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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Revealing High-Temperature Reduction Dynamics of High-Entropy Alloy Nanoparticles via In Situ Transmission Electron Microscopy

Understanding the behavior of high-entropy alloy (HEA) materials under hydrogen (H 2 ) environment is of utmost importance for their promising applications in structural materials, catalysis, and energy-related reactions. Herein, the reduction behavior of oxidized FeCoNiCuPt HEA nanoparticles (NPs) in atmospheric pressure H-2 environment was investigated by in situ gas-cell transmission electron microscopy (TEM). The reduction reaction front was maintained at the external surface of the oxide. During reduction, the oxide layer expanded and transformed into porous structures where oxidized Cu was fully reduced to Cu NPs while Fe, Co, and Ni remained in the oxidized form. In situ chemical analysis showed that the expansion of the oxide layer resulted from the outward diffusion flux of all transition metals (Fe, Co, Ni, Cu). Revealing the H-2 reduction behavior of HEA NPs facilitates the development of advanced multicomponent alloys for applications targeting H 2 formation and storage, catalytic hydrogenation, and corrosion removal.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2026

Unraveling Defect-Dependent Conductivity-Type Switching in CuFe 2 O 4 for Enhanced Photoelectrocatalytic Reduction of Benzaldehyde

Photoelectrocatalytic (PEC) reduction provides a sustainable route for upgrading biomass-derived feedstocks with reduced energy requirements, yet remains largely unexplored beyond hydrogen evolution and CO 2 reduction due to the scarcity of stable photocathodes. Here, we report a defect-engineered CuFe 2 O 4 photocathode that enables directly quantified PEC reduction of benzaldehyde to benzyl alcohol using a singlecomponent, earth-abundant oxide. By controlling annealing temperature and oxygen partial pressure, CuFe 2 O 4 is systematically tuned from n-type to p-type conductivity. Electrochemical measurements, X-ray and ultraviolet photoelectron spectroscopy, and firstprinciples defect calculations collectively show that oxygen-rich annealing conditions suppress deep donor-type oxygen vacancies while stabilizing shallow acceptor-type copper vacancies, resulting in enhanced hole concentration and improved charge transport. In a mixed acetonitrile/water electrolyte employing 1,4-benzoquinone as a redox mediator, the optimized CuFe 2 O 4 photocathode achieves stable photoelectrochemical operation over 18 h under continuous illumination with a benzyl alcohol production rate of 2.57 μmol/h at −0.50 V vs Ag/AgNO 3 , corresponding to a Faradaic efficiency of 51.3%. This PEC approach lowers the required applied potential by ∼1 V compared to traditional electrocatalytic methods, offering a more energy-efficient route for carbonyl reduction. These findings establish CuFe 2 O 4 as a viable photocathode platform for sustainable photoelectrocatalytic organic transformations under mild reaction conditions.

benzaldehyde reduction↗
DOE OSTI2022

Role of Bimetallic Interactions in the Enhancement of Catalytic CO 2 Reduction by a Macrocyclic Cobalt Catalyst

The use of two metal centers in a CO 2 reduction catalyst that work together synergistically, with similar or complementary functions, can potentially lead to a significant reduction in overpotential, enhance catalytic activity and/or selectivity, and/or enable access to cascade strategies where each metal center catalyzes a different step in the conversion of CO 2 to a fuel. Here, the bimetallic reactivity of two metal centers has been identified as the primary route for the reduction of CO 2 to CO promoted by the macrocycle, [Co(HMD)] 2+ (HMD = 5,7,7,12,14,14-hexamethyl-1,4,8,11-tetraazacyclotetradeca-4,11-diene), based on the experimental characterization of all major steps of the proposed catalytic cycle using pulse radiolysis time-resolved IR (PR-TRIR) spectroscopy, corroborated by density functional theory (DFT) calculations and IR spectroelectrochemistry (IR-SEC). A bimetallic intermediate is formed in situ from two singly reduced [Co(HMD)] + species bridged by a CO 2 molecule, and the presence of a coordinating species, e.g., formate anion, appears to assist in the formation of such an intermediate. In this work, it has been demonstrated that this reactivity enables access to elementary steps with lower energy requirements, resulting in overall catalysis being kinetically more facile compared to the mononuclear pathway. A two-step approach that combines chemical reduction followed by PR-TRIR has been successfully used for probing the structure and reactivity of reactive intermediates involved in the advanced stages of a catalytic cycle, which are rarely interrogated using experimental techniques.

