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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Elemental Characterization of Neutron-Irradiated Tungsten Using the GD-OES Technique

In reactor-relevant fusion divertor conditions, tungsten (W) will be used as an armor material due to its excellent thermal properties. It will be exposed to impurities from numerous sources, including ion implantation and mixing, neutron transmutation, low-Z plasma-facing-component (PFC) redeposition and codeposition of deuterium and tritium fuel, and trapped helium bubbles. The impurity plasma material–interaction effects are a concern because they can cause gradual degradation of the material and of plasma performance due to dust formation, fuel retention, and even changes to the thermal and mechanical properties of the W armor. It is crucial to measure the amount of impurities in W, and the glow discharge–optical emission spectroscopy (GD-OES) technique is exceptionally well suited for analysis of irradiated samples. GD-OES can measure a sample’s elemental composition by sputtering the surface of the sample, ionizing the eroded material, and measuring the optical emission of the excited atoms. In order for the GD-OES technique to be applied to neutron-irradiated tungsten samples, a mounting system for miniature samples was designed. The sample mounting and centering procedure was successful in measuring the depth distribution of control W and W alloy sample elemental concentrations. These control depth spectra will be used as elemental references for postirradiated samples. The residence time of surface layers was measured, a comparison of signals from different anodes was completed, and the influence of initial surface roughness or nonuniformity was understood. The depth distribution of an arc-welded W-0.4% rhenium (Re) alloy was measured to have a stable Re signal that was distributed evenly in the W matrix. Here, the methods developed here will allow for quantification of impurities and transmutation amounts in neutron-irradiated W. GD-OES is a powerful tool but requires calibration and careful optimization of the parameters to obtain meaningful results.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Challenges of relaxed n -type GaP on Si and strategies to enable low threading dislocation density

We directly show that doping type strongly affects the threading dislocation density (TDD) of relaxed GaP on Si, with n-type GaP having a TDD of ~3.1 × 10 7 cm -2 , nearly 30× higher than both p-type and unintentionally doped GaP at ~1.1 × 10 6 cm -2 . Such a high TDD is undesirable since n-GaP on Si serves as the starting point for the growth of epitaxial III-V/Si multi-junction solar cells. After highlighting additional challenges for highly n-doped GaP on Si including increased surface roughness, anisotropic strain relaxation, and inhomogeneous TDD distributions from blocking of the dislocation glide, we go on to show that the TDD of n-GaP on Si rises by 10× as the doping concentration increases from ~5 × 10 16 to ~2 × 10 18 cm -3 . Next, we investigate the effects of additional dopant choices on the TDD, determining that electronic effects dominate over solute effects on the dislocation velocity at these concentrations. Finally, we demonstrate the respective roles of compressively strained superlattices, low-temperature initiation, and lowered n-type doping concentration on reducing the TDD for n-GaP on Si. By combining all three, we attain relaxed n-GaP on Si with a TDD of 1.54(±0.20) × 10 6 cm -2 , approaching parity with p-GaP on Si. Such high-quality n-GaP on Si will play an important role in boosting the efficiency of epitaxial III-V/Si multi-junction solar cells.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Process and feedstock driven microstructure for laser powder bed fusion of 316L stainless steel

Here in the pursuit of improving additively manufactured (AM) component quality and reliability, fine-tuning critical process parameters such as laser power and scan speed is a great first step toward limiting defect formation and optimizing the microstructure. However, the synergistic effects between these process parameters, layer thickness, and feedstock attributes (e.g. powder size distribution) on part characteristics such as microstructure, density, hardness, and surface roughness are not as well-studied. In this work, we investigate 316L stainless steel density cubes built via laser powder bed fusion (L-PBF), emphasizing the significant microstructural changes that occur due to altering the volumetric energy density (VED) via laser power, scan speed, and layer thickness changes, coupled with different starting powder size distributions. This study demonstrates that there is not one ideal process set and powder size distribution for each machine. Instead, there are several combinations or feedstock/process parameter ‘recipes’ to achieve similar goals. This study also establishes that for equivalent VEDs, changing powder size can significantly alter part density, GND density, and hardness. Through proper parameter and feedstock control, part attributes such as density, grain size, texture, dislocation density, hardness, and surface roughness can be customized, thereby creating multiple high-performance regions in the AM process space.

