical systems are often influenced by the heterogeneous distribution of active sites, surface defects, and catalyst particle sizes. In this mini review, we highlight an emerging field of interfacial science that isolates the impact of specific chemical species by preparing precisely‐defined EEIs and visualizing the reactivity of their individual components using single‐entity characterization techniques. We highlight the broad applicability and versatility of these methods, along with current state‐of‐the‐art instrumentation and future opportunities for these approaches to address key scientific challenges related to batteries, chemical separations, and fuel cells. We establish that controlled preparation of well‐defined electrodes combined with single entity characterization will be crucial to filling key knowledge gaps and advancing the theories used to describe and predict chemical and physical processes occurring at EEIs and accelerating new materials discovery for energy applications.

Edgecomb, Joseph↗

DOE OSTI2024

Electrochemical Imaging of Precisely‐Defined Redox and Reactive Interfaces

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Computational fluid dynamics modeling and analysis of silica nanoparticle synthesis in a flame spray pyrolysis reactor

Flame Spray Pyrolysis (FSP) is a method for large-scale production of nanoparticles and nanoscale powders employed in a wide range of industrial applications. Particle size and morphology are complex functions of the physicochemical phenomena occurring in the FSP reactor. An extensive study of FSP-related phenomena can be utilized to develop effective strategies for achieving desired particle size/morphology and scaling up the overall yield of an FSP system. In this work, a computational fluid dynamics (CFD) model of an FSP reactor is developed to simulate the coupling of key phenomena involved in the particle synthesis process: liquid spray breakup and evaporation, mixing, combustion, and particle formation/growth of silica nanoparticles. Herein, the particle sizes and their distributions from the CFD simulations are validated against experimental data. Subsequently, the simulations are utilized to investigate the impact of process parameters on the resultant flame dynamics and particle growth. Firstly, the CFD results show that the particle sizes are strongly correlated with the precursor concentration in the solvent. At lower precursor concentrations, the spread of the distribution is relatively insensitive to the value of the concentration. At higher concentrations, the spread is higher as the collision probability between particles is higher. Secondly, increasing the pilot flow rate increases the length of the pilot flames impacting the local ignition location of the spray flame. Lastly, it is shown that the dispersion gas flow rate strongly influences the spray flame shape. This shape can be used for control of particle growth as it helps determine the regions of high temperature and the residence time of the particles in the high temperature region enabling the design and process optimization of the FSP reactor.

42 ENGINEERING↗

DOE OSTI2022

Relativistic non-thermal particle acceleration in two-dimensional collisionless magnetic reconnection

Magnetic reconnection, especially in the relativistic regime, provides an efficient mechanism for accelerating relativistic particles and thus offers an attractive physical explanation for non-thermal high-energy emission from various astrophysical sources. I present a simple analytical model that elucidates key physical processes responsible for reconnection-driven relativistic non-thermal particle acceleration in the large-system, plasmoid-dominated regime in two dimensions. The model aims to explain the numerically observed dependencies of the power-law index $p$ and high-energy cutoff $\gamma _c$ of the resulting non-thermal particle energy spectrum $f(\gamma )$ on the ambient plasma magnetization $\sigma$ , and (for $\gamma _c$ ) on the system size $L$ . In this self-similar model, energetic particles are continuously accelerated by the out-of-plane reconnection electric field $E_{\rm rec}$ until they become magnetized by the reconnected magnetic field and eventually trapped in plasmoids large enough to confine them. The model also includes diffusive Fermi acceleration by particle bouncing off rapidly moving plasmoids. I argue that the balance between electric acceleration and magnetization controls the power-law index, while trapping in plasmoids governs the cutoff, thus tying the particle energy spectrum to the plasmoid distribution.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Combined Effect of the Wegener–Bergeron–Findeisen Mechanism and Large Eddies on Microphysics of Mixed-Phase Stratiform Clouds

