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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 271 records · Page 15

High-Temperature Active Magnetic Bearing Development for Supercritical CO 2 Machinery Applications

Hermetic machinery utilizing gas bearings for MW-scale supercritical CO 2 (sCO 2 ) machinery applications can have significantly lower power loss and enable improved cycle efficiency compared to conventional machinery with oil-lubricated bearings. Active magnetic bearings (AMBs) are another option anticipated to have similar power loss and load capacity to gas bearings as well as offering larger mechanical tolerances, the ability to tune properties, and high reliability due to lack of mechanical wear. AMBs also have proven commercial experience at MW-scale, though environments for high-temperature sCO 2 power cycle machinery conditions are novel. Besides the potential impact of AMBs for sCO 2 turbomachinery, the technology also offers promising benefits for steam and gas turbines for power generation, compressors and expanders for industrial heat and power, and in other oil and gas and space applications. The goals of this project were to conceptual design an AMB and perform material testing. Conceptual designs for radial and thrust AMBs were produced based on a hermetically-sealed sCO 2 machinery waste-heat recovery (WHR) application for sizing and loads, and choosing a target design temperature of 540°C useful for high-temperature sCO 2 turbines for concentrating solar power (CSP) applications. Conceptual designs were initially developed for multiple radial and thrust AMBs with spreadsheet-based calculations before selecting one of each to develop further using higher-fidelity design methods for magnetic and structural performance. It was found that the radial AMB at 540°C was feasible, but the thrust AMB needed to be limited to 315°C for high-speed operation. The decision for a reduced-temperature thrust AMB was the result of several significant conclusions: 1) Hiperco 50A, originally chosen for good magnetic performance at high temperature, had insufficient strength for high-speed operation, so it was replaced with 17-4 PH. 2) The reduced magnetic performance from 17-4 PH yielded a larger bearing size, reducing the strength margin. 3) This ultimately led to a creative design implementing a more-compact E-core topology, compared to the original (conventional) C-core, and an integral shaft-disk with Hirth joint connection. These conceptual designs are unique for the size and temperature in CO 2 , relevant for MW-scale CSP applications. Long term, high temperature test data was generated for several materials, filling a void in the current body of literature. Corrosion and magnetic performance measurements were produced for PM materials (Alnico 5-7C, Alnico 9C, and SmCo) with and without nickel-coating for environments of high-temperature CO 2 up to 550°C at atmospheric pressure and 450°C at 103 bar for up to 6,000 hours. Corrosion measurements were also produced for Hiperco 50, a SM material relevant for AMB laminations, with and without C5 coating. Comparisons were also made for 450°C and 550°C, atmospheric pressure air exposures up to 5,000 hours. Results generally show that coatings can be effective at improving oxidation resistance of the bare materials, and Alnicos generally outperformed SmCo after high-temperature exposure. In addition to technical feasibility demonstrated by the design, economic feasibility was demonstrated by updating the TEA from the reference machine, re-evaluating it with CAPEX and OPEX to reflect estimated changes from process-lubricated bearings to AMBs. AMBs were shown to be comparable in performance to process-lubricated bearings, still showing a notable improvement over conventional machinery architecture with oil-lubricated bearings.

42 ENGINEERING↗

Radiocarbon of soil CO2 efflux and soils with experimental soil warming and drying in lowland tropical forests in Panama

In 2019, we measured the Δ14C and δ13C of soil respired carbon dioxide (CO2) in Panamanian forests that are subject to either in situ experimental soil warming (4C above ambient temperature to 1.2 m depth) or in situ experimental drying (50% throughfall exclusion). The warming site and one drying site are both within the Barro Colorado Nature Monument in nearby and similar forests on similar soils, enabling direct comparison of warming and drying effects on soil CO2 efflux. A second drying experiment is on the northern side of the Panama Isthmus on infertile soils where mean annual precipitation is greater, representative of a broad geographic area of the tropics. Given the seasonality of these forests, we performed measurements at stages of the seasonal cycle for which we expected the largest variation in CO2 efflux between control and experimental plots based on previous studies – the wet season (October-December) and dry season (March/April) or dry-to-wet season transition (May). This dataset includes Δ14C and δ13C of in situ soil surface CO2 flux as well as CO2 flux rates, volumetric soil moisture, soil temperature, and calculated partitioning of the fraction of total soil respiration from heterotrophs vs roots at the time of isotope sampling in AllSites_SoilResp_14C_data.xlsx. This dataset also includes Δ14C and δ13C of bulk soil, density fractions, and CO2 respired during laboratory incubations in AllSites_bulk_soil14C.xlsx. Datafiles are also available in csv format.

