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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Measurements of emanation of Ar-37 and Ar-39 from irradiated rocks and powders

The emanation fraction of radionuclides has been highlighted as a known source of uncertainty in the estimation of radionuclide source signatures from underground nuclear tests and other nuclear activities, particularly in the case of activation products. A system was developed at Pacific Northwest National Laboratory to quantify the emanation fraction of argon from samples ranging in particle size from powder to small rocks. Seven materials, two powders and five rock types, were irradiated with fission spectrum neutrons and the emanation fraction of 37 Ar was measured. Additional measurements were made of the 39 Ar emanation for four of these materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Machine Learning Enabled Sensor Fusion for In-Situ Defect Detection in Laser Powder Bed Fusion

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. The current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques such as X-Ray Computed Tomography (XCT), which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. RTX Technologies Research Center (RTRC) has licensed ORNL’s Peregrine software package – a printer- and camera-agnostic data analytics tool designed specifically for detecting process anomalies using in situ data collected during powder bed printing. The goal of this project was to feed temporally rich, multi-modal sensor data, including visible light, integrated near infrared (NIR), and spatially mapped co-axial melt pool thermal emission data into Peregrine to enable detection of subsurface flaws. XCT data was used as ground truth training data to allow Peregrine’s deep learning algorithms to recognize anomalies in these complex data streams in both test artifacts and industrially relevant geometries. Completion of this program has seen the successful implementation of multi-modal, multi-layer sensor data footprints for training of machine learning models in Peregrine. Flaws detected in XCT data have been successfully detected directly from this in situ data footprint, and initial analyses of the in situ probability-of-detection has been conducted, showing performance levels commensurate with traditional non-destructive evaluation (NDE) methods. The in situ monitoring methodology was then applied to an industrially relevant component that was using post-build NDE, highlighting the utility of the proposed method for hard-to-inspect AM components. As a direct result of this program, two journal manuscripts [1], [2] have been published in Additive Manufacturing, with additional manuscripts planned following program completion.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder for Lithium-Ion Battery Anodes from Bulk Polyethylene Waste

Upcycling plastic waste into graphite can potentially be used to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing, and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create a stable carbon char, then be converted into a highly crystalline bulk graphite powder using a Fe-based catalytic process. The PE-derived graphite demonstrates excellent electrochemical performance as an anode material for lithium-ion batteries.

Gao, Yuan↗
DOE OSTI2025

Microstructural evaluation of thin-wall sections of 316L stainless steel produced by laser powder-bed fusion processing

Laser powder bed fusion (LBPF) is a method of additive manufacturing (AM) that offers a means to fabricate complex components with features which rely upon the mechanical integrity of thin-wall (less than 0.4 mm thick) structures. The microstructure of a 316L AM thin wall is investigated as metallographically prepared from a cylindrical shell. Optimization is pursued through mechanical polishing and chemical etching to minimize the effects of surface roughness. Microanalysis measurements of the sectioned component reveal the sample has high microstructural fidelity, uniform composition and phase content across grain as well as powder layer boundaries within the thin wall. The results are attributed to a uniform thermal gradient at the part scale during rapid solidification.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Demonstration of Electroreduction Technology to Convert GNF Uranium Oxide Powder to Metal

Global Nuclear Fuel – Americas LLC (GNF) has partnered with Argonne National Laboratory to demonstrate electroreduction of uranium oxides produced by deconversion of UF 6 to uranium metal through the Gateway for Accelerated Innovation in Nuclear (GAIN) program under the U.S. Department of Energy to accelerate the domestic production of metallic advanced reactor fuels. Electroreduction of uranium oxide was first demonstrated and patented by Argonne in the early 2000s as a technology to convert used oxide nuclear fuel from light water reactors to metal for further fuel reprocessing. More recently, electroreduction has been proposed as a front-end technology for metallization of uranium oxides produced by deconversion of UF 6 and for scrap recovery of oxide materials. During the electroreduction process, UO 2 powder is contained in a stainless-steel mesh basket with a cathode lead located in the center of the UO 2 bed. The basket is immersed in lithium chloride molten salt electrolyte containing 1 wt% lithium oxide along with a platinum anode and a nickel/nickel oxide (Ni/NiO) reference electrode. Current is applied to the cell between the cathode and anode to reduce the UO 2 to metallic uranium via a solid-state reduction reaction. Oxide ions released from the UO 2 during reduction are transported through the salt to the anode where oxygen gas is evolved. Once reduction is complete, the basket containing the metallicized uranium is removed from the salt and can be processed to remove the salt and consolidate the uranium into an ingot for use in metallic fuel fabrication. This project was performed to provide evidence of the electroreduction technology readiness level for metallization of UO 2 powder, identify and retire technical risks for industrialization of electroreduction, and accelerate the path to commercialization for metallic fast reactor fuel production. To that end, five electroreduction tests were performed with UO 2 provided by GNF and the resulting product was analyzed for the extent of conversion to metal and for impurity contents of the metal product to verify that electroreduction does not introduce impurities that would prevent use of the product in metallic fuel fabrication.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Powder metallurgy hot isostatic pressing - workshop report