Abstract The process of glaciation in mixed-phase stratiform clouds was investigated by a novel Lagrangian–Eulerian model (LEM) in which thousands of adjoining Lagrangian parcels moved within a turbulent-like velocity field with statistical parameters typical of the Arctic boundary layer. We used detailed bin microphysics to describe the condensation/evaporation processes in each parcel, in which droplets, aerosols, and ice particles were described using size distributions of 500 mass bins. The model also calculated aerosol mass inside droplets and ice particles. Gravitational sedimentation of droplets and ice particles was also accounted for. Assuming that droplet freezing is the primary source of ice particles, the Arctic clouds observed in Indirect and Semi-Direct Aerosol Campaign (ISDAC) were successfully simulated. The model showed that at a low ice particle concentration typical of ISDAC, large vortices (eddies) led to a quasi-stationary regime, in which mixed-phase St existed for a long time. The large eddies controlled the water partitioning in the mixed-phase clouds. Droplets formed and grew in updrafts, typically reaching the cloud top, and evaporated in downdrafts. Ice particles grew in updrafts and downdrafts. The Wegener–Bergeron–Findeisen (WBF) mechanism was efficient in downdrafts and some parts of updrafts, depending on ice concentration and vertical velocity. At low ice concentrations, the effect of ice on the phase partitioning was negligible. In this regime, liquid droplets were found near the cloud top, whereas ice particles precipitated through the cloud base. When ice concentration exceeded about 10 L −1 , the WBF mechanism led to glaciation of almost the entire cloud, with the exception of narrow cloud regions associated with strong updrafts. At ice particle concentrations of a few tens per liter, the oscillatory regime took place due to the ice–liquid interaction. The microphysical structure of mixed-phase St forms as a combined effect of cloud dynamics (large eddies) and the WBF mechanism.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

NCSU RDMA data

NCSU RDMA Data Level b1: QC checks applied to measurements Data Format: CSV Description: See "instrument description Site: Houston, TX; Tracking Aerosol Convection interactions ExpeRiment (HOU) Location: Houston, TX; AMF1 (main site for TRACER) Facility Code: M1 Category: Aerosol Properties Data Type: PI Data Source Instrument/Data: Nano-Scanning Mobility Particle (SMPS); A Radial Differential Mobility Analyzer (RDMA) coupled with 1 Condensation Particle Counter Start Date: 2022-06-01 End Date: 2022-9-26 Contact PI: Markus Petters (mdpetter@ncsu.edu) Funding Source: DOE ASR award US Department of Energy, Office of Science, Biological and Environment Research (grant no. DE-SC 0021074) Instrument description The NCSU RDMA was operated at a sheath-to-sample flow ratio of 5:1.5 L min−1. The RDMA was configured to scan from 5 to 55 nm. It was located into the temperature-controlled trailer adjacent to the NCSU Flux Tower to observe size distributions of the aerosols.The sample line was dried with three silica-gel driers in series, and then neutralized with X-ray neutralizer. Please contact mdpetter@ncsu.edu for further information.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1973

Airborne Laser Polar Nephelometer

A polar nephelometer has been developed at NCAR to measure the angular variation of the intensity of light scattered by air molecules and particles. The system has been designed for airborne measurements using outside air ducted through a 5-cm diameter airflow tube; the sample volume is that which is common to the intersection of a collimated source beam and the detector field of view within the airflow tube. The source is a linearly polarized helium-neon laser beam. The optical system defines a collimated field-of-view (0.5deg half-angle) through a series of diaphragms located behind a I72-mm focal length objective lens. A photomultiplier tube is located immediately behind an aperture in the focal plane of the objective lens. The laser beam is mechanically chopped (on-off) at a rate of 5 Hz; a two-channel pulse counter, synchronized to the laser output, measures the photomultiplier pulse rate with the light beam both on and off. The difference in these measured pulse rates is directly proportional to the intensity of the scattered light from the volume common to the intersection of the laser beam and the detector field-of-view. Measurements can be made at scattering angles from 15deg to 165deg with reference to the direction of propagation of the light beam. Intermediate angles are obtained by selecting the angular increments desired between these extreme angles (any multiple of 0.1deg can be selected for the angular increment; 5deg is used in normal operation). Pulses provided by digital circuits control a stepping motor which sequentially rotates the detector by pre-selected angular increments. The synchronous photon-counting system automatically begins measurement of the scattered-light intensity immediately after the rotation to a new angle has been completed. The instrument has been flown on the NASA Convair 990 airborne laboratory to obtain data on the complex index of refraction of atmospheric aerosols. A particle impaction device is operated simultaneously to collect particles from the same airflow tube used to make the scattered-light measurements. A size distribution function is obtained by analysis of the particles collected by the impaction device. Calculated values of the angular variation of the scattered-light intensity are obtained by applying Mie scattering theory to the observed size distribution function and assuming different values of the complex index of refraction of the particles. The calculated values are then compared with data on the actual variation of the scattered-light intensity obtained with the polar nephelometer. The most probable value of the complex refractive index is that which provides the best fit between the experimental light scattering data and the parameters calculated from the observed size distribution function.

