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DOE OSTI2024

Single crystal growth, chemical defects, magnetic and transport properties of antiferromagnetic topological insulators ( Ge 1 – δ – x Mn x ) 2 Bi 2 Te 5 ( x ≤ 0.47 , 0.11 ≤ δ ≤ 0.20 )

Magnetic topological insulators provide a platform for emergent phenomena arising from the interplay between magnetism and band topology. Here we report the single crystal growth, crystal structure, magnetic and transport properties, as well as the neutron scattering studies of topological insulator series (Ge 1–δ–x Mn x ) 2 ⁢Bi 2 ⁢Te 5 (x ≤ 0.47, 0.11 ≤ δ ≤ 0.20). Upon doping up to x = 0.47, the lattice parameter c decreases by 0.8%, while the lattice parameter a remains nearly unchanged. Significant Ge vacancies and Ge/Bi site mixing are revealed via elemental analysis as well as refinements of the neutron and x-ray diffraction data, resulting in holes dominating the charge transport. At x = 0.47, below 10.8 K, a bilayer A-type antiferromagnetic ordered state emerges, featuring an ordered moment of 3.0(3) μ B /Mn at 5 K, with the c axis as the easy axis. Magnetization data unveils a much stronger effective interlayer antiferromagnetic exchange interaction and a much smaller uniaxial anisotropy compared to MnBi 2 ⁢Te 4 . We attribute the former to the shorter nearest-neighbor Mn-Mn interlayer superexchange path and the latter to the smaller ligand-field splitting in (Ge 1–δ–x ⁢Mn x ) 2 ⁢Bi 2 ⁢Te 5 . Finally, our study demonstrates that this series of materials holds promise for the investigation of the layer Hall effect and quantum metric nonlinear Hall effect.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Multidimensional Rietveld refinement of high-pressure neutron diffraction data of PbNCN

High-pressure neutron powder diffraction data from PbNCN were collected on the high-pressure diffraction beamline SNAP located at the Spallation Neutron Source (SNS) of Oak Ridge National Laboratory (Tennessee, USA). The diffraction data were analyzed using the novel method of multidimensional (two dimensions for now, potentially more in the future) Rietveld refinement and, for comparison, employing the conventional Rietveld method. To achieve two-dimensional analysis, a detailed description of the SNAP instrument characteristics was created, serving as an instrument parameter file, and then yielding both cell and spatial parameters as refined under pressure for the first time for solid-state cyanamides/carbodiimides. The bulk modulus B 0 = 25.1 (15) GPa and its derivative B ′ 0 = 11.1 (8) were extracted for PbNCN following the Vinet equation of state. Surprisingly, an internal transition was observed beyond 2.0 (2) GPa, resulting from switching the bond multiplicities (and bending direction) of the NCN 2− complex anion. The results were corroborated using electronic structure calculation from first principles, highlighting both local structural and chemical bonding details.

Meinerzhagen, Yannick↗

DOE OSTI2026

Structural Conservation of the A 1 Binding Site in Photosystem I across Cyanobacteria and Green Algae

Time-resolved step-scan Fourier transform infrared (FTIR) difference spectroscopy was used to obtain (A 1 − − A 1 ) FTIR difference spectra from photosystem I (PSI) samples isolated from eight phylogenetically diverse cyanobacterial strains and one green alga, totaling 13 PSI preparations. These included samples from cells grown under farred light and PSI in monomeric, dimeric, trimeric, and tetrameric states. Spectral profiles were shown to be independent of oligomeric state. Remarkably, all (A 1 − − A 1 ) FTIR difference spectra exhibited high similarity, underscoring the robustness of the technique and indicating minimal experimental variability. This congruence reveals a highly conserved environment for the phylloquinone cofactor at the A 1 binding site across diverse taxa. Conserved bands associated with the A 0 pigment further suggest structural continuity from A 0 to A 1 . To leverage this consistency, we constructed a composite (A 1 − − A 1 ) FTIR difference spectrum by averaging all 13 spectra. This composite spectrum provides enhanced resolution, enabling unambiguous identification of previously unresolved bands. The fact that a highly resolved composite spectrum can be obtained by averaging demonstrates the similarity in the spectra from the different types of samples. Band assignments were refined using prior studies, yielding an improved spectral framework for future investigations of PSI electron transfer cofactors.