54 ENVIRONMENTAL SCIENCES↗

The Analog Front-end for the LGAD Based Precision Timing Application in CMS ETL

The analog front-end for the Low Gain Avalanche Detector (LGAD) based precision timing application in the CMS Endcap Timing Layer (ETL) has been prototyped in a 65 nm CMOS mini-ASIC named ETROC0. Serving as the very first prototype of ETL readout chip (ETROC), ETROC0 aims to study and demonstrate the performance of the analog frontend, with the goal to achieve 40 to 50 ps time resolution per hit with LGAD (therefore reach about 30ps per track with two detector-layer hits per track). ETROC0 consists of preamplifier and discriminator stages, which amplifies the LGAD signal and generates digital pulses containing time of arrival and time over threshold information. This paper will focus on the design considerations that lead to the ETROC front-end architecture choice, the key design features of the building blocks, the methodology of using the LGAD simulation data to evaluate and optimize the front-end design. The ETROC0 prototype chips have been extensively tested using charge injection and the measured performance agrees well with simulation. The initial beam test results are also presented, with time resolution of around 33 ps observed from the preamplifier waveform analysis and around 41 ps from the discriminator pulses analysis. A subset of ETROC0 chips have also been tested to a total ionizing dose of 100 MRad with X-ray and no performance degradation been observed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

TRANSLATE - a Monte Carlo simulation of electron transport in liquid argon

Here, the microphysics of electron and photon propagation in liquid argon is a key component of detector design and calibrations needed to construct and perform measurements within a wide range of particle physics experiments. As experiments grow in scale and complexity, and as the precision of their intended measurements increases, the development of tools to investigate important microphysics effects impacting such detectors becomes necessary. In this paper we present a new time-domain Monte Carlo simulation of electron transport in liquid argon. The simulation models the TRANSport in Liquid Argon of near-Thermal Electrons (TRANSLATE) with the aim of providing a multi-purpose software package for the study and optimization of detector environments, with a particular focus on ongoing and next generation liquid argon neutrino experiments utilizing the time projection chamber technology. TRANSLATE builds on previous work of Wojcik and Tachiya, amongst others, introducing additional processes, including ionization, thus modeling the full range of drift electron scattering interactions. The simulation is validated by benchmarking its performance with swarm parameters from data collected in experimental setups operating in gas and liquid.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Revealing the Nanostructure of Mesoporous Fuel Cell Catalyst Supports for Durable, High-Power Performance

Achieving high power performance and durability with low Pt loadings are critical challenges for proton exchange membrane fuel cells. PtCo catalysts developed on new carbon black supports show promise by simultaneously providing good oxygen reduction kinetics and local oxygen transport. We investigate the role of nanoscale morphology in the performance of these catalysts supported on accessible (HSC-e and HSC-f) and conventional (Ketjen Black) porous carbons using 3D electron tomography, nitrogen sorption, and electrochemical performance measurements. We find that the accessible porous carbons have hollow interiors with mesopores that are larger and more numerous than conventional porous carbons. However, mesopore-sized openings (>2 nm width) are too rare to account for significant oxygen transport. Instead we propose the primary oxygen transport pathway into the interior is through 1–2 nm microporous channels permeating the carbon. The increased mesoporosity in the accessible porous carbons results in a shorter diffusion pathlength through constrictive, tortuous micropores in the support shell leading to lower local oxygen transport resistance. In durability testing, the accessible porous carbons show faster rates of electrochemical surface area loss, likely from fewer constrictive pores that would mitigate coarsening, but maintain superior high current density performance at end of test from the improved local oxygen transport.