Grams, Gerald W.↗

DOE OSTI2022

Modeling Solution Drying by Moving a Liquid-Vapor Interface: Method and Applications

A method of simulating the drying process of a soft matter solution with an implicit solvent model by moving the liquid-vapor interface is applied to various solution films and droplets. For a solution of a polymer and nanoparticles, we observe “polymer-on-top” stratification, similar to that found previously with an explicit solvent model. Furthermore, “polymer-on-top” is found even when the nanoparticle size is smaller than the radius of gyration of the polymer chains. For a suspension droplet of a bidisperse mixture of nanoparticles, we show that core-shell clusters of nanoparticles can be obtained via the “small-on-outside” stratification mechanism at fast evaporation rates. “Large-on-outside” stratification and uniform particle distribution are also observed when the evaporation rate is reduced. Polymeric particles with various morphologies, including Janus spheres, core-shell particles, and patchy particles, are produced from drying droplets of polymer solutions by combining fast evaporation with a controlled interaction between the polymers and the liquid-vapor interface. Our results validate the applicability of the moving interface method to a wide range of drying systems. The limitations of the method are pointed out and cautions are provided to potential practitioners on cases where the method might fail.

36 MATERIALS SCIENCE↗

DOE OSTI2023

TGA Study of the Reaction Kinetics of a CuFeMnAlO 4+δ Oxygen Carrier for Methane Chemical Looping Combustion under High Pressure and Atmospheric Pressure Conditions

Reduction and oxidation kinetics of a CuFeMnAlO 4+δ oxygen carrier for methane were studied using an atmospheric thermogravimetric analyzer (TGA) and a pressurized TGA. Important parameters such as temperature (500–900 °C), particle size distribution (150–650 μm), and partial pressures of reactants (methane and oxygen) were evaluated. Results showed that the reduction of the oxygen carrier was not affected by particle size distribution studied in this work, and that above 750 °C, the effect of the temperature on oxygen carrier reduction started to diminish. The reaction time approaches an asymptotic limit as methane partial pressure increases. For oxygen carrier oxidation, it was found that the rate of oxidation increased with increasing oxygen concentration. The effect of the oxygen concentration was more noticeable when the oxygen concentration was below 7.5%. Because of the inherent feature of the oxygen carrier, its chemical looping with oxygen uncoupling property was also assessed. A phase boundary-controlled shrinking sphere model was used to model the test data from the TGAs. Modeling results showed that the oxygen carrier reduction had a reaction order of 1 with an activation energy of ∼46 kJ/mol. Oxygen carrier oxidation demonstrated a reaction order of 1.1 with an activation energy of ∼55 kJ/mol. Additionally, the differences of the experimental results between the atmospheric pressure TGA and the pressurized TGA were discussed in detail and the limitations of the pressurized TGA were highlighted.

Hydrocarbons↗

DOE OSTI2021

Accelerator Real-time Edge AI for Distributed Systems (READS) (Proposal)

Over the last decade, Machine Learning (ML) technologies have slowly made their way into the accelerator community. Rapid advances in recent years in deep learning, particularly reinforcement learning for control system applications and the accessibility of deep learning in embedded hardware, have generated renewed interest and spawned a number of applications. The Fermilab Accelerator Complex, shown in Fig. 1, has provided High Energy Physics (HEP) experiments with proton beams for nearly fifty years. The current focus of the laboratory is its world-class experimental program at the intensity frontier. While increasing beam intensity certainly presents its own challenges, preserving beam size while minimizing beam losses – particles lost through interactions with the beam vacuum pipe – turns out to be, in many ways, the main challenge. The accelerator is controlled via a complex system of hundreds of thousands of devices. Enabling fine tuning and real-time optimization of their parameters using ML methods and stepping beyond experience-based reasoning of human operators are key to the success of future intensity upgrades. Our objective will be to integrate ML into accelerator operations and furthermore, provide an accessible framework, which can also be used by a broad range of other accelerator systems with dynamic tuning needs.

