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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Nevada National Security Site E-Tunnel Wastewater Disposal System Quarterly Monitoring Report, Water Pollution Control Permit NEV 96021 (First Quarter Calendar Year 2020)

This report includes the results of monthly inspections and monitoring for January, February, and March 2020. Monthly inspections and monitoring were conducted on January 15, February 12, and March 17, 2020. Inspections include a visual assessment of the berms, ponding, water levels relative to the overflow pipes, tunneling or burrowing into the berms, soil conditions on and around the berms, erosion or sloughing of the slopes of the berms, seeps at the toe of the berms, deep-rooting botanicals on the berms, and fencing. Monthly monitoring includes measurements of the instantaneous flow rate, hydrogen ion activity (pH), and specific conductance of the E-Tunnel Wastewater Disposal System discharge.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

E-Tunnel Wastewater Discharge Permit Quarterly Monitoring Report

Monitoring and sampling activities are performed at the E-Tunnel Wastewater Disposal System (ETDS) in accordance with the requirements of Water Pollution Control (WPC) Permit NEV 96021, Revision 1, which is effective October 1, 2013. Although the end date of the WPC permit is September 21, 2018, provided Nevada Division of Environmental Protection (NDEP), in a letter date September 21, 2018, provided guidance that indicated the WPC Permit NEV 96021, Revision 1, is in effect until NDEP notifies the U.S. Department of Energy, National Nuclear Security Administration Nevada Field Office otherwise. This QMR includes the results of monthly inspections and monitoring for April, May, and June 2020. Monthly inspections and monitoring were conducted on April 21, May 28, and June 24 2020. Inspections include a visual assessment of the berms, ponding, water levels relative to the overflow pipes, tunneling or burrowing into the berms, seeps at the toe of the berms, deep-rooting botanicals on the berms, and fencing. Monthly monitoring includes measurements of the instantaneous flow rate, hydrogen ion activity (pH), and specific conductance of the ETDS discharge.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Surface Structure of Reacting Solid Ramjet Fuels

Solid fuel ramjets are a developing technology that will enable extended range for supersonic vehicles. The simplicity of the system in terms of moving parts results in the performance being dictated by the solid fuel combustion processes. The physics near the surface, particularly in the fuel-rich recirculation zone, are challenging to resolve due to flow opacity. Here, regression rate measurements of hydroxyl-terminated polybutadiene from a miniature, portable slab burner are reported. Mass-averaged regression rates agree with correlations from the literature, suggesting that the proper physics in the burner are captured. Synchrotron-based phase-contrast imaging is used to quantify local surface features, including a multiphase froth layer, molten polymer transport, and local regression rate measurements in the recirculation zone. Regression rates near the inlet are less than the mass-averaged values, whereas near the reattachment point the local value exceeds the mass-averaged values. Further, the observed froth layer is as large as 2 mm near the inlet and decreases to sub-millimeter thicknesses near the reattachment point. An analytical heat transfer model is used to quantify the influence of the surface froth layer on the regression rates. Results indicate that the froth layer has an insulating effect and will reduce the local regression rate.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

TEAMER – Enhanced Flow Measurement for Aquantis Tidal Turbine Test

The AQ10 is a floating, two-bladed, passive yawing tidal turbine developed by Aquantis that has a 10-meterrotor diameter, 160 kW rating, and employs reliable off-the-shelf powertrain and power conversion hardware. Aquantis is planning on-water turbine power performance and loads (blade loading and thrust)testing, where the turbine will be pushed through still water up to 4 knots and placed in a ‘station keeping’ tow in a tidal race up to its rated speed. On-water testing will be conducted using vessels and floating platforms on the sea surface to improve ease of testing and reduce disturbance to the environment. In this TEAMER project, Pacific Northwest National Laboratory (PNNL) will conduct water velocity and turbulence measurements in front of the turbine during on-water testing using acoustic Doppler instrumentation. By measuring both the tidal current flowing past the turbine and the resulting electrical power output, test results will provide a power curve (power vs flow speed) for the turbine up to rated power. Measurements of turbulence and velocity shear in front of the rotor will also provide information to assess the structural response of the rotor blades. With this analysis, Aquantis can use the performance and loads data to validate Tidal Bladed and OpenFAST simulations of the measured operating conditions. Measuring the power performance of a prototype turbine is a valuable step to improving device development and conducting a complete power performance assessment to IEC/TS 62600-200 standards in the future.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