Electrochemistry↗

Demonstration and performance of an online data selection algorithm for liquid argon time projection chambers using MicroBooNE

The MicroBooNE detector is a liquid argon time projection chamber (LArTPC) that produces three-dimensional images of particle interactions using ionization charge collected by anode wire plane arrays and scintillation light collected by a light detection system. In addition to testing long-standing experimental neutrino anomalies and performing measurements of neutrino interactions with argon nuclei using the Fermilab Booster Neutrino Beam, MicroBooNE aims to develop methodologies for rare beyond the Standard Model and off-beam physics searches. Looking ahead to the upcoming Deep Underground Neutrino Experiment (DUNE), with MicroBooNE serving as a valuable testbed, achieving high sensitivity and livetime for off-beam physics while satisfying data processing and storage constraints will require data-driven, intelligent, and online or real-time data selection techniques. These techniques are essential for reducing data rates and preserving rare signals with high accuracy. In this paper, we describe a fast data selection algorithm suitable for online execution to identify electrons from stopping cosmic ray muons in the MicroBooNE detector utilizing ionization charge information, and present its performance. This represents the first demonstration of online data selection in a LArTPC using real data and charge information exclusively and provides an important proof-of-principle for applying such techniques to other LArTPC experiments such as the Short-Baseline Near Detector and DUNE.

Abratenko, P. [Tufts U. (main)]↗

Regional Assessment for the CO 2 Storage Potential in the Northern Niagaran Pinnacle Reef Trend

The Midwest Regional Carbon Sequestration Partnership (MRCSP) was founded in 2003 as part of the U.S. Department of Energy’s (DOE’s) Regional Carbon Sequestration Partnership initiative. Since its founding, MRCSP has made significant strides toward making CCUS a viable option for states in the region. The public/private consortium, funded through the DOE Regional Carbon Sequestration Initiative, brings together nearly 40 industry partners and 10 states. Battelle, as the project lead, oversees research, development and operations and coordinates activities among the partners. The incremental, phased approach has built a valuable knowledge base for the industry and paved the way for commercial-scale adoption of CCUS technologies. From 2008 to 2020, MRCSP Phase III focused on the development of large-scale injection projects. This report is part of a series of reports prepared under the Midwestern Regional Carbon Sequestration Partnership (MRCSP) Phase III (Development Phase). These reports summarize and detail the findings of the work conducted under the Phase III project. The report describes the regional analysis of the Northern Niagaran Pinnacle Reef Trend (NNPRT) in Northern Michigan as part of the MRCSP programs Regional Assessment goals. The goal of this task was to perform an initial assessment of the geologic storage capacity and injectivity of the Northern Fairway of Michigan’s Niagaran Reef Trend. This was achieved through three main objectives: 1) development of a reef atlas, 2) understanding the regional trends in geology, and 3) estimating CO 2 and CO 2 -EOR resources. Data collected across multiple subtasks were integrated into a mappable database that could be accessed from many of the leading software. The reef atlas was used to map the reefs and associated characteristics across the entire NNPRT. Several methodologies were explored to estimate the CO 2 and CO 2 -EOR resources across the trend which included three scenarios: 1) storage only using fluid substitution and volumetric estimations, 2) CO 2 -EOR which applied proximity analysis concepts and measured performance metrics from the Core Energy reefs to predict performance at all oil reefs, and 3) enhanced storage scenario which combined CO 2 -EOR with fluid substitution to represent maximized storage after completion of CO 2 -EOR.

01 COAL, LIGNITE, AND PEAT↗

Recommendations for Secure Transport: Material Conveyance Physical Protection Technology

Nuclear material is at higher risk of theft and sabotage during transport than during any other phase of the nuclear fuel lifecycle. Nuclear materials are transported in the public domain where adversaries have an upper hand by taking advantage of the time and location of the theft or sabotage attempt. As such, even modest threat profiles for transport of nuclear and radioactive material can require substantial detection and delay measures to support timely response. Conveyance tracking augmented with technology that improves on-the-scene situational awareness at a remote monitoring center has been adopted as a de-facto standard approach for transportation security. At present, the extended tracking and situational awareness capabilities needed for a nuclear material shipment, as is provided by the purpose designed, Transportation – Security, Tracking and Reporting (T-STAR) System, do not exist in a single commercial off-the-shelf (COTS) solution. Typically, the COTS systems that excel in one area are deficient in other areas, presenting challenges to designing well-rounded, robust systems. Still, COTS solutions can offer the basic set of tracking and situational awareness capabilities by indicating last update time, current location, and route taken. By incorporating vehicle and driver performance measures via the vehicle’s controller area network (CAN bus) and video alongside other data streams allows telemetry and other shipment information to be assessed in novel ways.This paper describes the operation, capabilities and features of various conveyance protection systems and approaches, assesses emerging technologies and how they could be used through a unified interface, and enumerates additional ways to provide early detection using vehicle, onboard technologies, effective delay technologies and approaches and simple equipment to improve protection during transport.

