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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Antarctic Meltwater Accelerates Southern Ocean Evolution Under Projected Atmospheric Warming

Increasing basal meltwater from Antarctic ice shelves may impact the Southern Ocean properties that feed back on the rate of melting. We investigate this feedback in a high‐emissions scenario using an Earth‐system model with interactive ice‐shelf basal melting, an improvement on previous studies that did not have the capability to evolve melt rates and the ocean state self‐consistently. We find that when interactive melt increases, it primarily accelerates the evolution of a spatial pattern of continental shelf warming and cooling that is initiated by freshening and sea‐ice formation decline due to projected atmospheric warming. The competition between enhanced warming at depth from reduced ventilation and enhanced continental shelf cooling from reduced dense water export leads to net ~35% reduction in ice‐shelf meltwater input into the Southern Ocean over the 21st century. Omitting this feedback introduces a bias in the timing of projected ocean‐melt‐driven ice loss from Antarctica.

58 GEOSCIENCES↗
DOE OSTI2025

Crystallization of nanopore-confined imidazolium ionic liquids probed by temperature-resolved in situ grazing-incidence wide angle X-ray scattering (GIWAXS)

The crystallization behavior of ionic liquids (ILs) 1-butyl-3-methylimidazolium [BMIM] hexafluorophosphate [PF 6 ] and chloride [Cl] is investigated upon confinement in 2.3 or 8.2 nm diameter silica nanopore arrays, along with the effects of covalently modifying the pore walls with 1-(3-trimethoxysilylpropyl)3-methylimidazolium [TMS-MIM] + groups. In situ grazing-incidence wide angle x-ray scattering (GIWAXS) is performed during heating from as low as -110 °C to room temperature. Partially ordered “nanodomains” are observed in both ILs in the bulk molten state, but they are disrupted by nanoconfinement. Melting point depression consistent with capillary effects is observed for [BMIM][PF 6 ] in 2.3 nm pores. However, the melting point is elevated for [BMIM][PF 6 ] in 8.2 nm pores, which provide sufficient space to stabilize the crystalline phase. For [BMIM][Cl], crystallization is observed only in 8.2 nm bare silica pores, but the melting point is severely depressed. Tethering with IL-like [TMS-MIM + ] also promotes the crystallization of [BMIM][PF 6 ], resulting in elevated melting points. The combined effects of a larger pore size and pore surface tethering on [BMIM][PF 6 ] result in a single stable crystal phase that persists from -140 °C to 25 °C (vs. the bulk melting point of -11 °C). These results show that when ILs are used in confined systems, complex crystallization behavior can emerge depending on the counterion, pore size, and surface modification that require consideration of ion layering in the confined space in addition to surface free energy effects.

He, Yuxin [University of Kentucky, Lexington, KY (↗
DOE OSTI2024

Density of molten oxides measured in an aero-acoustic levitator

Knowing the thermophysical properties of high-temperature melts can aid the design of melt processes and validate atomic structural models, such as those used in studying glass formation. Property measurements on such melts are challenging, however, due to container-related contamination and heterogeneous nucleation. Containerless processing techniques that employ levitation can be used to avoid these obstacles. In that context, we demonstrate here the application of silhouette imaging to measure the density of molten oxides in an aero-acoustic levitation instrument (AAL). The AAL combines gas jet levitation with actively controlled acoustic positioning to enable full optical access to samples ca. 2–4 mm in diameter, which are laser beam heated and melted. The cross sections of molten drops are imaged using a monochromatic light source and narrowband-filtered camera. Melt volume is calculated from the cross sections and used to find density at several temperatures ranging 1530–1920 K, including up to 350 K of supercooling. We report densities for CaAl 2 O 4 , Ca 12 Al 14 O 33 , CaSiO 3 , their Fe 2 O 3 -bearing analogs, and 83TiO 2 -17RE 2 O 3 (RE = La or Nd). These provide important benchmarks of the capabilities, measurement uncertainties, and future outlook for this technique.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Temperature and conductivity in shock compressed bridgmanite MgSiO 3 up to 2 TPa

