Search NASA⌕ Search

SEARCH · Search NASA

Results for “surface additives”

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.

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

At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Predicting Pit Stability On Additively Manufactured SS316 Via Finite Element Modeling [Slides]

Pit growth and repassivation are complex, with many interconnecting geometric and environmental parameters to consider. Experimentally, it is difficult to isolate these individual parameters to study their effect on the stability of pits. To enable these studies, a finite element modeling approach has been developed to allow systematic testing of parameters that impact a pit’s stability. The specific parameters studied were the cathode diameter, the pit diameter and shape, and the water layer thickness. Hemispherical and rectangular-based pits were studied to determine the impact of the overall pit shape. Pit stability results were compared with mathematical calculations based on the Maximum Pit Model, for both 50% saturation and 100% saturated salt film coverage. Further studies expanded the range of pit geometry to those relevant to additively manufactured surfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Near-Infrared Noise in Intense Electron Beams

Requirements for the noise in electron beams (NEB) have recently approached the Shot-noise level in some new applications. The density fluctuations of intense beams in the near-infrared (NIR) region are being measured at the Fermilab Accelerator Science and Technology (FAST) facility. The main goal of the experiment is to accurately compare the Shot-noise model with the observations of optical transition radiation (OTR) generated by a relativistic electron beam ($\gamma \approx 63$), transiting an Aluminium metal surface. In addition, some evidence for longitudinal space-charge-induced microbunching for the chicane-compressed beam was obtained with coherent enhancements up to 100 in the various bandwidth-filtered NIR OTR photodiode signals. With micropulse charges up to 1 nC, the beam parameters are close to those proposed for a stage in an Electron-Ion Collider (EIC) with coherent electron cooling (CEC). In this paper we present the current progress of the NEB project and compare the low electron energy measurements with ImpactX simulations.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Machine Learning for Predictive Performance Analysis in Charged Particle Beam Tools

Imaging methods driven by probes, electrons, and ions have played a dominant role in modern science and engineering. Opportunities for machine vision and AI that focus on consumer problems like driving and feature recognition, are now presenting themselves for automating aspects of the scientific processes. This proposal aims to enable and drive discovery in ultra-low energy implantation by taking advantage of faster processing, flexible control and detection methods, and architecture-agnostic workflows that will result in higher efficiency and shorter scientific development cycles. Custom microscope control, collection and analysis hardware will provide a framework for conducting novel in situ experiments revealing unprecedented insight into surface dynamics at the nanoscale. Ion implantation is a key capability for the semiconductor industry. As devices shrink, novel materials enter the manufacturing line, and quantum technologies transition to being more mainstream. Traditional implantation methods fall short in terms of energy, ion species, and positional precision. Here we demonstrate 1 keV focused ion beam Au implantation into Si and validate the results via atom probe tomography. We show the Au implant depth at 1 keV is 0.8 nm and that identical results for low energy ion implants can be achieved by either lowering the column voltage, or decelerating ions using bias – while maintaining a sub-micron beam focus. We compare our experimental results to static calculations using SRIM and dynamic calculations using binary collision approximation codes TRIDYN and IMSIL. A large discrepancy between the static and dynamic simulation is found that is due to lattice enrichment with high stopping power Au and surface sputtering. Additionally, we demonstrate how model details are particularly important to the simulation of these low-energy heavy-ion implantations. Finally, we discuss how our results pave a way to much lower implantation energies, while maintaining high spatial resolution.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Accelerated Snowmelt Protocol to Simulate Climate Change Induced Impacts on Snowpack Dependent Ecosystems

Field studies that simulate the effects of climate change are important for a predictive understanding of ecosystem responses to a changing environment. Among many concerns, regional warming can result in advanced timing of spring snowmelt in snowpack dependent ecosystems, which could lead to longer snow-free periods and drier summer soils. Past studies investigating these impacts of climate change have manipulated snowmelt with a variety of techniques that include manual snowpack alteration with a shovel, infrared radiation, black sand and fabric covers. Within these studies however, sufficient documentation of methods is limited, which can make experimental reproduction difficult. Here, we outline a detailed plot-scale protocol that utilizes a permeable black geotextile fabric deployed on top of an isothermal spring snowpack to induce advanced snowmelt. The method offers a reliable and cost-effective approach to induce snowmelt by passively increasing solar radiation absorption at the snow surface. In addition, control configurations with no snowpack manipulation are paired adjacent to the induced snowmelt plot for experimental comparison. Past and ongoing deployments in Colorado subalpine ecosystems indicate that this approach can accelerate snowmelt by 14-23 days, effectively mimicking snowmelt timing at lower elevations. This protocol can be applied to a variety of studies to understand the hydrological, ecological, and geochemical impacts of regional warming in snowpack dependent ecosystems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Measurement and Simulation of Ultra-Low-Energy Ion–Solid Interaction Dynamics