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

Exchange Coupling Determines Metal-Dependent Efficiency for Iron- and Cobalt-Catalyzed Photochemical CO 2 Reduction

Catalysts promoting multielectron charge delocalization offer selectivity for the CO 2 reduction reaction (CO 2 RR) over the competing hydrogen evolution reaction. Here, we show metal–ligand exchange coupling as an example of charge delocalization that can determine the efficiency for photocatalytic CO 2 RR. A comparative evaluation of iron and cobalt complexes supported by the redox-active ligand tpyPY2Me establishes that the two-electron reduction of [Co(tpyPY2Me)] 2+ ([Co] 2+ ) occurs at potentials 770 mV more negative than the [Fe(tpyPY2Me)] 2+ ([Fe] 2+ ) analogue by maximizing the exchange coupling in the latter compound. The positive shift in the reduction potential promoted by metal–ligand exchange coupling drives [Fe] 2+ to be among the most active and selective molecular catalysts for photochemical CO 2 RR reported to date, maintaining up to 99% CO product selectivity with total turnover numbers (TONs) and initial turnover frequencies exceeding 30,000 and 900 min –1 , respectively. In contrast, [Co] 2+ shows much lower CO 2 RR activity, reaching only ca. 600 TON at 83% CO product selectivity under similar conditions accompanied by rapid catalyst decomposition. Further, the spin density plots of the two-electron reduced [Co] 0 complex implicate a paramagnetic open-shell doublet ground state compared to the diamagnetic open-shell singlet ground state of reduced [Fe] 0 , rationalizing the observed negative shift in two-electron reduction potentials from the [M] 2+ species and lowered CO 2 RR efficiency for the cobalt complex relative to its iron congener. This work emphasizes the contributions of multielectron metal–ligand exchange coupling in promoting effective CO 2 RR and provides a starting point for the broader incorporation of this strategy in catalyst design.

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

Controlling Product Selectivity in Photochemical CO 2 Reduction with the Redox Potential of the Photosensitizer

The ability to selectively reduce CO 2 to a particular product or mixture of products is expected to play a key role in mitigation strategies aiming to alleviate the devastating impact of this greenhouse gas in our climate and oceans. Among those, the production of liquid solar fuels from CO 2 and H 2 O will likely need cascade strategies involving multiple catalysts carrying out different functions. This will require that the catalysts doing the initial CO 2 reduction steps deliver the right product or products to downstream catalysts. CO, H 2 and formate are the most common products in CO 2 reduction by molecular catalysts. Here, in this work, we demonstrate control over the selectivity of C 1 products in photochemical CO 2 reduction with the same catalyst, simply by changing the redox potential of the photosensitizer and/or the water concentration. Turnover numbers for CO generation with one of the photosensitizers under anhydrous conditions reached 85,000, one of the largest values reported to date. A combination of experimental results and DFT calculations show that control of the selectivity is achieved, in part, due to the interplay between regimes under kinetic or thermodynamic control. These regimes are largely dictated by the proton sources and the CO 2 reduction byproducts generated.

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

Catalytic Oxygen Reduction for Deep O 2 Removal from CO 2 Streams

Streams of CO 2 from various capture processes may contain several impurities of which O 2 is often overlooked as a problematic impurity. Because of its reactivity, the National Energy Technology Laboratory has recommended a stringent limit, less than 10 ppm, for the O 2 level in treated CO 2 products for safe transport, storage, and utilization. Here, in this study, a variety of catalytic oxygen reduction approaches using commercial automotive exhaust emission catalysts are evaluated for O 2 removal from CO 2 streams using different reducing agents, including H 2 , CO, CH 3 OH, and CH 4 . When the amount of reductant added into the feed is carefully controlled, H 2 , CO, or CH 3 OH can effectively remove O 2 from 1.5% to below 10 ppm with a single-reactor design (>99.93% removal efficiency), while simultaneously meeting the impurity limits for other species. With CH 4 as a reductant, it is challenging to simultaneously meet the the O 2 and CO specifications in a single-reactor design because CH 4 also reacts with CO 2 to produce high levels of CO in the stream (at several hundred ppm). A dual-reactor design is developed to enable the use of CH 4 , a readily available and low-cost reductant, for the purification of CO 2 streams to meet the specifications for O 2 and other impurities.