The melting behavior and transport properties of MgSiO 3 at multi-megabar pressures remain poorly constrained despite their importance for high-pressure silicate physics. Here we report the first direct measurements of temperature and optical reflectivity in shock-compressed bridgmanite (MgSiO 3 ) using laser-driven decaying shock compression combined with velocimetry and optical pyrometry. Temperature and reflectivity data spanning approximately 4000–60 000 K were used to constrain the MgSiO 3 melting curve and to infer its electrical conductivity. We find that the MgSiO 3 melting curve becomes shallower than that of iron above 400 GPa, yielding lower melting temperatures in planetary mantles than predicted by several previous theoretical estimates. Across the solid-liquid transition, the inferred electrical conductivity increases significantly, reaching ∼2000 Ω cm −1 . These results provide experimental benchmarks for theoretical models of silicate melting and transport under extreme pressure-temperature conditions.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Robust Solar Receivers Using MAX Phase Materials

This work was supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy under the Solar Energy Technologies Office Award Number 35928. The objective of the proposed effort was to develop and optimize additive manufacturing technologies for low-cost fabrication of high-temperature receivers using MAX phase-based materials (Ti 3 SiC 2 and Ti 3 AlC 2 ). MAX phase materials are a group of ternary metal carbides and nitrides where M stands for an early transition metal element, A is a group 13–16 element, and X is C and/or N. In Phase 1, the binder jetting additive manufacturing process was used to synthesize and characterize the Ti 3 SiC 2 MAX phase material. The typical process involved first producing a TiC preform using binder jetting followed by infiltration of the preform with silicon melt to form Ti 3 SiC 2 in situ. The reaction-infiltrated samples showed formation of MAX phase in the sample core; however, the surface showed cracking. Various process conditions—cooling rates, hold times, Si proportion, etc.—were varied to minimize the surface cracking. The fabricated MAX phase core was characterized by microstructure analysis and evaluations of mechanical properties such as hardness and thermal shock. In Phase 2, the focus included fabrication of Ti 3 SiC 2 MAX phase materials by spark plasma sintering (SPS) and synthesis of Ti 3 AlC 2 MAX phase materials by the Al melt infiltration process. It is expected that Al infiltration will not cause sample cracking, since Al does not expand during solidification. In addition, other processing approaches were investigated to fabricate the MAX phase materials, such as SPS with a graphite bedding approach for producing short-length Ti 3 AlC 2 MAX phase tubes for demonstration of prototypical Concentrating Solar Power receiver tubes. Fabricated samples underwent thermo-mechanical testing to validate the materials for the solar receiver application at temperatures >1000°C. In Phase 3, the effort focused on the development and optimization of the Ti-Al-C MAX phase composite material using the Al melt infiltration approach. We started with optimization of precursor powders and making preform structures by either pressing them in a die or using the binder jetting additive manufacturing process followed by Al melt infiltration. In addition, we investigated the formation of preform structures by cold isostatic pressing followed by Al melt infiltration for making Ti-Al-C MAX phase composite. Thermo-mechanical characterizations, such as creep, strength, and thermal shock, were conducted to establish the structures’ performance.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Investigations into the Ternary NaF-KF-UF4 Salt System – Phase A