Ion implantation is a key capability for the semiconductor industry. As devices shrink, novel materials enter the manufacturing line, and quantum technologies transition to being more mainstream. Traditional implantation methods fall short in terms of energy, ion species, and positional precision. Here, we demonstrate 1 keV focused ion beam Au implantation into Si and validate the results via atom probe tomography. We show the Au implant depth at 1 keV is 0.8 nm and that identical results for low-energy ion implants can be achieved by either lowering the column voltage or decelerating ions using bias while maintaining a sub-micron beam focus. We compare our experimental results to static calculations using SRIM and dynamic calculations using binary collision approximation codes TRIDYN and IMSIL. A large discrepancy between the static and dynamic simulation is found, which is due to lattice enrichment with high-stopping-power Au and surface sputtering. Additionally, we demonstrate how model details are particularly important to the simulation of these low-energy heavy-ion implantations. Finally, we discuss how our results pave a way towards much lower implantation energies while maintaining high spatial resolution.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Viral Capsid Change upon Encapsulation of Double-Stranded DNA into an Infectious Hypodermal and Hematopoietic Necrosis Virus-like Particle

In this study, we aimed to encapsulate the sizable double-stranded DNA (dsDNA, 3.9 kbp) into a small-sized infectious hypodermal and hematopoietic necrosis virus-like particle (IHHNV-VLP; T = 1) and compared the changes in capsid structure between dsDNA-filled VLP and empty VLP. Based on our encapsulation protocol, IHHNV-VLP was able to load dsDNA at an efficiency of 30–40% (w/w) into its cavity. Structural analysis revealed two subclasses of IHHNV-VLP, so-called empty and dsDNA-filled VLPs. The three-dimensional (3D) structure of the empty VLP produced in E. coli was similar to that of the empty IHHNV-VLP produced in Sf9 insect cells. The size of the dsDNA-filled VLP was slightly bigger (50 Å) than its empty VLP counterpart; however, the capsid structure was drastically altered. The capsid was about 1.5-fold thicker due to the thickening of the capsid interior, presumably from DNA–capsid interaction evident from capsid protrusions or nodules on the interior surface. In addition, the morphological changes of the capsid exterior were particularly observed in the vicinity of the five-fold axes, where the counter-clockwise twisting of the “tripod” structure at the vertex of the five-fold channel was evident, resulting in a widening of the channel’s opening. Whether these capsid changes are similar to virion capsid maturation in the host cells remains to be investigated. Nevertheless, the ability of IHHNV-VLP to encapsulate the sizable dsDNA has opened up the opportunity to package a dsDNA vector that can insert exogenous genes and target susceptible shrimp cells in order to halt viral infection.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Forecasting ground-based sensitivity to the Rayleigh scattering of the CMB in the presence of astrophysical foregrounds

The Rayleigh scattering of cosmic microwave background (CMB) photons off the neutral hydrogen produced during recombination effectively creates an additional scattering surface after recombination that encodes new cosmological information, including the expansion and ionization history of the universe. A first detection of Rayleigh scattering is a tantalizing target for next-generation CMB experiments. We have developed a Rayleigh scattering forecasting pipeline that includes instrumental effects, atmospheric noise, and astrophysical foregrounds (e.g., Galactic dust, cosmic infrared background, or CIB, and the thermal Sunyaev-Zel'dovich effect). We forecast the Rayleigh scattering detection significance for several upcoming ground-based experiments, including SPT-3G+, Simons Observatory, CCAT-prime, and CMB-S4, and examine the limitations from atmospheric and astrophysical foregrounds as well as potential mitigation strategies. When combined with Planck data, we estimate that the ground-based experiments will detect Rayleigh scattering with a significance between 1.6 and 3.7, primarily limited by atmospheric noise and the CIB.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2026

Coming Closer to High Frequency Gravitational Wave Detection With MAGO

In the last years, low frequency gravitational waves (GWs) have been consistently measured by the LIGOVirgo collaboration, but little to no attention has been paid to higher frequencies GWs in the range of 10 kHz to 100 MHz, at which confirmation for current theories or even new physics could be hidden. The MAGO 2.0 project aims at filling this gap in the parameter space using superconducting radio-frequency (SRF) cavities. Exploiting the excellent Q-factors of these resonators, we plan to detect tiny harmonic deformations induced by GWs which change the boundary conditions of the oscillating electromagnetic field. We present the results of the first cold tests ran at DESY and FNAL using the cavity prototype built 20 years ago at the end of the MAGO collaboration, characterizing the RF spectrum, Q-factor and surface resistance. Additionally we introduce the mechanical vibration spectrum characterization and the RF response of the cavity with the injection of a “fake GW” signal using piezoelectric actuators.