The findings of the powder metallurgy (PM) hot isostatic pressing (HIP) workshop confirmed that the accelerated adoption of this technology requires the following action items: 1. By 2035, the HIP infrastructure must be scaled to sizes larger than 4 .0 meters for manufacturing components relevant to energy and defense industries at large. 2. The community must develop cost-effective and agile standards, qualifications, and certification pathways for these HIP parts. 3. At the same time, domestic powder production should be expanded to a wide range of metallic alloys, including Cr-Mo steels, stainless steels, and titanium- and nickel-based superalloys, as well as to emerging alloy classes in the refractory space. 4. The above initiatives can be enhanced by implementing digital modeling and controls, including AI-driven simulations, in situ monitoring, and digital twins.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Microstructural and Hall–Petch Analysis of Additively Manufactured Ferritic Alloy Using 2507 Duplex Stainless Steel Powder

The powder bed fusion–laser beam (PBF-LB) process, a method of additive manufacturing (AM), was used to print duplex stainless steel (DSS) using commercial-grade 2507 powders. While conventionally processed DSS has a two-phase microstructure consisting of 50% austenite and 50% ferrite, the PBF-LB-printed 2507 alloy was nearly 100% ferrite. Optimal processing conditions that minimized porosity were determined to be 290 W laser power and 1000 mm/s scan speed, and grain size, texture, and phases were characterized as a function of laser power and scan speed. Grain size increased with increasing laser power but decreased with increasing scan speed. A <100> texture diminished with increasing scan speed from 1000 mm/s to 1400 mm/s. No austenite phase was detected. Transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM) characterization revealed nanoscale chromium nitride precipitates in the ferritic matrix (incoherent hexagonal close-packed (HCP) precipitates at grain boundaries and coherent body-centered cubic (BCC) precipitates within the grains) and a high density of tangled dislocations. Tensile tests of as-printed alloys showed a yield strength of 570 MPa, an ultimate tensile strength of 756 MPa, and an elongation to failure of 10%. The tensile properties were analyzed based on the observed microstructure considering grain size, nanoscale precipitates, and the high density of dislocations.

Crystallography↗
DOE OSTI2020

Investigation of Bone Growth in Additive-Manufactured Pedicle Screw Implant by Using Ti-6Al-4V and Bioactive Glass Powder Composite

In this study, we optimized the geometry and composition of additive-manufactured pedicle screws. Metal powders of titanium-aluminum-vanadium (Ti-6Al-4V) were mixed with reactive glass-ceramic biomaterials of bioactive glass (BG) powders. To optimize the geometry of pedicle screws, we applied a novel numerical approach to proposing the optimal shape of the healing chamber to promote biological healing. We examined the geometry and composition effects of pedicle screw implants on the interfacial autologous bone attachment and bone graft incorporation through in vivo studies. The addition of an optimal amount of BG to Ti-6Al-4V leads to a lower elastic modulus of the ceramic-metal composite material, effectively reducing the stress-shielding effects. Pedicle screw implants with optimal shape design and made of the composite material of Ti-6Al-4V doped with BG fabricated through additive manufacturing exhibit greater osseointegration and a more rapid bone volume fraction during the fracture healing process 120 days after implantation, per in vivo studies.

stress-shielding effect↗
DOE OSTI2024

Enhancement of γ/γ’ Microstructured Cobalt Superalloys Produced from Atomized Powder by Creating a Harmonic Structure

A material’s properties must be continuously improved to meet the demands of extreme conditions in high-temperature applications. It is demonstrated that γ-γ’ Co-based superalloys could surpass the yield stress of Ni-based superalloys at high temperature due to the γ-γ’ structure. The powders were subjected to a harmonic modification in order to refine the grain structure on the surface and to activate the sintering process. This study examines how harmonic structure affects microstructure and mechanical properties at high temperatures. Spark Plasma Sintering (SPS) was used for consolidation to maintain the ultrafine grain size microstructure of the powder. Compression tests were conducted from room temperature (RT) to 750 °C to assess the mechanical properties of the material. Yield stress values obtained from harmonic structures are four times higher than those obtained from cast alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Using Complementary Methods of Synchrotron Radiation Powder Diffraction and Pair Distribution Function to Refine Crystal Structures with High Quality Parameters—A Review

