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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

ECAR-6581 Rev 0 Hydraulic Assessment of Conceptual Design of Ring-type Spacer for MARVEL Reactor

The fuel rods in the nuclear reactor core can be deformed due to various reasons, such as thermal expansion, the effect of irradiation, hydrodynamic effects, etc. The deformation of the fuel rods can lead to contact between them, which can deteriorate the coolability of the nuclear fuel and increase the potential risk of failure. To prevent the fuel rods from coming into contact with each other, a ring-type spacer may be introduced in the MARVEL reactor. However, the ring spacers can result in an additional pressure drop, which could restrict the natural circulation operation of the MARVEL reactor. Therefore, this ECAR will examine the additional pressure drop caused by the introduction of the ring-type spacer by comparing with the bare rod condition.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2022

Resonant acoustic monitoring of damage in plug‐screw feeders

Abstract Plug‐screw feeders are critical in many industrial processes for compressing slurry materials via a rotating plug‐screw feeder. Over time, increasing plug‐screw feeder wear will eventually lead to catastrophic mechanical failure. Early detection of the wear state can prevent unplanned catastrophic failures resulting in operational shut‐downs, costly repairs, and most importantly the health and safety of workers. We present a theoretical basis for a noninvasive, in operando acoustic resonant technique to monitor the wear state of plug‐screw feeders. The technique is based on tracking the resonant acoustic modes of the plug‐screw feeder, which are sensitive to the plug‐screw feeder geometry, material, and operating conditions. We implemented a multivariate polynomial model to estimate the plug‐screw feeder wear state using multiple acoustic resonances by simulating the acoustic resonant modes for two categories of wear (tip and thread damage) that are common in plug‐screw feeders. Fitting multiple resonances to the polynomial model, we demonstrate accurate estimation of the total mass loss, as well as characterization of the type of damage (i.e., tip vs. thread). Current approaches for monitoring plug‐screw feeder wear rely on shutting down the operation and visually inspecting the plug‐screw feeder. The presented acoustic technique offers a noninvasive, in operando measurement approach that mitigates unplanned catastrophic failures. The acoustic resonance technique presented in the paper has a broad range of industrial applications including the Pharmaceutical, Mining, Integrated Biorefineries (IBR), and Additive Manufacturing industries, to name a few.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Substation Secondary Asset Health Monitoring and Management System (SSHM)

Electric Power Group, LLC (EPG) was awarded DOE OE0000850 to design, develop, and demonstrate a real-time software application for substation secondary equipment health monitoring and management at host utility American Electric Power (AEP), a cost share partner. This project addresses the need for monitoring substation equipment health and providing operators with tools to identify and take pre-emptive action to avoid catastrophic equipment failure. By monitoring synchrophasor data in real time, data anomalies that indicate potential asset failure can be detected and alerts can be sent to operators in time to take corrective actions. EPG developed two data driven algorithms to identify abnormal equipment signature patterns as well as a method using substation linear state estimation (SLSE). The software has been deployed on hardened PC’s and tested and validated for cost share partner AEP’s substations - 138kV and 765 kV. The SSHM software has been accepted by AEP and final demonstration of DOE - OE0000850 for AEP and DOE was successfully completed on March 17th, 2020. EPG developed the Substation Secondary Asset Health Monitoring (SSHM) Platform to analyze equipment failure signatures in PMU data and alert substation personnel when pre-emptive inspection, repairs and other actions are warranted to prevent potential catastrophic failures. This is the first system that automatically monitors the health of substation secondary assets and alerts users to emerging failures using synchrophasor measurements. SSHM uses high resolution PMU data from PTs, CTs, and CCVTs to analyze equipment signatures and identify anomalies that are precursor indicators of potential equipment failure. When an anomaly is detected, there is a likelihood of potential failure of monitored equipment, the system alerts the user with visual alarms including alarm trend charts and indicator lights on a oneline diagram of the substation.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Evaluating the Effect of Vane Trailing Edge Flow on Turbine Rim Sealing

