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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 OSTI2023

Near-MHz temperature and H 2 O measurements in post-detonation fireballs of 25 g hemispherical explosives using scanned-wavelength-modulation spectroscopy

A laser absorption spectroscopy diagnostic integrated within a hardened optical probe was used to measure temperature and water mole fraction at 500 kHz in post-detonation fireballs of explosives. In the experiments, an exploding-bridgewire detonator initiated a 25 g hemisphere of explosive (N5 or PETN). This produced a hemispherical fireball that traveled radially towards a hardened measurement probe. The probe contained a pressure transducer and optical equipment to pitch fiber-coupled laser light across a 12.6 cm gap onto a detector. Tunable diode lasers emitting near 7185.6 and 6806 c m − <#comment/> 1 were used to measure the absorbance spectrum of H 2 O utilizing peak-picking scanned-wavelength-modulation spectroscopy with a scan frequency of 500 kHz and modulation frequencies of 35 and 45.5 MHz, respectively. This enabled measurements of temperature and X H 2 O in the shock-heated air and trailing fireball at 500 kHz. Time histories of pressure, temperature, and H 2 O mole fraction were acquired at different standoff distances to quantify how the fireball evolved in space and time as well as to compare measured quantities between PETN and N5 fireballs. The standard deviation of temperature and X H 2 O during one representative test were found to be 17 K (1.3%) and 0.011 (5%), respectively. These measurements demonstrate this diagnostic’s ability to provide rapid and reliable measurements in harsh, highly transient post-detonation environments produced by solid explosives.

Schwartz, Charles J.↗
NASA NTRS1996

An Intense Slit Discharge Source of Jet-Cooled Molecular Ions and Radicals (T(sub rot) less than 30 K)

A novel pulsed, slit supersonic discharge source is described for generating intense jet-cooled densities of radicals (greater than 10(exp 12)/cu cm) and molecular ions (greater than 10(exp 10)/cu cm) under long absorption path (80 cm), supersonically cooled conditions. The design confines the discharge region upstream of the supersonic expansion orifice to achieve efficient rotational cooling down to 30 K or less. The collisionally collimated velocity distribution in the slit discharge geometry yields sub-Doppler spectral linewidths, which for open-shell radicals reveals spin-rotation splittings and broadening due to nuclear hyperfine structure. Application of the slit source for high-resolution, direct IR laser absorption spectroscopy in discharges is demonstrated on species such as OH, H3O(+) and N2H(+).

Anderson, David T.↗
DOE OSTI2023

Laser-direct-drive fusion target design with a high- Z gradient-density pusher shell

Laser-direct-drive fusion target designs with solid deuterium-tritium (DT) fuel, a high-Z gradient-density pusher shell (GDPS), and a Au-coated foam layer have been investigated through both 1D and 2D radiation-hydrodynamic simulations. Compared with conventional low-Z ablators and DT-push-on-DT targets, these GDPS targets possess certain advantages of being instability-resistant implosions that can be high adiabat (α ≥ 8) and low hot-spot and pusher-shell convergence (CR hs ≈ 22 and CR PS ≈ 17), and have a low implosion velocity (v imp < 3 × 10 7 cm/s). Using symmetric drive with laser energies of 1.9 to 2.5 MJ, 1D LILAC simulations of these GDPS implosions can result in neutron yields corresponding to >~50–MJ energy, even with reduced laser absorption due to the cross-beam energy transfer (CBET) effect. Two-dimensional DRACO simulations show that these GDPS targets can still ignite and deliver neutron yields from 4 to ~10 MJ even if CBET is present, while traditional DT-push-on-DT targets normally fail due to the CBET-induced reduction of ablation pressure. If CBET is mitigated, these GDPS targets are expected to produce neutron yields of >20 MJ at a driven laser energy of ~2 MJ. Here are the key factors behind the robust ignition and moderate energy gain of such GDPS implosions are as follows: (1) The high initial density of the high-Z pusher shell can be placed at a very high adiabat while the DT fuel is maintained at a relatively low-entropy state; therefore, such implosions can still provide enough compression ρR >1 g/cm 2 for sufficient confinement; (2) the high-Z layer significantly reduces heat-conduction loss from the hot spot since thermal conductivity scales as ~1/Z; and (3) possible radiation trapping may offer an additional advantage for reducing energy loss from such high-Z targets.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Mid Infra-Red Laser Sensor for Continuous Sulfur Trioxide Monitoring to Improve Coal-Fired Power Plant Performance during Flexible Operations

