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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

A case study on parallel HDF5 dataset concatenation for high energy physics data analysis

In High Energy Physics (HEP), experimentalists generate large volumes of data that, when analyzed, helps us better understand the fundamental particles and their interactions. This data is often captured in many files of small size, creating a data management challenge for scientists. In order to better facilitate data management, transfer, and analysis on large scale platforms, it is advantageous to aggregate data further into a smaller number of larger files. However, this translation process can consume significant time and resources, and if performed incorrectly the resulting aggregated files can be inefficient for highly parallel access during analysis on large scale platforms. In this paper, we present our case study on parallel I/O strategies and HDF5 features for reducing data aggregation time, making effective use of compression, and ensuring efficient access to the resulting data during analysis at scale. We focus on NOvA detector data in this case study, a large-scale HEP experiment generating many terabytes of data. Here, the lessons learned from our case study inform the handling of similar datasets, thus expanding community knowledge related to this common data management task.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS1979

Measurement in multiphase reacting flows

A survey is presented of diagnostic techniques and measurements made in multiphase reacting flows. The special problems encountered by the presence of liquid droplets, soot and solid particles in high temperature chemically reacting turbulent environments are outlined. The principal measurement techniques that have been tested in spray flames are spark photography, laser anemometry, thermocouples and suction probes. Spark photography provides measurement of drop size, drop size distribution, drop velocity, and angle of flight. Photographs are analysed automatically by image analysers. Photographic techniques are reliable, inexpensive and proved. Laser anemometers have been developed for simultaneous measurement of velocity and size of individual particles in sprays under conditions of vaporization and combustion. Particle/gas velocity differentials, particle Reynolds numbers, local drag coefficients and direct measurement of vaporization rates can be made by laser anemometry. Gas temperature in sprays is determined by direct in situ measurement of time constants immediately prior to measurement with compensation and signal analysis by micro-processors. Gas concentration is measured by suction probes and gas phase chromatography. Measurements of particle size, particle velocity, gas temperature, and gas concentration made in airblast and pressure atomised liquid spray flames are presented.

Chigier, N. A.↗
DOE OSTI2023

Investigation of Nanoparticle Degradation in Hydrogen Fuel Cell Systems through Automated Electron Microscopy

Proton exchange membrane fuel cells (PEMFC) are promising devices for the deployment of hydrogen-powered heavy-duty vehicles, providing a higher efficiency for similar driving range and fueling time than the existing ones. However, PEMFCs still encounter durability challenges mainly due to catalyst degradation in the cathode. Mitigating these performance losses requires a better understanding of the degradation mechanisms under heavy-duty accelerated stress tests (ASTs) [1]. Scanning transmission electron microscopy (STEM) combined with energy dispersive X-ray spectroscopy (EDS) are key tools for the analysis of Pt and PtCo nanoparticle size, spatial distribution and composition [2]. Electron tomography is also used to determine the rate and type of degradation of catalyst nanoparticles as a function of their position on the carbon support. In this work, automated data acquisition software, paired with a custom Python code, have been used to study the effect of different accelerated stress tests (ASTs) on nanoparticle coarsening [2]. Figure 1 shows high-angle annular dark-field (HAADF)-STEM images and EDS maps comparing the cathodes of membrane electrode assemblies (MEAs) following an electrocatalyst AST performed under H2/N2 with that of the heavy-duty AST performed under H2/air. We will discuss how AST conditions affect considerably the spatial distribution of the nanoparticles across the electrode between the membrane and microporous layer. Although the median particle size increased more in the MEA aged under the heavy-duty AST, as determined using a high-throughput image analysis, the quantitative EDS measurements demonstrate that the electrocatalyst AST resulted in more Pt and Co dissolution from the cathode, which is another important indicator of electrocatalyst degradation. We will further present the impact of the relative humidity (% RH) on the degradation mechanisms demonstrated using the same approach. Electron tomography has been used to distinguish the Pt nanoparticles residing on the carbon support surface (exterior) from those within the pore structure (interior) in order to determine the relative stability of interior and exterior nanoparticles. As shown in Figure 2, we will compare the Pt catalyst particle size at the beginning of test (BOT) and end of test (EOT), and discuss the importance of automating the electron tomography workflow, i.e. acquisition, reconstruction, and visualization, to increase sampling and determine the standard deviation of these measurement. The outlook for utilizing low-dose cryo-tomography for limiting damage to the catalyst, support, and especially proton-conducting ionomer will also be discussed [3].