43 PARTICLE ACCELERATORS↗

NASA NTRS1986

Shuttle Imaging Radar - Physical controls on signal penetration and subsurface scattering in the Eastern Sahara

Interpretation of Shuttle Imaging Radar-A (SIR-A) images by McCauley et al. (1982) dramatically changed previous concepts of the role that fluvial processes have played over the past 10,000 to 30 million years in shaping this now extremely flat, featureless, and hyperarid landscape. In the present paper, the near-surface stratigraphy, the electrical properties of materials, and the types of radar interfaces found to be responsible for different classes of SIR-A tonal response are summarized. The dominant factors related to efficient microwave signal penetration into the sediment blanket include (1) favorable distribution of particle sizes, (2) extremely low moisture content and (3) reduced geometric scattering at the SIR-A frequency (1.3 GHz). The depth of signal penetration that results in a recorded backscatter, here called 'radar imaging depth', was documented in the field to be a maximum of 1.5 m, or 0.25 of the calculated 'skin depth', for the sediment blanket. Radar imaging depth is estimated to be between 2 and 3 m for active sand dune materials. Diverse permittivity interfaces and volume scatterers within the shallow subsurface are responsible for most of the observed backscatter not directly attributable to grazing outcrops. Calcium carbonate nodules and rhizoliths concentrated in sandy alluvium of Pleistocene age south of Safsaf oasis in south Egypt provide effective contrast in premittivity and thus act as volume scatterers that enhance SIR-A portrayal of younger inset stream channels.

Schaber, G. G.↗

NASA NTRS1997

Cratering on Titan: A Pre-Cassini Perspective

The NASA-ESA Cassini mission, comprising a formidably instrumented orbiter and parachute-borne probe to be launched this October, promises to reveal a crater population on Titan that has been heretofore hidden by atmospheric haze. This population on the largest remaining unexplored surface in the solar system will be invaluable in comparative planetological studies, since it introduces evidence of the atmospheric effects of cratering on an icy satellite. Here, I highlight some impact features we may hope to find and could devote some modeling effort toward. Titan in a Nutshell: Radius= 2575 km. Density= 1880 kg/cubic m consistent with rock-ice composition. Surface pressure = 1.5 bar. Surface gravity = 1.35 m/square s Atmosphere -94% N2 6% CH, Surface temperature = 94K Tropopause temperature = 70K at 40 km alt. Probable liquid hydrocarbon deposits exist on or near the surface.Titan in a Nutshell: Radius= 2575 km. Density= 1880 kg/cubic m consistent with rock-ice composition. Surface pressure = 1.5 bar. Surface gravity = 1.35 m/square s; Atmosphere about 94% N2 6% CH, Surface temperature = 94K Tropopause temperature = 70K at 40 km alt. Probable liquid hydrocarbon deposits exist on or near the surface. Titan is comparable to Callisto and Ganymede for strength/gravity, Mars/Earth/Venus for atmospheric interaction, and Hyperion, Rhea, and Iapetus for impactor distribution. The leading/trailing asymmetry of crater density from heliocentric impactors is expected to be about 5-6, in the absence of resurfacing. Any Saturnocentric impactor population is likely to alter this. In particular the impact disruption of Hyperion is noted; because of the 3:4 orbital resonance with Titan, fragments from the proto-Hyperion breakup would have rapidly accreted onto Titan. Titan's resurfacing history is of course unknown. The disruption of impactors into fragments that individually create small craters is expected to occur. A crude estimate suggests a maximum separation of about 2 km (compared with 4 km on Venus, or 0.5 km on Earth). Crater chains are unlikely on Titan, since impactors must pass close enough to Saturn to be tidally disrupted; as a result, they would suffer aerodynamic disruption. Crater counting on adjacent satellites gives densities of about 200 per 10 (exp 6) square km for 20-km-diameter craters. However, the presence of a thick atmosphere leads to atmospheric shielding, depleting the relative abundance of small craters. This has been evaluated by models, and the relative abundance of small craters may be due to a diagnostic atmospheric collapse. A number of radar-dark "splotches" have been detected on Venus; these have been attributed to the interaction of the surface with the atmospheric shockwave produced by the Tunguska-like explosion of a bolide in the atmosphere. Simple analogy suggests that similar features might occur on Titan, but the shocked mass density (which controls the momentum coupling between the surface and the shockwave) of Titan's cold N2 atmosphere is about 20x smaller than that of Venus's hot CO2 atmosphere. Unless ice is much more easily turned to rubble than is rock, such features seem less probable on Titan. When the energy deposited by an impact forms a fireball with an equilibrate greater than one scale height, the fireball expands upward and can distribute ejecta. on ballistic exoatmospheric trajectories. On Venus this process is believed to be responsible for the parabolic features; the interaction of various-sized particles falling through the atmosphere with the zonal wind field winnows the particles to form a parabolic deposit. Although such a process is possible on Titan, the large scale height at higher altitudes would make it more difficult. Comparison with craters on other icy satellites suggests that craters on Titan will be fairly shallow (depth/diameter about 0.1) and craters greater than 10 km in diameter will have central peaks or domed bases, perhaps with central pits. The formation of ejecta. blankets may involve the atmosphere in a significant way, both by restraining the expansion of the ejecta cloud and by influencing the thermal history of the ejecta. Compared with Venus, Titan's atmosphere will chill an impact melt somewhat quickly, so the long ejecta flows seen on Venus seem less likely, detailed modeling needs to be performed to determine the impact melt production. Crater topography on Titan may be highlighted by the influence of liquids forming crater lakes. Craters with central peaks will typically form ring-shaped lakes, although horseshoe-shaped takes may be common; domed craters with central pits may even form bullseye lakes with islands with central ponds. If liquids have covered a substantial part of Titan's surface for a substantial period, hydroblemes and tsunami deposits may be common.