Abstract Modern gas turbine development continues to move toward increased overall efficiency, driven in part by higher firing temperatures that point to a need for more cooling air to prevent catastrophic component failure. However, using additional cooling flow bled from the upstream compressor causes a corresponding detriment to overall efficiency. A primary candidate for cooling flow optimization is purge flow, which contributes to sealing the stator–rotor cavity and prevents ingestion of hot main gas path (MGP) flow into the wheelspace. Previous research has identified that the external main gas path flow physics play a significant role in driving rim seal ingestion. However, the potential impact of other cooling flow features on ingestion behavior, such as vane trailing edge (VTE) flow, is absent in the open literature. This paper presents experimental measurements of rim cavity cooling effectiveness collected from a one-stage turbine operating at engine-representative Reynolds and Mach numbers. Carbon dioxide (CO2) was used as a tracer gas in both the purge flow and vane trailing edge flow to investigate flow migration into and out of the wheelspace. Results show that the vane trailing edge flow does in fact migrate into the rim seal and that there is a superposition relationship between individual cooling flow contributions. Computational fluid dynamics (CFD) simulations using unsteady Reynolds-averaged Navier–Stokes (URANS) were used to confirm VTE flow ingestion into the rim seal cavity. Radial and circumferential traverse surveys were performed to quantify cooling flow radial migration through the main gas path with and without vane trailing edge flow. The surveys confirmed that vane trailing edge flow is entrained into the wheelspace as purge flow is reduced. Local CO2 measurements also confirmed the presence of VTE flow deep in the wheelspace cavity.

Engineering↗
DOE OSTI2024

Interim Development of new Class B Code Case with Variable Design Lifetime and enhanced design rules to guard against cyclic structural failure mode

This report summarizes updates on the ongoing development of the new American Society of Mechanical Engineers Section III, Division 5, Class B rules to address the potential failure modes of Class B components. An initial design-by-analysis approach and supporting design rules are presented. The elastic-perfectly plastic (EPP) analysis approach has been adopted for primary stress limit and ratcheting check to prevent the component failure against the structural failure mode against primary load and strain accumulation due to cyclic loads. The creep-fatigue damage assessment uses explicitly defined elastic follow-up calculated from the stress concentration region of given component. Damage fraction calculation uses a novel coupled approach to capture the influence of the elastic follow-up and provide adequate conservatism for Class B components. The proposed Class B rules does not use the stress classification approach and uses the combined loads to assess component.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Scalable Unit Commitment with Security Constrained AC Power Flow via ADMM and Hybrid Modeling Strategies

This research introduces a more efficient way to optimize power grid operations, breaking the problem into manageable steps and using advanced mathematical techniques to speed up calculations. By incorporating smart heuristics, improved preprocessing, and contingency analysis, the approach allows operators to make better decisions faster. These innovations enhance our understanding of how to optimize energy generation, making it possible to anticipate failures before they happen, reduce system costs, and improve overall grid performance. Ultimately, this research helps bridge the gap between theoretical models and real-world applications, paving the way for a smarter, more resilient power grid. This research directly benefits the public by making electricity more affordable, reliable, and sustainable. By improving how power grids schedule and distribute electricity, the project helps energy providers reduce operational costs, which can lead to lower electricity prices for consumers. Additionally, the ability to predict and prevent power system failures enhances grid reliability, reducing the likelihood of blackouts that can disrupt homes, businesses, and critical infrastructure such as hospitals. From an environmental perspective, optimizing power generation reduces energy waste and lowers carbon emissions, contributing to cleaner air and a more sustainable energy system. Furthermore, with extreme weather events becoming more frequent, these advancements make the power grid more resilient, ensuring communities are better prepared for emergencies and natural disasters. By strengthening the nation's energy infrastructure, this research plays a crucial role in improving economic stability, public safety, and environmental sustainability.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Electrically Accelerated Mechanochemical Film Formation by a Phosphonium Phosphate Ionic Liquid: An In Situ Chemical Kinetics Investigation