Amichi, Lynda↗
DOE OSTI2022

Particle phase-state variability in the North Atlantic free troposphere during summertime is determined by atmospheric transport patterns and sources

Abstract. Free tropospheric aerosol particles have important but poorly constrained climate effects due to transformations of their physicochemical properties during long-range transport. In this study, we investigate the chemical composition and provide an overview of the phase states of individual particles that have undergone long-range transport over the North Atlantic Ocean in June and July 2014, 2015, and 2017 to the Observatory of Mount Pico (OMP) in the Azores. The OMP is an ideal site for studying long-range-transported free tropospheric particles because local emissions have a negligible influence and contributions from the boundary layer are rare. We used the FLEXible PARTicle Lagrangian particle dispersion model (FLEXPART) to determine the origins and transport trajectories of sampled air masses and found that most of them originated from North America and recirculated over the North Atlantic Ocean. The FLEXPART analysis showed that the sampled air masses were highly aged (average plume age >10 d). Size-resolved chemical compositions of individual particles were probed using computer-controlled scanning electron microscopy with an energy-dispersive X-ray spectrometer (CCSEM-EDX) and scanning transmission X-ray microscopy with near-edge X-ray absorption fine structure spectroscopy (STXM-NEXAFS). CCSEM-EDX results showed that the most abundant particle types were carbonaceous (∼ 29.9 % to 82.0 %), sea salt (∼ 0.3 % to 31.6 %), and sea salt with sulfate (∼ 2.4 % to 31.5 %). We used a tilted stage interfaced within an environmental scanning electron microscope (ESEM) to determine the phase states of individual submicron particles. We found that most particles (∼ 47 % to 99 %) were in the liquid state at the time of collection due to inorganic inclusions. Moreover, we also observed substantial fractions of solid and semisolid particles (∼ 0 % to 30 % and ∼ 1 % to 42 %, respectively) during different transport patterns and events, reflecting the particles' phase-state variability for different atmospheric transport events and sources. Combining phase state measurements with FLEXPART CO tracer analysis, we found that wildfire-influenced plumes can result in particles with a wide range of viscosities after long-range transport in the free troposphere. We also used temperature and RH values extracted from the Global Forecast System (GFS) along the FLEXPART-simulated path to predict the phase state of the particles during transport and found that neglecting internal mixing with inorganics would lead to an overestimation of the viscosity of free tropospheric particles. Our findings warrant future investigation aiming at the quantitative assessment of the influence of internal mixing on the phase states of the individual particles. This study also provides insights into the chemical composition and phase state of free tropospheric particles, which can help models to reduce uncertainties about the effects of ambient aerosol particles on climate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1996

Determination of Shed Ice Particle Size Using High Speed Digital Imaging

A full scale model of an aircraft engine inlet was tested at NASA Lewis Research Center's Icing Research Tunnel. Simulated natural ice sheds from the engine inlet lip were studied using high speed digital image acquisition and image analysis. Strategic camera placement integrated at the model design phase allowed the study of ice accretion on the inlet lip and the resulting shed ice particles at the aerodynamic interface plane at the rear of the inlet prior to engine ingestion. The resulting digital images were analyzed using commercial and proprietary software to determine the size of the ice particles that could potentially be ingested by the engine during a natural shedding event. A methodology was developed to calibrate the imaging system and insure consistent and accurate measurements of the ice particles for a wide range of icing conditions.