A knowledge gap exists in the data and understanding of fresh fuel salt and irradiated multicomponent fuel salt systems thermophysical properties. Quantifying these properties is necessary for the design and construction of test reactors, as well as the licensing of future commercial molten-salt reactors. To facilitate thermal property determination on a proposed fuel salt composition for Seaborg Technologies, several samples containing depleted uranium tetrafluoride (UF4), sodium fluoride (NaF), and potassium fluoride (KF) were blended, and a melt temperature analysis was performed. From the melting temperature analysis, it was determined that sample Seaborg-7, a ternary salt composition of 26.4UF4-24.7KF-48.9NaF (mol%), was very near a ternary eutectic point. Therefore, thermal properties such as melting temperature, salt stability, density, heat capacity, thermal diffusivity, and viscosity were experimentally determined on the Seaborg-7 salt. These measurements document the baseline properties of fresh fuel salt as a function of temperature, where future experiments on irradiated fuel salt will provide a holistic perspective on the change of thermophysical properties during reactor operations. Several precision instruments were used to collect property data, and instrument calibrations and data collection were performed and documented in a standardized and reproducible manner with meticulous detail. This process ensured that the measurement procedures and resulting data can readily be duplicated elsewhere. The Seaborg-7 salt was shown to be stable at temperatures up to 900°C, as no mass change was observed upon repeated heating and cooling. The peak melting temperature was determined to be 547°C (557°C endset). The enthalpy of fusion (??H?_fus^o) was determined to be 167.5 ± 2.7 J/g while the enthalpy of crystallization (??H?_c^o) was determined to be -147.8 ± 13.3 J/g. In addition to the eutectic melting peak, upon heating, several pre eutectic peaks were observed, occurring at 470°C (onset) and 499°C (peak). Specific heat capacity measurements showed a slightly increasing trend with respect to temperature in the solid phase, while the liquid-specific heat capacity showed a somewhat flat trend with an average value of 106.1 ± 1.24 J/mol·K between 600 to 800°C. Three independent trials using the Seaborg-7 salt determined the density to be ?(T) = 4.908 – 0.000363·T(°C), validated between 32 to 200°C, and ?(T) = 4.808 – 0.00113·T(°C), validated between ~575 to 850°C. Thermal diffusivity was determined for the liquid state and is represented by the linear equation y = 0.1581 + 0.000207·T(°C) between 550 to 850°C. The viscosity was determined from 600 to 800°C and is represented by the exponential fit equation, ? (mPa·s) = 736.58e^(-0.006·T(°C)). This report documents the conclusion of fuel salt thermophysical property measurements for the Seaborg SPP, Phase A project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Implementation of disruptive designs for gas turbine components using direct energy deposition additive manufacturing

This research aims to develop a framework for establishing the correlation between in-situ monitoring data, process parameters, and microstructure evolution in blown-powder laser-directed energy deposition (DED) additive manufacturing (AM). To achieve this, a comprehensive manufacturing framework has been developed, spanning from in-situ data acquisition, melt-pool simulation, microstructure modeling, and statistical microstructure quantification. A machine learning-based surrogate model is constructed to predict melt pool geometry directly from in-situ coaxial camera data. The surrogate model is trained using outputs from a high-fidelity melt pool simulation, which provides accurate melt pool dimension data under varying process conditions. The predicted melt pool geometry is then used as input to a microstructure model to predict microstructural features. To rigorously compare and analyze microstructures, the project introduces statistical metrics that quantify differences based on key features such as morphology and texture. Microstructures are represented using advanced statistical descriptors including angular chord length distribution, two-point spatial statistics, orientation distribution function, and global spherical harmonic. These representations are used to compute four distinct “dissimilarity scores” that quantitatively capture differences in texture and morphology. This framework is demonstrated to enable automated calibration of simulation parameters by minimizing discrepancies between simulated and target microstructures. The technology developed in this project enables direct correlation between in-situ monitoring data and resulting microstructure, paving the way for adaptive microstructure control in metal AM. This capability strengthens the connection between process parameters and final material properties, facilitating more precise and reliable material design.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Low-cost and high-performance heat exchangers for CSP

This project aimed to design and manufacture a low-cost and high-performance, particle–to–sCO 2 heat exchanger (HX) for Concentrated Solar Power (CSP) using additive manufacturing (AM). Three enabling technologies will be integrated to achieve the targeted cost and performance. The first technology is the extreme high‐speed laser materials deposition (LMD) AM process known by its German acronym EHLA that was invented at the Fraunhofer Institute for Laser Technology. The EHLA process utilizes a specially designed powder-feeding nozzle that enables a laser to melt the powder particles above the melt pool, in contrast to the conventional LMD process where the powders are melted inside the melt pool. EHLA enables much faster deposition rate than conventional LMD without the need to wait for the powders to melt. The second technology is an innovative double-helical HX geometry that can be easily fabricated using the EHLA process by rotating a rod at a high-speed to take advantage of the high EHLA deposition rate. The double-helical fins separate the hot region (the hot particle side) and the cold region (the sCO 2 side) and provide large heat transfer surface area without a large pressure drop on the sCO 2 side. The particle side will have a larger gap to facilitate the particle flow. The outer rims of the double helixes can be sealed off using the same AM process. After sealing-off, additional double helixes can be built radially on top of the first set to improve HX performance. The HX can be installed vertically for gravity-driven flow of the hot particles if necessary. The third technology is a low-cost high-temperature alumina-forming austenitic (AFA) steel TMA-6350 that has creep and oxidation resistance up to 1100 °C. These technologies together will enable high-performance and low-cost HXs for particle–to–sCO 2 for CSP.

