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DOE OSTI2021

High-speed synchrotron X-ray imaging of directed energy deposition of titanium: effects of processing parameters on the formation of entrapped-gas pores

Laser based directed energy deposition (DED) is a competitive method for repairing and remanufacturing metallic parts used in numerous industries including aerospace and biomedical. However, the numerous dynamic phenomena associated with the DED process often result in defects such as entrapped-gas pores, lack of fusion, and undesirable anisotropic properties. The entrapped-gas pore, being one of the most common issues, not only influences melt-pool dynamics but also reduces the fabrication quality and mechanical properties of parts fabricated by the DED process. To reduce and further understand this issue, the real-time observation of the pore formation process needs to be studied first. To directly observe the phenomena in the melt pool, high-speed techniques are needed because rapid solidification leads to rapid pore formation and movement. In-situ high-speed X-ray has been proven to be an effective method in investigating the melt pool dynamics and pore formation mechanisms in the laser powder bed fusion process, in which the fabrication process is quite different from that in DED. Here, the high-speed X-ray method is extended to study the formation of entrapped-gas pores. The real-time formation and quantitative analysis of pores under each set of processing parameters (particle velocity, laser power, and spot welding dwelling time of stationary laser) in the DED process are investigated. We found that the DED with a higher particle velocity (3.19 m/s) produced a smaller average pore size of 27.8 µm and a lower pore area fraction of 0.52%. The DED under lower laser power (156 W) generated a smaller average pore size of 20.3 µm and a lower pore area fraction of 1.94%. The shorter dwelling time (10 ms) benefited the decrease of both average pore size and pore area fraction.

Defect↗

DOE OSTI2023

A fully coupled thermal–microstructural–mechanical finite element process model for directed energy deposition additive manufacturing of Ti–6Al–4V

A fully coupled thermal–microstructural–mechanical finite element modelling framework is developed to investigate the distortion and residual stresses during directed energy deposition (DED) of multi-phase Ti–6Al–4V alloy. The Johnson–Cook constitutive model is used to predict the yield strength of each phase as a function of strain, strain rate and temperature where the flow stress is calculated by a linear mixing rule based on the volumetric phase fractions. A thin-walled rectangular sample is chosen as the reference geometry and the results are compared with experimentally measured in situ thermal history and distortion data, where a reasonable agreement is achieved. The proposed modelling framework with physics-based material constitutive model provides useful information for a better understanding of process–microstructure–property relations in additive manufacturing by DED.

Tunay, Merve↗

DOE OSTI2020

Melt pool size control through multiple closed-loop modalities in laser-wire directed energy deposition of Ti-6Al-4V

Not Available

Gibson, B. T.↗

NASA NTRS1991

Energy deposition by X-ray photoelectrons into interstellar molecular clouds

The deposition of energy by 100-10,000 eV electrons into molecular hydrogen and helium gas of cosmic abundances and fractional ionization ranging from 10 to the -12th to 0.1 is considered. In order to account for energy deposition by both discrete and continuous degradation processes, the loss spectrum, a form of the Spencer-Fano degradation spectrum particularly suited to describing electron energy deposition in a partially ionized gas is considered. The calculated excitation and ionization yields drop as the fractional ionization increases. The dependences of these yields on fractional ionization are fitted to a form suitable for swift numerical computation.

Voit, G. M.↗

NASA NTRS2000

CLUST - EVAP Monte Carlo Simulation Applications for Determining Effective Energy Deposition in Silicon by High Energy Protons

