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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

High-energy neutrino emission from magnetized jets of rapidly rotating protomagnetars

ABSTRACT Relativistic jets originating from protomagnetar central engines can lead to long duration gamma-ray bursts (GRBs) and are considered potential sources of ultra-high-energy cosmic rays and secondary neutrinos. We explore the propagation of such jets through a broad range of progenitors, from stars which have shed their envelopes to supergiants which have not. We use a semi-analytical spin-down model for the strongly magnetized and rapidly rotating protoneutron star (PNS) to investigate the role of central engine properties such as the surface dipole field strength, initial rotation period, and jet opening angle on the interactions and dynamical evolution of the jet-cocoon system. With this model, we determine the properties of the relativistic jet, the mildly relativistic cocoon, and the collimation shock in terms of system parameters such as the time-dependent jet luminosity, injection angle, and density profile of the stellar medium. We also analyse the criteria for a successful jet breakout, the maximum energy that can be deposited into the cocoon by the relativistic jet, and structural stability of the magnetized outflow relative to local instabilities. Lastly, we compute the high-energy neutrino emission as these magnetized outflows burrow through their progenitors. Precursor neutrinos from successful GRB jets are unlikely to be detected by IceCube, which is consistent with the results of previous works. On the other hand, we find that high-energy neutrinos may be produced for extended progenitors like blue and red supergiants, and we estimate the detectability of neutrinos with next generation detectors such as IceCube-Gen2.

Astronomy & Astrophysics↗
DOE OSTI2020

Aerosol jet printed capacitive strain gauge for soft structural materials

Soft structural textiles, or softgoods, are used within the space industry for inflatable habitats, parachutes and decelerator systems. Evaluating the safety and structural integrity of these systems occurs through structural health monitoring systems (SHM), which integrate non-invasive/non-destructive testing methods to detect, diagnose, and locate damage. Strain/load monitoring of these systems is limited while utilizing traditional strain gauges as these gauges are typically stiff, operate at low temperatures, and fail when subjected to high strain that is a result of high loading classifying them as unsuitable for SHM of soft structural textiles. For this work, a capacitance based strain gauge (CSG) was fabricated via aerosol jet printing (AJP) using silver nanoparticle ink on a flexible polymer substrate. Printed strain gauges were then compared to a commercially available high elongation resistance-based strain gauge (HE-RSG) for their ability to monitor strained Kevlar straps having a 26.7?kN (6?klbf) load. Dynamic, static and cyclic loads were used to characterize both types of strain monitoring devices. Printed CSGs demonstrated superior performance for high elongation strain measurements when compared to commonly used HE-RSGs, and were observed to operate with a gauge factor of 5.2 when the electrode arrangement was perpendicular to the direction of strain.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Techno-economic prospects for producing Fischer-Tropsch jet fuel and electricity from lignite and woody biomass with CO 2 capture for EOR

This work explores the prospective techno-economic performance of facilities that produce low- and net-negative-carbon liquid transportation fuels and electricity with CO 2 capture for enhanced oil recovery. The lignite and biomass-to-jet fuel process is based on KBR’s TRIG gasifier, Rectisol (for sulfur removal and CO 2 capture), fixed-bed low temperature Fischer-Tropsch synthesis of liquid fuels, and Brayton/Rankine combined cycles to convert synthesis/refining off-gases and waste heat to electricity. This work leverages a recent, highly-detailed assessment of a prospective first-of-a-kind (FOAK) demonstration facility to develop highly detailed Aspen Plus process simulations for nine prospective N th -of-a-kind (NOAK) plant equipment configurations. Component-level capital costs from the FOAK study are scaled and adjusted to reflective prospective learning-by-doing to estimate capital costs for the NOAK designs. NOAK plant economic performance is found to be largely insensitive to variations in plant configurations and electricity output fraction, but biomass input fraction significantly affects profitability. Facilities that consume only carbon–neutral biomass, with no lignite co-feed, have significantly net-negative carbon emissions and the most favorable prospective economics when carbon emissions are priced. For these facilities, the crude oil price required for plant economic viability falls rapidly from $\$$100/bbl as carbon emission prices increase above $\$$120/tonne CO 2eq . In general, plants that co-fire lignite with biomass are less profitable (than 100% biomass plants) due to their higher net greenhouse gas emissions.