Powertrains in electric vehicles are exposed to stray currents that accelerate wear and cause failure of mechanical components. These durability issues are further aggravated when using low-viscosity lubricants, which are desired for energy efficiency but create harsher contact conditions at sliding interfaces. This study investigates a phosphonium phosphate ionic liquid as a performance-enhancing additive in a low-viscosity base oil for lubricating electrified sliding interfaces. Ionic liquids can adsorb and react on contact interfaces via stress-assisted chemical reactions, generating nanometric tribofilms that provide protection against wear. However, the effect of electric fields on the mechanochemistry of ionic liquids is poorly understood, hindering their adoption in lubricants for electrified powertrains. This article reports an in situ optical interferometry study of ionic liquid derived tribofilm growth kinetics at stressed sliding/rolling interfaces under direct currents. The application of electric currents accelerated tribofilm formation up to a critical current density (∼1.4 A/mm 2 ), beyond which pitting-induced wear dominated. The tribofilms were composed of iron phosphates, iron oxides, and carbon species, with iron oxides becoming predominant under applied currents. These tribofilms prevented the scuffing failure of steel surfaces under electrified conditions. Based on the results, a kinetic model is proposed that integrates electric current effect into the classical stress-assisted thermal activation framework to allow prediction of tribofilm growth at electrified sliding contacts. This framework provides crucial guidance for designing next-generation lubricants for electrified transportation and power generation systems.

additives↗
DOE OSTI2022

Compressible battery foams to prevent cascading thermal runaway in Li-ion pouch batteries

Lithium-ion battery packs require thermal management to achieve optimum life and safety. This is becoming crucial for battery packs composed of high-energy-density cells. Pouch cells themselves achieve highest packaging efficiency but require additional structural support and thermal management when grouped into modules, especially under abusive conditions such as thermal runaway. Novel foam battery pads have demonstrated to cushion volume changes of pouch cells and are reengineered in this study to mitigate cell-to-cell thermal runaway propagation. The compressible pads are made of polyurethane foams incorporating flame-retardant additives or coatings, including intumescent and fire wall materials. Here their performances were evaluated by conducting nail penetration tests on modules composed of pouch cells at 100% state of charge (SOC), with the foams placed in between the cells. Experimental results show cascading thermal runaway was considerably delayed by polyurethane foams incorporating flame-retardant additives or coatings. Complete prevention of cascading failure was achieved with dense polyurethane foams with multilayered coatings of both fire wall and intumescent materials.

25 ENERGY STORAGE↗
DOE OSTI2024

Towards Resilient Near Real-Time Analysis Workflows in Fusion Energy Science

Nuclear fusion holds the promise of an endless source of energy. Several research experiments across the world and joint modeling and simulation efforts between the nuclear physics and high performance computing communities are actively preparing the operation of the International Thermonuclear Experimental Reactor (ITER). Both experimental reactors and their simulated counterparts generate data that must be analyzed quickly and in a resilient way to support decision making for the configuration of subsequent runs or prevent a catastrophic failure. However, the cost if the traditional techniques used to improve the resilience of analysis workflows, i.e., replicating datasets and computational tasks, becomes prohibitive with explosion of the volume of data produced by modern instruments and simulations. Therefore, we advocate in this paper for an alternate approach based on data reduction and data streaming. The rationale is that by allowing for a reasonable, controlled, and guaranteed loss of accuracy it becomes possible to transfer smaller amounts of data, shorten the execution time of analysis workflows, and lower the cost of replication to increase resilience. We develop our research and development roadmap towards resilient near real-time analysis workflows in fusion energy science and present early results showing that data streaming and data reduction is a promising way to speed up the execution and improve the resilience of analysis workflows.

Suter, Fred↗
DOE OSTI2024

Cy-Phy ADS: Cyber Physical Anomaly Detection Framework for EV Charging Systems

Today’s large-scale Electric Vehicle (EV) infrastructures are heavily dependent on information communication technologies to maintain their operation and to support communication within sub-system components as well as the outside world. These technologies are vulnerable to various cyber and physical threats. Timely identification and mitigation of these threats are critical for improving human safety, avoiding economic losses, and preventing catastrophic system failures. By addressing this, our work presents a ResNet Autoencoder (AE) based Cyber-Physical Anomaly Detection System (Cy-Phy ADS) for detecting anomalies in EV Controller Area Network (CAN) protocol communication. It consists of four main components: Cyber-Physical Feature Extractor, ResNet AE-based Anomaly Detection Framework, Cyber-Physical Health Metric (CPHM), and Visualization Dashboard. The presented framework was trained and tested using CAN data collected from the EV charging system testbed at the Idaho National Laboratory. The presented Cy-Phy ADS compared against six widely used unsupervised anomaly detection algorithms: One Class Support Vector Machine (OCSVM), Variational Autoencoder (VAE), LSTM Autoencoder (LSTM AE), Isolation Forest (IForest), Principle Component Analysis (PCA) and Local Outlier Factor (LOF). Here the presented approach showed the highest accuracy among the compared methods. Further, the proposed approach showed comparable performance in terms of precision, F1, and False positive rate. It also showed the lowest training and inference time compared to the neural network-based baseline algorithms compared against with. Additionally, the Cy-Phy ADS has advantages such as unsupervised training, the ability to provide a holistic metric for system health characterization, and non-linear feature extraction.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Early Detection of Li-Ion Battery Thermal Runaway Using Commercial Diagnostic Technologies