The CLUST-EVAP is a Monte Carlo simulation of the interaction of high energy (25 - 400 MeV) protons with silicon nuclei. The initial nuclear cascade stage is modeled using the CLUST model developed by Indiana University over 30 years ago. The second stage, in which the excited nucleus evaporates particles in random directions, is modeled according to the evaporation algorithm provided by H. H. K. Tang of IBM. Using the CLUST-EVAP code to model fragment produ6tion and the Vavilov-Landau theory to model fluctuations in direct ionization in thin silicon layers, we have predicted energy deposition in silicon components for various geometrical configurations. We have compared actual measurements with model predictions for geometry's such as single, thin silicon particle detectors, telescopic particle detectors flown in space to measure the environment, and thin sensitive volumes of modern micro-electronic components. We have recently compared the model predictions with actual measurements made by the DOSTEL spectrometer flown in the Shuttle payload bay on STS-84. The model faithfully reproduces the features and aids in interpretation of flight results of this instrument. We have also applied the CLUST-EVAP model to determine energy deposition in the thin sensitive volumes of modern micro-electronic components. We have accessed the ability of high energy (200 MeV) protons to induce latch-up in certain devices that are known to latch up in heavy ion environments. However, some devices are not nearly as susceptible to proton induced latch-up as expected according to their measured heavy ion latch-up cross sections. The discrepancy is believed to be caused by the limited range of the proton-silicon interaction fragments. The CLUST-EV AP model was used to determine a distribution of these fragments and their range and this is compared to knowledge of the ranges required based on the known device structure. This information is especially useful in accessing the risk to on-orbit perfonnance in a heavy ion environment based on testing performed with only protons.

ONeill, Pat M.↗

DOE OSTI2020

Collinear dual-pulse laser optical breakdown and energy deposition

A non-equilibrium model for laser-generated plasmas is used to represent collinear dual nano-second-pulse interactions. In the specific case considered, the breakdown is initiated with an ultraviolet (UV) laser pulse at 266 nm, which pre-ionizes the gas, and it is followed by a near-infrared (NIR) pulse at 1064 nm, which deposits significant energy into the ionized mixture. The model is validated against corresponding experiments, and simulation results are interrogated to understand key features of the plasma-kernel dynamics and the post-discharge hydrodynamics. The hydrodynamics of the non-equilibrium plasma is governed by the two-temperature Navier–Stokes equations accounting for both multiphoton ionization and inverse bremsstrahlung. The interaction between the laser beam and the plasma is modeled based on the radiative transfer equation. The temporal and spatial offsets of the two pulses can generate ionization kernels with different topology and dynamics. It is shown that the UV pre-ionization pulse can tailor the plasma region, leading to a larger ionized volume than would occur for a single-pulse breakdown, and it increases the efficiency of the energy deposition for the following NIR discharge. Vorticity in the early post-discharge phase is generated via baroclinic torque from the misalignment of the radial gradient of density (sudden gas expansion) and the strong pressure gradient (initiated by energy deposition from the laser beam). It is predicted that the collinear dual pulse can be designed to specify the plasma kernel size, shape, and maximum temperature in the breakdown phase, and the initial post-breakdown vorticity and plasma-core decay.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Deposition Height Prediction in Directed Energy Deposition

Using 316L stainless steel as a model material, reduced-order models are developed to predict capture efficiency, deposition height, and site-specific hardness in directed energy deposition. Capture efficiency is predicted over a 15 to 55 pct range using a dimensionless number derived from processing conditions and thermophysical properties. Deposition height is predicted over a 0.3 to 1.3 mm range without in situ sensing or prior training data, using two models based on the same mass and energy-balance principles. Predictions are compared with machine learning approaches. A quantitative relationship links deposition height, primary dendrite arm spacing (PDAS), and hardness: heights of 0.3 to 1.1 mm correspond to PDAS values of 2.7 to 5.1 µm and Vickers hardness (HV) of 160 to 219. Thinner layers cool more rapidly, producing finer microstructures and higher hardness. Samples fabricated with in situ variations in deposition height exhibited up to 55 HV differences between thick and thin regions, demonstrating that local control of deposition height enables predictive, site-specific hardness within a single build. These results establish deposition height prediction as a pathway for a priori process design and property control in directed energy deposition for 316L stainless steel.

Kunkel, William [Univ. of Wisconsin, Madison, WI (↗

DOE OSTI2022

In situ X-ray imaging of directed energy deposition of metals: The comparisons of delivery performance between spherical and irregular powders

Not Available

Wang, Hui↗

DOE OSTI2024

Comprehensive study of the cold-temperature directed energy deposition: Multi-physics modelling and experimental validation

Not provided.

