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DOE OSTI2024

Multiscale porosity characterization in additively manufactured polymer nanocomposites using micro-computed tomography

Extrusion-based additive manufacturing (AM) of polymer composites exhibits complex thermally driven phenomena that introduce severe discontinuities in the internal structure across length scales, especially voids or porosity. This study utilizes a high-throughput porosity characterization technique to analyze large datasets from numerous micro-computed tomography (mu CT) scans to capture the influence of AM print parameters on the size, shape, and location of porosity across multiple print layers (up to a few cm) on fused granular fabrication (FGF) printers. The materials investigated include nanocomposite formulations based on commercially relevant nylon-12 and polyether ketone ketone (PEKK) materials comprising nano- or micro- sized fillers. The estimated global porosity follows an inverse linear correlation against the bulk density of the printed samples. Increasing the extrusion multiplier (EM) and the nozzle temperature while decreasing the print speeds reduces the global porosity. Outlier analyses (local porosity morphology) show that faster print speeds and higher extrusion rates result in long, slender inter-layer voids, while lower nozzle temperatures lead to large, symmetrical, inter-bead voids (at the bead junction). Lack of active chamber temperature increases inter-layer and intra-bead voids with a two-fold increase in global porosity. Overall, the micro filler-reinforced composites exhibit higher global porosity than nanofiller-reinforced composites, which is attributed to the increased mismatch in the thermal expansion coefficient between the filler and the polymers used in the study.

36 MATERIALS SCIENCE↗

DOE OSTI2026

The porosity surrounding carbides and second phase stringers in monolithic U-10Mo fuel plate after irradiation

Post-irradiation microstructure characterization plays an important role in qualifying the low-enriched uranium (LEU) monolithic U-10 wt%Mo plate-type fuel for United States high-performance research reactors (USHPRRs) program. Inhomogeneous features resulting from manufacturing and irradiation processes, including carbides, second phase stringers, and extensive void spaces caused by the combining of small porosities, may increase the risk of heat concentration in local regions of the fuel plate over the operating conditions. In this study, characteristics of carbides, stringers, and porosity after multiple levels of irradiation at varying fission densities were studied by electron microscopes to decipher the morphology of pores and the porosity evolution in U-10 wt%Mo. For carbides, the result shows that porosities start forming on UMo grain boundaries, then on UMo/carbides interfaces as the burn-up going higher. However, the porosities surrounding carbides grow larger than the ones on UMo grain boundaries. The porosities around the uranium carbides could interconnect to form larger void space. The study revealed that the void spaces larger than 5 µm were found around uranium carbides after high burnup, while no evidence was observed to support the similar voids formed near second phase stringers even though the size of the stringers (> 50 µm) was much larger than uranium carbides (< 20 µm). The evolution of porosities suggests that the formation of second phase stringers may not create more significant porosities compared to regular uranium carbides regions during fuel operating conditions.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Deconvoluting the benefits of porosity distribution in layered electrodes on the electrochemical performance of Li-ion batteries

Thick Lithium Ion Battery (LIB) electrodes suffer from poor rate capability and high ionic impedance due to their thickness and mesostructure. Therefore, optimizing thick electrode architectures becomes crucial. In this work, we report a systematic assessment of the ionic resistance in heterogeneous porous electrodes through the combination of computational simulations using a 4D-resolved model and experimental measurements. The first part of the study is devoted to a general assessment of Electrochemical Impedance Spectroscopy (EIS) spectra, mapping the impact of ionic and electronic resistances on the overall impedances of uncalendered and calendered LiNi 1/3 Mn 1/3 Co 1/3 O 2 , LiFePO 4 and graphite electrodes. In the second part, in silico-generated electrodes with different porosities are used in computational EIS simulations to analyze the impact of the electrode porosity on the ionic impedance. As expected, the results show that a lower porosity leads to a higher ionic impedance because of a higher electrode tortuosity factor. Furthermore, in silico-generated electrodes with different porosities were stacked and assembled to create heterogeneities of porosity along the thickness, and used in computational EIS and galvanostatic discharge simulations. The computational results show that the porosity heterogeneity along the electrode thickness has a significant effect on the ionic impedance and capacity of the electrode. The electrode architecture with progressively decreasing porosity from separator to current collector shows the highest performance, a trend validated by our in house experimental EIS and galvanostatic discharge also reported in this manuscript. Overall, we conclude that the ionic resistance in a thick electrode can be effectively reduced through proper tuning of the porosity heterogeneity. The proposed heterogeneous electrode architectures presented here could enormously help building efficient thick electrodes for LIBs.