Charge transfer↗

DOE OSTI2026

Highly Efficient Selection of High-redshift Emission-line Galaxies for Future DESI-like Surveys with Deep Multiband Imaging

Emission-line galaxies (ELGs) are an important tracer of baryon acoustic oscillations (BAOs) and large-scale structure at z > 1. In this work, we investigate the feasibility of using deep wide-area multiband imaging (e.g., from the Rubin Observatory) to efficiently select high-redshift ELGs. Using Hyper Suprime-Cam grizy photometry and COSMOS2020 many-band photometric redshifts, we design simple color cuts guided by a probabilistic random forest classifier to select galaxies at z = 1.1–1.6. We then empirically test and refine these color cuts using two samples of galaxies with deep spectroscopy and broad color coverage obtained with the Dark Energy Spectroscopic Instrument (DESI). Compared to DESI ELGs at z = 1.1–1.6, we achieve a higher redshift-measurement success rate (89% versus 69%), a much higher correct redshift-range success rate (84% versus 34%), and a far higher net surface density yield (1372 deg −2 versus 660 deg −2 ). Combining our sample with current DESI ELGs would increase the net ELG number density by a factor of ∼2.5, moving it out of the shot-noise limited regime and reducing the uncertainties on the BAO scale parameter at z = 1.1–1.6 by a factor of ∼2 at the highest redshifts. We also test selections using shallower photometry and obtain qualitatively similar results.

Salcedo Hernandez, Yoquelbin [University of Pittsb↗

DOE OSTI2026

21 cm Power Spectrum Analysis of North Celestial Pole Observations with the Tianlai Dish Pathfinder Array

The Tianlai Dish Pathfinder Array (TDPA) is a radio interferometer designed to test techniques for 21 cm intensity mapping in the post-reionization Universe as a means of measuring large-scale cosmic structure. Using nine nights of observations targeting the North Celestial Pole field, totaling approximately 107 hr of integration time, we analyze data in the frequency range 700–800 MHz (corresponding to redshift z ∼ 0.9). We do the data format conversion, radio frequency interference flagging, calibration, imaging and point source subtraction, and foreground removal via Singular Value Decomposition. The spherically averaged power spectrum Δ 2 (k) is obtained. Furthermore, this work successfully establishes and validates a comprehensive data analysis framework for the TDPA. We identify key improvements including sky model refinement, increased integration time, and pipeline optimization that will enable future detection of the 21 cm signal through auto-correlation and cross-correlation with optical galaxy surveys.

cosmology: large-scale structure of universe↗

DOE OSTI2025

Report on Preliminary Detailed Experimental Plan for Neutron Irradiation of A709 at ATR and HFIR

Advanced nuclear power technologies will use higher temperatures as a means to extract energy at a higher efficiency than current plants and therefore put a larger demand on the structural materials. Improved performance of structural materials could enable greater safety margins, longer plant lifetimes, and reduce maintenance costs. Alloy 709 is championed as the next generation of austenitic alloys for advanced nuclear reactors. In parallel to the ASME code case pursued, the AMMT program is initiating a neutron irradiation campaign to provide first-of-a-kind engineering data to establish operational design parameters and how the mechanical response is modified by environmental factors. This document refines the AMMT neutron irradiation campaign to a 4 year program to support the generation of creep knockdown factors for Alloy 709 and welded Alloy 709. The campaign is divided among two national laboratories, Oak Ridge National Laboratory and Idaho National Laboratory, to use the strengths of each laboratory. Through a cooperative plan, time-independent properties and time-dependent properties will be obtained across a large temperature window, nominally 300°C to 800°C, damage levels up to 10 dpa, and with and without the impacts of transmutation produced helium.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

Report on Preliminary Detailed Experimental Plan for Neutron Irradiation of A709 at ATR and HFIR

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Performance evaluation of the USGS velocity model for the San Francisco Bay Area