CO2 purification↗
DOE OSTI2020

Metal–Ligand Cooperativity via Exchange Coupling Promotes Iron- Catalyzed Electrochemical CO 2 Reduction at Low Overpotentials

Biological and heterogeneous catalysts for the electrochemical CO 2 reduction reaction (CO 2 RR) often exhibit a high degree of electronic delocalization that serves to minimize overpotential and maximize selectivity over the hydrogen evolution reaction (HER). Here, we report a molecular iron(II) system that captures this design concept in a homogeneous setting through the use of a redox non-innocent terpyridine-based pentapyridine ligand (tpyPY2Me). As a result of strong metal-ligand exchange coupling between the Fe(II) center and ligand, [Fe(tpyPY2Me)] 2+ exhibits redox behavior at potentials 640 mV more positive than the isostructural [Zn(tpyPY2Me)] 2+ analog containing the redox-inactive Zn(II) ion. This shift in redox potential is attributed to the requirement for both an open-shell metal ion and a redox non-innocent ligand. The metal-ligand cooperativity in [Fe(tpyPY2Me)] 2+ drives the electrochemical reduction of CO 2 to CO at low overpotentials with high selectivity for CO 2 RR (>90%) and turnover frequencies of 100,000 s -1 with no degradation over 20 h. The decrease in the thermodynamic barrier engendered by this coupling also enables homogeneous CO 2 reduction catalysis in water without compromising selectivity or rates. Synthesis of the two-electron reduction product, [Fe(tpyPY2Me)] o , and characterization by X-ray crystallography, Mössbauer spectroscopy, X-ray absorption spectroscopy (XAS), variable temperature NMR, and density functional theory (DFT) calculations, support assignment of an open-shell singlet electronic structure that maintains a formal Fe(II) oxidation state with a doubly reduced ligand system. Furthermore, this work provides a starting point for the design of systems that exploit metal-ligand cooperativity for electrocatalysis where the electrochemical potential of redox non-innocent ligands can be tuned through secondary metal-dependent interactions.

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

Bridge Sites of Au Surfaces Are Active for Electrocatalytic CO 2 Reduction

Prior in-situ attenuated total reflectance Fourier transform infrared (ATR-FTIR) studies of electrochemical CO 2 reduction catalyzed by Au, one of the most selective and active electrocatalysts to produce CO from CO 2 , suggest that the reaction proceeds solely on the top sites of the Au surface. This finding is worth updating with an improved spectroelectrochemical system where in-situ IR measurements can be performed under real reaction conditions that yield high CO selectivity. Herein, we report the preparation of a Au-coated Si ATR crystal electrode with both high catalytic activity for CO 2 reduction and strong surface enhancement of IR signals validated in the same spectroelectrochemical cell, which allows us to probe the adsorption and desorption behavior of bridge-bonded *CO species (*CO B ). In this study we find that the Au surface restructures irreversibly to give an increased number of bridge sites for CO adsorption within the initial tens of seconds of CO 2 reduction. By studying the potential-dependent desorption kinetics of *CO B and quantifying the steady-state surface concentration of *CO B under reaction conditions, we further show that *CO B are active reaction intermediates for CO 2 reduction to CO on the Au surface. At medium overpotential, as high as 38% of the reaction occurs on the bridge sites.

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

Widespread Wildfires Over the Western United States in 2020 Linked to Emissions Reductions During COVID-19

Widespread wildfires struck western United States in 2020, directly damaging properties and threatening human lives. Meanwhile, the COVID-19 pandemic rapidly spread across the globe in 2020, which disrupted human activities and resulted in substantial reductions in anthropogenic emissions. Here, we investigate the effects of the emissions reductions of aerosols, precursors, and greenhouse gases during the pandemic on wildfire weather conditions in 2020 over western United States by using an earth system model together with observational data. We show that the COVID-19 emissions reductions in model experiments increased surface air temperature and decreased precipitation and relative humidity due to a weakened moisture transport, which explains 10-40% of the observed increase in the risk of wildfires over western United States in 2020. In conclusion, this study suggests that COVID-19-related abrupt emissions reductions have an unexpected influence on wildfires, highlighting a different but important role of human activities in affecting wildfire risks.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Radiation-assisted electrochemical reduction of CO 2 to CO