Broughton, Howard↗
DOE OSTI2023

Analysis of neptunium oxides produced through modified direct denitration

Production of neptunium-237 ( 237 Np) target materials for plutonium-238 ( 238 Pu) radioisotope thermoelectric generators (RTGs) for deep space exploration requires advanced chemistry and engineering development. Currently, the domestic Pu-238 Supply Program at Oak Ridge National Laboratory produces neptunium dioxide (NpO 2 ) for target material using a modified direct denitration (MDD) flowsheet. Although the chemistry, reaction mechanisms, and product characteristics of MDD are well understood for uranium, corresponding studies of the neptunium system are still needed to continue optimization of target material properties, production equipment design, and production flowsheets. Here, the objective of this work is to characterize crystalline phases, morphology, surface texture, and particle size of NpO 2 produced via MDD reactions. Solid-phase characterization techniques, including powder X-ray diffraction (pXRD) and scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS), were employed to achieve this objective. Subsequent data processing using the Morphological Analysis for Material Attribution (MAMA) software was performed to analyze particle morphology and size. Broadly, the powders were found to contain a mixture of NpO 2 and Np 2 O 5 after denitration with a variety of morphologies. After high-firing, the product was found to be NpO 2 with a typical polycrystalline oxide morphology and a grain size ranging from 0.72 to 0.94 µm. These analyses provide knowledge on the reaction pathway for a non-traditional NpO 2 synthesis method and offer additional unique insight into production-scale environments for transuranic materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Novel Proppant Logging Technique for Infill Drilling of Unconventional Shale Wells

Summary During the development of an unconventional play, wells are drilled and completed in batches, and depending on the development plans, current and expected energy market trends, as well as other developmental considerations, new wells are drilled and hydraulically fractured later near existing producing laterals. This creates challenges in terms of optimizing resource recovery and reducing interwell communication. A novel approach is proposed that utilizes systematic composite sampling and analysis of drilling mud returns to look for and quantitatively identify sand particles. The workflow involves cleaning, drying, and segregation of samples into sizes of interest to us (size distribution of pumped proppant in offset parent wells). These samples are imaged at a very high resolution and analyzed for grains using characteristic optical imaging properties to classify proppant sand particles using computer vision algorithms. Further analysis, such as elemental compositional analysis, is used to validate the results from the imaging workflow. We present a case study from the Permian Basin, where a new child well was used as a test case to prove this technology at the Hydraulic Fracturing Test Site (HFTS-2) in Delaware Basin. We introduce new proppant parameters that help identify sustained proppant zones vs. localized propped fractures. We have used additional diagnostics and data collected at the test site to validate observations from the proppant log and have successfully interpreted significantly propped vs. unpropped zones. A key finding from this test has been the significant proppant transport distances observed away from parent wells. Observable proppant was found at a lateral distance of approximately 425 m for one set of parent wells and more than 915 m for another set of parent wells. While a major limitation of this technique is the sampling rate, given adequate sampling, the proposed technology represents a systematic and one-of-a-kind interpretation of spatial proppant distribution while drilling infill wells. It provides us with unique opportunities to better understand the current state of the reservoir being targeted, including zones that are likely highly drained relative to others, and how the planned hydraulic fracturing of child wells can be improved.

Energy & Fuels↗
NASA NTRS1972

Gas-core reactor power transient analysis.

The nuclear fuel in the gas-core reactor concept is a ball of uranium plasma radiating thermal photons. The photons are met by an inflowing hydrogen stream, which is seeded with submicron size, depleted uranium particles. A 'wall-burnout' condition exists if the thermal photons can reach the cavity liner because of insufficient absorption by the hydrogen. An analysis was conducted in order to determine the time for which the maximum steady state reactor power could be exceeded without damage to the cavity liner due to burnout. Wall-burnout time as a function of the power increase above the initial steady state condition is shown in a graph.

Kascak, A. F.↗
NASA NTRS1988

Particulate emissions from a mid-latitude prescribed chaparral fire

Particulate emission from a 400-acre prescribed chaparral fire in the San Dimas Experimental Forest was investigated by collecting smoke aerosol on Teflon and glass-fiber filters from a helicopter, and using SEM and EDAX to study the features of the particles. Aerosol particles ranged in size from about 0.1 to 100 microns, with carbon, oxygen, magnesium, aluminum, silicon, calcium, and iron as the primary elements. The results of ion chromatographic analysis of aerosol-particle extracts (in water-methanol) revealed the presence of significant levels of NO2(-), NO3(-), SO4(2-), Cl(-), PO4(3-), C2O4(2-), Na(+), NH4(+), and K(+). The soluble ionic portion of the aerosol was estimated to be about 2 percent by weight.