In this study, we evaluated the performance of the United States Geological Survey velocity model developed for the San Francisco Bay Area (SFBA), version 21.1. The evaluation was performed through high-resolution three-dimensional physics-based ground motion simulations of seven small-magnitude earthquakes (ranging from magnitude 3.8 to 4.4) that occurred on the eastern side of the San Francisco Bay. The simulations were performed in the frequency range from 0 to 5 Hz with a minimum shear-wave velocity of 250 m/s, which allowed the capture of wave propagation effects of the near-surface soft materials that characterize local basins. Based on the direct comparison of Fourier amplitude spectra between recorded and simulated ground motions for more than 250 stations, we found that the velocity model generally performs well in the frequency range of 0.2–5 Hz. The median value of the Fourier amplitude residuals was found to be near zero for all seven earthquakes. The slight over-prediction of 0.2 log-natural units at frequencies above 3 Hz in our simulations was attributed to the potentially inaccurate representation of the source radiation pattern by a double-couple point source model, and simple representation of shallow small-scale underground structural complexity in the velocity model. Maps of spectral amplitude differences between the simulated and recorded data were used to identify areas responsible for systematic ground motion over-predictions or under-predictions. For example, while some sub-domains over soft sediments show over-prediction patterns, the block east of the Hayward fault is prone to exhibit patterns of under-prediction. These maps can be used to guide future refinements of the SFBA velocity model. Since our simulation methodology allows for the decoupling of the source and wave propagation effects, the ground motion data generated by our simulations can also be used to quantify the epistemic uncertainty due to the velocity model, in empirically based ground motion estimates for the SFBA.

58 GEOSCIENCES↗

DOE OSTI2025

Development of Li–S Battery Cells with High Energy Density and Long Cycling Life

Lithium–sulfur (Li–S) batteries are considered one of the most promising next-generation energy storage technologies for electric vehicles, owing to their high energy density (up to three times greater than current lithium-ion batteries) and the low cost of sulfur (approximately 100 times cheaper than conventional cobalt oxide). However, several challenges hinder their commercial viability, including the electronically and ionically insulating nature of sulfur, polysulfide dissolution, and lithium dendrite growth. These issues significantly limit battery energy density and cycle life and must be addressed to enable successful commercialization. Current strategies involving porous carbon structures, additives, and electrocatalyst engineering have not fully resolved the polysulfide dissolution problem. While polysulfide-free cathode materials offer a promising solution, they often suffer from low sulfur content, leading to reduced discharge capacity and sluggish reaction kinetics. To overcome these limitations, we have developed novel soluble-polysulfide-free sulfur cathode active materials with a high sulfur content (>50 wt%). By integrating these cathodes with functional binders, optimized electrolyte formulations, and refined electrode fabrication techniques, we demonstrate Li–S batteries with both high energy density and long cycle life. This advancement brings the realization of low-cost, high-energy Li–S batteries significantly closer to practical application.

25 ENERGY STORAGE↗

DOE OSTI2025

Mitigate Stress Corrosion Cracking (SCC) in High-strength Al Castings (CRADA 508)

Development of high strength, corrosion resistant, aluminum alloys is important to a number of industries, including automotive, aerospace, power, etc. Understanding how processing methods such as casting, chemistry, additives and recycle content affect an alloy’s microstructure and performance in real world environments is crucial to their implementation. One major concern is how the repeated exposure to saline solutions can be detrimental to the structural integrity of aluminum alloy components. This study was undertaken as a collaboration between Eck Industries and PNNL to investigate the stress corrosion cracking (SCC) and corrosion behavior of aluminum alloys. This work examines the SCC response of three different materials set. First is cast A206 Al alloy produced by three different casting techniques (i.e., permanent mold, and sand casting with and without chill) and with or without nano forming additives as potential grain refiners. The second materials set comprises Al alloy tubes extruded by PNNL’s ShAPE process and produced using raw material with three different ratios of twitch and pre-consumer Al 6061 scrap. Finally, the third materials set comprises two Al-Si-Mg-Fe alloys with controlled Si% and Fe% to mimic recycle grade Al alloys. The corrosion behavior of these materials was characterized using SCC testing and scanning electrochemical cell microscopy (SECCM) technique; mechanical behavior was characterized using tensile testing, and microstructure was characterized using optical and electron microscopy techniques. Of the A206 Al alloys, the samples with nano forming additives performed poorly compared to those without. The best SCC performance (i.e. least degradation in mechanical properties) was demonstrated by A206 alloy sand cast with chill while the permanent mold sample showed the worst SCC performance. The SECCM was performed on A206 alloy sand cast with chill to understand the effect of microstructure and determine the location-dependent corrosion properties on grain boundaries (GB) and inside grains (IG) on the sample. The corrosion potential and current measured on GB and IG at various points on the sample established that the GB locations are more cathodic and corrosive than the IG locations. Further work needs to be conducted to investigate the mechanisms behind the observed dependence of SCC on casting technique and nano forming additives. Among the ShAPE extruded tubes, SECCM data suggests the decreasing order of tendency to corrode as follows: 100% twitch > 75% twitch > 50% twitch. Finally, both variants of the Al-Si-Mg-Fe alloys showed a large volume fraction of Fe- and Si-containing intermetallics and additional work is needed to discern differences in their respective corrosion responses. In summary, correlating local electrochemical behavior (e.g. via SECCM) with micro/nanostructure, in conjunction with bulk mechanical behavior, can help identify the right fabrication method and alloy chemistry to minimize SCC issues in Al alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Stacking polymorphism of PtSe 2 : its implication to layer-dependent metal-insulator transitions