25 ENERGY STORAGE↗

DOE OSTI2020

The effect of magnetic susceptibility and magnetic field strength on porosity estimates determined from low-field nuclear magnetic resonance

The presence of materials with high magnetic susceptibility are known to have an impact on 1H nuclear magnetic resonance (NMR) measurements and in laboratory data this often results in poor estimates of porosity from NMR data. To quantify and understand the cause of the poor NMR porosity estimations, in this laboratory study, we examine the effect of magnetic susceptibility, NMR measurement parameters, and NMR instrument design on NMR measurements. Data were collected with two instruments, each with a different Larmor frequency (2 MHz and 485 kHz), on water-saturated unconsolidated sediments with magnetic susceptibility values ranging from 3.6 × 10 -6 to 7020 × 10 -6 SI. The results show that for materials with low magnetic susceptibility (<378 × 10 -6 SI), the gravimetric porosity is accurately predicted from the NMR measurements. For the samples with high magnetic susceptibility (>987 × 10 -6 SI) the gravimetric porosity is poorly predicted from the 2 MHz NMR measurements made at all echo times (from 0.2 to 3.0 ms). In contrast, the gravimetric porosity is more accurately predicted at an echo time of 0.2 ms for measurements made using the 485 kHz instrument, although at larger echo times (>1.0 ms), the porosity estimate becomes poor. The 485 kHz NMR instrument has non-zero internal magnetic field gradients, similar to those found in borehole instruments, in contrast to the 2 MHz NMR instrument, which has a homogeneous applied magnetic field. Finally, we conclude that differences is the magnetic field strength and higher magnetic field inhomogeneities in the 485 kHz NMR instrument contribute to a reduction of the impact of inhomogeneities in the magnetic field caused by materials with high magnetic susceptibility, allowing for improved porosity estimation. These results indicate that NMR measurements collected at short echo times in low, inhomogeneous static fields, e.g., borehole instruments, may provide accurate estimates of porosity in water saturated sediments, even in the presence of magnetic minerals.

58 GEOSCIENCES↗

DOE OSTI2023

Engineering Redox Flow Battery Electrodes with Spatially Varying Porosity Using Non‐Solvent‐Induced Phase Separation

Redox flow batteries (RFBs) are a promising electrochemical platform for efficiently and reliably delivering electricity to the grid. Within the RFB, porous carbonaceous electrodes facilitate electrochemical reactions and distribute the flowing electrolyte. Tailoring electrode microstructure and surface area can improve RFB performance, lowering costs. Electrodes with spatially varying porosity may increase electrode utilization and provide surface area in reaction‐limited zones; however, the efficacy of such designs remains an open area of research. Herein, a non‐solvent‐induced phase‐separation (NIPS) technique that enables the reproducible synthesis of macrovoid‐free electrodes with well‐defined across‐thickness porosity gradients is described. The monotonically varying porosity profile is quantified and the physical properties and surface chemistries of porosity‐gradient electrodes are compared with macrovoid‐containing electrode, also synthesized by NIPS. Then, the electrochemical and fluid dynamic performance of the porosity‐gradient electrodes is evaluated, exploring the effect of changing the direction of the porosity gradient and benchmarking against the macrovoid‐containing electrode. Lastly, the performance is examined in a vanadium RFB, finding that the porosity‐gradient electrode outperforms the macrovoid electrode, is independent of gradient direction, and performs favorably compared to advanced electrodes in the contemporary literature. It is anticipated that the approach motivates further exploration of microstructurally tailored electrodes in electrochemical systems.