Cofer, Wesley R., III↗
DOE OSTI2023

Model-Free Approach for Profiling of Polydisperse Soft Matter Using Small Angle Scattering

A strategy for determining the size polydispersity of systems from their small angle coherent scattering is outlined. Here, using the method of moment expansion, we show that the various central moments representing the average particle size, variance of particle size, and skewness of size distribution function (SDF) for polydisperse systems can be extracted from spectral analysis without bias. When the degree of polydispersity is moderate, SDF can be further reconstructed based on the maximum entropy principle. Numerical benchmarking of a model study over a wide range of size nonuniformity demonstrates the validity of this analytical approach for quantifying the size distribution of general soft matter systems in a model-free manner. Furthermore, the efficacy of this method was validated by successfully applying it to the fitting of small-angle neutron scattering data obtained from L64 Pluronic micelles using various form factor models. The numerical and experimental verification underscores the reliability and versatility of this method in accurately characterizing the size distribution of complex soft matter systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1987

Analysis of counting errors in the phase/Doppler particle analyzer

NASA is investigating the application of the Phase Doppler measurement technique to provide improved drop sizing and liquid water content measurements in icing research. The magnitude of counting errors were analyzed because these errors contribute to inaccurate liquid water content measurements. The Phase Doppler Particle Analyzer counting errors due to data transfer losses and coincidence losses were analyzed for data input rates from 10 samples/sec to 70,000 samples/sec. Coincidence losses were calculated by determining the Poisson probability of having more than one event occurring during the droplet signal time. The magnitude of the coincidence loss can be determined, and for less than a 15 percent loss, corrections can be made. The data transfer losses were estimated for representative data transfer rates. With direct memory access enabled, data transfer losses are less than 5 percent for input rates below 2000 samples/sec. With direct memory access disabled losses exceeded 20 percent at a rate of 50 samples/sec preventing accurate number density or mass flux measurements. The data transfer losses of a new signal processor were analyzed and found to be less than 1 percent for rates under 65,000 samples/sec.

Oldenburg, John R.↗
NASA NTRS1990

Satellite measurements of large-scale air pollution - Methods

A technique for deriving large-scale pollution parameters from NIR and visible satellite remote-sensing images obtained over land or water is described and demonstrated on AVHRR images. The method is based on comparison of the upward radiances on clear and hazy days and permits simultaneous determination of aerosol optical thickness with error Delta tau(a) = 0.08-0.15, particle size with error + or - 100-200 nm, and single-scattering albedo with error + or - 0.03 (for albedos near 1), all assuming accurate and stable satellite calibration and stable surface reflectance between the clear and hazy days. In the analysis of AVHRR images of smoke from a forest fire, good agreement was obtained between satellite and ground-based (sun-photometer) measurements of aerosol optical thickness, but the satellite particle sizes were systematically greater than those measured from the ground. The AVHRR single-scattering albedo agreed well with a Landsat albedo for the same smoke.