09 BIOMASS FUELS↗
DOE OSTI2023

Studies of Low and Intermediate Temperature Oxidation of Propane up to 100 Atm in a Supercritical-Pressure Jet-Stirred Reactor

Here, the low and intermediate temperature oxidation of propane has been investigated by using a novel supercritical pressure jet stirred reactor (SP-JSR) with and without 20% CO 2 additions at fuel lean and rich conditions at 10 and 100 atm and 500–1000 K. The mole fractions of C 3 H 8 , O 2 , CO, CO 2 , CH 2 O, C 2 H 4 , CH 3 CHO, and C 3 H 6 were quantified by using a micro-gas chromatograph (µ-GC). The experiment showed that different from that of 10 atm, at 100 atm only a weak negative temperature coefficient (NTC) behavior was observed because of the significant shift of the intermediate temperature HO 2 chemistry to lower temperature. In addition, at 100 atm, existing models in literatures could successfully capture the onset temperatures of the low and intermediate chemistry, while under-predict the fuel oxidation quantitatively and fail to capture the NTC behavior between 650 and 780 K at both fuel lean and rich conditions. Similar discrepancy was observed in studies of n-butane and dimethyl ether (DME) oxidations in literatures, implying that there existed large uncertainties in hierarchy model development of fuels with low temperature chemistries at extremely high pressures. Reaction pathways and sensitivity analyses showed that RO 2 competing reactions through (P1) RO 2 = QOOH, (P2) RO 2 = C 3 H 6 + HO 2 , (P3) RO 2 + CH 2 O/HO 2 = RO 2 H + HCO / O 2 dominated the low and intermediate temperature chemistries, followed by HO 2 / H 2 O 2 chemistry at 100 atm, which differed from the dominant pathway through QOOH consumption reactions at lower pressures. Especially, P3 is a new pathway of RO 2 consumption at high pressures, which was not observed in importance at low pressures. Special attention should be paid to the accurate computations of n-C 3 H 7 O 2 / i-C 3 H 7 O 2 + CH 2 O and n-C 3 H 7 O 2 / i-C 3 H 7 O 2 + in the P3 pathway and n-C 3 H 7 O 2 / i-C 3 H 7 O 2 decomposition reactions in the P2 pathway at high pressures.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Hierarchically Informed Engineering Models for Predictive Modeling of Turbulent Premixed Flame Propagation in Pre- chamber Turbulent Jet Ignition

The goal of the project is to improve the predictive accuracy and efficiency of turbulent combustion sub-models for pre-chamber turbulent jet ignition (TJI). This goal is achieved through the development of a hierarchically informed engineering model for turbulent combustion in TJI. The model development starts with the highest level of model description of turbulent combustion with direct numerical simulation (DNS) from which fundamental characteristics and scaling properties of turbulent premixed flame propagation under TJI relevant conditions are obtained.

42 ENGINEERING↗
DOE OSTI2021

Collapsar R-process Yields Can Reproduce [Eu/Fe] Abundance Scatter in Metal-poor Stars

It is unclear if neutron star mergers can explain the observed r-process abundances of metal-poor stars. Collapsars, defined here as rotating massive stars whose collapse results in a rapidly accreting disk around a black hole that can launch jets, are a promising alternative. We find that we can produce a self-consistent model in which a population of collapsars with stochastic europium yields synthesizes all of the r-process material in metal-poor ([Fe/H] < - 2.5) stars. Our model reproduces the observed scatter and evolution of scatter of [Eu/Fe] abundances. We find that if collapsars are the dominant r-process site for metal-poor stars, r-process synthesis may be linked to supernovae that produce long γ-ray bursts. Our results also allow for the possibility that core-collapse supernovae beyond those that launch γ-ray bursts also produce r-process material (e.g., potentially a subset of Type Ic-BL supernovae). Furthermore, we identify collapsar jet properties (isotropic energy, engine luminosity, or engine time) that may trace r-process yield and verify that the amount of r-process yield produced per collapsar in our model ( ~ 0.07M⊙) is consistent with other independent estimates. In the future, achieving 0.05 dex precision on distribution scatter or a reliable selection function would further constrain our probe of r-process production. Our model would also hold for another prompt r-process site with a power-law yield, and work is needed to determine if, for example, fast-merging neutron stars can also explain abundance scatter.