Determination of the atomic-scale structures of certain fine-grained minerals using single-crystal X-ray diffraction (XRD) has been challenging because they commonly occur as submicron and nanocrystals in the geological environment. Synchrotron powder diffraction and scattering techniques are useful complementary methods for studying this type of minerals. In this review, we discussed three example studies investigated by combined methods of synchrotron radiation XRD and pair distribution function (PDF) techniques: (1) low-temperature cristobalite; (2) kaolinite; and (3) vernadite. Powder XRD is useful to determine the average structure including unit-cell parameters, fractional atomic coordinates, occupancies and isotropic atomic displacement parameters. X-ray/Neutron PDF methods are sensitive to study the local structure with anisotropic atomic displacement parameters (ADP). The results and case studies suggest that the crystal structure and high-quality ADP values can be obtained using the combined methods. The method can be useful to characterize crystals and minerals that are not suitable for single-crystal XRD.

58 GEOSCIENCES↗
DOE OSTI2024

Data and figures for "Integrated modeling of boron powder injection for real-time plasma-facing component conditioning"

This dataset contains raw and processed data, as well as supplementary figures used in the paper titled "Integrated modeling of boron powder injection for real-time plasma-facing component conditioning." The data includes simulation results for boron transport and deposition in DIII-D tokamak scenarios, and processed plots. It provides insights into the effects of boron powder injection on plasma-facing component conditioning and surface composition.

ablative particle injection↗
DOE OSTI2021

Experiment Based Superposition Thermal Modeling of Laser Powder Bed Fusion

This paper evaluates experiment-based superposition thermal modeling for Laser Powder Bed Fusion (LPBF) with a pulsed laser. An analytical pulsed laser thermal model establishes the modeling procedure. The framework inverts a powder bed’s single pulse temperature response from experimental spatiotemporal Short-Wave Infrared (SWIR) camera data. Superimposing this response along a scan path simulates multi-pulse LPBF. Results show the experimentally informed superposition model rapidly and accurately predicts a layer’s temperature history. The model has applications in correction of thermally driven LPBF errors and in-situ part qualification.

Lough, Cody↗
DOE OSTI2021

Electron Beam Powder Bed Fusion Additive Manufacturing of Refractory Metals

The processing of refractory metals via additive manufacturing (AM) presents an opportunity to fabricatecomponents not possible through traditional powder metallurgy techniques. However, processing via AM isextremely challenging and there exist a host of technological limitations still unaddressed. Molybdenumand tungsten are two materials of particular interest for nuclear energy generation applications. Themajority of existing work on the processing of these materials is focused on laser powder bed fusion whereasa smaller body of work exists for electron beam melting AM. In general, material with acceptable densitycan be obtained via both routes however cracking is much more difficult to mitigate against. Strongcrystallographic fiber textures have been observed across a range of refractory systems. In this work wepresent our recent findings on electron beam melting AM of pure tungsten and molybdenum. Wedemonstrate that defect-free material can be obtained in both systems with appropriate processing. Strongbuild direction crystallographic texture fibers are observed in both systems. In molybdenum the fibertexture has direct impact on the resulting tensile behavior. These results demonstrate that electron beamAM is a suitable technology for processing these difficult to fabricate materials.

Fernandez-Zelaia, Patxi↗
DOE OSTI2022

Systems and methods for powder bed additive manufacturing anomaly detection

Detection and classification of anomalies for powder bed metal additive manufacturing. Anomalies, such as recoater blade impacts, binder deposition issues, spatter generation, and some porosities, are surface-visible at each layer of the building process. A multi-scaled parallel dynamic segmentation convolutional neural network architecture provides additive manufacturing machine and imaging system agnostic pixel-wise semantic segmentation of layer-wise powder bed image data. Learned knowledge is easily transferrable between different additive manufacturing machines. The anomaly detection can be conducted in real-time and provides accurate and generalizable results.

Scime, Luke R.↗
DOE OSTI2023

Fundamentals of Polymer Crystallization in Laser Powder Bed Fusion for New Material Screening

Although laser powder bed fusion (PBF/LB) was one of the first industrially viable additive manufacturing (AM) methods for end-use part production, polyamides remain grossly dominant at both the commercial- and researchscale. The research community continues to develop and refine “rapid screening” methods for evaluating the suitability of a new polymer for PBF/LB. The so-called “SLS Process Window,” which is the difference between melting and crystallization temperature measured at 10 K min-1 as originally outlined in the patent literature, is perhaps the most often reported screening method. Although perhaps appropriate as part of a larger study, the simplistic guidelines put forth by the “SLS Process Window” are not sufficiently scientifically rigorous to understand how crystallization kinetics affects successful 3D printing. The common understanding of the SLS Process Window omits details from published theories of polymer crystallization. as evidenced by published assumptions and methods in PBF/LB process modeling papers. The authors explain polymer crystallization in the PBF/LB process context and propose replacing the “process window” with crystallization halftime and physical gelation for new material screening. These measurements better represent behavior critical for ensuring a lengthy coexistence of solid powder and molten polymer affecting warp-free parts.