25 ENERGY STORAGE↗

DOE OSTI2021

Effects of spatial energy distribution-induced porosity on mechanical properties of laser powder bed fusion 316L stainless steel

Laser powder bed fusion (LPBF) additive manufacturing (AM) offers a variety of advantages over traditional manufacturing, however its usefulness for manufacturing of high-performance components is currently hampered by internal defects (porosity) created during the LPBF process that have an unknown impact on global mechanical performance. By inducing porosity distributions through variations in print energy density and inspecting the resulting tensile samples using computed tomography, nearly 50,000 pores across 75 samples were identified. Porosity characteristics were quantitatively extracted from inspection data and compared with mechanical properties to understand the strength of relationships between porosity and global tensile performance. Useful porosity characteristics were identified for prediction of part performance. Results indicate that ductility and strain at ultimate tensile strength are the global tensile properties most significantly impacted by porosity and can be predicted with reasonable accuracy using simple porosity shape descriptors such as volume, diameter, and surface area. Moreover, it was found that the largest pores influenced behavior most significantly. Specifically, pores in excess of 125 µm in diameter were found to be a sufficient threshold for property estimation. These results establish an initial understanding of the complex defect-performance relationship in AM 316L stainless steel and can be leveraged to develop certification standards and improve confidence in part quality and reliability for the broader set of engineering alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2022

The impact of infill percentage and layer height in small-scale material extrusion on porosity and tensile properties

We report material extrusion additive manufacturing is prone to introducing porosity within the structure due to the layer-by-layer construction using elliptical beads of material. This open porosity ultimately plays a role in determining the mechanical properties of printed parts. The shape, size, and amount of porosity within a printed part is influenced by a variety of factors, including nozzle diameter, infill percentage, layer height, raster orientation, and print speed. While several studies have investigated these and other parameters’ effects on mechanical performance and porosity, better understanding the interconnected relationships is crucial in balancing the various input parameters to achieve maximum strength. This work initially examined the influence of key print parameters (infill percentage and layer height) on the internal porosity of a printed Acrylonitrile Butadiene Styrene (ABS) part. Then, the print parameters and internal porosity were statistically correlated to final mechanical properties. Porosity was further classified as either open or closed to differentiate between connected voids in the mesostructure from isolated voids within the material itself. Mechanical performance increased with an increasing density and infill percentage, displaying a 224 % increase in elastic modulus and a 150 % increase in ultimate tensile strength. The contribution of layer height was found to be conditional upon the infill percentage.

3D Printing↗

DOE OSTI2025

Benchmarking image processing techniques for porosity measurement in polymer additive manufacturing: Review and experimental analysis

An image processing workflow is proposed for porosity measurement in polymer additive manufacturing. Various techniques, including global and local thresholding, region growing, and K-means clustering, were applied to microscopic images of carbon fiber reinforced acrylonitrile butadiene styrene (CF-ABS) and benchmarked for their ability to accurately measure porosity. Global methods included Otsu, minimum error, iterative, and entropy-based thresholding, while local methods included Niblack, Bernsen, Sauvola, and Bradley-Roth algorithms. Artificial uneven illumination was introduced to test local adaptive thresholds. Results showed significant differences in porosity values across methods. Otsu, region growing, and K-means clustering excelled under uniform illumination, while Sauvola and Bradley-Roth performed better with uneven illumination. Comparison with X-ray computed tomography (XCT) revealed slightly lower porosity values (2.55 %) than optimized methods (2.73–2.79 %) due to XCT's lower resolution excluding smaller pores. While XCT offers finer pore detection, it limits sample volume and underestimates porosity due to spatial variation. Validation using artificial grayscale images with 5 % porosity confirmed that Otsu, Bradley-Roth, region growing, and Sauvola algorithms produced accurate results. Although tested on a single material system, these methods can be adapted to others with optimization. In conclusion, given XCT's high computational and time costs, this study highlights suitable image processing techniques as cost-effective alternatives for porosity analysis in polymer composites.