14 SOLAR ENERGY↗
DOE OSTI2025

Chemical Recycling of Plastic Waste to Higher Value Lubricants

The aim of this project was to develop scalable methods to convert plastic waste to petrochemical-equivalent feedstocks and demonstrate their utility in lubricant base oil and wax applications. These objectives were partially accomplished, by scaling up the synthesis of platinum-on-strontium titanate catalysts to twenty gram batches, scaling up the conversion of plastic waste to twenty-five grams of plastic, producing high-melt waxes and characterizing their properties, and demonstrating the purification of high-melt waxes. High-melt waxes are one petrochemical-equivalent feedstock that can be made from plastic waste, consisting of a hard wax with a melt point above 65 C. They are used as ingredients in hot melt adhesives, coatings, and cosmetics. Producing a petrochemical-equivalent feedstock from plastic waste provides an advantage in lower carbon footprint and manufacturing cost, as the waste feedstock costs less than crude oil.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

ISMIP6-based Antarctic projections to 2100: simulations with the BISICLES ice sheet model

The contribution of the Antarctic Ice Sheet is one of the most uncertain components of sea level rise to 2100. Ice sheet models are the primary tool for projecting future sea level contribution from continental ice sheets. The Ice Sheet Model Intercomparison for the Coupled Model Intercomparison Phase 6 (ISMIP6) provided projections of the ice sheet contribution to sea level over the 21st century, quantifying uncertainty due to ice sheet model, climate model, emission scenario, and uncertain parameters. We present simulations following the ISMIP6 framework with the BISICLES ice sheet model and new experiments extending the ISMIP6 protocol to more comprehensively sample uncertainties in future climate, ice shelf sensitivity to ocean melting, and their interactions. These results contributed to the land ice projections of Edwards et al. (2021), which formed the basis of sea level projections for the Sixth Assessment Report of the Intergovernmental Panel on Climate Change (AR6). Our experiments show the important interplay between surface mass balance processes and ocean-driven melt in determining Antarctic sea level contribution. Under higher-warming scenarios, high accumulation offsets more ocean-driven mass loss when sensitivity to ocean-driven melt is low. Conversely, we show that when sensitivity to ocean warming is high, ocean melting drives increased mass loss despite high accumulation. Overall, we simulate a sea level contribution range across our experiments from 2 to 178 mm. Finally, we show that collapse of ice shelves due to surface warming increases sea level contribution by 25 mm relative to the no-collapse experiments, for both moderate and high sensitivity of ice shelf melting to ocean forcing.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Effect of Si Content in Electrode and SiO2 Additions to the Slag during Electroslag Remelting

Evolution of Si concentration in 316 stainless steel electrodes was observed during a melting campaign consisting of recycling electroslag remelted (ESR) ingots to make new electrodes using vacuum induction melting (VIM). This campaign consisted of iterations of VIM + ESR operations to optimize melting parameters. The effect of Si content on the melt parameters and ingot quality was further evaluated and additions of SiO2 to the slag chemistry were studied using research-scale experiments, x-ray diffraction (XRF), combustion analysis, visual inspections, and computational tools. The Si concentration was found to decrease by approximately 600 ppm following ESR of 150 lb. research-scale electrodes. Eventually, this led to failure of the slag skin and direct ingot/crucible contact. Additions of SiO2 to the slag at levels matching the original calculated Si concentration in the electrode did not eliminate the slag skin failure and the current during steady state increased to maintain a constant melt rate. In this investigation, we propose a mechanism of slag skin failure consisting of local concentration of current density due to absence, or breakage, of the SiO2 layer around the molten metal drop during ESR. This theory was reinforced by additional experiments in which Nb was added to the electrode to change the structure of the oxide layer around the drops.

Jablonski, Paul↗
DOE OSTI2024

Sensors for passively measuring a maximum temperature of a nuclear reactor, and related methods

A sensor for passively measuring a maximum temperature within a nuclear reactor comprises a substrate, and a plurality of melt wires within a cavity defined within the substrate, at least one melt wire of the plurality of melt wires exhibiting a variable melting temperature along a length of the at least one melt wire. Related sensors and methods of forming the sensors are also disclosed.