316L stainless steel↗
DOE OSTI2020

Effect of Particle Spreading Dynamics on Powder Bed Quality in Metal Additive Manufacturing

Powder spreading precedes creation of every new layer in powder bed additive manufacturing (AM). The powder spreading process can lead to powder layer defects such as porosity, poor surface roughness and particle segregation. Therefore, the creation of homogeneous layers is the first task for optimal part printing. Discrete element methods (DEM) powder spreading simulations are typically limited to a single layer and/or small number of particles. Therefore, results from such model configurations may not be generalized to multiple layer processes. In this study, a computationally efficient multi-layer powder spreading DEM simulation model is proposed. The model is calibrated experimentally using static Angle of Repose measurements. The adhesion model parameter, cohesive energy density is related to adhesive surface energy and strain energy release rate parameters. The model results show that interaction between particle and the powder spreading rake leads to noticeable variation in packing density, surface roughness, dynamic angle of repose (AOR), particle size distribution, and particle segregation. Finally, the powder model is experimentally validated using a recoater spreading rig to measure the dynamic AOR at spreading speeds consistent with recoating speeds and layer heights used in AM processes.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Recycling of Pretreated Polyolefin-Based Ocean-Bound Plastic Waste by Incorporating Clay and Rubber

Plastic waste found in oceans has become a major concern because of its impact on marine organisms and human health. There is significant global interest in recycling these materials, but their reclamation, sorting, cleaning, and reprocessing, along with the degradation that occurs in the natural environment, all make it difficult to achieve high quality recycled resins from ocean plastic waste. To mitigate these limitations, various additives including clay and rubber were explored. In this study, we compounded different types of ocean-bound (o-HDPE and o-PP) and virgin polymers (v-LDPE and v-PS) with various additives including a functionalized clay, styrene-multi-block-copolymer (SMB), and ethylene-propylene-based rubber (EPR). Physical observation showed that all blends containing PS were brittle due to the weak interfaces between the polyolefin regions and the PS domains within the polymer blend matrix. Blends containing clay showed rough surfaces and brittleness because of the non-uniform distribution of clay particles in the polymer matrix. To evaluate the properties and compatibility of the blends, characterizations using differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and small-amplitude oscillatory shear (SAOS) rheology were carried out. The polymer blend (v-LDPE, o-HDPE, o-PP) containing EPR showed improved elasticity. Incorporating additives such as rubber could improve the mechanical properties of polymer blends for recycling purposes.

42 ENGINEERING↗
DOE OSTI2019

In Vitro Fabrication and Biocompatibility Assay of a Biomimetic Osteoblastic Niche

A novel HAp-CS/Gel biomimetic osteoblastic niche was fabricated by freeze-drying, and its mechanical strength and biocompatibility were characterized. HAp-CS/Gel scaffolds in various ratios of 100:5, 100:10, and 100:20 (CS/Gel to HAp) were prepared by freeze-drying prior to chemical cross-linking followed by infrared spectrum analysis, EDS, FITR, SEM, fluorescence microscopy, MTT, and ALP experiments. Results from the infrared spectrum analysis showed that HAp doping remained the surface morphology and the architecture of scaffold with interconnected pores in the size range of 135 to 150 μm. The HAp doping ratio of 100:20 was found to be optimal based on its high porosity of 90%, better water uptake folds of 19.1. In addition, EDS and FITR analyses demonstrated that HAps were uniformly distributed on the surface of a scaffold with aggregates and particles, which has sufficient roughness for cell attachment and proliferation of osteoblasts. Under SEM and fluorescent microscopy, osteoblasts seeded onto the scaffold showed evenly distributed viable cells, which is believed to form a biomimetic niche. In the present study, we further demonstrate that osteoblasts can maintain their function and grow well on the scaffold through MTT and ALP tests. Thus, the scaffold has favorable physical properties and biocompatibility to support the proliferation and differentiation of osteoblasts and further to support the constructs of biomimetic osteoblastic niche.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2019

Using a Canopy Model Framework to Improve Large-Eddy Simulations of the Neutral Atmospheric Boundary Layer in the Weather Research and Forecasting Model