SPRUCE Xylem Native Embolism and Leaf Traits of Picea mariana and Larix laricina, 2019

This data set contains measurements of native embolism in branch xylem and associated branch and leaf traits from Picea mariana (Black Spruce) and Larix laricina (Tamarack) from September-October 2019 at the SPRUCE experiment (Hanson et al. 2017). Data are presented in one comma-separated (*.csv) file. Native embolism, a measurement of in-situ embolism in the xylem tissue that blocks water movement, measurements were conducted at the end of the growing season on cut branches using the hydraulic pipette method (see Peters et al. 2023 for full method). In short, branch segments were connected to hydraulic apprentice and flow rates of perfusion liquid were measured using graduated pipettes and stopwatch. After initial conductance measurements, branch segments were flushed using vacuum infiltration and hydraulic conductance was remeasured to calculate the percent loss in conductance due to embolism (PLC). Three branch segments (distal, middle, and proximal) were measured from each branch representing different diameters size classes. This dataset also contains leaf area associated with each measured branch segment, calculate leaf mass per area (LMA), sapwood specific conductivity (Ks), leaf area specific conductivity (Kl) and the sapwood area to leaf area ratio (Huber value). Measurements were made on mature trees from all ten treatment enclosures. One branch from each of five trees per species were used from each enclosure where available. Some plots do not contain five individual Larix laricina, in which case all available trees were sampled. All measurements were conducted in late September/early October 2019, at the end of growing season but before Larix laricina needle senescence. There are 10 experimental plots at SPRUCE: five temperature treatments (+0, +2.25, +4.5, +6.75, +9°C) at ambient CO2, and the same five temperature treatments at elevated CO2 (+500 ppm). These data were collected after the treatments had been running in full for three years, meaning much of the material measured was grown under treatment conditions.

Huber value↗
DOE OSTI2023

Particulate matter sensor

Microfabricated PM sensors measure concentrations of particulate matter (PM) in air. Some sensors improve the accuracy of measurements by accounting for the effect of ambient conditions (e.g., temperature or humidity) on mass-sensitive elements employed to determine a mass of the PM in a stream of air. Some sensors improve the accuracy of measurements by controlling humidity in the stream of air measured by mass-sensitive elements. Some sensors employ a plurality of mass-sensitive elements to extend the useful life of the PM sensor. Some sensors employ one or more mass-sensitive elements and heating elements to cause deposition and allow measurement of different sizes of PM. Some sensors can measure mass concentration of coarse PM in addition to fine PM in a stream of air. Some sensors control the flow rate of a stream of air measured by mass-sensitive elements. Some sensors include features to mitigate electromagnetic interference or electromagnetic signal loss.

Paprotny, Igor↗
DOE OSTI2025

Steel Creek, Pen Branch, and D-Area Watershed Stream Gauging Stations

A network of stream gauging systems were installed in the Steel Creek, Pen Branch, D-Area Discharge Canal, and the D006 Stream in support of the groundwater modeling efforts for the P-Area Groundwater Operable Unit (OU); Chemical, Metals, and Pesticides (CMP) Pits OU; and the D-Area Watershed, respectively. Each location is monitored by a MACE Floseries3 FloPro data logger and a MACE doppler ultrasonic area/velocity sensor. Each stream gauging system is powered by an internal 12-volt battery supplied by a solar panel with a trickle charger. Information collected by each data logger is logged internally and telecommunicated via a cellular network to an online server for real time analysis and monitoring. The MACE doppler ultrasonic area/velocity sensor can measure stream depth and velocities to give output values of flow rates, total flow, net flow, and volumes. The water depth is measured by a ceramic pressure transducer located on the top of the sensor. The velocity is measured by a continuous wave doppler sensor to give an average velocity across the whole stream profile. This report discusses the equipment and methods used to install continuous stream gauging stations and provides a summary of data collected through FY2025.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Method and system to measure gas flow

A system for measuring gas flow generally including a passive acoustic wave generator disposed in a gas flow stream to passively generate an audio signal through vortex shedding, a sound capturing instrument disposed outside the gas stream to produce an electrical signal representative of the acoustic signal, a temperature sensor to obtain temperature measurements indicative of the temperature of the gas flow stream and a control system for determining the gas flow, such as velocity or flow rate, as a function of the acquired acoustic and temperature measurements. The acoustic wave generator includes a corrugated flow channel whose geometric design is so tuned to generate an acoustic emission whose frequency signature varies as a function of the gas flow velocity. The control system may acquires time-domain acoustic data, and process that data to obtain a frequency-domain representation from which gas velocity or gas flow rate can be determined.