Carbon monoxide (CO) is a versatile intermediate feedstock for many applications and can be produced through the electrochemical reduction of carbon dioxide (CO 2 ). However, current electrochemical CO production is hindered by high overall costs, primarily due to low conversion efficiencies and significant energy requirements. Herein, we report a unique way of enhancing the electrochemical reduction of CO 2 to CO using gamma (γ) photons. The γ-irradiation applied to the electrochemical cell setup induces the production of e˙ - , which results in an increased CO 2 ionization and production of excited CO 2 (CO$^{*}_{2}$) molecules via lower energy barrier. The ionized CO 2 ˙ - is quickly stabilized over a silver catalyst, providing an alternative low activation energy route for CO 2 reduction. In conclusion, a decrease in the overpotential barrier enhanced the electrochemical reduction of CO 2 to CO by 25%.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2021

Model Reduction by Generalized Falk Method for Efficient Field-Circuit Simulations

The Generalized Falk Method (GFM) for coordinate transformation, together with two model-reduction strategies based on this method, are presented for efficient coupled field-circuit simulations. Each model-reduction strategy is based on a decision to retain specific linearly-independent vectors, called trial vectors, to construct a vector basis for coordinate transformation. The reduced-order models are guaranteed to be stable and passive since the GFM is a congruence transformation of originally symmetric positive definite systems. We also show that, unlike the Pad´e-via-Lanczos (PVL) method, the GFM does not generate unstable positive poles while reducing the order of circuit problems. Further, the proposed GFM is also faster when compared to methods of the type Lanczos (or Krylov) that are already widely used in circuit simulations for electrothermal and electromagnetic problems. The concept of response participation factors is introduced for the selection of the trial vectors in the proposed model-reduction methods. Further, we present methods to develop simple equivalent circuit networks for the field component of the overall field-circuit system. The implementation of these equivalent circuit networks in circuit simulators is discussed. With the proposed model-reduction strategies, significant improvement on the efficiency of the generalized Falk method is illustrated for coupled field-circuit problems.

42 ENGINEERING↗
DOE OSTI2020

Threat Reduction Research Networks: Fostering Sustainable Collaborations Through Trainings for Genomics for Biosurveillance

Scientific research communities can be represented as heterogeneous or multidimensional networks encompassing multiple types of entities and relationships. These networks might include researchers, institutions, meetings, and publications, connected by relationships like authorship, employment, and attendance. We describe a method for efficiently and flexibly capturing, storing, and extracting information from multidimensional scientific networks using a graph database. The database structure is based on an ontology that captures allowable types of entities and relationships. This allows us to construct a variety of projections of the underlying multidimensional graph through database queries to answer specific research questions. We demonstrate this process through a study of the U.S. Biological Threat Reduction Program (BTRP), which seeks to develop Threat Reduction Networks to build and strengthen a sustainable international community of biosecurity, biosafety, and biosurveillance experts to address shared biological threat reduction challenges. Networks like these create connectional intelligence among researchers and institutions around the world, and are central to the concept of cooperative threat reduction. Our analysis focuses on a series of seven BTRP genome sequencing training workshops, showing how they created a growing network of participants and countries over time, which is also reflected in coauthorship relationships among attendees. By capturing concept and relationship hierarchies, our ontology-based approach allows us to pose general or specific questions about networks within the same framework. This approach can be applied to other research communities or multidimensional social networks to capture, analyze, and visualize different types of interactions and how they change over time.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

2‐Aminobenzenethiol‐Functionalized Silver‐Decorated Nanoporous Silicon Photoelectrodes for Selective CO 2 Reduction