Marconato, Giovanni [Hamburg U.]↗
DOE OSTI2022

Hydrodynamics of countercurrent flow in an additive-manufactured column with triply periodic minimal surfaces for carbon dioxide capture

Computational investigation of the countercurrent flows in an additively manufactured (AM) column packed with triply periodic minimal surface (TPMS) is challenging. Multiphase flow simulations using the volume of fluid (VOF) method can explain the column’s hydrodynamic characteristics, including interfacial area, liquid holdup, pressure drop, flow regime, etc. The interfacial area is a key factor dictating the mass transfer via the absorption process, and thereby the overall efficiency of the column. The impacts of a solvent's physical properties, liquid and gas loads, and contact angle on the hydrodynamics are extensively explored. The solvents include traditional solvent (monoethanolamine [MEA]) used in industry as well as a water-lean solvent (EEMPA) as prospective solvents for carbon capture. As expected, interfacial area and liquid holdup increase with increasing liquid loads (q L ). The EEMPA exhibits higher values for the interfacial area and liquid holdup compared to those for the MEA. The dry and wet pressure drops per unit length in the column at different gas loads (F G ) are calculated and further compared with the empirical correlations for traditional packings. At low gas loads, i.e., in the preloading regime, the predicted values of the wet and dry pressure drops match well with the corresponding values calculated from available correlations. The gas load has a marginal impact on the interfacial area at its lower value, but the higher value of F G (>2.18 $\sqrt{Pa}$) causes flooding in the column. The effect of varying contact angles on the interfacial area and liquid holdup in the preloading regime is also studied. Both interfacial area and liquid holdup decrease with the increase in the value of the contact angle. Altogether, the effect of the contact angle on interfacial area is more pronounced than other parameters influencing the interfacial area.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Electron beam surface remelting enhanced corrosion resistance of additively manufactured Ti-6Al-4V as a potential in-situ re-finishing technique

This study explores the effect of surface re-finishing on the corrosion behavior of electron beam manufactured (EBM) Ti-G5 (Ti-6Al-4V), including the novel application of an electron beam surface remelting (EBSR) technique. Specifically, the relationship between material surface roughness and corrosion resistance was examined. Surface roughness was tested in the as-printed (AP), mechanically polished (MP), and EBSR states and compared to wrought (WR) counterparts. Electrochemical measurements were performed in chloride-containing media. It was observed that surface roughness, rather than differences in the underlying microstructure, played a more significant role in the general corrosion resistance in the environment explored here. While both MP and EBSR methods reduced surface roughness and enhanced corrosion resistance, mechanical polishing has many known limitations. The EBSR process explored herein demonstrated positive preliminary results. The surface roughness (R a ) of the EBM-AP material was considerably reduced by 82%. Additionally, the measured corrosion current density in 0.6 M NaCl for the EBSR sample is 0.05 µA cm –2 , five times less than the value obtained for the EBM-AP specimen (0.26 µA cm –2 ).

42 ENGINEERING↗
DOE OSTI2024

Development of Surface Treatment Solutions for Stamping Tools Fabricated via Additive Manufacturing

Oak Ridge National Laboratory (ORNL) and H.E.F. USA, Inc. (HEF) partnered to develop wear resistant surface treatment of additive manufactured steels for stamping die applications under CRADA agreement NFE-19-07909. This project aimed at evaluating the ARCOR® process, developed by HEF, to improve the surface behavior of 410SS (stainless steel), 410NiMo SS, 630 SS, and Maraging 250 steel coupons and demo components, fabricated via wire arc additive manufacturing (WAAM), with and without post print heat treatment. The peak hardness achieved was ~1000 HV and above (Up to 1300 HV) for all materials under proper processing parameters, and far exceeded the target hardness of 746 HV (60 HRC). Finally, stamping tools were printed and nitrocarburized with the optimum parameters, and then went through 500 fabrication cycles. Characterization of the used 17-4PH stamping tool discovered no crack or delamination in the nitrocarburized layer and the interface between the nitrocarburized layer and substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2024