Cetiner, Mustafa S.↗
DOE OSTI2019

Validation of RELAP-7 for Forced Convective and Natural Circulation Reactor Flows

New reactor designs such as small modular reactors and newly proposed passive safety systems rely on natural circulation two-phase flow cooling of the reactor core under accident conditions. Without a pump to drive the flow, the circulation rate is a strong function of void fraction. Under these conditions where the flow rate, pressure drop, and heat transfer are all closely coupled through the mixture density, the accurate prediction of void fraction is pivotal. Furthermore, while these passive systems boast a more reliable cooling option, the sensitivity of the system to two-phase flow instabilities is more likely than in forced convective cooling and can result in dangerous density wave or flow excursion conditions. Improvement of one-dimensional system codes and further development of three-dimensional code capability are all important efforts in addressing these issues. The proposed work is a critical step towards providing confidence through validation of the capability of thermal-hydraulic tools to meet the emerging challenges in reactor simulation. Historically, system analysis codes develop a stiffness over time due to fine-tuning of adjustable code parameters that result in a reluctance or inability to adopt improved models. Therefore, a rigorous effort should be invested in preparation for RELAP-7 to identify required modeling improvements of constitutive relations and validation of the code applicability to the wide range of possible reactor flow conditions. Part of this validation involves the uncertainty quantification which is a critical step in the Code Scaling, Applicability, and Uncertainty (CSAU) methodology and Best-Estimate Plus Uncertainty (BEPU) licensing method. BEPU allows recovery of safety margins and potentially optimizing plant performance, resulting in economic benefit for the reactor operators. Beginning with the collection of past experimental data covering prototypic LWR conditions, this document reviews three critical datasets available for the validation of system codes. The experimental methods, procedures, facilities, instrumentation, and supplementary information are consolidated to aid the validation efforts of this work and future projects. These three datasets (824 conditions) are chosen due to their wide acceptance and demonstrated application for code validation. Two experimental datasets from the Nuclear Power Engineering Corporation (NUPEC) span prototypic conditions of Boiling Water Reactors (BWR) and Pressurized Water Reactors (PWR). These datasets are labeled as the BFBT (BWR Full-size Fine-mesh Bundle Test) and the PSBT (PWR Subchannel and Bundle Test) datasets respectively. The third dataset is taken in an internally heated annulus that is scaled based on a BWR subassembly and includes two-phase flows important to post-blowdown analysis. Together, the datasets consider the full range of pressure and mass flux expected in LWR forced convective flows from steady-state to long term cooling conditions. Recognizing the deficiency of available data under low-pressure, low-flow, a new natural circulation dataset consisting of 107 conditions is obtained. With system pressures ranging between 145 and 950 kPa, natural circulation is driven by a heat flux up to 275 kW/m2 in a 3 m long heated region of the annulus test section which is followed by a 2 m long unheated region before entering a condenser. Stable natural circulation flow rates in this facility were measured to be between 182 and 590 kg/m2-s. Pressure and temperature are measured at ten locations in the facility. In addition, measurements of void fraction, interfacial area concentration, and gas velocity are obtained at five axial locations in the annulus test section. The RELAP5-3D code demonstrates good accuracy for void fraction predictions in BFBT and PSBT benchmarks, but shows relatively large discrepancy in the annulus experiments at lower pressures. In two-phase natural circulation, large oscillations are observed in many system parameters during the simulation of 19 experiment cases which were conducted at low pressures, and the model shows good predictive performance with the remaining 88 experiment cases. However, some discrepancies in void fraction and temperature predictions are found which may require improved constitutive modeling under these low-pressure, low-flow condition. The quantified uncertainty in void fraction predictions in three forced convection benchmarks due to uncertainties in boundary conditions and geometries are relatively small, except for a few cases in the annulus experiment. The output uncertainty of the natural circulation model is quantified by considering the measurement error in boundary conditions, and it is shown that the output uncertainty ranges are relatively small for the range of conditions considered. Through this work, a clear pathway is provided for validation of RELAP7 once the code is available.