CHATHAM, CAMDEN A.↗
DOE OSTI2023

Reduced-temperature sintering of spinel-type coatings and layers with metallic alloy powder precursors

A method of forming a spinel coating on a substrate is disclosed including the steps of coating at least a portion of the substrate with a precursor including an alloy powder, and sintering the precursor at a temperature of less than 1000 degrees Celsius to form the spinel coating. The alloy powder used for the precursor can include particles having a particle size of less than 10 micrometers. The method can be utilized to form spinel coatings as contact surfaces between electrodes and interconnects of solid oxide fuel cell (SOFC) stacks.

Zhu, Jiahong↗
DOE OSTI2020

Assessment of Cold Spraying Mild-Steel Powder onto Mild-Steel Substrate for Development of Waste Tank Repair System - 20515

Infrastructure for nuclear waste storage and processing (e.g., waste tanks, transfer pipelines, evaporators) at the U.S. Department of Energy (DOE) Hanford Site has been in service well beyond its original design life. Past corrosion control methods at Hanford for waste tanks have not been fully successful, as evidenced by leaks forming in tank AY-102, the first double-shell tank (DST) constructed, and significant degradation detected in the primary tanks of AP-102 and AY-101. Failure of infrastructure components can pose a significant risk to the environment, worker safety, and project schedules. Therefore, remotely deployable methods for repairing and extending the service life of the existing tank waste infrastructure are needed. Cold spray has been identified as a potential technique for performing in situ repairs and material buildup for life extension of waste storage and processing infrastructure. Cold-spray repair methods and technology are well-established and are used extensively by industry and the military for making repairs using dissimilar materials. Pacific Northwest National Laboratory is evaluating the process of making repairs using mild-steel powder applied to a mild-steel substrate to minimize the galvanic corrosion potential. This paper presents the initial results for a feasibility ('go/no-go') assessment as to whether low-density deposits with sound metallurgic bonds, to build-back steel plate material, can be achieved using existing commercial cold-spray equipment. An assessment of steel-on-steel deposit is necessary to determine if cold spray is a viable candidate for DST carbon steel plate restoration/repair and thus DST service life extension. Powder properties and preparation requirements have been investigated and operating conditions and parameters for depositing a cold-spray buildup of mild steel on a mild-steel substrate have been determined. Soundness of metallurgic bonding as a function of the operating parameters exercised and results from applying cold spray to lay a deposit over simulated small-diameter flaws in 1/2-inch mild-steel plate are presented. Application of in situ cold-spray repair to the DOE complex has the potential to reduce cost and schedule impacts associated with component failures and the need to procure and construct replacement infrastructure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

DEVELOPMENT OF INEXPENSIVE HIGH TEMPERATURE NITI-BASED SHAPE MEMORY ALLOYS FOR POWDER BED ADDITIVE MANUFACTURING

NiTi and NiTi-based Shape Memory Alloys (SMA) exhibit a reversible solid-state phase transformation from martensite to austenite driven by thermal energy. High temperature (Mf>100°C) SMAs are martensite at room temperature and can be fabricated into solid-state actuators that return to a pre-programmed shape against a designed load after heating to transformation threshold. Reactive as-fabricated additively manufactured parts (4-D printing) is the current state of the art in manufacturing of SMAs but requires compositions compliant to rapid solidification. Existing actuator designs are developed from commercially available, highly investigated material compositions. However, existing high temperature high performance (high actuation strain, low thermal hysteresis) shape memory alloys contain significant (>10% at.) portions of high-cost Platinum Group Metals (PGMs). It is of significant scientific interest to investigate material compositions that are peer performing or superior to PGMs whose constituent elements represent a significant cost savings. Shape memory alloy properties vary significantly with small (0.1% at.) compositional changes making robust investigative sample sets very large. Computational material design can be deployed to shrink the compositional space of possible alloy combinations and reduce the experimental load in material discovery. Investigating shape memory effect (SME) and validating process additive process parameters for a single novel composition is cost intensive in both time and consumed materials. Additionally, sub-optimal processing, oxygen, or solidification rate sensitivity could render additively manufacturing specimens without micro, macro cracks, or significant chemical variance impossible. Unfortunately, such failure susceptibility cannot be simulated. Therefore, a research pathway to validate novel shape memory alloy compositions for powder bed fusion additive manufacturing without the need for powdered feedstock is also proposed. This research investigates novel high temperature shape memory alloys for actuators without platinum group alloying elements to discover one that could be commercially viable as an additive manufacturing feedstock.

Sundermann, Tayler↗