Shannon, Michael↗

Effects of composition and pressure on electronic states of iron in bridgmanite

Electronic states of iron in the lower mantle's dominant mineral, (Mg,Fe,Al)(Fe,Al,Si)O 3 bridgmanite, control physical properties of the mantle including density, elasticity, and electrical and thermal conductivity. However, the determination of electronic states of iron has been controversial, in part due to different interpretations of Mössbauer spectroscopy results used to identify spin state, valence state, and site occupancy of iron. We applied energy-domain Mössbauer spectroscopy to a set of four bridgmanite samples spanning a wide range of compositions: 10–50% Fe/total cations, 0–25% Al/total cations, 12–100% Fe 3+ /total Fe. Measurements performed in the diamond-anvil cell at pressures up to 76 GPa below and above the high to low spin transition in Fe 3+ provide a Mössbauer reference library for bridgmanite and demonstrate the effects of pressure and composition on electronic states of iron. Results indicate that although the spin transition in Fe 3+ in the bridgmanite B-site occurs as predicted, it does not strongly affect the observed quadrupole splitting of 1.4 mm/s, and only decreases center shift for this site to 0 mm/s at ~70 GPa. Thus center shift can easily distinguish Fe 3+ from Fe 2+ at high pressure, which exhibits two distinct Mössbauer sites with center shift ~1 mm/s and quadrupole splitting 2.4–3.1 and 3.9 mm/s at ~70 GPa. Correct quantification of Fe 3+ /total Fe in bridgmanite is required to constrain the effects of composition and redox states in experimental measurements of seismic properties of bridgmanite. Furthermore, in Fe-rich, mixed-valence bridgmanite at deep-mantle-relevant pressures, up to ~20% of the Fe may be a Fe 2.5+ charge transfer component, which should enhance electrical and thermal conductivity in Fe-rich heterogeneities at the base of Earth's mantle.

58 GEOSCIENCES↗

Back-Surface Passivation of CdTe Solar Cells Using Solution-Processed Oxidized Aluminum

Although back-surface passivation plays an important role in high-efficiency photovoltaics, it has not yet been definitively demonstrated for CdTe. Here, we present a solution-based process, which achieves passivation and improved electrical performance when very small amounts of oxidized Al 3+ species are deposited at the back surface of CdTe devices. The open circuit voltage (V oc ) is increased and the fill factor (FF) and photoconversion efficiency (PCE) are optimized when the total amount added corresponds to ~1 monolayer, suggesting that the passivation is surface specific. Addition of further Al 3+ species, present in a sparse alumina-like layer, causes the FF and PCE to drop as the interface layer becomes blocking to current flow. The optimized deposit increases the average baseline PCE for both Cu-free devices and devices where Cu is present as a dopant. The greatest improvement is found when the Al 3+ species are deposited prior to the CdCl 2 activation step and Cu is employed. In this case, the best-cell efficiency was improved from 12.6 to 14.4%. Furthermore, time-resolved photoluminescence measurements at the back surface and quantum efficiency measurements performed at the maximum power point indicate that the performance enhancement is due to a reduction in the interface recombination current at the back surface.

14 SOLAR ENERGY↗

Overview of high-density QCD studies with the CMS experiment at the LHC

We review key measurements performed by CMS in the context of its heavy ion physics program, using event samples collected in 2010-2018 with several collision systems and energies. These studies provide detailed macroscopic and microscopic probes of the quark-gluon plasma (QGP) created at the LHC energies, a medium characterized by the highest temperature and smallest baryon-chemical potential ever reached in the laboratory. Numerous observables related to high-density quantum chromodynamics (QCD) were studied, leading to some of the most impactful and qualitatively novel results in the 40-year history of the field. Using a dedicated high-multiplicity trigger in the first pp run, CMS discovered that small collision systems can exhibit signs of collectivity, a generic phenomenon with significant implications and presently understood to affect essentially all soft physics processes. This observation opened new paths to understand how fluidity and plasma properties emerge in QCD matter as a function of system size. Measurements of jet quenching have reached a completely new level of detail by directly assessing, for the first time, the medium modification of parton showers, as opposed to simply observing leading hadrons or di-hadrons. The first fully reconstructed beauty hadron and heavy-flavor jet nuclear modifications were also measured. The large size of the event samples, the precision of the measurements, and the extension of the probed kinematical phase space, allowed many other hard probes of the QGP medium to be explored in detail, leading to multiple groundbreaking findings. In particular, the seminal measurements of bottomonium suppression patterns answer fundamental questions that have been actively pursued, both theoretically and experimentally, by the community since the mid-1980s. We conclude by outlining the opportunities offered by the continuation of this physics program at the LHC.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Studies of a modulated Hall thruster