42 ENGINEERING↗
DOE OSTI2024

Concurrent measurement of strain and chemical reaction rates in a calcite grain pack undergoing pressure solution: Evidence for surface-reaction controlled dissolution

Pressure solution is inferred to be a significant contributor to sediment compaction and lithification, especially in carbonate sediments. For a sediment deforming primarily by pressure solution, the compaction rate should be directly related to the rate of calcite dissolution, transport along grain contacts, and calcite reprecipitation. Previous experimental work has shown that there is evidence that deformation in wet calcite grain packs is consistent with control by pressure solution, but considerable ambiguity remains regarding the rate limiting mechanism. We present the results of laboratory compaction experiments designed to directly measure calcite dissolution and precipitation rates (recrystallization rates) concurrently with strain rate to test whether measured rates are consistent with predicted rates both in absolute magnitude and time evolution. Recrystallization rates are measured using trace element chemistry (Sr/Ca, Mg/Ca) and isotopes (87Sr/86Sr) of fluids flowing slowly through a compacting grain pack as it is being triaxially compressed. Imaging techniques are used to characterize the grain contacts and strain effects in the post-experiment grain pack. Our data show that calcite recrystallization rates calculated from all three geochemical parameters are in approximate agreement and that the rates closely track strain rate. The geochemically inferred rates are close to predicted rates in absolute magnitude. Uncertainty in grain contact dimensions makes distinguishing between surface reaction control and diffusion control difficult. Measured reaction rates decrease faster than predicted from standard pressure solution creep flow laws. This inconsistency may indicate that calcite dissolution rates at grain contacts are more complex, and more time-dependent, than suggested by geometric models designed to predict grain contact stresses.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Plastic deformation of single crystals of the equiatomic Cr-Mn-Fe-Co-Ni high-entropy alloy in tension and compression from 10 K to 1273 K

In this report the plastic deformation behavior of single crystals of the quinary, equiatomic Cr-Mn-Fe-Co-Ni high-entropy alloy (HEA) with the face-centered cubic structure has been investigated in tension and compression as a function of crystal orientation and temperature from 10 K to 1373 K. The critical resolved shear stress (CRSS) for {111}<110> slip at room temperature is 42-45 MPa. It does not depend much on crystal orientation (i.e., the Schmid law holds true) and the sense (tension vs. compression) of the applied load. The CRSS for {111}<110> slip increases with the decrease in temperature, without showing any significant inertia effects at cryogenic temperatures below 77 K. Extrapolation from the measured yield stresses down to 10 K yields a CRSS value at 0 K of 168 MPa. At cryogenic temperatures, the measured strain-rate sensitivity of flow stress is consistent with a very small activation volume. The concept of stress equivalence holds true both for the temperature dependence of CRSS and the stress dependence of activation volume, indicating that solid-solution hardening is the major strengthening mechanism. Deformation twinning occurs at 77 K but not at room temperature, resulting in higher tensile elongation to failure at 77 K than at room temperature. Deformation twinning at 77 K occurs at a shear stress of 378 MPa on conjugate ($\bar1\bar11$) planes in the form of Lüders deformation after large plastic strain (about 85%) achieved by the stage I (easy glide) and stage II (linear work-hardening) deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Editors’ Choice—Flooded by Success: On the Role of Electrode Wettability in CO 2 Electrolyzers that Generate Liquid Products

Economic operation of carbon dioxide (CO 2 ) electrolyzers generating liquid products will likely require high reactant conversions and product concentrations, conditions anticipated to challenge existing gas diffusion electrodes (GDEs). Notably, electrode wettability will increase as lower surface tension products (e.g., formic acid, alcohols) are introduced into electrolyte streams, potentially leading to flooding. To understand the hydraulically stable operating envelopes in mixed aqueous-organic liquid domains, we connect intrinsic electrode wettability descriptors to operating parameters such as electrolyte flow rate and current. We first measure contact angles of water-organic product dilutions on polytetrafluoroethylene (PTFE) and graphite surfaces as planar analogues for GDE components. We then use material balances around the reactive gas-liquid-solid interface to calculate product mass fractions as functions of water sweep rate and current. Product composition maps visualize the extent to which changes in cell performance influence capillary pressure, a determinant of GDE saturation. Analyses suggest that formic acid mixtures pose little risk for GDE flooding across a wide range of conditions, but effluents containing <30% alcohol by mass may cause flooding. This study reveals opportunities to integrate microstructural features and oleophobic surface treatments into GDEs to repel aqueous-organic mixtures and expand the window of stable operating conditions.