A canopy model framework is implemented in the Weather Research and Forecasting Model to improve the accuracy of large-eddy simulations (LES) of the atmospheric boundary layer (ABL). The model includes two options that depend on the scale of surface roughness elements. A resolved canopy model, typically used to model flow through vegetation canopies, is employed when roughness elements are resolved by the vertical LES grid. In the case of unresolved roughness, a modified “pseudocanopy model” is developed to distribute drag over a shallow layer above the surface. Both canopy model options are validated against idealized test cases in neutral stability conditions and are shown to improve surface layer velocity profiles relative to simulations employing Monin–Obukhov similarity theory (MOST), which is commonly used as a surface boundary condition in ABL models. Use of the canopy model framework also leads to increased levels of resolved turbulence kinetic energy and turbulent stresses. Because LES of the ABL has a well-known difficulty recovering the expected logarithmic velocity profile (log law) in the surface layer, particular focus is placed on using the pseudocanopy model to alleviate this issue over a range of model configurations. Tests with varying surface roughness values, LES closures, and grid aspect ratios confirm that the pseudocanopy model generally improves log-law agreement relative to simulations that employ a standard MOST boundary condition. The canopy model framework thus represents a low-cost, easy-to-implement method for improving LES of the ABL.

17 WIND ENERGY↗
DOE OSTI2019

Bidirectional reflection of semitransparent polytetrafluoroethylene (PTFE) sheets on a silver film

In our recent work, record-high solar reflectance (exceeding 99%) has been demonstrated by placing a layer of highly scattering, semitransparent polytetrafluoroethylene (PTFE) sheet on top of a silver film. This can significantly improve the performance of daytime radiative cooling system. Although a PTFE slab of 10-mm thick acts as an excellent diffuse reflector, it is unclear how this dual-layer structure made of a thin PTFE on a mirror-like reflector will alter the bidirectional reflection. Here, we report measurements of the bidirectional reflectance distribution function (BRDF) of the dual-layer structure using a laser scatterometer at the wavelength of 635 nm. Measurements of the BRDF and the bidirectional transmittance distribution function (BTDF) of free-standing PTFE sheets are also performed. The measured BRDF for a PTFE sheet as thin as 236 μm on Ag is essentially diffuse except at large incidence angles. A Monte Carlo ray-tracing method incorporating both surface scattering and volumetric scattering is developed to theoretically model the BRDF in order to elucidate the underlying mechanisms. Finally, the numerical model captures the main features and can be used to study the bidirectional properties for PTFE sheets thinner than what is experimentally available.

42 ENGINEERING↗
DOE OSTI2018

Al{sub 2}O{sub 3}-TiC Composite Prepared by Spark Plasma Sintering Process: Evaluation of Mechanical and Tribological Properties

Al{sub 2}O{sub 3}-10TiC composites were synthesized by spark plasma sintering (SPS) process. Microstructural and mechanical properties of the composite reveal homogeneous distribution of the fine TiC particles in the matrix. The samples were produced with different sintering temperature, and it shows that the hardness and density gradually increases with increasing sintering temperature. Abrasion wear test result reveals that the composite sintered at 1500 °C shows high abrasion resistance (wt. loss ~ 0.016 g) and the lowest abrasion resistance was observed for the composite sample sintered at 1100 °C (wt. loss ~ 1.459 g). The profilometry surface roughness study shows that sample sintered at 1100 °C shows maximum roughness (R{sub a} = 6.53 µm) compared to the sample sintered at 1500 °C (R{sub a} = 0.66 µm) corroborating the abrasion wear test results.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effects of additively manufactured surface roughness on small diameter plenums with multiple side discharges for high temperature gas turbine blade cooling applications