Using diffusion Monte Carlo (DMC) and density functional theory (DFT) calculations, we examine the structural stability and interlayer binding properties of PtSe 2 . Our DMC study reveals that AA and AB-r bilayer stacking modes are nearly degenerate, highlighting the significant role of interlayer hybridization in offsetting the energy cost due to larger interlayer separations in the AB-r mode. Additionally, our DMC-benchmarked DFT calculations with the r 2 SCAN+rVV10 functional uncover pronounced stacking polymorphism in few-layer PtSe 2 , driven by degenerate AA and AB-r interfaces, which leads to substantial band gap variations across different stacking configurations. This polymorphism, along with selenium vacancies, influences a layer-dependent metal-insulator transition observed in few-layer PtSe 2 . Our findings emphasize the importance of both van der Waals interactions and interlayer hybridization in determining the phase stability and electronic properties of PtSe 2 , advancing our understanding of its fundamental properties and refining theoretical models for practical applications in nanoelectronic devices.

Electronic materials↗

DOE OSTI2024

Towards interpretable Cryo-EM: disentangling latent spaces of molecular conformations

Molecules are essential building blocks of life and their different conformations (i.e., shapes) crucially determine the functional role that they play in living organisms. Cryogenic Electron Microscopy (cryo-EM) allows for acquisition of large image datasets of individual molecules. Recent advances in computational cryo-EM have made it possible to learn latent variable models of conformation landscapes. However, interpreting these latent spaces remains a challenge as their individual dimensions are often arbitrary. The key message of our work is that this interpretation challenge can be viewed as an Independent Component Analysis (ICA) problem where we seek models that have the property of identifiability. That means, they have an essentially unique solution, representing a conformational latent space that separates the different degrees of freedom a molecule is equipped with in nature. Thus, we aim to advance the computational field of cryo-EM beyond visualizations as we connect it with the theoretical framework of (nonlinear) ICA and discuss the need for identifiable models, improved metrics, and benchmarks. Moving forward, we propose future directions for enhancing the disentanglement of latent spaces in cryo-EM, refining evaluation metrics and exploring techniques that leverage physics-based decoders of biomolecular systems. Moreover, we discuss how future technological developments in time-resolved single particle imaging may enable the application of nonlinear ICA models that can discover the true conformation changes of molecules in nature. The pursuit of interpretable conformational latent spaces will empower researchers to unravel complex biological processes and facilitate targeted interventions. This has significant implications for drug discovery and structural biology more broadly. More generally, latent variable models are deployed widely across many scientific disciplines. Thus, the argument we present in this work has much broader applications in AI for science if we want to move from impressive nonlinear neural network models to mathematically grounded methods that can help us learn something new about nature.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2024

Efficient and Photostable Organic Solar Cells Achieved by Alloyed Dimer Acceptors with Tailored Linker Structures