Abstract A molecularly thin layer of 2‐aminobenzenethiol (2‐ABT) was adsorbed onto nanoporous p‐type silicon (b‐Si) photocathodes decorated with Ag nanoparticles (Ag NPs). The addition of 2‐ABT alters the balance of the CO 2 reduction and hydrogen evolution reactions, resulting in more selective and efficient reduction of CO 2 to CO. The 2‐ABT adsorbate layer was characterized by Fourier transform infrared (FTIR) spectroscopy and modeled by density functional theory calculations. Ex situ X‐ray photoelectron spectroscopy (XPS) of the 2‐ABT modified electrodes suggests that surface Ag atoms are in the +1 oxidation state and coordinated to 2‐ABT via Ag−S bonds. Under visible light illumination, the onset potential for CO 2 reduction was −50 mV vs. RHE, an anodic shift of about 150 mV relative to a sample without 2‐ABT. The adsorption of 2‐ABT lowers the overpotentials for both CO 2 reduction and hydrogen evolution. A comparison of electrodes functionalized with different aromatic thiols and amines suggests that the primary role of the thiol group in 2‐ABT is to anchor the NH 2 group near the Ag surface, where it serves to bind CO 2 and also to assist in proton transfer.

Kan, Miao↗
DOE OSTI2024

Carbonic Anhydrase Variants Catalyze the Reduction of Dialkyl Ketones with High Enantioselectivity

Abstract Human carbonic anhydrase II (hCAII) naturally catalyzes the reaction between two achiral molecules—water and carbon dioxide—to yield the achiral product carbonic acid through a zinc hydroxide intermediate. We have previously shown that a zinc hydride, instead of a hydroxide, can be generated in this enzyme to create a catalyst for the reduction of aryl ketones. Dialkyl ketones are more challenging to reduce, and the enantioselective reduction of dialkyl ketones with two alkyl groups that are similar in size and electronic properties, is a particularly challenging transformation to achieve with high activity and selectivity. Here, we show that hCAII, as well as a double mutant of it, catalyzes the enantioselective reduction of dialkyl ketones with high yields and enantioselectivities, even when the two alkyl groups are similar in size. We also show that variants of hCAII catalyze the site‐selective reduction of one ketone over the other in an unsymmetrical aliphatic diketone. Computational docking of a dialkyl ketone to variants of hCAII containing the zinc hydride provides insights into the origins of the reactivity of various substrates and the high enantioselectivity of the transformations and show how a confined environment can control the enantioselectivity of an abiological intermediate.

Chen, Reichi↗
DOE OSTI2024

Does H 2 Temperature‐Programmed Reduction Always Probe Solid‐State Redox Chemistry? The Case of Pt/CeO 2

Abstract Redox reactions on the surface of transition metal oxides are of broad interest in thermo, photo, and electrocatalysis. H 2 temperature‐programmed reduction (H 2 ‐TPR) is commonly used to probe oxide reducibility by measuring the rate of H 2 consumption during temperature ramps, assuming that this rate is controlled by oxide reduction. However, oxide reduction involves several elementary steps, such as H 2 dissociation and H‐spillover, before surface reduction and H 2 O formation occur. In this study, we evaluated the kinetics of H 2 consumption over CeO 2 and Pt/CeO 2 with varying Pt loadings and structures to identify the elementary steps probed by H 2 ‐TPR. Literature often attributes changes in H 2 ‐TPR characteristics with Pt addition to increased CeO 2 reducibility. However, our analysis revealed that the H 2 consumption rate is measurement of the rate of H‐spillover at Pt‐CeO 2 interfaces and is determined by the concentration of Pt species on Pt nanoclusters that dissociate H 2 . Therefore, lower temperature H 2 consumption observed with Pt addition does not indicate higher CeO 2 reducibility. Measurements on samples with mixtures of Pt single‐atoms and nanoclusters demonstrated that H 2 ‐TPR can effectively quantify dilute Pt nanocluster concentrations, suggesting caution in directly linking H 2 ‐TPR characteristics to oxide reducibility while highlighting alternative material insights that can be gleaned.

Lee, Jaeha↗
DOE OSTI2020

Au x Pd (300‐ x ) Alloy Nanoparticles for the Oxygen Reduction Reaction in Alkaline Media

Abstract Au x Pd (300‐ x ) nanoalloys were prepared using a dendrimer‐templating method and their electrocatalytic efficiencies towards the oxygen reduction reaction (ORR) were analyzed in alkaline media. The composition‐dependent PdO x reduction potentials of the Au x Pd (300‐ x ) nanoalloys were correlated to the oxygen‐binding (O‐binding) energy of the catalysts. Multiple PdO x reduction peaks were present for the Au 150 Pd 150 and Au 50 Pd 250 catalysts. These peaks were assigned to the alloyed and bulk‐like Pd active sites on the alloyed surface. The results described here are significant because modulation of the O‐binding energies improved the ORR activity on the nanoalloys. Specifically, a linear trend in O‐binding energies of Au x Pd (300‐ x ) dendrimers (DENs) as a function of Pd composition resulted in a volcano‐shaped trend in ORR activity. The optimal O‐binding energy of Au 50 Pd 250 resulted in an approximate 89 mV shift in PdO x reduction relative to Pd 300 and a shift of approximately 76 mV in ORR peak potential.