Additive manufacturing↗

DOE OSTI2021

Secondary porosity prediction in complex carbonate reefs using 3D CT scan image analysis and machine learning

Development and preservation of carbonate porosity and permeability are critical to characterizing reservoirs. However, secondary porosity, such as vugs and fractures, are difficult to identify and require collection of expensive wireline tools or core sampling. Wireline logs and cores have traditionally been used to identify the presence of secondary porosity but fail to quantify the contribution to total reservoir porosity. Additionally, advanced wireline logs and core are not readily available for most wells. Dual energy CT scans were collected on whole core from the A-1 Carbonate and Brown Niagaran formations drawn from six wells in northern Michigan. 3D analysis techniques were applied to identify and isolate secondary porosity features. A series of machine learning and data analytics techniques were applied to the dataset to predict secondary porosity features on basic wireline logs. The predictive model successfully predicted secondary porosity with high confidence.

02 PETROLEUM↗

DOE OSTI2025

Detection of Part Porosity in Additive Manufacturing Using Machining

Monitoring of part porosity in additive manufacturing is critical for part qualification and process parameter development. This article describes the monitoring of porosity in additive manufacturing using machining. Grade 91 steel samples with different levels of porosity were additively manufactured using a laser blown-powder process. The samples were machined, and the tool position and cutting power were monitored using the machine controller and an external power transducer, respectively. Results show that the power transducer is sensitive to machining porosities. A novel approach using the standard deviation of cutting power was developed to determine the location of porosities along the length of the machining pass. Test cuts were completed at different machining process parameters. Results showed that the probability of detection was one for pore volume greater than 0.3 mm 3 at different machining parameters. In conclusion, although the detection of porosity using machining is a destructive method for evaluation, it offers a low-cost and fast approach for monitoring porosity in additive manufacturing.

36 MATERIALS SCIENCE↗

DOE OSTI2024

ThermoPore: Predicting part porosity based on thermal images using deep learning

Part qualification is often a critical and labor-intensive process in additive manufacturing, particularly in the detection of defects such as porosity, which stands to benefit significantly from advancements in machine learning. We present a deep learning approach for quantifying and localizing ex-situ porosity within Laser Powder Bed Fusion fabricated samples utilizing in-situ thermal image monitoring data. Our goal is to build the real time porosity map of parts based on thermal images acquired during the build. The quantification task builds upon the established Convolutional Neural Network model architecture to predict pore count and the localization task leverages the spatial and temporal attention mechanisms of the novel Video Vision Transformer model to indicate areas of expected porosity. Our model for porosity quantification achieved a R 2 score of 0.57 and our model for porosity localization produced an average Intersection over Union (IoU) score of 0.32 and a maximum of 1.0. This work is setting the foundations of part porosity “Digital Twins” based on additive manufacturing monitoring data and can be applied downstream to reduce time-intensive post-inspection and testing activities during part qualification and certification. In addition, we seek to accelerate the acquisition of crucial insights normally only available through ex-situ part evaluation by means of machine learning analysis of in-situ process monitoring data.

Deep learning↗

DOE OSTI2023

Mitigation of spall fracture by evolving porosity

Ductile materials subject to impact loading conditions can undergo spall fracture when an incoming compressive stress wave reflects off interfaces and free surfaces as a tensile stress wave. Experimental observations suggest that in ductile materials, spall fracture is driven by the evolution of porosity. However, the presence of initial porosity in ductile materials also introduces plastic compressibility, which can attenuate the incoming compressive stress wave and, as a result, reduce the amplitude of the reflected tensile stress wave. This, in turn, can mitigate or delay spall fracture. In this work, we report on finite deformation finite element calculations that analyze the response of porous ductile materials subjected to impact loading conditions. Two sets of calculations are carried out, in the first set the material contains initial porosity values ranging from 0% to 5% while in the second set the material also undergoes stress-controlled porosity nucleation. Both sets of calculations are carried out for a wide range of imposed impact velocities. Here, our results show that porosity in ductile materials can, under certain circumstances, mitigate spall fracture by attenuating stress waves. Results correlating the effects of impact velocity, initial porosity, and porosity nucleation on spall fracture are presented and the underlying mechanisms are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Micro- and nano-porosity of the active Alpine Fault zone, New Zealand