Abstract High power conversion efficiency (PCE) and long‐term stability are prerequisites for commercialization of organic solar cells (OSCs). Herein, two dimer acceptors (DYTVT and DYTCVT) are developed with different properties through linker engineering, and study their effects as alloy‐like acceptors on the photovoltaic performance and photostability of OSCs. These ternary OSCs effectively combine the advantages of both dimer acceptors. DYTVT, characterized by its high backbone planarity, ensures elevated electron mobility and high glass‐transition temperature (T g ), leading to efficient charge transport and enhanced photostability of OSCs. Conversely, DYTCVT, with its significant dipole moment and electrostatic potential, enhances compatibility of the alloy acceptors with donors and refines the blend morphology, facilitating efficient charge generation in OSCs. Consequently, D18:DYTVT:DYTCVT OSCs exhibit higher PCE (18.4%) compared to D18:MYT (monomer acceptor, PCE = 16.5%), D18:DYTVT (PCE = 17.4%), and D18:DYTCVT (PCE = 17.0%) OSCs. Furthermore, owing to higherT g of alloy acceptors (133 °C) than MYT (T g = 80 °C) and DYTCVT (T g = 120 °C), D18:DYTVT:DYTCVT OSCs have significantly higher photostability (t 80% lifetime = 4250 h under 1‐sun illumination) compared to D18:MYT (t 80% lifetime = 40 h) and D18:DYTCVT OSCs (t 80% lifetime = 2910 h).

Chemistry↗

DOE OSTI2025

Spin Dynamics of Triple-𝐐 Magnetic Orderings in a Triangular Lattice: Implications for Multi-𝐐 Orderings in General Two-Dimensional Lattices

Multi-𝐐 magnetic structures on two-dimensional (2D) lattices provide a key route to realizing topological physics in 2D magnetism. A major experimental challenge is to unambiguously confirm their formation by excluding the possibility of topologically trivial multidomain single- or double-𝐐 magnetic orders, which cannot be distinguished using conventional diffraction techniques. Here, we propose that long-wavelength spin dynamics offers a universal diagnostic for triangular lattices: Triple-𝐐 orders that preserve rotational symmetry and single- or double-𝐐 orders that break it exhibit qualitatively distinct anisotropies in their Goldstone-mode velocities, stemming from fundamental differences in their underlying spin configurations. We validate this concept using the metallic triangular-lattice antiferromagnet Co 0.325 ⁢TaS 2 , which hosts both a stripe-type single-𝐐 state and a triple-𝐐 tetrahedral ordering at different temperatures. Using inelastic neutron-scattering and spin dynamics simulations, we first refine the spin Hamiltonian by fitting the paramagnetic excitation spectra, allowing us to develop an unbiased model independent of magnetic ordering. We then show that the observed velocity profiles of the Goldstone modes agree with the high-temperature model’s predictions: markedly anisotropic for the single-𝐐 phase and near isotropic for the triple-𝐐 phase. Importantly, this contrast persists across various exchange parameters, highlighting its model-independent nature and suggesting potential applicability to other 2D lattice systems. Beyond the long-wavelength regime, we present a substantial discrepancy between the measured and simulated magnon spectra exclusively in the triple-𝐐 phase. We attribute this discrepancy to magnon energy renormalization arising from order-of-magnitude-enhanced magnon-magnon interactions in the triple-𝐐 phase, due to its noncollinear configuration. This work provides universal insight into the dynamical properties of topological multi-𝐐 magnetic orderings in 2D lattice structures, offering a broadly applicable diagnostic to distinguishing them from topologically trivial single- or double-𝐐 counterparts. The unequivocal confirmation of the triple-𝐐 structure in Co 0.325 ⁢TaS 2 further establishes it as a prominent material platform for exploring topological spin textures in the genuine 2D limit.

Park, Pyeongjae [Oak Ridge National Laboratory (OR↗

DOE OSTI2026

Taming nuclear mass models with Gaussian processes

We propose a new set of nuclear mass predictions based on multiple theoretical mass models. By employing Gaussian process regression with the Matérn kernel, we achieved root-mean-square (rms) deviations below 100 keV for the training dataset. The best-performing mass models achieved rms deviations below 150 keV for the new precise mass data from AME2020, whereas the ensemble average showed robust performance across the nuclear chart. Our approach uniquely combines: (1) systematic refinement of eight mass models through their residuals, (2) physics-informed features, including magic numbers, nucleon parity numbers, neutron excess, and nuclear collectivity, and (3) theory-to-theory validation demonstrating robust extrapolation capability. We find that the Matérn kernel provides superior uncertainty quantification compared to the RBF kernel, with a length-scale analysis revealing enhanced inter-nuclei correlations. We provide complete mass predictions for all unknown nuclides in AME2020, offering valuable constraints for nuclear structure studies and astrophysical modeling when used with proper uncertainty propagation.