Astronomy & Astrophysics↗
DOE OSTI2020

The Two-sided Jet Structures of NGC 1052 at Scales from 300 to 4 × 10{sup 7} Schwarzschild Radii

We investigated the jet width profile with distance along the jet in the nearby radio galaxy NGC 1052 at radial distances between ∼300 and 4 × 10{sup 7} Schwarzschild radii (R {sub S}) from the central engine on both their approaching and receding jet sides. The width of jets was measured in images obtained with the Very Long Baseline Interferometry (VLBI) Space Observatory Programme, the Very Long Baseline Array, and the Very Large Array. The jet width profiles of receding jets are apparently consistent with those of approaching jets throughout the measuring distance ranges, indicating symmetry at least up to the sphere of gravitational influence of the central black hole. The power-law index a of the jet width profile (w {sub jet} ∝ r {sup a}, where w {sub jet} is the jet width, r is the distance from the central engine in the unit of R {sub S}) apparently shows a transition from a ∼ 0 to a ∼ 1, i.e., the cylindrical-to-conical jet structures, at a distance of ∼1 × 10{sup 4} R {sub S}. The cylindrical jet shape at small distances is reminiscent of the innermost jets in 3C 84. Both the central engines of NGC 1052 and 3C 84 are surrounded by dense material, part of which is ionized and causes heavy free–free absorption.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

The putative center in NGC 1052

Context. Many active galaxies harbor powerful relativistic jets, however, the detailed mechanisms of their formation and acceleration remain poorly understood.Aims. To investigate the area of jet acceleration and collimation with the highest available angular resolution, we study the innermost region of the bipolar jet in the nearby low-ionization nuclear emission-line region (LINER) galaxy NGC 1052.Methods. We combined observations of NGC 1052 taken with VLBA, GMVA, and EHT over one week in the spring of 2017. Our study is focused on the size and continuum spectrum of the innermost region containing the central engine and the footpoints of both jets. We employed a synchrotron-self absorption model to fit the continuum radio spectrum and we combined the size measurements from close to the central engine out to ∼1 pc to study the jet collimation.Results. For the first time, NGC 1052 was detected with the EHT, providing a size of the central region in-between both jet bases of 43 μas perpendicular to the jet axes, corresponding to just around 250 RS (Schwarzschild radii). This size estimate supports previous studies of the jets expansion profile which suggest two breaks of the profile at around 3 × 103 RS and 1 × 104 RS distances to the core. Furthermore, we estimated the magnetic field to be 1.25 Gauss at a distance of 22 μas from the central engine by fitting a synchrotron-self absorption spectrum to the innermost emission feature, which shows a spectral turn-over at ∼130 GHz. Assuming a purely poloidal magnetic field, this implies an upper limit on the magnetic field strength at the event horizon of 2.6 × 104 Gauss, which is consistent with previous measurements.Conclusions. The complex, low-brightness, double-sided jet structure in NGC 1052 makes it a challenge to detect the source at millimeter (mm) wavelengths. However, our first EHT observations have demonstrated that detection is possible up to at least 230 GHz. This study offers a glimpse through the dense surrounding torus and into the innermost central region, where the jets are formed. This has enabled us to finally resolve this region and provide improved constraints on its expansion and magnetic field strength.Key words: methods: observational / techniques: high angular resolution / techniques: interferometric / galaxies: active / galaxies: jets / galaxies: Seyfert⋆⋆ NASA Hubble Fellowship Program, Einstein Fellow.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

An experimental and one-dimensional modeling analysis of turbulent gas ejection in pre-chamber engines

In this work, experimental results from a study on the evolution of gas jets ejected through the orifices of a pre-chamber in a heavy-duty optical engine are presented. The work examines conditions without fuel inside the main-chamber, which helps to describe the dynamics of the ejected gas jets without the interference of subsequent combustion in the main-chamber. Experimental diagnostics consist of high-speed visible intensified imaging and low-speed infrared imaging. Additionally a one-dimensional gas jet model is used to characterize the spatial distribution of the ejected flow, including parameters such as tip penetration, which are then validated based on experimental results. Different stages in the ejection of pre-chamber jets are identified, with chemical activity restricted to a maximum distance of 5 to 10 orifice diameters downstream of the orifice as indicated by the recorded visible radiation. Sensitivity of cycle-to-cycle variations in pre-chamber jet development to the air-to-fuel ratio in the pre-chamber observed in the experiments is in most part attributed to the variations in the timing of combustion initiation in the pre-chamber. The influence of the ejection flow on the penetration of the gas jet on a cycle-to-cycle basis is presented using the one-dimensional model. The one-dimensional model also indicates that the local flow exhibits highest sensitivity to operating conditions during the start of ejection until the timing when maximum flow is attained. Differences that exist during the decreasing mass-flow ejection time-period tend to smear out in part due to the transient slowdown of the ejection process.

