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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 OSTI2024

Spot pattern welding scanning strategy for sensor embedding and residual stress reduction in laser-foil-printing additive manufacturing

Here, this paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects. 304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size. Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part. To the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Thermo-rheological snapshot of melter feed conversion to glass

Slurry feed charged into an electric melter creates a layer of reacting and melting material (termed cold cap) that floats on the surface of molten glass. The rheological behavior of heated melter feed affects the spreading of slurry at the top of the cold cap and the stability of the primary foam, affecting cold-cap coverage and melter plenum temperatures. The apparent viscosity of a high-alumina high-level waste melter feed was assessed by thermomechanical analysis, high-temperature viscometer, and the hot stage microscopy method, yielding viscosity estimates from ≈10 7.5 Pa s at 550°C to ≈10 2.5 Pa s at 1050°C. As the temperature of feed materials increased, their state changed from rigid solid to dilatant fluid, to pseudoplastic bubbly liquid with dissolving solids, to fully developed foam, and finally to Newtonian glass melt.

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

Raptor: A Python Library for Porosity Predictions in Additive Manufacturing

Raptor is an efficient Python library for simulating stochastic lack-of-fusion (sLoF) defects in additive manufacturing (AM) processes. These defects arise from stochastic variations in the melt pool boundary leading to undermelting from insufficient overlap between adjacent melt pools or successive layers (Grasso & Colosimo, 2017; Khairallah et al., 2016). Performance variability of AM parts is a pressing challenge in qualification and certification of AM parts; this is in part due to the poorly understood formation rate and statistics of sLoF defects. Raptor is designed to capture the explicit morphologies of sLoF defects and their statistics to accelerate qualification and certification efforts of AM parts in critical applications.

Subraveti, Vamsi [Vanderbilt University]↗
DOE OSTI2022

Ice-shelf ocean boundary layer dynamics from large-eddy simulations

Abstract. Small-scale turbulent flow below ice shelves is regionally isolated and difficult to measure and simulate. Yet these small-scale processes, which regulate heat and salt transfer between the ocean and ice shelves, can affect sea-level rise by altering the ability of Antarctic ice shelves to “buttress” ice flux to the ocean. In this study, we improve our understanding of turbulence below ice shelves by means of large-eddy simulations at sub-meter resolution, capturing boundary layer mixing at scales intermediate between laboratory experiments or direct numerical simulations and regional or global ocean circulation models. Our simulations feature the development of an ice-shelf ocean boundary layer through dynamic ice melting in a regime with low thermal driving, low ice-shelf basal slope, and strong shear driven by the geostrophic flow. We present a preliminary assessment of existing ice-shelf basal melt parameterizations adopted in single component or coupled ice-sheet and ocean models on the basis of a small parameter study. While the parameterized linear relationship between ice-shelf melt rate and far-field ocean temperature appears to be robust, we point out a little-considered relationship between ice-shelf basal slope and melting worthy of further study.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Data-Driven Approaches for Bead Geometry Prediction Via Melt Pool Monitoring

In the realm of additive manufacturing, the selection of process parameters to avoid over and under deposition entails a time-consuming and resource-intensive trial-and-error approach. Given the distinct characteristics of each part geometry, there is a pressing need for advancing real-time process monitoring and control to ensure consistent and reliable part dimensional accuracy. Here, this research shows that support vector regression (SVR) and convolutional neural network (CNN) models offer a promising solution for real-time process control due to the models’ abilities to recognize complex, non-linear patterns with high accuracy. A novel experiment was designed to compare the performance of SVR and CNN models to indirectly detect bead height from a coaxial image of a melt pool from a single-layer, single bead build. The study showed that both SVR and CNN models trained on melt pool data collected from a coaxial optical camera can accurately predict the bead height with a mean absolute percentage error of 3.67% and 3.68%, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Fabricating Graphene Oxide/h-BN Metal Insulator Semiconductor Diodes by Nanosecond Laser Irradiation