A typical Hall thruster is powered from a DC power supply and operates with a constant discharge voltage. In operation, the discharge current is subject to strong low frequency oscillations (so-called breathing oscillations). Recent studies have shown that not only can these breathing oscillations be correlated with improved performance, but these oscillations can be induced and controlled by modulating the anode voltage. In this work, a systematic experimental study of the plasma flow in a modulated cylindrical Hall thruster was performed to characterize the effect of natural and modulated breathing oscillations on thruster performance. Measurements suggest that modulating the anode voltage in resonance with the natural breathing frequency does increase the thrust, but a corresponding phase alignment of discharge current and discharge voltage causes the efficiency gains to be insignificant. In addition, the outward shift of the acceleration region causes the plasma plume divergence to increase at the resonance condition and thereby, limit the thrust increase. Further, mechanisms underlying the relative phase between discharge current, ion current, and discharge voltage are investigated experimentally and corroborated with one-dimensional hybrid simulations of the thruster discharge.

modelling↗

Accelerating Resilience of the Community through Holistic Engagement and use of Renewables (ARCHER) Planning Framework

The primary objective of the Accelerating Resilience of the Community through Holistic Engagement and Use of Renewables (ARCHER) initiative was to identify and incorporate the unique variations in energy burden, social vulnerability, living conditions, and access to essential services that differ across communities. By accounting for these localized factors—down to the neighborhood level—the project supports more targeted and effective investments in community resilience. The framework seeks to establish practical planning guidance, methods, and performance measures for community energy resilience, integrate community-level and electric utility system resilience planning, and assess its effectiveness through comparison with conventional and operational planning approaches. A key component of the project was its data exchange platform, which is used to evaluate and demonstrate the tools, methodologies, and planning approaches developed through ARCHER. This open-source platform enables developers and vendors of distribution and outage management systems to build upon the research by incorporating its concepts into their own tools and workflows. This capability is enabled by the transparent availability of data, functional requirements, and the underlying information model. The project yielded several important insights. First, meaningful engagement with communities is essential to achieving comprehensive resilience outcomes. Second, resilience planning is most effective when electric grid considerations and broader community needs are addressed in a coordinated manner. Third, the use of platforms that allow for real-time input from communities can enhance utility responsiveness during restoration activities. Fourth, a structured and systematic planning approach can successfully translate ARCHER concepts into practice. Fifth, the development of an integrated metric that reflects both grid performance and community impacts provides a more holistic basis for evaluating resilience. Finally, incorporating community engagement and equity considerations into grid operations is critical, particularly during severe weather events that result in extended outages.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Induced Magnetic Fields in LBNF Horns and DUNE-PRISM Off-Axis Neutrinos

Deep Underground Neutrino Experiment (DUNE) is a next-generation, long-baseline neutrino oscillation experiment that will utilize an intense neutrino beam from Fermilab to measure neutrino oscillation parameters with unprecedented precision. The DUNE-PRISM near detector concept employs an off-axis measurement strategy to mitigate neutrino-nucleus interaction uncertainties; however, this approach relies critically on the accurate characterization of the neutrino flux. As statistical uncertainties are suppressed in the high-intensity Long Baseline Neutrino Facility (LBNF) beam, beamline focusing uncertainties, specifically those arising from focusing horn geometry, become an important systematic uncertainty source. This work presents Geant4 LBNF beam simulations quantifying one of the most important systematic uncertainties for off-axis fluxes: the impact of manufacturing tolerances in the LBNF horns. The focusing horns consist of coaxial inner and outer conductors. Ideally, the region inside the inner conductor is field-free, while the region between the inner and outer conductors serves as the focusing region, where the magnetic field follows a nominal $1/r$ dependence. However, inner conductor deformations such as eccentricity and ellipticity introduce asymmetry, inducing unintended magnetic fields inside the field-free region. Crucially, while the on-axis neutrino flux remains largely unaffected by these induced fields, the resulting flux fractional shifts become pronounced over a particular range of off-axis positions where the DUNE-PRISM program will perform measurements. Consequently, these inner conductor deformations can impact the precision of flux predictions, which could potentially degrade the sensitivity to oscillation parameters. Possible mitigation strategies for these effects will also be presented.