Trindell, Jamie A.↗
DOE OSTI2024

Potential reductions in fine particulate matter and premature mortality following implementation of air pollution controls on coal-fired power plants in India

Coal-fired power plants (CFPPs) account for > 70% of electricity generation in India, but < 5% of facilities have installed technologies for sulfur dioxide (SO 2 ) and nitrogen oxide (NO X ) removal. Emissions of these pollutants lead to the formation of fine particulate matter (PM 2.5 ) and an increased risk of premature mortality for exposed populations. Here, we use a nested version of the GEOS-Chem global chemical transport model (0.5° × 0.625° resolution) for India to estimate reductions in PM 2.5 concentrations that could have been achieved by implementing existing emission control technologies like flue-gas desulfurization (FGD) and/or selective catalytic reduction (SCR). We quantify the associated burden of disease using the integrated exposure response (IER) and global exposure mortality model (GEMM) functions and compare the costs of premature mortality to those for FGD installation. Model simulations for 2010 suggest installation of FGD would have reduced mean annual PM 2.5 concentrations across India by 8%, compared to 3% with SCR installation, and 11% with both FGD and SCR. A 7–28% reduction in PM 2.5 was simulated for local communities closest to CFPPs (same model grid cell), leading to up to 17% reduction in annual premature mortality. Overall, more than 0.21–0.48 million premature deaths would have been avoided over a 10-year period if FGD had been implemented on all CFPPs, compared to 0.09–0.21 million with SCR and 0.22–0.72 million with both FGD and SCR. Benefits associated with such actions are approximately $\$18.1$–$\$604$ billion USD per year, which is equivalent to ~ 0.44 to 10% of India’s GDP. These results suggest that monetary benefits from avoided premature mortality far outweigh the capital and operational costs of FGD and/or SCR installation of $\$19.5$ billion and/or $\$32.8$ billion per year, respectively. This information is essential because the high costs of installation and operation are often given as reasons for delaying installation and commissioning. Finally, we conclude that policy actions to control air pollution from CFPPs are economically justifiable.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗
DOE OSTI2026

Reduction of baseplate distortion during directed energy deposition using compliant features

Distortion in additive manufacturing (AM) remains a barrier to its adoption in precision industries. Baseplate warpage is one such issue which compromises the feasibility of post-process precision machining. The restriction to thermal contraction of the deposited part, imposed by the baseplate, generates bending moments, that in turn causes warpage. A novel distortion mitigation strategy using baseplates with integrated compliant features, which enables thermal contraction of the build is presented. Six unique design concepts are evaluated, including a solid reference, using two deposition geometries. A laser, hot-wire, directed energy deposition (DED) process is used to deposit a symmetric cylindrical part (C-part) and a T-shaped asymmetric part (T-part). Flatness deviation of baseplates is measured using structured light 3D scanning. Measurements reveal a reduction in net flatness deviation of 58.8% for the C-part and 40.9% for the T-part, compared to the solid reference. While most designs yielded reductions exceeding 30% and 20% for the C- and T-parts, respectively, one configuration resulted in increased deviation. Finite element (FE) simulations are performed to elucidate the underlying mechanisms affecting distortion of compliant baseplates during DED. Despite variations between predictions and measurements, agreement in the general trend is observed. It also revealed that initial flatness errors in baseplates significantly affect its deviation during deposition. Predictions indicate that compliant features significantly affect the thermal distribution as well as the evolution of flatness deviation in the baseplate during deposition. Notably, one design exhibited a reduction in distortion during cooling, following its initial increase during deposition. FE predictions show a maximum reduction of 60.9% and 38.8% in net flatness deviation for the C- and T-parts, respectively. The performance of compliant baseplates is found to be governed by both its the thermal and mechanical characteristics, which are crucial factors to be considered during design.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