Porosity reduction in rocks from a fault core can cause elevated pore fluid pressures and consequently influence the recurrence time of earthquakes. We investigated the porosity distribution in the New Zealand's Alpine Fault core in samples recovered during the first phase of the Deep Fault Drilling Project (DFDP-1B) by using two-dimensional nanoscale and three-dimensional microscale imaging. Synchrotron X-ray microtomography-derived analyses of open pore spaces show total microscale porosities in the range of 0.1 %–0.24 %. These pores have mainly non-spherical, elongated, flat shapes and show subtle bipolar orientation. Scanning and transmission electron microscopy reveal the samples' microstructural organization, where nanoscale pores ornament grain boundaries of the gouge material, especially clay minerals. Our data imply that (i) the porosity of the fault core is very small and not connected; (ii) the distribution of clay minerals controls the shape and orientation of the associated pores; (iii) porosity was reduced due to pressure solution processes; and (iv) mineral precipitation in fluid-filled pores can affect the mechanical behavior of the Alpine Fault by decreasing the already critically low total porosity of the fault core, causing elevated pore fluid pressures and/or introducing weak mineral phases, and thus lowering the overall fault frictional strength. We conclude that the current state of very low porosity in the Alpine Fault core is likely to play a key role in the initiation of the next fault rupture.

58 GEOSCIENCES↗

NASA NTRS1996

Porosity and Permeability of Chondritic Materials

We have investigated the porosity of a large number of chondritic interplanetary dust particles and meteorites by three techniques: standard liquid/gas flow techniques, a new, non-invasive ultrasonic technique, and image processing of backscattered images . The latter technique is obviously best suited to sub-kg sized samples. We have also measured the gas and liquid permeabilities of some chondrites by two techniques: standard liquid/gas flow techniques, and a new, non-destructive pressure release technique. We find that chondritic IDP's have a somewhat bimodal porosity distribution. Peaks are present at 0 and 4% porosity; a tail then extends to 53%. These values suggest IDP bulk densities of 1.1 to 3.3 g/cc. Type 1-3 chondrite matrix porosities range up to 30%, with a peak at 2%. The bulk porosities for type 1-3 chondrites have the same approximate range as exhibited by matrix, indicating that other components of the bulk meteorites (including chondrules and aggregates) have the same average porosity as matrix. These results reveal that the porosity of primitive materials at scales ranging from nanogram to kilogram are similar, implying similar accretion dynamics operated through 12 orders of size magnitude. Permeabilities of the investigated chondrites vary by several orders of magnitude, and there appears to be no simple dependence of permeability with degree of aqueous alteration, or chondrite type.

Zolensky, Michael E.↗

NASA NTRS1999

Interaction of Porosity with an Advancing Solid/Liquid Interface: a Real-Time Investigation

Problems associated with formation of porosity during solidification continue to have a daily impact on the metal forming industry. Several past investigations have dealt with the nucleation and growth aspects of porosity. However, investigations related to the interaction of porosity with that of a solidification front has been limited mostly to organic analogues. In this paper we report on real time experimental observations of such interactions in metal alloys. Using a state of the art X-Ray Transmission Microscope (XTM) we have been able to observe and record the dynamics of the interaction. This includes distortion of the solid/liquid interface near a poro.sity, solute segr,egation patterns surrounding a porosity and the change in shape of the porosity during interaction with an advancing solid/liquid interface. Results will be presented for different Al alloys and growth conditions. The experimental data will be compared to theory using a recently developed 2D numerical model. The model employs a finite difference approach where the solid/liquid interface is defined through the points at which the interface intersects the grid lines. The transport variables are calculated at these points and the motion of the solidification front is determined by the magnitude of the transport variables. The model accounts for the interplay of the thermal and solutal field and the influence of capilarity to predict the shape of the solid/liquid interface with time in the vicinity of porosity. One can further calculate the perturbation of the solutal field by the presence of porosity in the melt.