Kaufman, Yoram J.↗
NASA NTRS2004

Lunar and Planetary Science XXXV: Asteroids, Meteors, Comets

Reports included:Long Term Stability of Mars Trojans; Horseshoe Asteroids and Quasi-satellites in Earth-like Orbits; Effect of Roughness on Visible Reflectance Spectra of Planetary Surface; SUBARU Spectroscopy of Asteroid (832) Karin; Determining Time Scale of Space Weathering; Change of Asteroid Reflectance Spectra by Space Weathering: Pulse Laser Irradiation on Meteorite Samples; Reflectance Spectra of CM2 Chondrite Mighei Irradiated with Pulsed Laser and Implications for Low-Albedo Asteroids and Martian Moons; Meteorite Porosities and Densities: A Review of Trends in the Data; Small Craters in the Inner Solar System: Primaries or Secondaries or Both?; Generation of an Ordinary-Chondrite Regolith by Repetitive Impact; Asteroid Modal Mineralogy Using Hapke Mixing Models: Validation with HED Meteorites; Particle Size Effect in X-Ray Fluorescence at a Large Phase Angle: Importance on Elemental Analysis of Asteroid Eros (433); An Investigation into Solar Wind Depletion of Sulfur in Troilite; Photometric Behaviour Dependent on Solar Phase Angle and Physical Characteristics of Binary Near-Earth-Asteroid (65803) 1996 GT; Spectroscopic Observations of Asteroid 4 Vesta from 1.9 to 3.5 micron: Evidence of Hydrated and/or Hydroxylated Minerals; Multi-Wavelength Observations of Asteroid 2100 Ra-Shalom: Visible, Infrared, and Thermal Spectroscopy Results; New Peculiarities of Cometary Outburst Activity; Preliminary Shape Modeling for the Asteroid (25143) Itokawa, AMICA of Hayabusa Mission; Scientific Capability of MINERVA Rover in Hayabusa Asteroid Mission; Characteristics and Current Status of Near Infrared Spectrometer for Hayabusa Mission; Sampling Strategy and Curation Plan of Hayabusa Asteroid Sample Return Mission; Visible/Near-Infrared Spectral Properties of MUSES C Target Asteroid 25143 Itokawa; Calibration of the NEAR XRS Solar Monitor; Modeling Mosaic Degradation of X-Ray Measurements of 433 Eros by NEAR-Shoemaker; Scattered Light Remediation and Recalibration of near Sheomaker s NIS Global Dataaset at 433 Eros; Evaluation of Preparation and Measuring Techniques for Interplanetary Dust Particles for the MIDAS Experiment on Rosetta; Chiron: a Proposed Remote Sensing Prompt Gamma Ray Activation Analysis Instrument for a Nuclear Powered Prometheus Mission;From Present Surveying to Future Prospecting of the Asteroid Belt; Asteroid Physical Properties Probe Microgravity Testing of a Surface Sampling System for Sample Return from Small Solar System Bodies;and Penetrator Coring Apparatus for Cometary Surfaces.

Source record↗
NASA NTRS1993

Proposal for a Universal Particle Detector Experiment

The Universal Particle Detector Experiment (UPDE), which consists of parallel planes of two diode laser beams of different wavelengths and a large surface metal oxide semiconductor (MOS) impact detector, is proposed. It will be used to perform real-time monitoring of contamination particles and meteoroids impacting the spacecraft surface with high resolution of time, position, direction, and velocity. The UPDE will discriminate between contaminants and meteoroids, and will determine their velocity and size distribution around the spacecraft environment. With two different color diode lasers, the contaminant and meteroid composition will also be determined based on laboratory calibration with different materials. Secondary particles dislodged from the top aluminum surface of the MOS detector will also be measured to determine the kinetic energy losses during energetic meteoroid impacts. The velocity range of this instrument is 0.1 m/s to more than 14 km/s, while its size sensitivity is from 0.2 microns to millimeter-sized particles. The particulate measurements in space of the kind proposed will be the first simultaneous multipurpose particulate experiment that includes velocities from very slow to hypervelocities, sizes from submicrometer- to pellet-sized diameters, chemical analysis of the particulate composition, and measurements of the kinetic energy losses after energetic impacts of meteroids. The experiment will provide contamination particles and orbital debris data that are critically needed for our present understanding of the space environment. The data will also be used to validate contamination and orbital debris models for predicting optimal configuration of future space sensors and for understanding their effects on sensitive surfaces such as mirrors, lenses, paints, and thermal blankets.

Lesho, J. C.↗
DOE OSTI2026

NanoPSD: A software for automatic detection of Nano-Particle Shape Distribution in electron microscopy images