Bae, Yuri [U. Minnesota, Minneapolis (main)] (ORCI↗

Machine-to-machine variability of roughness and corrosion in additively manufactured 316L stainless steel

Numerous studies on the corrosion response of metal AM have been conducted. Nonetheless, the specimens being tested are commonly ground or polished to remove the outer as-built surface. If metal AM is truly going to be employed as a transformative technology that can produce complex shapes that do not require traditional machining, then the material needs to be evaluated in the as-built state. The reality is that AM alloys have shown significant inconsistencies regarding as-built surface texture, topology, and residual stress. One metric that has shown significant unpredictability in the literature is the susceptibility to localized corrosion of typically passive alloys, such as stainless steel (SS). There are a large number of studies that have attempted to understand the corrosion response of metal AM materials, but these studies are typically performed on materials that have been printed on a single machine and often mechanically polished to a smooth finish. This study compares the corrosion response of as-built AM, laser-beam powder bed fusion (LB-PBF), 316L SS parts that have been fabricated on five different machines. The majority of this work focused on understanding the susceptibility to localized corrosion of AM metals with respect to machine-dependent variables, namely surface roughness, and build angle. Surface roughness data was collected using scanning white light triangulation, laser scanning confocal microscopy, and coherence scanning interferometry. The results show that there is significant variability (p two-tail < 0.05) in the susceptibility to local corrosion initiation of LB-PBF 316L SS samples built on different machines. Surface oxides were probed with electron dispersive spectroscopy and revealed that variations in local corrosion susceptibility likely arise from differences in the stability of the passive film caused by chemical segregation, unique microstructure, and tortuous roughness features at the as-built surfaces. The variability of roughness and corrosion properties from test samples printed on different machines was corroborated by property measurements performed at five different testing sites, proving reproducibility of the data. Most importantly, this study shows that if the as-built surface layer is removed through grinding or electropolishing the machine-to-machine variation observed in the corrosion susceptibility is reduced.

36 MATERIALS SCIENCE↗

Deep Optical Switching on Subpicosecond Timescales in an Amorphous Ge Metamaterial

Active nanostructured optical components show promise as potential building blocks for novel light-based computing and data processing architectures. However, nanoscale all-optical switches that have low activation powers and high-contrast ultrafast switching have been elusive so far. Here, pump–probe measurements performed on amorphous-Ge-based micro-resonator metasurfaces that exhibit strong resonant modes in the mid-infrared are reported. Relative change is observed in transmittance of ΔT/T ≈ 1 with picosecond (down to τ ≈ 0.5 ps) free carrier relaxation rates, obtained with very low pump fluences of 50 μJ cm –2 . In this work, these observations are attributed to efficient free carrier promotion, affecting light transmittance via high quality-factor optical resonances, followed by an increased electron–phonon scattering of free carriers due to the amorphous crystal structure of Ge. Full-wave simulations based on a permittivity model that describes free-carrier damping through crystal structure disorder find excellent agreement with the experimental data. These findings offer an efficient and robust platform for all-optical switching at the nanoscale.

36 MATERIALS SCIENCE↗

Development of Quality Control Methods for Robust and Reliable Sensor Design

The successful adoption of additive manufacturing for the rapid prototyping of printed sensors requires the establishment of quantifiable metrics that can interrogate device performance. One measure of performance is the adhesion strength between the substrate and sensor interface, which is critical since the strength of this interface can dictate the accuracy and reliability of the printed sensor. In this work, a non-contact laser-induced spallation technique was used to quantify the adhesion of silver prints on an aluminum alloy substrate. The laser-based method was compared to a standardized pull-off adhesion test, which provided baseline measurements of adhesion strength. The sintering conditions were shown to play an important role in the film-substrate adhesion strength, as well as the cohesion and ductility of the film itself. The methods and results described in this work supports the establishment of process control steps that are necessary for verifying the reliability of printed devices prior to its deployment in critical experiments.

36 MATERIALS SCIENCE↗