Engineering↗

NASA NTRS2016

Asteroid Fragmentation Approaches for Modeling Atmospheric Energy Deposition

During asteroid entry, energy is deposited in the atmosphere through thermal ablation and momentum-loss due to aerodynamic drag. Analytic models of asteroid entry and breakup physics are used to compute the energy deposition, which can then be compared against measured light curves and used to estimate ground damage due to airburst events. This work assesses and compares energy deposition results from four existing approaches to asteroid breakup modeling, and presents a new model that combines key elements of those approaches. The existing approaches considered include a liquid drop or "pancake" model where the object is treated as a single deforming body, and a set of discrete fragment models where the object breaks progressively into individual fragments. The new model incorporates both independent fragments and aggregate debris clouds to represent a broader range of fragmentation behaviors and reproduce more detailed light curve features. All five models are used to estimate the energy deposition rate versus altitude for the Chelyabinsk meteor impact, and results are compared with an observationally derived energy deposition curve. Comparisons show that four of the five approaches are able to match the overall observed energy deposition profile, but the features of the combined model are needed to better replicate both the primary and secondary peaks of the Chelyabinsk curve.

Modeling↗

DOE OSTI2022

Impact of Nozzle Condition on Powder Catchment Efficiency for Coaxial Powder Direct Energy Deposition

Blown powder directed energy deposition is well-designed for fine resolution additive manufacturing processing. Coaxial powder deposition heads use an outer layer of shielding gas directed by an outer nozzle to prevent oxidation occurring during the powder melting process. Powder blown feedstock catchment efficiency can be as low as 50-80% whereas wire deposition systems are closer to 98% efficient. The present study evaluates the impact of directed energy deposition nozzle condition on catchment efficiency. Changes in the overall outer shielding gas nozzle length has been found to increase material usage efficiency by 10% through convergence of the powder flow. The results of this experiment show that for coaxial powder deposition head design, if the standoff distance can safely be decreased, powder catchment efficiency can be increased as the outer shielding gas nozzle is increased in length, or the standoff distance is decreased.

Heinrich, Lauren↗

DOE OSTI2022

Impact of Nozzle Condition on Powder Catchment Efficiency for Coaxial Powder Direct Energy Deposition

Heinrich, Lauren↗

DOE OSTI2020

A Review on Metallic Alloys Fabrication Using Elemental Powder Blends by Laser Powder Directed Energy Deposition Process

The laser powder directed energy deposition process is a metal additive manufacturing technique, which can fabricate metal parts with high geometric and material flexibility. The unique feature of in-situ powder feeding makes it possible to customize the elemental composition using elemental powder mixture during the fabrication process. Thus, it can be potentially applied to synthesize industrial alloys with low cost, modify alloys with different powder mixtures, and design novel alloys with location-dependent properties using elemental powder blends as feedstocks. This paper provides an overview of using a laser powder directed energy deposition method to fabricate various types of alloys by feeding elemental powder blends. At first, the advantage of laser powder directed energy deposition in manufacturing metal alloys is described in detail. Then, the state-of-the-art research and development in alloys fabricated by laser powder directed energy deposition through a mix of elemental powders in multiple categories is reviewed. Finally, critical technical challenges, mainly in composition control are discussed for future development.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Impact of the delayed energy deposition in TREAT on transient dynamics

Estimating the energy released during a reactivity insertion accident (RIA) is of prime importance. TREAT is an experimental reactor designed to simulate these transients. Typically, models of these transients assume instantaneous energy deposition. However, a delayed energy deposition component exists. This work leverages the advanced capabilities of ALFRED, a high-fidelity Monte Carlo code for particle transport, to study the impact of this delayed component on RIA transient dynamics in TREAT. The study reveals that the delayed component can affect the energy released by up to $3\%$ for natural pulse transients. Understanding the impact of the delayed energy deposition component will enable the development of more accurate models, which will assist in designing experiments in TREAT and evaluating their safety.