During the course of this project, we performed exhaustive research and development of SO3/H2SO4 sensing technology for coal-fired power plant applications (Figure 1). The development culminated in a successful field campaign of a prototype continuous real-time H2SO4 monitor at a coal-fired power plant (TRL 6) accomplishing the primary goal of the project. The developed sensors utilize tunable laser absorption spectroscopy (TLAS) operating in the mid-infrared (Mid-IR) wavelength region, which is the so-called “molecular fingerprint” region. Systems operating in the Mid-IR have orders of magnitude more sensitivity than systems operating at shorter wavelengths, such as near-infrared (NIR). However, NIR systems are more widespread due to more mature supporting technology (e.g., fiber optics, optical components, etc.). In this project, we not only produced a specific Mid-IR sensor, we also advanced Mid-IR sensor technology in general through the development and demonstration of such supporting technology. In this project, we also developed proprietary broad tuning lasers enabling the ability to effectively measure SO3, H2SO4, H2O, and SO2. Different molecular species have unique spectral signatures that can be probed with lasers operating at different wavelengths. Standard TLAS uses relatively narrow wavelength tuning distributed feedback (DFB) lasers, which can typically only target a single species with narrow features, and are not appropriate for species with broad features, such as SO3 or H2SO4. In contrast, by developing unique, broad-tuning laser technology, we were able to measure these species, as well as SO2 and H2O simultaneously. Furthermore, to enable real-time analysis at a power plant, we modified a commercially available heated gas cell to operate in the Mid-IR wavelength range and fiber coupled the lasers to enable remote delivery of the beams. To generate reference data (library spectra), our collaborators at the University of California Irvine (UCI) developed a catalytic SO3 generation facility. It is worth mentioning that representative H2SO4 and SO3 Mid-IR spectra are not a part of any publicly available database and the data generated under this project is a valuable resource in and of itself. In addition, based on the UCI study we determined that detection of SO3 is complicated by the very strong SO2 absorption. For that reason, we concentrated on H2SO4 detection. Since SO3 and H2SO4 exist in a flue gas in a state of equilibrium, which depends on temperature and humidity, by measuring water concentration and controlling the temperature of the gas cell, we developed an approach to determine SO3 concentration from the H2SO4 measurement. During the development phase of the project, we performed three testing campaigns at our collaborator’s FERCo flue gas facility with conditions representative of the coal-fired power plant (~ 40ppm SO3, 1700ppm to 2800 ppm SO2, 10% water) with the exception of particulate matter. After three test campaigns at FERCo we performed field testing at Harrison Power Station. The final system was mounted on a duct and measured H2SO4, SO2 and water. The tests were highly successful with a demonstrated real-time H2SO4 precision of 1 ppm with a 1 second update. Our collaborators at EPRI conducted an industry survey and determined that there is a very high interest for the SO3/H2SO4 monitoring in the power generation industry as well as in heavy industries in general. Furthermore, work performed by OptoKnowledge beyond the scope of this project under a synergistic DOE SBIR determined another approach to SO3 detection. We applied for Phase II on this SBIR for development a of versatile SO3/H2SO4 sensor but were not selected. We are currently looking for another opportunity to leverage all the technological advancements produced by this project including but not limited to the flue gas facility at UCI, the hardware and software developed, and relationships with FERCo, EPRI CEMTEK, and Harrison Station.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1984

The 12 micron band of ethane - High-resolution laboratory analysis with candidate lines for infrared heterodyne searches

Attention is given to the results of a laboratory study of the v9 band of ethane at 12 microns, using both high resolution Fourier transform and diode laser absorption spectroscopy. The analysis to which about 2000 transitions in this band have been subjected includes the normal rotational terms as well as the higher order effects of l-doubling, l-resonance, internal rotation, and a Coriolis resonance with the 3v4 state. A model is presented for the v9 band which is able to reproduce the observed features to an accuracy of better than 0.001/cm, and a list has been compiled for v9 transitions, occurring near C-14O2 laser lines, that are good candidates for laser heterodyne searches.