25 ENERGY STORAGE↗
DOE OSTI2022

Monitoring Noble Gases (Xe and Kr) and Aerosols (Cs and Rb) in a Molten Salt Reactor Surrogate Off-Gas Stream Using Laser-Induced Breakdown Spectroscopy (LIBS)

In this study with surrogate materials we show that laser-induced breakdown spectroscopy (LIBS) is a robust tool with promising capability toward monitoring gaseous (Xe and Kr) and aerosol (Cs and Rb) species in an off-gas stream from a molten salt reactor (MSR). MSRs will continually evolve fission products into the cover gas flowing across the reactor headspace. The cover gas entrains Xe and Kr gases, along with aerosol particles, before passing into an off-gas treatment system. Univariate models of Xe and Kr peaks showed a strong correlation to concentration indicated by their coefficients of determination of 0.983 and 0.997, respectively. Multivariate models were built for all four analytes using partial least squares regression coupled with preprocessing steps including normalization, trimming, and/or genetic algorithm derived filters. The models were evaluated by predicting the concentrations of the analytes in four validation samples, in which all calibration models were successfully validated at a confidence interval of 99.9%. Finally, pressure controllers were used to regulate the mass flow rate of Kr flowing into the measurement cell in sinusoidal and stepwise waveforms to test the real-time monitoring capabilities of the regression models. Both univariate and partial least squares Kr models were able to successfully quantify the gas concentration in the real-time evaluation. The root mean squared error of prediction (RMSEP) values for these real-time tests were calculated to be 0.051, 0.060, and 0.121 mol% demonstrating the measurement systems’ capability to perform online monitoring with acceptable accuracy.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

E-Tunnel wastewater discharge permit quarterly monitoring report. Water pollution control permit Nev 96021, third quarter 2020

Monitoring and sampling activities are performed at the E-Tunnel Wastewater Disposal System (ETDS ) in accordance with the requirements of Water Pollution Control (WPC) Permit NEV 96021, Revision 1, which is effective October 1, 2013. Although the end date of the WPC permit is September 30, 2018, the Nevada Division of Environmental Protection (NDEP), in a letter dated September 21, 2018, provided guidance that indicated the WPC Permit NEV 96021, Revision 1, is in effect until NDEP notifies the U.S. Department of Energy, National Nuclear Security Administration Nevada Field Office otherwise. This QMR includes the results of monthly inspections and monitoring for July, August, and September 2020. Monthly inspections and monitoring were conducted on July 21, August 19, and September 16, 2020. Inspections include a visual assessment of the berms, ponding, water levels relative to the overflow pipes, tunneling or burrowing into the berms, soil conditions on and around the berms, erosion or sloughing of the slopes of the berms, seeps at the toe of the berms, deep-rooting botanicals on the berms, and fencing. Monthly monitoring includes measurement s of the instantaneous flow rate, hydrogen ion activity (pH), and specific conductance of the ETDS discharge. The report will be submitted to the State of Nevada.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

On the Fidelity of Computational Models for the Flow of Milled Loblolly Pine: A Benchmark Study on Continuum-Mechanics Models and Discrete-Particle Models

The upstream of bioenergy industry has suffered from unreliable operations of granular biomass feedstocks in handling equipment. Computational modeling, including continuum-mechanics models and discrete-particle models, offers insightful understandings and predictive capabilities on the flow of milled biomass and can assist equipment design and optimization. This paper presents a benchmark study on the fidelity of the continuum and discrete modeling approaches for predicting granular biomass flow. We first introduce the constitutive law of the continuum-mechanics model and the contact law of the coarse-grained discrete-particle model, with model parameters calibrated against laboratory characterization tests of the milled loblolly pine. Three classical granular material flow systems (i.e., a lab-scale rotating drum, a pilot-scale hopper, and a full-scale inclined plane) are then simulated using the two models with the same initial and boundary conditions as the physical experiments. The close agreement of the numerical predictions with the experimental measurements on the hopper mass flow rate, the hopper critical outlet width, the material stopping thickness on the inclined plane, and the dynamic angle of repose, clearly indicates that the two methods can capture the critical flow behavior of granular biomass. The qualitative comparison shows that the continuum-mechanics model outperforms in parameterization of materials and wall friction, and large-scale systems, while the discrete-particle model is more preferred for discontinuous flow systems at smaller scales. Industry stakeholders can use these findings as guidance for choosing appropriate numerical tools to model biomass material flow in part of the optimization of material handling equipment in biorefineries.

