Results for “AM Powder Characterization” — Page 38

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Texture evolution during processing and post-processing of maraging steel fabricated by laser powder bed fusion

Abstract In this study, the evolution of solidification texture during LPBF of Ti-free grade 300 maraging steel, and its effect on texture development during subsequent post-fabrication heat treatments was characterized using Electron Backscatter Diffraction (EBSD). It was found that in the as-fabricated state, no texture was observed in the room temperature martensitic phase. However, the reconstructed parent austenite phase displayed a Cube texture with a minor fraction of Rotated Goss texture. During subsequent aging treatments involving two different routes, namely direct aging of the as-fabricated samples, and conventional solution treatment + aging of the as-fabricated samples, significant changes in the texture components of parent austenite were observed, whereas no changes in texture were observed in the room temperature martensitic phase. During direct aging, it was found that with an increase in the aging temperature up to 520 °C, the texture components of the parent austenite changed from Cube/Rotated Goss to Brass, whereas during the conventional solution treatment and aging cycle, interestingly a change in texture component to rotated copper was observed. The transitions in texture components have been discussed using the concepts of recrystallization and twinning in austenite during annealing and/or aging, and strain energy release maximization (SERM) theory. Furthermore, the importance of these preferred orientations on the mechanical properties was quantified using transformation potential diagrams.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Model-based quantification of margins and uncertainties in metal additive manufacturing for process design and qualification

Laser powder bed fusion (LPBF) Additive Manufacturing (AM) has the potential to enable the production of components with novel designs and material properties unachievable otherwise. However, process repeatability is a challenge, making qualification ill-defined and greatly reducing the utility of what could be an important manufacturing technology. In this work, a combination of modeling, uncertainty quantification (UQ), and experimentation are used in an effort to predict and bound the range of possible outcomes of the LPBF process. Quantities of interest predicted are melt pool dimensions, microstructure features, and mechanical distortions. A combination of high fidelity thermal-fluid models, microstructure growth models, and reduced fidelity, rapid thermal and mechanical models are used. Uncertainty propagation techniques are used to predict probability distributions of quantities of interest from estimates of process uncertainties. Repeated experiments are done to quantify observed probability distributions and compared to predicted distributions to determine if predictions are precise and accurate. Novel modeling methods are microstrucutre characterization techniques are also discussed. It is found that high fidelity models do a generally good job bounding experimentally observed melt pool morphologies for both bead-on-plate and powder bed cases. Microstructure models are able to bound a number of experimentally observed microstructure statistics, but with low precision due to challenges with calibrating the microstructure growth model parameters. A developed modified inherent strain distortion model does not accurately predict observed distortions. A lumped laser distortion model shows promise in being both accurately and precisely bounding observed outcomes from the deflection comb build, but requires further evaluation on more builds and geometries.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Prediction of the J C (B) Behavior of Bi-2212 Wires at High Field

Bi-2212 wires have been produced for much of the last decade with varying architectures, powder sources and great variability of final J c (B) properties. As Bi-2212 transitions from an R&D materials development to a magnet technology, means to predictably forecast J c (B) become increasingly valuable. Here we report on characterizations of short samples having J c (15T, 4.2 K) varying from 1210 to 6560 A/mm 2 , measured in fields up to 31 T, and drawn from 10 billets. Using both 4 K transport and variable temperature VSM measurements capable of probing the 20 K irreversibility field, B irr = μ 0 H k , we discovered that the vortex pinning properties are very stable across these wires, which all used the same standard powder composition (Bi 2.17 Sr 1.94 Ca 0.89 Cu 2.00 O 8+x ), even though it has been made by three different manufacturers over nine years. We conclude that a power-law fit J c ∝ B -α , where α = 0.280 (σ = 0.015), works well at 4.2 K over the field range of at least 3-30 T and that μ 0 H k (20 K) remains stable at 8.6 ± 0.4 T. We conclude that the dominant current limiting mechanism predicting J c (B) in Bi-2212 is the effective filament connectivity. J c (B) at high fields may thus be predicted by simple I c measurements at easily accessible fields in the 3-15 T range.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Crystal structure of butenafine hydrochloride, C 23 H 28 NCl