Daw, Joshua↗
DOE OSTI2024

Effect of cold-cap-bottom shear stress on primary foam stability

Here, we analyze the heat transfer between the melt pool and the layer of reacting materials called cold cap, which is the determining factor for the glass production rate in Joule-heated air-bubbled nuclear waste glass melters. We consider the effects of bubbling rate, melt viscosity, melt thermal conductivity, conversion kinetics, and shear rate at the cold-cap bottom, and develop simple relationships for the cold-cap bottom temperature and glass production rate. We show that the melt convection enhances the heat transfer to the cold cap by suppressing the thermal boundary layer and primary foam, while the conversion kinetics opposes these effects. Additionally, we mention how dissolving silica particles affects the primary foam stability and discuss the limitations of the presented approach for vigorously foaming feeds.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Time-Resolved X-ray Emission Spectroscopy and Resonant Inelastic X-ray Scattering Spectroscopy of Laser Irradiated Carbon

The existence of liquid carbon as an intermediate phase preceding the formation of novel carbon materials has been a point of contention for several decades. Experimental observation of such a liquid state requires nonthermal melting of solid carbon materials at various laser fluences and pulse properties. Reflectivity experiments performed in the mid-1980s reached opposing conclusions regarding the metallic or insulating properties of the purported liquid state. Time-resolved X-ray absorption studies showed shortening of C–C bonds and increasing diffraction densities, thought to evidence a liquid or glassy carbon state, respectively. Nevertheless, none of these experiments provided information on the electronic structure of the proposed liquid state. Herein, we report the results of time-resolved resonant inelastic X-ray scattering (RIXS) and time-resolved X-ray emission spectroscopy (XES) studies on amorphous carbon (a-C) and ultrananocrystalline diamond (UNCD) as a function of delay time between the irradiating pulse and X-ray probe. For both a-C and UNCD, we attribute decreases in RIXS or XES signals to transition blocking, relaxation, and finally, ablation. Increased signal at 20 ps following the irradiation of the UNCD is attributed to the probable formation of nanoscale structures in the ablation plume. Further, differences in the amount of signal observed between a-C and UNCD are explained by the difference in sample thickness and, specifically, incomplete melting of the UNCD film. Comparisons to spectral simulations based on MD trajectories at extreme conditions indicate that the carbon state in our experiments is crystalline. Normal mode analysis confirmed that symmetrical bending or stretching of the C–C bonds in the diamond lattice results in XES spectra with small intensity differences. Overall, we observed no evidence of melting to a liquid state, as determined by the lack of changes in the spectral properties for up to 100 ps delays following the melting pulses.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Calibration and validation of the foundation for a multiphase strength model for tin

In this work, the Common Model of Multi-phase Strength and Equation of State (CMMP) model was applied to tin. Specifically, calibrations of the strength-specific elements of the CMMP foundation were developed with a combination of experiments and theory, and then the model was validated experimentally. The first element of the foundation is a 10 multi-phase analytic treatment of the melt temperature and the shear modulus for the solid phases. These models were parameterized for each phase based on ab initio calculations using the software VASP (Vienna Ab initio Simulations Package) based on density functional theory (DFT). The shear modulus model for the ambient β phase was validated with ultrasonic sound speed measurements as a function of pressure and temperature. The second element of the foundation is a viscoplastic strength model for the β phase, upon which strength for inaccessible higher-pressure phases can be scaled as necessary. The stress-strain response of tin was measured at strain rates of 10 -3 to 3 x 10 3 s -1 and temperatures ranging from 87 to 373 K. The Preston-Tonks-Wallace (PTW) strength model was fit to that data using Bayesian model calibration. For validation, six forward and two reverse Taylor impact experiments were performed at different velocities to measure large plastic deformation of tin at strain rates up to 10 5 s -1 . The PTW model accurately predicted the deformed shapes of the cylinders, with modest discrepancies attributed to the inability 20 of PTW to capture the effects of twinning and dynamic recrystallization. Some material in the simulations of higher velocity Taylor cylinders reached the melting temperature, thus testing the multiphase model because of the presence of a second phase, the liquid. In simulations using a traditional modeling approach, the abrupt reduction of strength upon melt resulted in poor predictions of the deformed shape and non-physical temperatures. With CMMP, the most deformed material points evolved gradually to a mixed solid-liquid but never fully liquid state, never fully lost strength, 25 stayed at the melt temperature as the latent heat of fusion was absorbed, and predicted the deformed shape well.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Laser powder bed fusion parameter estimation with k-NN