In Situ Prediction of Microstructure and Mechanical Properties in Laser-Remelted Al-Si Alloys: Towards Enhanced Additive Manufacturing

Laser surface remelting of aluminum alloys has emerged as a promising technique to enhance mechanical properties through refined microstructures. This process involves rapid cooling rates ranging from 10 3 to 10 8 °C/s, which increase solid solubility within aluminum alloys, shifting their eutectic composition to a larger value of silicon content. Consequently, the resulting microstructure combines a strengthened aluminum matrix with silicon fibers. This study focuses on the laser scanning of Al-Si aluminum alloy to reduce the size of aluminum matrix spacings and transform fibrous silicon particles from micrometer to nanometer dimensions. Analysis revealed that the eutectic structure contained 17.55% silicon by weight, surpassing the equilibrium eutectic composition of 12.6% silicon. Microstructure dimensions within the molten zones, termed ‘melt pools’, were extensively examined using Scanning Electron Microscopy (SEM) at intervals of approximately 20 μm from the surface. A notable increase in hardness, exceeding 50% compared to the base plate, was observed in the melt pool regions. Thus, it is exemplified that laser surface remelting introduces a novel strengthening mechanism in the alloy. Moreover, this study develops an in situ method for predicting melt pool properties and dimensions. A predictive model is proposed, correlating energy density and spectral signals emitted during laser remelting with mechanical properties and melt pool dimensions. This method significantly reduces characterization time from days to seconds, offering a streamlined approach for future studies in additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Parametrically designed surface topography on CAD models of additively manufactured lattice structures for improved design validation

Additively Manufactured (AM) lattice structures of the laser powder bed fusion (LPBF) process generally have different surface geometries depending on the overhang angle and location. This means that the design validation stage is often challenging, considering it is based on an ideal Computer Aided Design (CAD) model that is not truly representative, since the AM part will be different in terms of dimensional accuracy and surface finish. Previous studies have relied on the design of surface textures that are independent of the overhang angle, or techniques based on directly using X-ray Computed Tomography (XCT) data. In this paper, a new technique for designing surface texture on the CAD of lattices has been investigated and correlated with areal surface roughness parameters. After extracting areal surface parameters from the XCT data of the lattice, the method allowed for the design of this surface texture on the part CAD taking in consideration if its up skin or down skin, without using XCT data as the main input. By applying this method, it is possible to obtain a lattice CAD model with a designed surface texture and geometry that is more representative of the actual AM lattice. The mean deviation between the CAD model with the designed surface and the XCT was a third of the one between the XCT and the initial CAD. The proposed method allows for designing and replicating LPBF AM surfaces on the CAD of a lattice, taking into consideration the dimensional deviation caused by AM surfaces, especially on overhangs. Assuming that an LPBF AM process is stable and produces approximately the same AM surface, this method can be used to predict the geometry of a lattice, providing a cost-effective and efficient methodology that minimizes the time needed for design validation.

42 ENGINEERING↗
DOE OSTI2022

On the additivity of climate responses to the volcanic and solar forcing in the early 19th century