Lorenz, R. D.↗

DOE OSTI2025

PowderJet: Spherical metal powder production via multi-orifice droplet-on-demand metal jetting

Leading metal additive manufacturing techniques, such as laser powder bed fusion and directed energy deposition, rely on high-quality spherical metal powders. However, traditional powder production methods like gas atomization face limitations, including low in-spec yield, asphericity, and internal porosity. We introduce PowderJet, a powder production platform that uses electromagnetic pulses to eject liquid metal droplets from a multi-orifice nozzle. Unlike stochastic methods, PowderJet tightly controls powder size, distribution, and purity through a droplet-on-demand approach. We detail the system’s design, operation, and performance using a combined experimental and computational fluid dynamics (CFD) framework. Initial results with Al4008 and Cu110 alloys demonstrate successful production, yielding unsieved aluminum powder batches with a mean diameter of 200 µm and a narrow size distribution (15 µm standard deviation). The produced powders are highly spherical, achieving a roundness > 0.95. PowderJet operates with a small melt volume (3 mL) and supports continuous refilling, enabling production rates between 30 and 140 cm³/hr depending on jetting frequency, number of orifices and particle size. CFD simulations show that future systems could achieve rates exceeding 1000 cm³/hr for particle sizes as small as 40 µm. PowderJet’s high yield of in-spec powder makes it ideal for producing precious or hazardous materials that are inefficient to manufacture using conventional methods. This platform offers a scalable, precise, and efficient solution for producing high-quality powders tailored for advanced manufacturing applications.

Atomization↗

DOE OSTI2020

Zeolite Nanosheets Stabilize Catalyst Particles to Promote the Growth of Thermodynamically Unfavorable, Small–Diameter Carbon Nanotubes

A challenge in the synthesis of single–wall carbon nanotubes (SWCNTs) is the lack of control over the formation and evolution of catalyst nanoparticles and the lack of control over their size or chirality. Here, zeolite MFI nanosheets (MFI–Ns) are used to keep cobalt (Co) nanoparticles stable during prolonged annealing conditions. Environmental transmission electron microscopy (ETEM) shows that the MFI–Ns can influence the size and shape of nanoparticles via particle/support registry, which leads to the preferential docking of nanoparticles to four or fewer pores and to the regulation of the SWCNT synthesis products. The resulting SWCNT population exhibits a narrow diameter distribution and SWCNTs of nearly all chiral angles, including sub–nm zigzag (ZZ) and near–ZZ tubes. Theoretical simulations reveal that the growth of these unfavorable tubes from unsupported catalysts leads to the rapid encapsulation of catalyst nanoparticles bearing them; their presence in the growth products suggests that the MFI–Ns prevent nanoparticle encapsulation and prologue ZZ and near–ZZ SWCNT growth. Furthermore, these results thus present a path forward for controlling nanoparticle formation and evolution, for achieving size– and shape–selectivity at high temperature, and for controlling SWCNT synthesis.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Nanotomographic observation and statistical analysis of overcharging induced cracks in LiCoO 2 single crystalline particles

Particle fracture represents an important mode of battery electrode degradation. Extensive cracking occurs in the layered oxide cathodes of lithium-ion rechargeable batteries when they are charged beyond safe operational voltages. In this paper, we analyze the morphology and distribution of cracks in over 100 overcharged LiCoO 2 (LCO) single-crystalline particles imaged via X-ray nanotomography. Herein, we observe a strong particle size dependence in both nucleation and growth of cracks, with percentage of cracked particles, crack size, and crack surface area per unit volume all increasing significantly with particle volume. Increasing the cutoff voltage above 4.6V is found to trigger much more pronounced crack growth, which we attribute to the large misfit stress caused by the H1-3 to O1 phase transition. This study offers valuable statistical insights into the fracture behavior of layered oxide cathodes and reveals the importance of particle size control on electromechanical degradation of battery electrodes.

25 ENERGY STORAGE↗