The crystal structure of butenafine hydrochloride has been solved and refined using synchrotron X-ray powder diffraction data, and optimized using density functional theory techniques. Butenafine hydrochloride crystallizes in space group P2 1 (#4) with a = 13.94807(5), b = 9.10722(2), c = 16.46676(6) Å, β = 93.9663(5)°, V = 2086.733(8) Å 3 , and Z = 4. Butenafine hydrochloride occurs as a racemic co-crystal of R and S enantiomers of the cation. The crystal structure is characterized by parallel stacks of aromatic rings along the b-axis. Each cation forms a strong discrete N–H∙∙∙Cl hydrogen bond. The chloride anions also act as acceptors in several C–H∙∙∙Cl hydrogen bonds from methylene, methyl, and aromatic groups. The powder pattern has been submitted to ICDD for inclusion in the Powder Diffraction File™ (PDF®).

36 MATERIALS SCIENCE↗

DOE OSTI2017

Postsynthetic Functionalization of Mg-MOF-74 with Tetraethylenepentamine: Structural Characterization and Enhanced CO 2 Adsorption

Postsynthetic functionalization of magnesium 2,5-dihydroxyterephthalate (Mg-MOF-74) with tetraethylenepentamine (TEPA) resulted in improved CO 2 adsorption performance under dry and humid conditions. XPS, elemental analysis, and neutron powder diffraction studies indicated that TEPA was incorporated throughout the MOF particle, although it coordinated preferentially with the unsaturated metal sites located in the immediate proximity to the surface. Neutron and X-ray powder diffraction analyses showed that the MOF structure was preserved after amine incorporation, with slight changes in the lattice parameters. The adsorption capacity of the functionalized amino-Mg-MOF-74 (TEPA-MOF) for CO 2 was as high as 26.9 wt % versus 23.4 wt % for the original MOF due to the extra binding sites provided by the multiunit amines. Here, the degree of functionalization with the amines was found to be important in enhancing CO 2 adsorption, as the optimal surface coverage improved performance and stability under both pure CO 2 and CO 2 /H 2 O coadsorption, and with partially saturated surface coverage, optimal CO 2 capacity could be achieved under both wet and dry conditions by a synergistic binding of CO 2 to the amines as well as metal centers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2017

Microstructure Evolution During Continuous Cooling in AISI 5140 Steel Processed by Induction Heating Chromizing

In this study, induction heating chromizing (IHC) and box-type furnace heating chromizing (BFHC) were conducted on commercial AISI 5140 steels, respectively. Microstructure, microhardness and wear resistance of the chromized samples were characterized. The results show that the IHC samples have thicker Cr coating layer and stronger interface bond due to pre-compressive stress among the packed powders. Three kinds of microstructures including alloyed cementite (AC-layer), fine pearlite zone (FP-zone) and carbon-poor zone (CP-zone) are formed near the interface in the IHC samples. The main reason given for this is that different contents of Cr and C have different effects on pearlite phase and morphology. The IHC sample shows better wear properties due to its stronger interface bonding strength than that of the BFHC sample. The formation mechanism of CP-zone and its influences on microhardness and wear resistance are also discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Revisiting the Kitaev material candidacy of Ir 4 + double perovskite iridates

Quantum magnets with significant bond-directional Ising interactions, so-called Kitaev materials, have attracted tremendous attention recently in the search for exotic spin liquid states. Here we present a comprehensive set of measurements that enables us to investigate the crystal structures, Ir 4+ single-ion properties, and magnetic ground states of the double perovskite iridates La 2 BIrO 6 (B = Mg, Zn) and A 2 CeIrO 6 (A = Ba, Sr) with a large nearest-neighbor distance >5 angstrom between Ir 4+ ions. Our neutron powder diffraction data on Ba 2 CeIrO 6 can be refined in the cubic space group Fm$\overline{3}$m, while the other three systems are characterized by weak monoclinic structural distortions. Despite the variance in the noncubic crystal field experienced by the Ir 4+ ions in these materials, x-ray absorption spectroscopy and resonant inelastic x-ray scattering are consistent with J eff = 1/2 moments in all cases. Furthermore, neutron scattering and resonant magnetic x-ray scattering show that these systems host A-type antiferromagnetic order. These electronic and magnetic ground states are consistent with expectations for face-centered-cubic magnets with significant antiferromagnetic Kitaev exchange, which indicates that spacing magnetic ions far apart may be a promising design principle for uncovering additional Kitaev materials