Atakan, A. K.↗
DOE OSTI2021

Measurement of neutral gadolinium oscillator strengths using dual-comb absorption spectroscopy in laser-produced plasmas

The oscillator strengths of 43 transitions of neutral gadolinium from 530 to 535 nm were determined based on high-resolution absorption spectra measured by probing a laser-produced plasma (LPP) using time-resolved dual-comb spectroscopy (DCS). Absorption spectra were measured at various time delays, ranging from 33 to 252 µs after the onset of the plasma formation, over which the temperature and number density varied as the ablation plume evolved. A Boltzmann analysis was used to determine the excitation temperature and column density of Gd in the ablation plume, based on measured absorption from 20 Gd I spectral lines with known oscillator strengths. Oscillator strengths were then determined for additional dipole-allowed Gd I transitions identified in the absorption spectra, 19 of which were previously unreported. Oscillator strengths of all measured transitions were compared with literature values when available and show good agreement in most cases. Time-resolved measurement of atomic absorption in the cooling plasma provides access to a range of excitation temperatures and optical densities for the atoms in the ablation plume, allowing repeated measurements under different conditions, thereby improving confidence in the results. The high spectral bandwidth and resolution capabilities of DCS make it well-suited to measuring the dense optical spectrum of Gd, and the technique is applicable to other elements, especially lanthanides and actinides.

(280.4788) Optical Sensing, (280.5395) Plasma Diag↗
NASA NTRS2015

Monitoring Atmospheric CO2 From Space: Challenge & Approach

Atmospheric CO2 is the key radiative forcing for the Earth's climate and may contribute a major part of the Earth's warming during the past 150 years. Advanced knowledge on the CO2 distributions and changes can lead considerable model improvements in predictions of the Earth's future climate. Large uncertainties in the predictions have been found for decades owing to limited CO2 observations. To obtain precise measurements of atmospheric CO2, certain challenges have to be overcome. For an example, global annual means of the CO2 are rather stable, but, have a very small increasing trend that is significant for multi-decadal long-term climate. At short time scales (a second to a few hours), regional and subcontinental gradients in the CO2 concentration are very small and only in an order of a few parts per million (ppm) compared to the mean atmospheric CO2 concentration of about 400 ppm, which requires atmospheric CO2 space monitoring systems with extremely high accuracy and precision (about 0.5 ppm or 0.125%) in spatiotemporal scales around 75 km and 10-s. It also requires a decadal-scale system stability. Furthermore, rapid changes in high latitude environments such as melting ice, snow and frozen soil, persistent thin cirrus clouds in Amazon and other tropical areas, and harsh weather conditions over Southern Ocean all increase difficulties in satellite atmospheric CO2 observations. Space lidar approaches using Integrated Path Differential Absorption (IPDA) technique are considered to be capable of obtaining precise CO2 measurements and, thus, have been proposed by various studies including the 2007 Decadal Survey (DS) of the U.S. National Research Council. This study considers to use the Intensity-Modulated Continuous-Wave (IM-CW) lidar to monitor global atmospheric CO2 distribution and variability from space. Development and demonstration of space lidar for atmospheric CO2 measurements have been made through joint adventure of NASA Langley Research Center and Exelis, Inc. As prototype space IPDA lidars, airborne laser absorption lidar systems operating in 1.57 CO2 absorption band have been developed and tested through lab, ground-based range, and flight campaigns. Very encouraging results have been obtained. The signal-to-noise ratio (SNR) for clear sky IPDA measurements of CO2 differential absorption optical depth (DAOD) for a 10-s integration over vegetated areas with about 10 km range was found to be as high as 1300, resulting in an error 0.077% or equivalent CO2 mixing ratio (XCO2) column precision of ~0.3 ppm. Precise range measurements using the IM-CW lidar approach were also achieved, and the uncertainties have been shown to be at sub meter level. Based on the airborne lidar development, space lidar and atmospheric CO2 observations are simulated. It shows that with the IM-CW approach, accurate atmospheric CO2 measurements can be achieved from space, and a space mission such as that proposed by the DS will meet science goals of atmospheric CO2 monitoring.