The rate of electric vehicle (EV) adoption, powered by the Li-ion battery, has grown exponentially; largely driven by technological advancements, consumer demand, and global initiatives to reduce carbon emissions. As a result, it is imperative to understand the state of stability (SoS) of the cells inside an EV battery pack. That understanding will enable the warning of or prevention against catastrophic failures that can lead to serious injury or even, loss of life. The present work explores rapid electrochemical impedance spectroscopy (EIS) coupled with gas sensing technology as diagnostics to monitor cells and packs for failure markers. These failure markers can then be used for onboard assessment of SoS. Experimental results explore key changes in single cells and packs undergoing thermal or electrical abuse. Rapid EIS showed longer warning times, followed by VOC sensors, and then H 2 sensors. While rapid EIS gives the longest warning time, with the failure marker often appearing before the cell vents, the reliability of identifying impedance changes in single cells within a pack decreases as the pack complexity increases. This provides empirical evidence to support the significant role that cell packaging and battery engineering intricacies play in monitoring the SoS.

25 ENERGY STORAGE↗
DOE OSTI2023

High Power Radiofrequency Operation of the Radiofrequency Quadrupoles in the Spallation Neutron Source

The Spallation Neutron Source (SNS) recently took delivery of a third Radiofrequency Quadrupole (RFQ03) that will ultimately be installed on the front-end (FE) of the SNS Linac. The first RFQ (RFQ01) operated in the SNS FE for more than a decade before being replaced with the second RFQ (RFQ02). RFQ01 was relocated to the Beam Test Facility (BTF) where it operated for five more years. The RFQ02 was initially installed in the BTF for high power testing and used with H- beam for BTF operation. It replaced RFQ01 in the SNS FE in 2017 and has been operating for beam production since then. There are some differences between the three RFQs. RFQ01 has a square cross-section with pi-mode stabilizing loops (PISLs) with the structure being fabricated using two layers of materials, GlidCop outside and OFHC inside. RFQ02 and RFQ03 has an octagonal cross-section with end-wall stabilizer rods and was fabricated using OFHC only. RFQ01 suffered some field flatness distortion incidents that resulted in degradation in beam transmission efficiency and required RF tuning. RFQ02 has performed well but had a melted RF seal in the high energy end wall, that was ultimately mitigated by a redesign of the end flange seals. The SNS decided to order RFQ03 that has a design that followed that of RFQ02 closely, but end-wall contacts were modified to prevent RF seal failure. This report presents the testing, installation, high power RF operation, and design improvements of the RFQ03.

Ren, Haitao↗
DOE OSTI2020

Performance Evaluation of AG-1 FC HEPA Filters and Medium in Nuclear Complex Facilities - 20434