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Impact of pellet preparation on reflectance measurements of ammonium sulfate by single-angle reflectance spectroscopy

The optical constants, n and k, are required to model the reflection, refraction and transmission of light at the first surface interface of a material, as well as its propagation through the material; here n corresponds to the real component and k the imaginary component of the refractive index. Several different spectroscopic methods have been used to determine the n and k values for different materials, including single angle reflectance spectroscopy and ellipsometry. The single-angle reflectance method quantitatively records the specular reflectance R(v) from a plane parallel face of the material and uses the Kramers-Kronig transform to extract the n and k values. For most compounds, however, it is difficult to obtain a single crystal or high-quality window of sufficient planarity and of the appropriate dimensions (several mm) to make the measurement. For this reason, we further investigate the use of pressed pellets of neat powdered substances to measure optical constants of these substances using the single-angle reflectance method. We have found that surface roughness can significantly influence the measured quantitative reflectance spectrum R(v) and, consequently, the derived n and k parameters. A collaborative study between Defence Research and Development Canada (DRDC) - Valcartier Research Center and Pacific Northwest National Laboratory (PNNL) has been carried out using different pellets of neat ammonium sulfate [(NH4)2SO4] to show how parameters such as the relative fraction of particle sizes for the component powder along with the grinding process of the pure compound all can affect the reflectance spectrum used to derive the optical constants. All pressed pellets were characterized by single-angle reflectance spectroscopy.

Diaz, Emmanuela↗

DOE OSTI2017

Growth of Ambient Induced Surface Impurity Species on Layered Positive Electrode Materials and Impact on Electrochemical Performance

Surface impurity species, most notably Li 2 CO 3 , that develop on layered oxide positive electrode materials with atmospheric aging have been reported to be highly detrimental to the subsequent electrochemical performance. LiNi 0.8 Co 0.15 Al 0.05 O 2 (NCA) was used as a model layered oxide compound to evaluate the growth and subsequent electrochemical impact of H 2 O, LiHCO 3 , LiOH and Li 2 CO 3 . Methodical high temperature annealing enabled the systematic removal of each impurity specie, thus permitting the determination of each specie's individual effect on the host material's electrochemical performance. Extensive cycling of exposed and annealed materials emphasized the cycle life degradation and capacity loss induced by each impurity, while rate capability measurements correlated the electrode impedance to the impurity species present. Based on these characterization results, this work attempts to clarify decades of ambiguity over the growth mechanisms and the electrochemical impact of the specific surface impurity species formed during powder storage in various environments.

25 ENERGY STORAGE↗

DOE OSTI2022

Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

Selective laser melting (SLM) additive manufacturing (AM) exhibits uncertainties, where variations in build quality are present despite utilizing the same optimized processing parameters. In this work, we identify the sources of uncertainty in SLM process by in-situ characterization of SLM dynamics induced by small variations in processing parameters. We show that variations in the laser beam size, laser power, laser scan speed, and powder layer thickness result in significant variations in the depression zone, melt pool, and spatter behavior. On average, a small deviation of only ~5% from the optimized/reference laser processing parameter resulted in a ~10% or greater change in the depression zone and melt pool geometries. For spatter dynamics, small variation (10 μm, 11%) of the laser beam size could lead to over 40% change in the overall volume of the spatter generated. The responses of the SLM dynamics to small variations of processing parameters revealed in this work are useful for understanding the process uncertainties in the SLM process.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Toward extreme high-temperature supercritical CO 2 power cycles: Leakage characterization of ceramic 3D-printed heat exchangers