Lin, Bing↗
NASA NTRS2024

Fundamental Experimental Tests and Modeling of LOX/CH4 Engines at High Pressures

In recent years, the space travel industry has grown exponentially, resulting in the need for a low-cost, efficient rocket engine fuel. As such, there has been renewed interest in utilizing liquid natural gas (LNG) as it is less likely to soot than kerosene-based fuels and has widespread availability and low cost of use as compared to the traditional RP-X and even liquid methane (LCH4) fuels due to the reduced need for refinement. However, current literature does not fully cover varying blends of natural gas and the effects that impurities have on natural gas/methane fuels, with most studies being confined to low-pressure applications. Therefore, new experimental ignition delay time measurements at rocket engine relevant pressures are essential to ensure current chemical kinetic models capture the ignition behavior at these elevated conditions and to determine the optimal purity levels for a reliable, cost-efficient, aerospace-grade LCH4/LNG fuel. The current work explores various blends of natural gas/methane fuel with various impurities, including higher hydrocarbons as well as nitrogen-carriers. A shock tube study was carried out to study the ignition delay times and carbon monoxide time histories of these natural gas blends utilizing chemiluminescence and laser absorption spectroscopy at 20, 50 and 100 atm over temperatures ranging from 1400-1700K and at an equivalence ratio of 1. The experimental data was then compared to two different chemical kinetic mechanisms: the industry-standard GRI 3.0 and the in-house UCF 2022. The data is used to improve chemical kinetic mechanisms and modeling of LNG fuels for rocket engine applications.

Methane↗
DOE OSTI2025

Low-mode nonuniformity in direct-drive ICF implosions due to laser smoothing techniques employed on OMEGA

For successful laser-direct-drive inertial confinement fusion implosions, the laser irradiation must be highly uniform over the target surface. On OMEGA, multiple laser beams are used to illuminate targets quasi-uniformly. High-mode-number nonuniformities due to laser speckle on each individual beam are reduced by splitting each beam into two orthogonal polarizations (i.e., polarization smoothing, or PS) and a range of wavelengths (i.e., smoothing by spectral dispersion) that are dispersed at the target plane. However, cross-beam energy transfer (CBET) is sensitive to both the polarizations and wavelengths of the interacting beams, so the interplay between CBET and the laser-smoothing schemes results in unique intensity variation across each beam profile, which is a systematic source of low-mode drive nonuniformity on OMEGA. Here, we model these effects and find that the predicted ℓ = 1 mode in the laser-absorption distribution is consistent with the systematic core-flow direction that has been determined from the OMEGA implosion database. We also observe good agreement with the measured core-flow directions for two specific sets of implosions (one with PS, the other without PS) when we also account for the measured beam mispointing and the beam power imbalance.

Crossed beam scattering↗
NASA NTRS1996

Infrared laser spectroscopy of jet-cooled carbon clusters: the nu 5 band of linear C9

The nu 5 antisymmetric stretching vibration of 1 sigma+g C9 has been observed using direct infrared diode laser absorption spectroscopy of a pulsed supersonic cluster beam. Twenty-eight rovibrational transitions measured in the region of 2079-2081 cm-1 were assigned to this band. A combined least squares fit of these transitions with previously reported nu 6 transitions yielded the following molecular constants for the nu 5 band: nu 0 = 2 079.673 58(17) cm-1, B"= 0.014 321 4(10) cm-1, and B'=0.014 288 9(10) cm-1. The IR intensity of the nu 5 band relative to nu 6 was found to be 0.108 +/- 0.006. Theoretical predictions for the relative intensities vary widely depending upon the level of theory employed, and the experimental value reported here is in reasonable agreement only with the result obtained from the most sophisticated ab initio calculation considered (CCSD).

Non-NASA Center↗
DOE OSTI2024

Kinetics and Mechanism of the Singlet Oxygen Atom Reaction with Dimethyl Ether

Here, we combine in situ laser spectroscopy, quantum chemistry, and kinetic calculations to study the reaction of a singlet oxygen atom with dimethyl ether. Infrared laser absorption spectroscopy and Faraday rotation spectroscopy are used for the detection and quantification of the reaction products OH, H 2 O, HO 2 , and CH 2 O on submillisecond time scales. Fitting temporal profiles of products with simulations using an in-house reaction mechanism allows product branching to be quantified at 30, 60, and 150 Torr. The experimentally determined product branching agrees well with master equation calculations based on electronic structure data and transition state theory. The calculations demonstrate that the dimethyl peroxide (CH 3 OOCH 3 ) generated via O-insertion into the C–O bond undergoes subsequent dissociation to CH 3 O + CH 3 O through energetically favored reactions without an intrinsic barrier. This O-insertion mechanism can be important for understanding the fate of biofuels leaking into the atmosphere and for plasma-based biofuel processing technologies.