The early 19th century was the coldest period over the past 500 years, when strong tropical volcanic events and a solar minimum coincided. The 1809 unidentified eruption and the 1815 Tambora eruption happened consecutively during the Dalton minimum of solar irradiance; however, the relative role of the two forcing (volcano and solar) agents is still unclear. In this study, we examine the responses from a set of early 19th century simulations with combined and separated volcanic and solar forcing agents, as suggested in the protocol for the past1000 experiment of the Paleoclimate Modelling Intercomparison Project – Phase 4 (PMIP4). From 20-member ensemble simulations with the Max Planck Institute Earth system model (MPI-ESM1.2-LR), we find that the volcano- and solar-induced surface cooling is additive in the global mean/large scale, regardless of combining or separating the forcing agents. The two solar reconstructions (SATIRE (Spectral and Total Irradiance REconstruction-Millennia model) and PMOD (Physikalisch-Meteorologisches Observatorium Davos)) contribute to a cooling before and after 1815 of ~0.05 and ~0.15 K monthly average near-surface air cooling, respectively, indicating a limited solar contribution to the early 19th century cold period. The volcanic events provide the main cooling contributions, inducing a surface cooling that peaks at ~0.82 K for the 1809 event and ~1.35 K for Tambora. After the Tambora eruption, the temperature in most regions increases toward climatology largely within 5 years, along with the reduction of volcanic forcing. In the northern extratropical oceans, the temperature increases slowly at a constant rate until 1830, which is related to the reduction of seasonality and the concurrent changes in Arctic sea-ice extent. The albedo feedback of Arctic sea ice is found to be the main contributor to the Arctic amplification of the cooling signal. Several non-additive responses to solar and volcanic forcing happen on regional scales. In the atmosphere, the stratospheric polar vortex tends to strengthen when combining both volcano and solar forcing, even though the two forcing agents separately induce opposite-sign changes in stratospheric temperatures and zonal winds. In the ocean, when combining the two forcings, additional surface cold water propagates to the northern extratropics from the additional solar cooling in the tropics, which results in regional cooling along the propagation. Overall, this study not only quantifies the surface responses from combinations of the volcano and solar forcing, but also highlights the components that cannot be simply added from the responses of the individual forcing agents, indicating that a relatively small forcing agent (such as solar in early 19th century) can impact the response from the large forcing (such as the 1815 Tambora eruption) when considering regional climates.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Relationships between fault characteristics and seismic responses in a large lab-scale tri-axial injection test conducted on a faulted Castlegate Sandstone

Here to investigate mechanisms causing microseismicity (M w < 2) at a CO 2 injection site, a large-scale triaxial block experiment was carried out on a faulted (saw-cut) cubic-meter of Castlegate Sandstone. The experiment consisted of injection tests at varying differential stresses, while monitoring and recording pore pressure and acoustic emissions (AEs). During the experiment, ~33,000 AEs and ~14 mm of horizontal displacement/slip, like a strike-slip fault movement, occurred. To understand the AE responses and ascertain fault characteristics near the located AEs, we modeled the topography of the fault surface, fault aperture, and fault-gouge thickness using pre- and post-experiment laser scans of the fault surface on each half of the block. Additionally, we characterized surface roughness parallel and perpendicular to slip. Models show crushing and flattening of the fault surfaces can be linked to the spatiotemporal distribution of AEs within 50 mm of the fault surface. Approximately 65% of AEs were in areas with small aperture (≤300 μm); thicker fault gouge was observed in adjacent areas with wider aperture and shows a two-fold reduction in grain size relative to unaltered Castlegate Sandstone. This work provides a conceptual understanding on fault surface evolution, which can be applied towards modeling of seismic slip.

58 GEOSCIENCES↗
DOE OSTI2020

Investigating relationship between surface topography and emissivity of metallic additively manufactured parts

Due to the direct relationship between thermal history and mechanical behavior, in situ thermal monitoring is key in gauging quality of parts produced with additive manufacturing (AM). Accurate monitoring of temperatures in an AM process requires knowledge of environment and object parameters including object emissivity. The emissivity is dependent on several variables, including: wavelength, material composition, temperature, and surface topography. Researchers have been concerned with the thermal emissivity dependence on temperature since large ranges are seen in metal powder bed processes, but there is also an extensive range of surfaces produced by AM. This work focused on discovering what roughness characteristics control thermal emissivity through investigation of prototypic 316 stainless steel AM samples produced with a range of build conditions on a laser powder bed fusion machine. Through experimental measurements of emissivity using hemispherical directional reflectance (HDR), guided by simulations using a finite-difference time-domain (FDTD) Maxwell solver, it was found that combinations of existing roughness parameters describing both height and slope of the surface correlate well with emissivity changes. Furthermore, these parameters work well due to their apt description of surface features encouraging internal reflection, which is the phenomenon that increases emissivity when a surface falls under the geometric optical region conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cast or Additively Manufactured Coils with End Turn Enhanced Heat Transfer Surfaces for Spray or Jet Cooling

Cast or additively manufactured coils present a new opportunity for creativity in thermal management of electric machines. Improvements to the heat transfer of spray or jet cooling of coil end turns through the incorporation of pins or enhanced heat transfer surfaces in the cast end turn surfaces is explored. The thermal response of cast copper half-turns is measured for a range of spray/jet volumetric flow rates and ohmic loss heat fluxes. A significant reduction, ~30%, in the steady state temperature and increased spray cooling heat transfer coefficients was experimentally measured when the pins or enhanced heat transfer surfaces are incorporated.

33 ADVANCED PROPULSION SYSTEMS↗