High Efficiency Particulate Air (HEPA) filters are credited as the final barrier against the release of radioactive aerosol contamination in nearly every operating U. S. Department of Energy (DOE) and National Nuclear Security Agency (NNSA) nuclear facility. The Institute for Clean Energy Technology (ICET) at Mississippi State University maintains a research program that studies various aspects of these components of containment systems and seeks to answer key questions from across the industry. This programmatic overview will include results from recent and ongoing studies, including a study on filter design and performance envelope, degradation due to aging or fatigue, fire event impact on HEPA filters, and accelerated aging of medium and component parts. ICET has completed a study helping to define the threshold for combined elevated temperature and relative humidity resistance of separator style and separator-less style HEPA filters that are used in DOE complexes. The study provides experimental data that considers elevated temperature, elevated relative humidity (RH), and target differential pressure (dP) in an attempt to gain a better understanding or more comprehensive insight into the operating envelope of different configurations of ASME (American Society for Mechanical Engineers) AG-1 Section FC filters. Test variables including air temperature ranges of 48.88 deg. C, 54.44 deg. C, or 60 deg. C (120, 130, or 140 deg. F); air RH ranges including 60-70%, 80%, or 90+% with initial filter dP of either 497.68 Pa, 746.52 Pa, or 995.36 Pa (2 inches water column (in. w. c.), 3 in. w. c., or 4 in. w. c.) included for full bracketing of each set of conditions. A study examining the effects of aging and fatigue on nuclear grade HEPA filters and medium elucidates the physical properties of media along with testing of new and aged ASME AG-1 HEPA filters. In addition to performing autopsies of the tested, aged filters to help better understand the service life of their performance, newly designed accelerated aging chambers allow new medium to undergo accelerated aging and exposure treatments. Evaluation of degradation in physical properties and functionality requires a high population of aged filters of different ages, designs, manufacturers, and operational histories. The limited availability of this population and the impropriety of looking solely at formulations and components from past years requires experimental design that will provide foresight into future filter performance. This undertaking therefore involves not only properties analysis of aged medium from different operational histories, ages, designs, and manufacturers, but also prescience in analytical goals via accelerated aging studies of newly manufactured media. A more complete understanding of the mechanisms of degradation from past formulations as well as current and future formulations is possible. Accelerated Aging of newly manufactured media utilizes exposure treatments based on the Arrhenius equation to artificially age medium and therefore glimpse into the future. Evaluation of current media properties This testing allows for the comparison of performance and durability of new filters under upset or design basis conditions with aged filters that were in service under ambient conditions and other aged filters retained in storage. Susceptibility of HEPA filters to the effects of combustion byproducts, heat, and water is also being studied in an attempt to gain understanding on the prevention of filter failures during fire events in nuclear facilities. ICET seeks to determine the effect of filter performance due to smoke loading using characterized smoke from variable fuel compositions, geometries, and loads; the smoke capacity of various filters with different burning conditions, heat release rates and transport, as well as mass transport from the air stream will be studied in low flow containment systems. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Distributed Quantum-Enhanced Optimization: A Topographical Preconditioning Approach for High-Dimensional Search

Optimization problems become fundamentally challenging as the number of variables increases. Because the volume of the search space grows exponentially, classical algorithms frequently fail to locate the global minimum of non-convex functions. While quantum optimization offers a potential alternative, mapping continuous problems onto near-term quantum hardware introduces severe scaling limits and barren plateaus. To bridge this gap, we propose the Distributed Quantum-Enhanced Optimization (D-QEO) framework. Instead of forcing the quantum processor to find the exact minimum, we use it simply as a topographical preconditioner. The QPU maps the landscape to locate the most promising basin of attraction, generating high-quality seed points for a classical GPU-accelerated solver to refine. To make this approach viable for utility-scale problems, we exploit the mathematical structure of separable functions. This allows us to cut a 50-qubit (i.e., $2^{50}$) global search space into independent and manageable sub-spaces using 5-qubit subcircuits. By executing these fragments concurrently with CUDA-Q, we completely bypass the overhead of cross-register entanglement and classical tensor knitting for separable functions. Benchmarks on the 10-dimensional Rastrigin and Ackley functions show that D-QEO prevents the exponential failure rates observed in purely classical algorithms. Furthermore, this quantum warm-start significantly reduces the number of classical BFGS iterations required to converge, providing a highly practical blueprint for utilizing near-term quantum resources in complex global search.

Soos, Dominik [Old Dominion U.]↗
DOE OSTI2022

Controlling dendrite propagation in solid-state batteries with engineered stress

Metal-dendrite penetration is a mode of electrolyte failure that threatens the viability of metal-anode-based solid-state batteries. Whether dendrites are driven by mechanical failure or electrochemical degradation of solid electrolytes remains an open question. If internal mechanical forces drive failure, superimposing a compressive load that counters internal stress may mitigate dendrite penetration. Here, we investigate this hypothesis by dynamically applying mechanical loads to growing dendrites in Li 6.6 La 3 Zr 1.6 Ta 0.4 O 12 solid electrolytes. Operando microscopy reveals marked deflection in the dendrite growth trajectory at the onset of compressive loading. For sufficient loading, this deflection averts cell failure. Using fracture mechanics, we quantify the impact of stack pressure and in-plane stresses on dendrite trajectory, chart the residual stresses required to prevent short-circuit failure, and propose design approaches to achieve such stresses. For the materials studied here, we show that dendrite propagation is dictated by electrolyte fracture, with electronic leakage playing a negligible role.