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

Laser Measurements and Modeling of Shock Tunnel Freestream Velocity and Multispecies Thermal Nonequilibrium

Coherent anti-Stokes Raman scattering (CARS) and nitric oxide molecular tagging velocimetry (NO-MTV) were used to characterize the freestream in Sandia’s Hypersonic Shock Tunnel (HST) using a burst-mode laser operated at 100 kHz. Experiments were performed at nominal freestream velocities of 3 and 4 km/s using both air and N 2 test gas. The CARS diagnostic provides nonequilibrium characterization of the flow by measuring vibrational and rotational temperatures of N 2 and O 2 , which are compared to NO temperatures from separate laser absorption experiments. Simultaneous, collinear freestream velocities were measured using NO MTV along with pitot pressure measurements. Furthermore, this extensive freestream dataset is compared to nonequilibrium CFD that is capable of modeling species-specific, vibrational temperatures throughout the nozzle expansion. Significant nonequilibrium between vibrational and rotational temperatures was measured at each flow condition. N 2 exhibits the most nonequilibrium, followed by O 2 and NO. The CFD model captures this trend, although it consistently overpredicts N 2 and O 2 vibrational temperatures. At 3 km/s, the modeled NO nonequilibrium is underpredicted, whereas it is overpredicted at 4 km/s. Good agreement is seen between CFD and the velocity and rotational temperature measurements. Experiments with water added to the test gas yielded no discernable difference in vibrational relaxation.

Aerodynamics↗
DOE OSTI2020

Isopropanol dehydration reaction rate kinetics measurement using H 2 O time histories

H 2 O formation during thermal decomposition of isopropanol was measured behind reflected shock waves at temperatures ranging from 1127 to 1621 K at an average pressure of 1.42 atm using a laser absorption technique. Of the five modern chemical kinetics models used to compare the H 2 O time histories, the model from Li et al (Combust. Flame 2019;207:171-185) showed the best overall agreement. Sensitivity and rate of production analyses using the Li et al model (as well as those from AramcoMech 3.0, CRECK, and Togbe et al (Energy Fuel. 2011;25:676-683)) showed unimolecular dehydration of isopropanol, iC 3 H 7 OH ⇌ H 2 O + C 3 H 6 (R1), is nearly the sole reaction controlling H2O production at early times, allowing for an a priori measurement of the forward rate constant k 1 . The Arrhenius expression k1 (s –1 ) = 2.60 × 10 13 exp(-31 120 K/T) was determined to represent best the data from this study. According to the models and previous experimental investigations, the pressure investigated is well within the high-pressure limit (HPL) for this reaction. Additional, higher-pressure experiments also confirmed the HPL assumption. An uncertainty analysis was performed by varying secondary reactions within their uncertainties and examining their effect on the overall prediction, establishing an uncertainty within ±20% for all but the highest temperature cases, which have a maximum uncertainty of ±40%. Experiments conducted with a radical trapper, toluene, showed little influence from radical chemistry, suggesting this estimated uncertainty is fairly conservative. Experimental data from Heyne et al (Z Phys Chem. 2015;229:881-907) were found to be in good agreement with the rate measurements from this study and, therefore, a second Arrhenius expression, k 1 (s –1 ) = 2.11 × 10 13 exp(-30 820 K/T), was found to represent both datasets well. This second expression has a larger temperature range of 976-1621 K. Here the present study provides the first high-temperature data collected for this reaction, adding to the limited data available for isopropanol in the literature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

What can we learn from N 2 O isotope data? – Analytics, processes and modelling

The isotopic composition of nitrous oxide (N 2 O) provides useful information for evaluating N 2 O sources and budgets. Due to the co–occurrence of multiple N 2 O transformation pathways, it is, however, challenging to use isotopic information to quantify the contribution of distinct processes across variable spatiotemporal scales. Here, we present an overview of recent progress in N 2 O isotopic studies and provide suggestions for future research, mainly focusing on: analytical techniques; production and consumption processes; and interpretation and modelling approaches. Comparing isotope–ratio mass spectrometry (IRMS) with laser absorption spectroscopy (LAS), we conclude that IRMS is a precise technique for laboratory analysis of N 2 O isotopes, while LAS is more suitable for in situ/inline studies and offers advantages for site–specific analyses. When reviewing the link between the N 2 O isotopic composition and underlying mechanisms/processes, we find that, at the molecular scale, the specific enzymes and mechanisms involved determine isotopic fractionation effects. In contrast, at plot–to–global scales, mixing of N 2 O derived from different processes and their isotopic variability must be considered. We also find that dual isotope plots are effective for semi–quantitative attribution of co–occurring N 2 O production and reduction processes. More recently, process–based N 2 O isotopic models have been developed for natural abundance and 15 N–tracing studies, and have been shown to be effective, particularly for data with adequate temporal resolution. Here, despite the significant progress made over the last decade, there is still great need and potential for future work, including development of analytical techniques, reference materials and inter–laboratory comparisons, further exploration of N 2 O formation and destruction mechanisms, more observations across scales, and design and validation of interpretation and modelling approaches. Synthesizing all these efforts, we are confident that the N 2 O isotope community will continue to advance our understanding of N 2 O transformation processes in all spheres of the Earth, and in turn to gain improved constraints on regional and global budgets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Propagation of Input Uncertainties in Numerical Simulations of Laser Powder Bed Fusion