Sen, S.↗

NASA NTRS2001

Friction Factor Characterization for High-Porosity Random Fiber Regenerators

NASA Glenn Research Center, the Department of Energy (DOE), and Stirling Technology Company (STC) of Kennewick, Washington are developing a Stirling convertor for a high-efficiency Stirling Radioisotope Power System to provide electric power for NASA Space Science Missions. STC is developing the 55-We Technology Demonstration Convertor (TDC) under contract to DOE. Steady-flow tests were completed to determine the friction factor for the high-porosity regenerators that are used in the TDC. STC fabricated a flow test fixture and three random fiber regenerator test samples, one each at approximately 80, 88, and 96 percent porosities. The flow tests were then completed by the NASA Glenn Flow Calibration Laboratory, and the data reduced to Reynolds number and friction factor. The results showed that the 80 and 88 percent porosity samples had similar characteristics while the 96 percent porosity sample had significantly higher friction factors for given Reynolds numbers compared to the samples with lower porosities. Comparisons were also made between the test data and existing correlations. STC used this data to derive a modified regenerator friction factor correlation for use in the Stirling design code GLIMPS for porosities greater than 88 percent. Using this new correlation, the final optimized regenerator design porosity was reduced from 96 to 90 percent.

Thieme, Lanny G.↗

DOE OSTI2023

Variable-porosity panel systems and associated methods

Variable-porosity panel systems and associated methods. A variable-porosity panel system includes a panel assembly with an exterior layer defining a plurality of exterior layer pores and a sliding layer adjacent to the exterior layer and defining a plurality of sliding layer pores. The variable-porosity panel system additionally includes a shape memory alloy (SMA) actuator configured to translate the sliding layer relative to the exterior layer to modulate a porosity of the panel assembly. The SMA actuator includes an SMA element configured to exert an actuation force on the sliding layer and at least partially received within an SMA element receiver of the sliding layer. The SMA element extends out of the sliding layer only at a sliding layer first end. A method of operating the variable-porosity panel system includes assembling the variable-porosity panel system and/or transitioning the panel assembly of the variable-porosity panel system among the plurality of panel configurations.

Calkins, Frederick T.↗

DOE OSTI2025

Porosity in nuclear graphite and its impact on nuclear reactor science and criticality safety applications

Porosity in nuclear-grade graphite significantly influences its low-energy neutron scattering, yet its effect on underlying phonon properties remains debated. Here, this work integrates inelastic and small-angle neutron scattering (INS/SANS) experiments, advanced atomistic simulations with a novel machine-learned potential (DeepMD), total cross-section measurements, and neutronics calculations (SCALE, MCNP, OpenMC) to investigate porosity’s impact on neutron thermalization. INS measurements on diverse graphite grades reveal no discernible porosity effect on phonon spectra, which align with crystalline graphite. Conversely, total cross-section data below ≈10 meV show increased scattering attributable to SANS. Our DeepMD simulations demonstrate that realistic micropores do not distort phonon spectra, challenging the assumptions in current ENDF/B-VIII.1 porosity thermal scattering laws (TSLs). These TSLs, based on random atom removal, produce unphysical phonon spectra and inflate inelastic cross-sections. Augmenting a crystalline TSL with an SANS component accurately captures experimental total cross-sections. Neutronics benchmarks (ICSBEP/IRPhE) show ENDF porosity TSLs unphysically increase neutron multiplication factor, keff. Crucially, incorporating SANS physics (NCrystal/OpenMC) indicates accurately modeled porosity negligibly affects keff, reactor physics, or criticality safety.

Critical benchmarks↗