25 ENERGY STORAGE↗
DOE OSTI2020

Predicting cell-to-cell failure propagation and limits of propagation in lithium-ion cell stacks

Thermal runaway of lithium-ion batteries is a risk that is magnified when stacks of lithium-ion cells are used for large scale energy storage. When limits of propagation can be identified so that systems can be designed to prevent large scale cascading failure even if a failure does occur, these systems will be safer. This work addresses the prediction of cell-to-cell failure propagation and the propagation limits in lithium-ion cell stacks to better understand and identify safe designs. A thermal-runaway model is presented based on recent developments in thermochemical source terms. It is noted that propagating failure is characterized by temperatures above which calorimetry data is available. Results show high temperature propagating failure predictions are too rapid unless an intra-particle diffusion limit is included, introducing a Damköhler number limiter into the rate expression. This new model form is evaluated against cell-to-cell failure propagation where the end cell of a stack is forced into thermal runaway through a nail-induced short circuit. Limits of propagation for this configuration are identified. Results show cell-to-cell propagation predictions are consistent with measurements over a range of cell states of charge and with the introduction of metal plates between cells to add system heat capacity representative of structural members. This consistency extends from scenarios where propagation occurs through scenarios where propagation is prevented.

25 ENERGY STORAGE↗
DOE OSTI2021

Predicting Cement-Sheath Integrity with Consideration of Initial State of Stress and Thermoporoelastic Effects

In conventional wellbore-integrity analysis, the cement sheath’s initial state of stress and transient thermoporoelastic effects are often neglected. However, the initial state of stress is prerequisite information for accurately predicting the safe operating conditions that prevent a cemented well from being damaged. In addition, transient thermoporoelastic effects can have a profound effect on when damage will occur. Here in this paper, we propose a model that includes these effects to predict the safe operating pressures and temperatures that will prevent cement-sheath failure. For the initial state of stress, we proposed an empirical model using measurements. Subsequent stress changes are evaluated by a fully coupled transient thermoporoelastic model to analyze the mechanical behavior of the cement sheath. We predict the safe operating envelope (SOE) for shear, tensile, and debonding cement-sheath failures caused by pressure and temperature perturbations after the cement sets. Our model predicts that pore pressure is a key factor for cement failure, especially for rapid temperature changes. If the formation is low permeability, the transient pore pressures are amplified, causing the risk of damage to increase. Compared with conventional thermoelastic models, the thermoporoelastic model predicts a smaller SOE when heating the internal casing fluid and a larger envelope when cooling the internal casing fluid. Finally, the heating rate was considered with respect to field applications. The heating rate was also considered, and slower heating/cooling rates can prevent damage to the cement sheath. Finally, the thermoporoelastic model was applied to explain several laboratory and field experiments and achieved good matches.

02 PETROLEUM↗
DOE OSTI2024

Effect of Internal Structure on Warpage in a Large-Scale Additive Manufacturing Process With Bio-Derived Composites

Extrusion-based large-format additive manufacturing (LFAM) often results in unintended deformation and failures due to thermal residual stress between layers. This LFAM involves a hot molten polymer deposited on a previously deposited and cooled layer, generating a temperature mismatch between the layers. The temperature discrepancy causes a thermal contraction mismatch, generating thermal residual stress. Due to the residual stress, printed structures experience warpage and delamination Therefore, understanding the heat distribution behavior is essential to preventing undesired deformation and failures. The goal of this study is to investigate the effect of infill patterns on heat distribution and deformation in an LFAM system. Wood fiber-reinforced polylactic acid was used as a sustainable and low-cost reinforcement material. A numerical model was developed to predict the temperature and deformation field with thermo-mechanical properties, which were measured by a dynamic mechanical analysis and a thermal expansion test. Simulations were performed on a box geometry with three different infill patterns. The simulation model was verified with temperature data gathered from an infrared camera. The results show good agreement between predicted and measured temperature profiles. The developed simulation model was applied to a roof tray with different infill patterns for a case study. We found that the different thermal mass distributions resulting from the various infill patterns affected the heat distribution and deformation. These findings contribute to a better understanding of the thermal and mechanical behavior of LFAM.

Jo, Eonyeon↗