Combined heat and power (CHP) applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy (DOE). One area that is currently being studied includes the potential benefits of CHP turbine operation at higher turbine inlet temperatures. Internal cooling concepts enabled by additive manufacturing (AM) are of primary interest. Here, the effectiveness of internal cooling is hindered by many factors such as velocity distribution of the cooling air to the hot surface considering impingement cooling. To simulate cooling air exiting from a series of orifices for internal cooling in an airfoil, a straight smooth wall tubing with multiple side discharging orifices is used and compared to additively manufactured tubing (Ti6Al4V Grade 23) with orifice size and spacing as well as inner and outer diameters identical to the smooth wall tubing. Similar to flow discharging form perforated pipes, the flow discharged from individual orifices along the tubes in this study is found to be nonuniformly distributed, and the horizontal (axial direction) momentum can be observed from the experimental data. Discharge velocities have been measured with two-dimensional (2D) particle imaging velocimetry (PIV) and single element hot wire anemometry. Numerical analysis has also been conducted to predict the velocity distributions along the orifices in the smooth wall and additive manufacturing (AM) tubing, which are inherited with surface roughness. Numerical and measured results in this study are compared, presented, and discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

3D Printed Parahydrophobic Surfaces as Multireaction Platforms

We report Parahydrophobic surfaces (PHSs) composed of arrays of cubic μ-pillars with a double scale of roughness and variable wettability were systematically obtained in one step and a widely accessible stereolithographic Formlabs 3D printer. The wettability control was achieved by combining the geometrical parameters (H = height and P = pitch) and the surface modification with fluoroalkyl silane compounds. Homogeneous distribution of F and Si atoms onto the pillars was observed by XPS and SEM-EDAX. A nano-roughness on the heads of the pillars was achieved without any post-treatment. The smallest P values lead to surfaces with static contact angles (CAs) >150° regardless of the H utilized. Interestingly, the relationship 0.6 ≤ H/P ≤ 2.6 obtained here was in good agreement with the H/P values reported for nano- and submicron pillars. Furthermore, experimental CAs, advancing and receding CAs, were consistent with the theoretical prediction from the Cassie–Baxter model. Structures covered with perfluorodecyltriethoxysilane with high H and short P lead to PHSs. Conversely, structures covered with perfluorodecyltrimethoxysilane exhibited a superhydrophobic behavior. Finally, several aqueous reactions, such as precipitation, coordination complex, and nanoparticle synthesis, were carried out by placing the reactive agents as microdroplets on the parahydrophobic pillars, demonstrating the potential application as chemical multi-reaction array platforms for a large variety of relevant fields in microdroplet manipulation, microfluidics systems, and health monitoring, among others.

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

New Insights into Nonthermal Plasma-Assisted Poly(vinyl alcohol) Depolymerization Catalyzed by TiO 2

Here, in this study, we investigated the solid residual poly(vinyl alcohol) (PVA) and TiO 2 after nonthermal air, CO 2 , and N 2 plasma depolymerization in the absence and presence of TiO 2 . Scanning electron microscopy studies showed the absence of highly viscous tar and carbonaceous residues on the surfaces of PVA and TiO 2 . In the absence of TiO 2 , PVA particles exhibited micron-sized holes on their surfaces, whereas in the presence of TiO 2 , the surface roughness of PVA particles was observed at the submicron scale. These observations suggest that TiO 2 facilitates the even distribution of nonthermal plasma at a submicron scale, leading to a more uniform depolymerization of PVA surfaces. Raman, Fourier transform infrared spectroscopy, and X-ray absorption spectroscopy showed that (i) the surface of residual PVA contains mainly ketone functional groups and less C-H bonds than the pristine PVA and (ii) further confirmed the absence of highly viscous tar and carbonaceous residues on both used TiO 2 and residual PVA. The nuclear magnetic resonance and mass spectroscopy suggested that the PVA is growing back to poly polyvinyl acetate by the esterification reaction, and the ethers are produced by the acetal reaction between PVA and aldehyde. The transmission electron microscopy and X-ray diffraction analysis indicated no major crystal structural change of the TiO 2 catalyst after the plasma reactions. This study demonstrates that nonthermal plasma-assisted depolymerization is a viable alternative to thermal depolymerization, offering the unique advantage of converting polymer wastes into gaseous small organic molecules without generating recalcitrant viscous tar and carbonaceous residues on the surfaces of the polymer and TiO 2 catalysts.