Jin, Wencheng↗
DOE OSTI2023

Anomaly Detection in Liquid Sodium Cold Trap Operation with Multisensory Data Fusion Using Long Short-Term Memory Autoencoder

Sodium-cooled fast reactors (SFR), which use high temperature fluid near ambient pressure as coolant, are one of the most promising types of GEN IV reactors. One of the unique challenges of SFR operation is purification of high temperature liquid sodium with a cold trap to prevent corrosion and obstructing small orifices. We have developed a deep learning long short-term memory (LSTM) autoencoder for continuous monitoring of a cold trap and detection of operational anomaly. Transient data were obtained from the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The cold trap purification at METL is monitored with 31 variables, which are sensors measuring fluid temperatures, pressures and flow rates, and controller signals. Loss-of-coolant type anomaly in the cold trap operation was generated by temporarily choking one of the blowers, which resulted in temperature and flow rate spikes. The input layer of the autoencoder consisted of all the variables involved in monitoring the cold trap. The LSTM autoencoder was trained on the data corresponding to cold trap startup and normal operation regime, with the loss function calculated as the mean absolute error (MAE). The loss during training was determined to follow log-normal density distribution. During monitoring, we investigated a performance of the LSTM autoencoder for different loss threshold values, set at a progressively increasing number of standard deviations from the mean. The anomaly signal in the data was gradually attenuated, while preserving the noise of the original time series, so that the signal-to-noise ratio (SNR) averaged across all sensors decreased below unity. Results demonstrate detection of anomalies with sensor-averaged SNR < 1.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Vibroacoustic Process Monitoring of 5-Stage Centrifugal Contactors

Vibroacoustic monitoring was investigated to aid in informing process operators with parameters regarding aqueous separation techniques. These techniques have a wide range of applications including nuclear fuel reprocessing. A small-scale solvent extraction system was set up with five magnetic drive contactors and two piston pumps to collect realistic operation. Vibration sensors were placed on three of the contactors and both pumps, and a microphone was placed near the system. Contactor rotational speed and pump flow rate were varied with known values to compare against measured vibroacoustic signatures. Spectral analysis allowed for the determination of contactor rotational speed and the ratio of organic to aqueous flow rate, an important parameter for ensuring optimal extraction. Vibration metrics such as kurtosis and crest factor provided additional details regarding individual rotational speeds and have potential in examination of faults for predictive maintenance. Overall, results indicate the capability of vibroacoustic monitoring to improve operator awareness and process outcomes.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Deconvoluting sources of variability in aerosol jet printing using light scattering measurements

Aerosol jet printing (AJP) is a digital additive manufacturing technique for hybrid and conformal electronics, where its contactless deposition readily enables patterning over 3D surface topography. However, the complexity of aerosol transport physics makes deposition rate sensitive to process variability, hindering widespread industry adoption. Light scattering measurements have recently been demonstrated as a capable tool for measuring deposition rate in real time, enabling closed-loop control and in-situ qualification frameworks. These inline optical measurements present further opportunity as a diagnostic tool to understand the effects of secondary process parameters affecting vapor–liquid equilibrium and heat and mass transport during deposition. Downstream of the optical measurement cell, changing the sheath gas flow rate, increasing temperature via an inline heater, and adding solvent vapor via a sheath gas bubbler were observed to alter drying physics during sheath-collimation, and thereby impaction efficiency. Further upstream, the introduction of solvent vapor via a carrier gas bubbler and liquid build-up in the printhead were seen to affect the quantitative relationship between the light scattering data and the true deposition rate. Using this information, tightened controls of meaningful secondary parameters were implemented to improve the batch-to-batch consistency for printing a dielectric ink. In addition to advancing AJP process reliability for production, this work demonstrates the capability of inline optical measurements to provide insight into process physics and deconvolute competing mechanisms that underly variability.

additive manufacturing↗