Gaussian processes↗

DOE OSTI2025

Integrated Molten Salt Reactor Modeling Capabilities in NEAMS Thermal Hydraulics Tools

The DOE neams program supports a full range of computational thermal fluids analysis capabilities and code developments for a broad range of advanced reactor concepts. The research and development approach under the thermal fluids technical area synergistically combines three length and time scales in a hierarchical multi-scale approach. To enable multi-scale thermal fluids capability using these codes, a key joint effort has been underway to develop an integrated system- and engineering-scale thermal fluids analysis capability, through integration of SAM and Pronghorn codes, both based on the MOOSE framework. This report summarizes recent advances in developing an integrated system- and engineering-scale modeling capability for the msr concept, which has gained significant interest in recent years. A consistent framework was established by coupling Pronghorn and SAM through the Saline interface, with thermophysical properties provided by the Molten Salt Thermal Property Database (MSTDB-TP). Further improvements were made to the coupling schemes and domain-overlapping strategies, enhancing the stability and robustness of multi-code simulations. Verification and validation efforts demonstrate the accuracy of this integration across a range of benchmark problems, including one-dimensional heated pipe flows, three-dimensional natural convection loops with evolving isotopic compositions, and \gls{msre} demonstration cases. Within Pronghorn, new capabilities were introduced to model corrosion and noble-metal plating phenomena, supported by an extended thermal-hydraulics framework and refined turbulence treatments. To capture two-phase flow behavior, a multiphase Euler–Euler model was implemented in Pronghorn, including advanced closure relations, high-resolution advection techniques, and capillary force reconstruction. Preliminary verification cases confirm the fidelity of the approach, while planned validation efforts target canonical multiphase benchmarks and application to msr components such as the msre pump bowl. Finally, updates to SAM’s msr mass transfer modeling were extended to consider noble gas migration into porous structures like graphite. The point kinetics model was updated to include reactivity feedback contributions from any defined species, such as xenon. The gas transport model was expanded for applicability to gas mixtures, bubble efflux phenomena, and species transport between liquid and gas phases. A selection of multi-scale Sherwood number correlations from MOSCATO/NekRS and multi-phase correlations from literature have been added for improved accuracy in calculating mass transfer coefficients. A companion effort on developing system-level redox corrosion has also been incorporated into SAM. Collectively, these enhancements strengthen the predictive capability of SAM and Pronghorn for simulating MSR thermal-hydraulics, corrosion, multiphase behavior, and fission-product transport, providing a more complete toolset for design, safety analysis, and licensing support of next-generation \gls{msr}s.

42 - ENGINEERING↗

DOE OSTI2024

An Analytical Tool to Evaluate Defect Thermodynamics of (La,Ba)Fe1-xMxO3-δ Perovskites for Solid-Oxide Cell Applications

A modeling tool of the defect thermodynamics of (La,Ba)Fe1-xMxO3-δ perovskites which includes energetic information about oxygen vacancy formation, hydration, hydride formation, and charge disproportionation reactions has been developed1. This tool incorporates defect energies and entropies expressed as sixth order polynomial functions to allow refinements of the defect reaction equilibrium constants in the thermodynamic analysis. Calculation of (La,Ba)Fe1-xMxO3-δ Brouwer diagrams as a function of pO2/pH2O and pH2/H2O in a range of temperatures of interest is facilitated by this modeling tool. The results obtained can provide direct guidance how the electronic and ionic defect concentrations of the triple conducting perovskite materials can be used to optimize performance of solid oxide cells for energy applications. The impact of magnetic and electronic structures of the perovskites on the defect reaction energies and entropies as obtained from density function theory modeling and the role played by hydride defect species will also be discussed.

Lee, Yueh-Lin↗

DOE OSTI2024

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

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

36 MATERIALS SCIENCE↗