To employ graphene’s rapid conduction in 2D devices, a heterostructure with a broad bandgap dielectric that is free of traps is required. Within this paradigm, h-BN is a good candidate because of its graphene-like structure and ultrawide bandgap. We show how to make such a heterostructure by irradiating alternating layers of a-C and a-BN film with a nanosecond excimer laser, melting and zone-refining constituent layers in the process. With Raman spectroscopy and ToF-SIMS analyses, we demonstrate this localized zone-refining into phase-pure h-BN and rGO films with distinct Raman vibrational modes and SIMS profile flattening after laser irradiation. Furthermore, in comparing laser-irradiated rGO-Si MS and rGO/h-BN/Si MIS diodes, the MIS diodes exhibit an increased turn-on voltage (4.4 V) and low leakage current. The MIS diode I-V characteristics reveal direct tunneling conduction under low bias and Fowler-Nordheim tunneling in the high-voltage regime, turning the MIS diode ON with improved rectification and current flow. This study sheds light on the nonequilibrium approaches to engineering h-BN and graphene heterostructures for ultrathin field effect transistor device development.

2D materials↗
DOE OSTI2021

Through a glass darkly: In-situ x-ray computed tomography imaging of feed melting in continuously fed laboratory-scale glass melter

his study describes the first direct in-situ 3-D observation of a steady-state melting process by imaging a laboratory-scale slurry-fed glass melter in operation by x-ray computed tomography. Features of the reacting glass-feed, the foam layer underneath, and cavities in the glass melt pool are reconstructed in three-dimensional images. A slurry pool formed in a deep central caldera of dense dried feed, which penetrated into the glass melt. Slurry overflow from the caldera led to fast-dried and highly porous feed structure. A thin layer of foam separated the caldera from the melt. Bubbles ?5-15 mm in diameter were seen to grow beneath the reacting feed and move through the melt to escape at the edge. Pore morphology is benchmarked against computed tomography scans of a pellet of reacting simulated waste glass feed, and evolved gas analysis describes the gases generated as a function of temperature. Cooling artifacts are imaged and compared to previous studies of quenched cold caps. Detailed understanding of processes occurring during the conversion process in and below the reacting feed layer is necessary for the development of representative models of the melting process.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Results of the second Ice Shelf–Ocean Model Intercomparison Project (ISOMIP+)

Ocean-driven basal melting of Antarctic ice shelves plays an important role in the mass loss of the Antarctic Ice Sheet. Ice shelf cavity-resolving ocean models are a valuable tool for understanding ice shelf-ocean interactions and for simulating projections of ice shelf and ocean states under future climate. Designed to assess the current state of ice shelf–ocean modelling, the second Ice Shelf–Ocean Model Intercomparison Project, ISOMIP+, consists of 12 ocean model configurations submitted with a common, idealised experimental setup. Here, we focus on the experiments Ocean0–2 (Asay-Davis et al., 2016), which are ocean models with idealised, static ice shelf geometries, but where the ocean reaches a balance with prescribed far-field ocean conditions. Different thermal transfer coefficient values (ranging from 0.011 to 0.2) are used for each model in the melting parameterisation to achieve a common, tuned melt rate since the models cover a range of types of vertical coordinates, ice–ocean boundary layer treatments, and numerical schemes. These model differences lead to spread in the resultant ocean properties, circulation, boundary-layer structure and spatial distribution of melting. We also highlight similarities between models, such as a shared linear relationship across most models between melt rate and overturning and barotropic streamfunctions during the spin-up and spin-down, demonstrating a robust relationship between melt and circulation across models and forcing conditions. The ISOMIP+ results provide a systematic comparison of ice shelf cavity-capable ocean models. However, we also demonstrate the need for realistic ice shelf–ocean model intercomparison projects (some already underway) to assess model biases and inter-model variation against sparse observations. Further research is needed to understand the differences between models and further improve our modelled representations of the ice–ocean boundary layer and ice shelf cavity circulation.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

In-situ X-ray and visual observation of foam morphology and behavior at the batch-melt interface during melting of simulated waste glass