We report future supercritical carbon dioxide (sCO 2 ) Brayton power cycles demand high-performance gas-to-gas heat exchangers (HXs) operating under extreme temperature and pressure conditions at which most existing superalloy materials fail to function safely. Ceramic HXs are deemed excellent candidates for advanced sCO 2 power plants as they can withstand high-temperature working environments. Particularly, ceramic 3D printing enables compact HX topologies employing complex and efficient heat transfer features. However, ceramic 3D-printed walls separating hot and cold flow streams are susceptible to a through-plane leakage inherent to a powder-based manufacturing process, including ceramic 3D printing. A potential leakage through ceramic separating walls poses a significant challenge in developing reliable ceramic 3D-printed HXs and could deteriorate thermal performance. In this study, various parameters, including feedstock slurry, 3D-printing direction, and post-processing conditions, are considered, for the first time, to characterize the argon gas leakage rate associated with alumina 3D-printed parts. Three 3D-printed ceramic structures of flat plates, curved tubes, and small-scale plate-and-frame HXs with various thicknesses are systematically studied to determine powder and ceramic 3D-printing conditions to eliminate the through-plane leakage. The results showed that an alumina 3D-printed plate with a thickness of 0.75 mm demonstrates a permeability of 6 x 10 -4 milli-darcy. An alumina 3D-printed tube with a wall thickness of 0.9 mm revealed a permeability of 9.6 x 10 -7 milli-darcy. Furthermore, leakage test results of functional 3D-printed modules showed a dependency on the 3D-printing direction. Particularly, alumina cell-scale HXs employing 1.5-mm-thick horizontal and vertical 3D-printed separating walls demonstrated impermeability and gas permeability of 7.2 x 10 -5 millidarcy, respectively. Insights gained from the present study facilitate the development of complex ceramic 3D-printed HXs and other balance of plant components for next-generation high-temperature high-pressure sCO 2 power cycles.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Understanding Flow Characteristics in Metal Additive Manufacturing

In fluid flow, the frictional effects from interior surfaces of flow components create pressure loss across the surface. Understanding this inherent pressure loss due to friction and other phenomena is important when designing a flow system. For conventional manufacturing, friction loss has been empirically studied and is well known in the engineering community. However, newer manufacturing techniques, such as laser powder bed fusion (LPBF), an additive manufacturing technique, need to be understood. The inherent flow conditions resulting from the additive processes were studied. Test samples were printed with the flow path oriented in the vertical direction with different channel diameters to characterize the inherent fundamental flow properties of the process. Moody diagrams were replicated for a greater understanding of possibilities and shortfalls when implementing LPBF into design applications. Experimental flow testing revealed that greater effective sand grain roughness resulted from this process when compared to conventional machining methods. This roughness did not correlate well to the average roughness measured with a laser scanning microscope but was consistent with the average particle size of the powder metal feedstock.

42 ENGINEERING↗

DOE OSTI2017

Spray-drying as a tool to disperse conductive carbon inside Na 2 FePO 4 F particles by addition of carbon black or carbon nanotubes to the precursor solution

In this work, Na 2 FePO 4 F-carbon composite powders were prepared by spray-drying a solution of inorganic precursors with 10 and 20 wt% added carbon black (CB) or carbon nanotubes (CNTs). In order to compare the effect of CB and CNT when added to the precursor solutions, the structural, electrochemical, and morphological properties of the synthesized Na 2 FePO 4 F-xCB and Na 2 FePO 4 F-xCNT samples were systematically investigated. In both cases, X-ray diffraction shows that calcination at 600 °C in argon leads to the formation of Na 2 FePO 4 F as the major inorganic phase. 57Fe Mössbauer spectroscopy was used as complementary technique to probe the oxidation states, local environment, and identify the composition of the iron-containing phases. The electrochemical performance is markedly better in the case of Na 2 FePO 4 F-CNT (20 wt%), with specific capacities of about 100 mAh/g (Na 2 FePO 4 F-CNT) at C/4 rate vs. 50 mAh/g for Na 2 FePO 4 F-CB (20 wt%). SEM characterization of Na 2 FePO 4 F-CB particles revealed different particle morphologies for the Na 2 FePO 4 F-CNT and Na 2 FePO 4 F-CB powders. The carbon-poor surface observed for Na 2 FePO 4 F-CB could be due to a slow diffusion of carbon in the droplets during drying. On the contrary, Na 2 FePO 4 F-CNT shows a better CNT dispersion inside and at the surface of the NFPF particles that improves the electrochemical performance.

25 ENERGY STORAGE↗