Laser powder bed fusion has the potential of redefining state-of-the-art processing and production methods, but defect formation and inconsistent build quality have limited the implementation of this process. Numerical models are widely used to study this process and predict the formation of these defects. Presently, the uncertainties of model input parameters and thermophysical properties used by these numerical simulations have not been investigated. In the present study, the uncertainty in these input parameters and material properties are quantified for laser powder bed fusion, with and without a simulated powder bed, to determine their influence on the predictive accuracy of an experimentally validated numerical model. Accounting for all possible sources of uncertainty quickly becomes computationally expensive on account of the curse of dimensionality. Uncertainty in laser absorption, solid, and liquid specific heat of the metal were found to have the largest effect on model prediction reliability with or without the use of a powder bed. Results also illustrate that accounting for these three uncertain parameters still captures the majority of model prediction uncertainty. Furthermore, the methodology of this study may be used to understand the uncertainty in as-built microstructure through propagation to microstructure prediction models, or applied under processing conditions where high Péclet numbers are observed and the thermal convection and fluid flow within the molten pool are substantial.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

In-situ Observations of Directed Energy Deposition Additive Manufacturing Using High-Speed X-ray Imaging

In laser-based directed energy deposition (DED) additive manufacturing, interactions among the laser beam, particle flow, and melt pool influence the properties of the solidified final part. Two separate DED systems, one with high powder flow rates to represent industrial-scale DED processing and the other with low powder flow rates for individual particle tracking, were synchronized with the high-speed imaging setup at the Advanced Photon Source in Argonne National Laboratory. In-situ x-ray imaging of the DED process using both systems highlighted the influence of powder flow rates. Increased powder flow rates resulted in less laser absorption into the melt pool, leading to a transition from a keyhole mode to a melt pool without a keyhole but with surface fluctuations due to powder flow. Increased velocities of particles during powder flow resulted in a decrease in particle melting times and a greater propensity for porosity formation. Altogether, better understanding of the interactions that occur during various scales of the DED process will enable flexibility, control, and new materials development in DED-based additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Operando visualization of porous metal additive manufacturing with foaming agents through high-speed x-ray imaging

Porous metals find extensive applications in soundproofing, filtration, catalysis, and energy-absorbing structures, thanks to their unique internal pore structure and high specific strength. In recent years, there has been an increasing interest in fabricating porous metals using additive manufacturing (AM), leveraging its unique advantages, including improved design freedom, spatial material control, and cost-effective small-batch production. In this study, we conducted pioneering operando visualization of AM porous metal using a laser powder bed fusion (L-PBF) setup combined with a high-speed synchrotron x-ray imaging system. Single track printing experiments using Ti6Al4V (Ti64) combined with titanium hydride (TiH 2 ) and sodium carbonate (Na 2 CO 3 ) as foaming agents, with varying mixing ratios were performed under different processing conditions. Here. the results elucidate the dynamic development of porosity formation. The average pore size is significantly influenced by the particle size of foaming agents when pore coalescence is absent. For all foaming agent content tested in the current study, the number of pores is found to be more sensitive to changes in laser power than in laser scanning speed. Increasing linear energy density (increasing laser power or reducing laser scanning speed) promotes the foaming agent activation thereby porosity formation. However, high linear energy density skews pore distribution towards the surface despite forming deeper melt pools. In addition, the impact of additional factors including foaming agent's laser absorptivity and decomposition kinetics with respect to AM time scales should be carefully considered to avoid ineffective activation of foaming agents during the AM of porous metals.

36 MATERIALS SCIENCE↗