73 - NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1973

Calculation of energy deposition distributions for simple geometries

When high-energy charged particles pass through a thin detector, the ionization energy loss in that detector is subject to fluctuations or straggling which must be considered in interpreting the data. Under many conditions, which depend upon the charge and energy of the incident particle and the detector geometry, the ionization energy lost by the particle is significantly different from the energy deposited in the detector. This problem divides naturally into a calculation of the energy loss that results in excitation and low-energy secondary electrons which do not travel far from their production points, and a calculation of energy loss that results in high-energy secondary electrons which can escape from the detector. The first calculation is performed using a modification of the Vavilov energy loss distribution. A cutoff energy is introduced above which all electrons are ignored and energy transferred to low energy particles is assumed to be equivalent to the energy deposited by them. For the second calculation, the trajectory of the primary particle is considered as a source of secondary high-energy electrons. The electrons from this source are transported using Monte Carlo techniques and multiple scattering theory, and the energy deposited by them in the detector is calculated. The results of the two calculations are then combined to predict the energy deposition distribution. The results of these calculations are used to predict the charge resolution of parallel-plate pulse ionization chambers that are being designed to measure the charge spectrum of heavy nuclei in the galactic cosmic-ray flux.

Watts, J. W., Jr.↗

DOE OSTI2024

Coaxial color channel focus evaluation to estimate standoff height in directed energy deposition additive manufacturing

Directed energy deposition (DED) is an additive manufacturing process that is being rapidly adopted by industry and is well suited for the fabrication of complex components in a variety of metal alloys. In laser cladding systems such as DED, powder is blown in a stream to a metal substrate coincident with a laser necessary to deposit molten metal with 3D spatial control. The focus of both the laser and the powder stream are crucial, and best deposition occurs at a predetermined standoff height between the build surface and the print head. Generally, no monitoring of this distance is implemented in commercial DED systems. Due to potential over or under building, the standoff height often changes over time but tends to self-correct. However, inexpensive and minimally intrusive methods to identify optimal standoff are required to provide real-time control to maintain the optimal distance. The present work explores the quantification of the focus of the three-color channels of a coaxial camera to determine the standoff height. An experiment was performed in which a 254 mm wall is built and the standoff height, initially 5.0 mm below the optimal position, was then intentionally increased every 25.4 mm of wall length by an amount of 1.0 mm to a final position 7.0 mm above optimal. Computer vision is demonstrated to monitor the amount of focus in each color band and estimate standoff distance. Finally, a response can be calculated in under 40 ms using simple hardware and can work in most laser-based DED systems.

36 MATERIALS SCIENCE↗

DOE OSTI2021

In situ X-ray imaging of pore formation mechanisms and dynamics in laser powder-blown directed energy deposition additive manufacturing

Directed energy deposition (DED) additive manufacturing (AM) is receiving growing attention in many applications, such as repair, remanufacturing, and fabrication of functionally graded structures. However, the laser-matter interactions and melt pool dynamics in laser DED with powder flow are still unclear, particularly in how pores form and flow inside the melt pool during the process. Understanding the porosity formation mechanisms is critical in the qualification, certification, and overall properties of a DED AM part. Porosity is a common phenomenon and can significantly hinder the quality of DED fabricated parts, as the pores can act as sites of crack nucleation and propagation. Here in this paper, we reveal four types of pore formation mechanisms through in-situ and operando high-speed high-resolution X-ray imaging in the DED AM process. Our results confirm that porosity within the feedstock powder induces pores in the process. We also observed pore formation mechanisms unique to the laser-based, powder-blown DED process as a result of powder delivery, keyhole dynamics, melt pool dynamics, and shield gas. High-speed X-ray images provide direct evidence for pore formation mechanisms and show that the pores related to the interaction between the delivered powder and melt pool are the largest in size in laser-based powder-blown DED AM. These results will guide porosity mitigation, elimination, and control in DED AM.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Track Structure Components: Characterizing Energy Deposition from Direct and Peripheral Hits in Spherical Cells

Energy deposition by ionizing radiation in micrometric targets (microdosimetry), representative of cells, is very important to understand the effect of radiation and the cellular and biological response. Microdosimetry is used to estimate quality factors for risk assessment in radiation protection and quantify Relative Biological Effectiveness (RBE) for treatment planning of hadron radiation therapy. Radiation physics has shown that ionizing radiation deposit their energy in a complex manner, the track structure. Consequently, energy deposited in a target is a function of factors like the ion type, its energy and the irradiated volume.

Ianik Plante↗