Accurate quantification of the size and morphology of nanoparticles from electron microscopy (EM) images is essential to understand growth mechanisms, surface reactivity, and functional behavior in nanoscale materials. Manual analysis remains slow, subjective, and difficult to reproduce in large datasets. We introduce NanoPSD (Nano-Particle Shape Distribution), an open-source and fully automated framework for quantitative particle detection and morphology analysis from EM images. NanoPSD integrates adaptive contrast enhancement, polarity-agnostic scale-bar detection, Optical Character Recognition (OCR)-based calibration, and classical segmentation via Otsu thresholding with morphological refinement. Particle contours are used to extract geometric descriptors, including equivalent circular diameter, aspect ratio, circularity, and solidity, enabling automated classification into spherical, rod-like, and aggregate morphologies. The framework supports both single-image and batch processing, generating publication-quality visualizations, LaTeX-ready tables, and structured comma-separated values (CSV) datasets. As a demonstration, we applied NanoPSD to plasma-synthesized nanoparticle samples diagnosed via transmission electron microscopy (TEM). The code produced statistically robust size and morphology distributions spanning a few to tens of nanometers with minimal user supervision. The pipeline demonstrates high reproducibility and scalability, processing large image collections with consistent calibration and output formatting. Its modular design enables seamless integration of future deep-learning-based segmentation models, providing a pathway toward intelligent, data-driven electron microscopy analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The influence of temperature history and flow mixing on the vapor-phase speciation of uranium oxide nanoparticles

The transport of radioactive material following a nuclear event depends heavily on fallout characteristics (e.g., composition, shape, and size), which in turn are controlled by the conditions under which the fallout forms. To this end, we use a novel plasma flow reactor (PFR) to explore how conditions including temperature history and gas mixing influence the chemical speciation and physical characteristics of uranium oxide nanoparticles. The PFR consists of a glass tube attached to an inductively coupled plasma (ICP) torch via an adaptor piece (ring flow injector) located downstream of the plasma-generating RF coil. We increase the gas flow rates from normal ICP operating conditions to higher values both upstream at the RF coil and downstream at the ring flow injector to create four distinct temperature profiles and two distinct gas flow mixing conditions (normal and higher Ar atomic ratios). Ex situ transmission electron microscopy (TEM) analysis is used to determine the crystal structure, morphology, and size distribution of the synthesized particles as a function of temperature and mixing. The particles display a striking dependence on these conditions in terms of the resulting speciation of uranium oxide: lower temperature (higher upstream) and slower cooling (normal downstream with normal Ar atomic ratio mixing) favor the formation of α-UO 3 particles, while faster cooling (higher downstream with higher Ar atomic ratio mixing) and higher temperature (normal upstream) favor the formation of UO 2 particles. The extent of gas mixing dictates particle aggregation: better mixing encourages the particles to aggregate more extensively. Here these results demonstrate the sensitivity of uranium to initial local conditions and can be used to improve our understanding of the kinetics that drive uranium speciation and ultimately inform fallout transport models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

A numerical investigation of coal particle modeling for the inlet section of a pressurized oxy-combustion burner

Concerns over climate change have led to numerous efforts to develop low-carbon technologies, and pressurized oxy-combustion (POC) is a promising candidate to reduce carbon emissions in the power industry. Designing an effective burner for such technologies is vital for the development of these and other coal combustion technologies. Because of the high pressure, the volume fraction of coal particles at the fuel inlet of the pressurized oxy-combustor burner is close to or even higher than the maximum limit for commercial CFD codes (e.g., ANSYS FLUENT). At these high particle volume fractions, the interactions among particles, fluid flow and wall need to be re-evaluated. The present computational work is a first step in a systematic analysis of the influence of various parameters, like method of particle release, release location, and particle size, in a pilot-scale POC combustor, developed at Washington University in St. Louis (WUSTL). In the POC process, pulverized coal is burned under elevated pressure in an O2-CO2 environment. Specifically, a 15-bar, 100 kWth, POC combustor is modeled employing Ansys FLUENT commercial sodtware using the Reynolds-Averaged Navier-Stokes (RANS) approach. It is revealed that for this pilot-scale, pressurized burner, velocity profiles in the near-wall region exhibit some anomalies. In order to investigate the influence of particle loading in the near-wall region, particle release location was investigated. The numerical simulations incorporate the coupling between the turbulent flow and the particles. A sensitivity investigation of particle release location found that by tuning the release location, the velocity profile can be consistent with the pure gas flow velocity profile. More importantly, the particle releasing location also affects flame stability. Particle size was also found to have a significant impact on particle trajectory, flame stability and temperature. Finally, Large Eddy Simulations (LES) were performed and compared with the results from two-dimensional RANS.

Li, Lei↗
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↗