Abstract Laser powder bed fusion (L-PBF) is a technique within additive manufacturing that uses a high power density laser to build parts from fused powdered metal alloy. This technology is well equipped to produce complex parts with otherwise impossible features, such as hidden voids or lattice structures. Alongside capability, reliability and quality are key characteristics considered when choosing a manufacturing method, and these are gaining attention as this method becomes more prevalent in industry. One main indicator of a stable L-PBF process is consistent melt pool geometry, and the properties of which are likely to determine the quality of the part produced. As computing power and sensing technologies become more advanced, this melt pool geometry could be studied in real time. This work addresses the challenge by leveraging a k-nearest neighbor (k-NN) model to identify key features within melt pool imagery and predict the energy density. The k-NN model was trained on data provided by the National Institute of Standards and Technology (NIST). Data preprocessing was performed on the images to extract features that were used in the k-NN model. This approach was used to accurately infer the energy density of unseen layers within the same part. The algorithm was subsequently tested with unique scan strategies and found to reasonably estimate the energy density of different parts. A fivefold cross validation found the algorithm to be consistently predicting the class of 91.4% of the in situ melt pool images.

Jung, Patrick (ORCID:0000000267890859)↗
DOE OSTI2025

Multiscale investigation of thermomechanical and compositional developments in Ni alloy 718 under laser processing

Laser processing has been widely employed in various applications due to its exceptional spatial resolution. However, the rapid temperature gradients generated in localized areas present significant challenges for experimental characterization using conventional instruments. To characterize Ni alloy 718 during laser processing, we employed in-situ synchrotron X-ray diffraction with a high-speed detector, a method particularly well-suited for probing processes with high temporal and spatial resolution. Through a series of in-situ experiments, we investigated the local variations in the evolution of microstructures and thermomechanical behaviors within a keyhole mode melt pool. The in situ macroscopic thermomechanical behaviors were quantified using an empirical model derived from diffraction patterns, with experimental results showing reasonable agreement with finite element analysis. Various laser parameters were tested to assess their influences on the residual strains in the melt pools. The results revealed that the residual strain in the keyhole mode melt pool is relatively insensitive to variations in the parameters and is smaller than that in the melt pool created under conduction mode laser scanning. Additionally, we analyzed the shapes of individual diffraction spots, providing insights into the plastic behaviors and compositional developments in the resolidified alloy. The analysis confirmed that compositional variations in a dendritic microstructure manifest as asymmetric broadening of the diffraction spots.

Ni alloy 718↗
DOE OSTI2024

A Gaussian Process-Based extended Goldak heat source model for finite element simulation of laser powder bed fusion additive manufacturing process

In this study, laser powder bed fusion (L-PBF) additive manufacturing (AM) is a key enabling technology to manufacture highly complex and integrated metallic structures. In L-PBF AM process, the melting of the metal powders and the layers underneath can be governed by either “conduction mode” or “keyhole mode”, with the keyhole mode reportedly leading to porosity and decreased strength and ductility by many studies. In part scale simulations, finite element (FE) model is often used to study the temperature distribution during printing and to predict the residual stress, where a volumetric heat flux with a Gaussian or a double ellipsoidal (Goldak) distribution is often applied as the laser heat source. However, the above heat source models can only capture the melt pool shape in the conduction mode, and fail to capture the transition to keyhole melting mode when the process parameters change. To overcome this inaccuracy, an extended Goldak heat source model is proposed by introducing a laser penetration term as a function of laser parameters obtained from a Gaussian-Process (GP) model. The model is validated by “2D pad” AlSi10Mg L-PBF experiments under a wide range of laser power, scan speed, and laser focus offset, and the results show the model successfully captures the measured melt pool shape in all conditions.

36 MATERIALS SCIENCE↗