1-D gas jet model↗
DOE OSTI2024

The Dependence of Gamma-Ray Burst Jet Collimation on Black Hole Spin

Gamma-ray bursts (GRBs) are the most luminous events in the Universe and are excellent laboratories to study extreme physical phenomena in the cosmos. Despite a long trajectory of progress in understanding these highly energetic events, there are still many observed features that are yet to be fully explained. Observations of the jet opening angle of long gamma-ray bursts (LGRBs) suggest that LGRB jets are narrower for those GRBs at higher redshift. This phenomenon has been explained in the context of collimation by the stellar envelope, with denser (lower metallicity) stars at higher redshifts able to collimate the jet more effectively. However, until now, the dependence of the jet opening angle on the properties of the central engine has not been explored. We investigate the effect of black hole spin on the jet collimation angle for a magnetically launched jet, using the general relativistic radiation magnetohydrodynamical code ν bhlight . We present 3D results for a range of spin values. The simulations show that higher-spinning black holes tend to create narrower jets. If indeed LGRB progenitors in the early Universe are able to produce black hole central engines with higher spin, this could account for at least some of the observed jet opening angle-redshift correlation.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Understanding and mitigating process drift in aerosol jet printing

Aerosol jet printing offers a versatile, high-resolution prototyping capability for flexible and hybrid electronics. Despite its rapid growth in recent years, persistent problems such as process drift hinder the adoption of this technology in production environments. Here we explore underlying causes of process drift during aerosol jet printing and introduce an engineered solution to improve deposition stability. In this work it is shown that the ink level within the cartridge is a critical factor in determining atomization efficiency, such that the reduction in ink volume resulting from printing itself can induce significant and systematic process drift. By integrating a custom 3D-printed cartridge with an ink recirculation system, ink composition and level within the cartridge are better maintained. This strategy allows extended duration printing with improved stability, as evidenced by 30 h of printing over 5 production runs. This provides an important tool for extending the duration and improving reliability for aerosol jet printing, a key factor for integration in practical manufacturing operations.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hydrothermal catalysis of waste greases into green gasoline, jet, and diesel biofuels in continuous flow supercritical water

Production of green gasoline, jet, and diesel biofuels from waste greases was achieved using a novel hydrothermal, continuous-flow catalytic process operating under supercritical water conditions, with recycled water the only added chemical. Thermally and chemically stable catalysts were explored to optimize yields of liquid biofuels and to minimize production of gases and acidic compounds. A 50:50 mixture of brown and yellow waste greases converted into 76.6 wt% liquid biocrude (BC); the remainder converted to water and gases. Less than 0.2% of the FS formed carbon char (mainly amongst catalyst particles). Various tubular reactors (Inconel, ® Hastelloy®, titanium, stainless) showed no interior defects, erosion, or mass loss after runs. Here, the titanium catalyst was fully recovered and regenerated back to its original potency. The BC was further refined into 28%, 48%, 20%, and 4 wt%, respectively for green gasoline, jet, diesel, and bunker. Biofuels were analyzed for compound class compositions and reaction mechanisms were proposed. The hundreds of identified fuel products (C3-C35) from processing oleic acid as a pure model compound were identified. The neat green gasoline and diesel biofuels along with a 50% green jet blend (with petroleum Jet A) were tested in appropriate spark ignition, turbine, and diesel engines at University of MN Engine Labs. Biofuels achieved 107.7%, 97.2%, and 101.3% engine power performance levels relative to petroleum fuels (91-Octane, Jet A, #2 Diesel) along with lower CO and pollutant emissions. Biofuels passed ASTM fuel specifications (D4814, D7566, D975) including mandated corrosion and low sulfur limits of all three biofuels.