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

Underlying mechanism of structural transformation between GaSb and GaAs response to intense electronic excitation

Ion irradiation of semiconductors has emerged as a promising approach for fabricating self-organized nanosystems with high atomic precision, despite often being accompanied by undesirable phenomena. Exploring the mechanisms underlying structural transformations is crucial for assessing nanostructure array types under complex irradiation environments. By quantitatively calculating the thermodynamically driven processes and analyzing the impact of intrinsic structural parameters, distinct structural transformations in response to intense electronic excitation are systematically investigated in gallium antimonide (GaSb) and gallium arsenide (GaAs) systems. In high-energy regimes, the nanofibers layer of GaSb exhibits intriguing structural discrepancy, characterized by partial nanofibers with coherent boundaries, interspersed nanopores accompanied by antisite defects and Ga precipitates, distinguishing to a series of discontinuous latent tracks that emerged within cylindrical trajectories in GaAs. Furthermore, significant diffusion behaviors of the nanohillocks are discovered in GaAs, with higher average roughness than GaSb, driven by the gradient stress distribution influenced by the free-surface effects. The deposition energy for melting phase formation, Gibbs free energy, and Ga diffusion coefficients contribute to the distinctive structural features, evidencing relatively stable morphological configurations and higher irradiation resistance in GaAs. Consequently, special optoelectronic properties associated with structural discrepancies facilitate the design and optimization of material functionalities by irradiation technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Distinct roles of land cover in regulating spatial variabilities of temperature responses to radiative effects of aerosols and clouds

Surface temperature responses to radiative perturbations due to aerosols and clouds are complicated by the land surface properties. To disentangle these complexities, this study, from a terrestrial surface energy budget perspective, isolates the underlying biophysical processes from the instantaneous radiative effects of aerosols and clouds on surface temperature using the National Center for Atmospheric Research Community Earth System Model version 1.2.1. It is found that in comparison with the global heterogeneous distributions of instantaneous radiative perturbations at the surface induced by aerosols and clouds, the spatial variations of the corresponding surface temperature responses to aerosol direct radiative effects (DRE) during the daytime and cloud radiative effects (CRE) during the nighttime are amplified. It is because of the consistent global distribution of the local surface climate sensitivity (a function of land cover properties such as surface roughness and Bowen ratio) with those of daytime DRE and nighttime CRE. By applying identical anthropogenic aerosol and precursor emissions over eight major past, present and projected future anthropogenic aerosol emitting regions (i.e. Brazil, China, East Africa, India, Indonesia, South Africa, United States and Western Europe), surface temperature responses to aerosol radiative cooling in the daytime and cloud radiative warming in the nighttime over these regions positively regulated by local surface climate sensitivities are prominent.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Effect of CO 2 -brine-rock reactions on pore architecture and permeability in dolostone: Implications for CO 2 storage and EOR

Geologic carbon sequestration (GCS) is considered a feasible technology for storing substantive volumes of greenhouse gases in subsurface geological formations. In the reservoir, far from carbon dioxide (CO 2 ) injection wells or in post-injection scenarios, diffusion dominates over advection. This condition conjoins with spatially distributed geochemical reactions to induce heterogeneous changes in pore architecture, i.e. pore body and throat sizes or surface roughness. These changes can affect CO 2 transport properties and storage capacity. In this work, we investigated mineral dissolution and precipitation in dolomite samples saturated with a CO 2 -saturated brine at 93 °C and 34.5 MPa, aged without flow. Two rock types samples, i.e. intergranular- and vuggy-dominant, were selected to investigate changes in pore size, porosity and permeability under reactive conditions. Mineral dissolution and precipitation were characterized using scanning electron microscopy. Changes in pore size were quantified via time-domain nuclear magnetic resonance (TD-NMR) transverse relaxation time (T 2 ) and diffusion coefficient (D) distributions. We show that mineral dissolution likely occurs in highly permeable pathways. These observations are confirmed through analysis of (T 2 ) and diffusion coefficient (D) distributions. In contrast to results during CO 2 -enriched brine continuous injection, mineral precipitation was observed in micropores. The leftward shift of the T 2 peaks, corresponding to micropores, also evidenced mineral precipitation in lowpermeability zones. However, microscale alterations resulted only in a subtle increase in porosity and permeability. Results in this study shed light on effects of geochemical reactions on alteration of rock properties in diffusion-dominated regions during CO 2 storage.