09 BIOMASS FUELS↗
DOE OSTI2020

A direct numerical simulation of Jet A flame kernel quenching

The safe operation of aeronautical engines requires an understanding of flame ignition, propagation and extinction. In this study, direct numerical simulations are performed using a 29 species reduced chemical mechanism for jet fuel surrogate Jet A to understand the flame quenching process. Here, initially laminar spherical flames of varying sizes and equivalence ratios are subject to an identical periodic domain of decaying and isotropic high intensity turbulence with a turbulent Reynolds number of 2400. All cases become quenched, except for the larger kernel with lower Karlovitz number. An analysis of the flame structure shows broadened preheat zone, flame shortening on the product side, differential species diffusion and partial fuel pyrolysis in the fresh mixture. Two extinction mechanisms are identified arising from flame shortening and high flame stretch. Flame shortening occurs due to turbulence-chemistry interactions that resemble the flame–flame interaction in a laminar counterflow reactant-to-reactant configuration, which contorts and breaks up the ignition kernel. Flame stretch is a local effect that attenuates the heat release rate and causes the flame to retreat towards the product mixtures, similar to what has been observed for reactant-to-product laminar counterflow flames. Chemical explosive mode analysis was also performed to quantify the flame structure and local combustion mode. The diffusion–reaction balance in pinched-off flame islands favors extinction of these smaller structures, while auto-ignition modes are observed within the flame kernel after fresh mixture is engulfed and preheated in the product kernel. Statistics of the density-weighted displacement speed conditional on local combustion mode indicates strong correlation between the local extinction mode and negative displacement speed. The local balance between diffusion and reaction ultimately determines the propensity for local extinction in both laminar and turbulent flames, the extent of which has an impact on global flame propagation.

42 ENGINEERING↗
DOE OSTI2021

Numerical investigation of a fueled pre-chamber spark-ignition natural gas engine

Pre-chamber spark-ignition (PCSI) is a leading advanced ignition concept for internal combustion engines with the potential to enable diesel-like efficiency in medium-duty/heavy-duty (MD/HD) natural gas (NG) engines. By leveraging distributed ignition sources from multiple turbulent jets, the PCSI technology can deliver extremely short combustion duration in ultra-lean mixtures and significantly improve the engine thermal efficiency. However, in the automotive industry there is a lack of adequate science base and predictive simulation tools required for commercial development of PCSI engines. Here, in this study, Reynolds-Average Navier-Stokes simulations are carried out to describe the combustion process in lean-burn NG engines, focusing on the combustion modeling approach. Two combustion models, multi-zone well-stirred reactor (MZ-WSR) and G-equation, are used to simulate the combustion process in an MD NG engine equipped with a fueled-PCSI system for four operating conditions close to the lean operating limit. A skeletal chemical mechanism and a laminar flame speed tabulation are used to compute the combustion accurately. Simulation results are compared with experimental data regarding measured cylinder pressure, heat release rate, and combustion duration. By dividing the PCSI combustion process into four distinct phases, the difference between the two models’ results for each phase is analyzed in detail. The MZ-WSR model overestimates the combustion duration for early flame kernel growth in the pre-chamber due to the lack of a specific formulation to take turbulence-chemistry interaction into account. Despite the prolonged combustion duration and low pressure built-up inside the pre-chamber, the model matches the combustion rate in the main-chamber. In contrast, the G-equation model delivers good agreements for the pre-chamber combustion and turbulent jet-driven combustion processes. However, the model starts to underestimate the combustion rate in the main-chamber, especially under ultra-lean mixture conditions. Finally, improvements are needed for both models to simulate the later combustion stage that occurred in the near-wall regions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Sustainability assessment of alternative jet fuel for the U.S. Department of Defense

The United States Department of Defense (DoD) is considering replacing the 2.8 billion gallons of petroleum jet fuel consumed within the continental United States (CONUS) annually with alternative jet fuels to reduce vulnerability to price and supply fluctuations and improve sustainability. We evaluate the feasibility of replacing DoD CONUS jet fuel with alternative jet fuel from domestic feedstocks and assess the cost, greenhouse gas (GHG) emissions, energy balance, land, water, and fertilizer impacts of nine alternative jet fuel pathways. The feedstocks include terrestrial crops (soy, corn, wood, and grass), marine microalgae, and by-products (forestry residue, municipal solid waste, and waste oil) converted by extraction, fermentation, or thermo-chemical conversion, paired with upgrading steps. We found that domestic biomass feedstocks can meet the DoD CONUS jet fuel demand without significantly affecting food supply. Alternative pathways cost more than petroleum jet fuel ($0.78 l -1 and emitting 89 g CO 2 equivalent (CO 2e ) MJ -1 ), but many lowered GHG emissions. The forestry residue and waste oil pathways yielded the lowest costs ($\$0.92$ and $\$0.82$ l -1 , respectively), decreased emissions (23 and 35 g CO 2 e MJ -1 , respectively), and had negligible effects on land, water, and fertilizer resources. Finally, tradeoffs among sustainability metrics are further explored with a sensitivity analysis and by evaluating carbon-cost scenarios.

09 BIOMASS FUELS↗
DOE OSTI2020

Using Thermodynamic Availability to Predict the Transitional Film Reynolds Number between the Droplet and Jet Modes in Falling Liquid between Horizontal Tubes

The objective of this paper is to propose and validate a model for predicting the transitional film Reynolds number between the droplet and jet modes of falling film flows. The proposed model relies on thermodynamic availability with no fitting to mode transition data. The model directly predicts the numerical values of the transitional film Reynolds numbers at different operating conditions. The results of the model are validated against 43 experimental data points from the literature, which cover 10 working fluids and a wide range of tube geometries. The accuracy of the proposed model in predicting the validation data is -on average- more than 20 % better than that of the widely used Re = a (Ga) b and Re = a (Ga) b (S/ξ) c models. The model also achieves low computation time (less than 30 seconds for the 43 validation data points). The model presented in this paper has the potential of integration with heat transfer, mass transfer, and pressure drop models for optimizing the design and operation of falling film heat and mass exchangers.

42 ENGINEERING↗
DOE OSTI2025

The separatrix electron density in JET, ASDEX upgrade and alcator C-Mod H-mode plasmas: A common evaluation procedure and correlation with engineering parameters

The separatrix electron density is an important parameter for core-edge scenario integration in tokamak devices, as it influences plasma confinement, divertor detachment and disruption avoidance. This quantity has been measured in H-mode discharges on JET, ASDEX Upgrade and Alcator C-Mod by applying the same fitting function to Thomson scattering measurements, and by employing the same analysis technique based on scrape-off layer power balance. To estimate the power crossing the separatrix, the inter-ELM time derivative of the plasma energy d W /d t has been experimentally evaluated and found to be approximately a constant fraction of the absorbed heating power. Correlations between n e,sep and engineering parameters have been investigated, revealing that n e,sep scales with the divertor neutral pressure p 0,div in a similar manner across all devices. Additionally, when n e,sep is normalized to the obtained n e,sep dependency, no clear correlation with the plasma current is found. These observations are in agreement with the 2-point model, which suggests that the upstream separatrix density is mainly set by the recycling at the divertor target.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Impact of droplet oxidation on mechanical properties of an Al-7Si-0.4Mg alloy fabricated with liquid metal jetting

Droplet-on-demand liquid metal jetting (DOD-LMJ) is a new method for additive manufacturing of bulk structural alloys. Here, we report on the microstructure, tensile, and fatigue properties of an Al-7Si-0.4Mg (A356) alloy fabricated with LMJ. Liquid metal droplets were shielded by high-purity Ar gas shroud during deposition. Atom probe tomography revealed that a few nanometers thick (Al-Mg-Si)-O oxide film formed on the droplets despite Ar gas shielding. Tensile tests on peak-aged LMJ A356 alloy showed that yield strength was isotropic (250 MPa), but ductility was lower in the build direction (6.1 ± 1.4 %) compared to the transverse direction (9.4 ± 1.0 %). Lower ductility in the build direction was attributed to delamination of metal-oxide interfaces at layer boundaries. The ductility and yield strength of LMJ A356 were similar to cast A356 and laser powder bed fused (LPBF) A357 alloys, indicating the limited impact of oxide film on tensile properties. The oxide film severely impacted the fatigue properties. Fatigue resistance of LMJ A356 was limited by fatigue crack initiation at lack-of-fusion defects and fatigue crack propagation along layer boundaries by delamination of the metal-oxide interface. The fatigue strength of LMJ A356 at 60 MPa was lower than cast A356 and LPBF A357 alloys in the peak-aged condition. This research underscores the need for managing droplet oxidation during LMJ additive manufacturing of structural alloys.

42 ENGINEERING↗