58 GEOSCIENCES↗
DOE OSTI2021

Lattice Boltzmann Modeling of Drying of Porous Media Considering Contact Angle Hysteresis

Drying of porous media is governed by a combination of evaporation and movement of the liquid phase within the porous structure. Contact angle hysteresis induced by surface roughness is shown to influence multi-phase flows, such as contact line motion of droplet, phase distribution during drainage and coffee ring formed after droplet drying in constant contact radius mode. However, the influence of contact angle hysteresis on liquid drying in porous media is still an unanswered question. Lattice Boltzmann model (LBM) is an advanced numerical approach increasingly used to study phase change problems including drying. In this paper, based on a geometric formulation scheme to prescribe contact angle, we implement a contact angle hysteresis model within the framework of a two-phase pseudopotential LBM. The capability and accuracy of prescribing and automatically measuring contact angles over a large range are tested and validated by simulating droplets sitting on flat and curved surfaces. Afterward, the proposed contact angle hysteresis model is validated by modeling droplet drying on flat and curved surfaces. Then, drying of two connected capillary tubes is studied, considering the influence of different contact angle hysteresis ranges on drying dynamics. Finally, the model is applied to study drying of a dual-porosity porous medium, where phase distribution and drying rate are compared with and without contact angle hysteresis. The proposed model is shown to be capable of dealing with different contact angle hysteresis ranges accurately and of capturing the physical mechanisms during drying in different porous media including flat and curved geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Designing a Convection‐Cloud Chamber for Collision‐Coalescence Using Large‐Eddy Simulation With Bin Microphysics

Abstract Collisional growth of cloud droplets is an essential yet uncertain process for drizzle and precipitation formation. To improve the quantitative understanding of this key component of cloud‐aerosol‐turbulence interactions, observational studies of collision‐coalescence in a controlled laboratory environment are needed. In an existing convection‐cloud chamber (the Pi Chamber), collisional growth is limited by low liquid water content and short droplet residence times. In this work, we use numerical simulations to explore various configurations of a convection‐cloud chamber that may intensify collision‐coalescence. We employ a large‐eddy simulation (LES) model with a size‐resolved (bin) cloud microphysics scheme to explore how cloud properties and the intensity of collision‐coalescence are affected by the chamber size and aspect ratio, surface roughness, side‐wall wetness, side‐wall temperature arrangement, and aerosol injection rate. Simulations without condensation and evaporation within the domain are first performed to explore the turbulence dynamics and wall fluxes. The LES wall fluxes are used to modify the Scalar Flux‐budget Model, which is then applied to demonstrate the need for non‐uniform side‐wall temperature (two side walls as warm as the bottom and the two others as cold as the top) to maintain high supersaturation in a tall chamber. The results of LES with full cloud microphysics reveal that collision‐coalescence is greatly enhanced by employing a taller chamber with saturated side walls, non‐uniform side‐wall temperature, and rough surfaces. For the conditions explored, although lowering the aerosol injection rate broadens the droplet size distribution, favoring collision‐coalescence, the reduced droplet number concentration decreases the frequency of collisions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Experimental approach for development of a powder spreading metric in additive manufacturing

The powder spreading is a vital step of powder-based additive manufacturing (AM) processes. The quality of spread powder can considerably influence the properties of fabricated parts. Poorly packed powder beds with high surface roughness result in printed part layers with large porosity and low dimensional accuracy, leading to poor mechanical properties. Therefore, the powder spreadability and its dependence on process parameters and powder characteristics should be quantified to improve the efficiency of powder-based AM methods. This study proposes a novel dimensionless powder spreadability metric that can be commonly used in different powder-based AM processes. The quality of spread powder in terms of powder bed density and surface roughness was evaluated by adjusting the process parameters including recoating velocity and layer thickness, and powder characteristics including particle size distribution. In addition, the dynamic repose angle was proposed and examined as another powder spreadability metric. Furthermore, the results showed that these two proposed metrics were strongly correlated and lower recoating velocity and larger layer thickness led to higher spreadability and lower dynamic repose angle.

36 MATERIALS SCIENCE↗