We report to attain a basic understanding of the primary foam structure and behavior, which affects the heat and mass transfer and the efficiency of the glass melting process, we investigated the primary foam layer under the glass batch floating on molten glass. The primary foam affects mass transfer during batch melting, in turn affecting the melting process. The recently performed direct in-situ three-dimensional X-ray computed tomography of the batch melting in a laboratory-scale melter vessel allowed us to visualize the features of the reacting batch layer and the foam that develops at its bottom, though with an insufficient resolution of images. In this study, we obtained better temporal and spatial resolution using the two-dimensional X-ray radiography and visual observation of the structure and behavior of transient primary foam as it formed and decayed. As soon as the batch was charged onto the melt surface, foam bubbles began to evolve, grow, and coalesce, forming a primary foam layer, 5-10 mm thick, within tens of seconds. This foam layer was sustained by ongoing gas evolving reactions counterbalanced by bubble coalescence into cavities that moved sideways and escaped to the atmosphere. Eventually, the entire remaining batch turned into foam that gradually decayed at the melt surface. The decay rate agreed with literature observations of surface foam produced by secondary foaming.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Electrochemical behavior and separation of iodide in molten LiF-NaF-KF melt

This work studied the electrochemical behavior of iodide in molten LiF-NaF-KF mixture and the separation of iodide from the molten salt at 973 K using a graphite working electrode. The cyclic voltammetry (CV) and chronoamperometry (CA) measurements indicated an anodic passivation layer was formed on the graphite electrode in this melt and the layer blocked the charge transfer across the electrolyte/electrode interface. However, the added I- ions could pass through the passivation layer and were oxidized at the graphite electrode. The characterization of the obtained products proved that iodide ions was efficiently oxidized to I2 gas during electrolysis. Furthermore, the graphite anode showed excellent stability without any obvious change in dimensions after electrolysis, which showed the high current efficiency of I2 evolution reaction. Thus, the graphite electrode was possible to be served as an excellent anode to separate other anions (such as Br) from molten fluoride salts.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Ceramic encapsulated metal phase change material for high temperature thermal energy storage

Thermal energy storage (TES) is a broad-based technology for reducing CO₂ emissions and advancing concentrating solar, fossil, and nuclear power through improvements in efficiency and economics. Phase change materials (PCMs) are of interest as TES media because of their ability to store large amounts of heat in relatively small volumes. The volume expansion during a phase change, typically between a solid and liquid, can cause breakage of protective coatings. This paper reports on the fabrication of a ceramic encapsulated metal (CEM) high temperature TES technology using a rotary calcining furnace and a fluidized bed chemical vapor deposition coating technique. Aluminum beads were chosen as the PCM because Al has a high melting point (660 °C), low cost, high heat of fusion, and an ability to form a thin, strong alumina layer capable of supporting the Al melt for subsequent processing. Quite remarkably, this study shows that 1 mm diameter Al can be fluidized up to at least 1500 °C in an appropriate atmosphere while maintaining a spheroid geometry. This allowed for producing a first of a kind CEM whereby Al particles were encapsulated in pyro-carbon (PyC) and high purity, dense chemical vapor deposited SiC. The CEM with a PyC only coating was exposed to thermal cycling to test the performance with a differential scanning calorimeter; the melting point and latent heat were measured to be 648.4 ± 2.8 °C and 293.3 ± 6.2 J/g respectively. It was demonstrated that the CEM design is possible to produce, laying the foundation for manufacturing of high temperature, tunable, TES media.

25 ENERGY STORAGE↗
DOE OSTI2020

Laser Powder Bed Fusion Additive Manufacturing In-Process Monitoring and Optimization Using Thermionic Emission Detection

In this project, the emission of electrons during laser powder bed fusion additive manufacturing was identified and investigated to resolve the underlying dynamics driven by laser-material interactions. Laser powder bed fusion involves the selective laser melting of metal powder particles layer by layer which fuse together forming a larger 3D structure. Laser-based additive manufacturing approaches such as laser powder bed fusion hold the potential to revolutionize manufacturing of complex metal components in the aerospace, medical, and automotive industries. However, the difficulty in producing defect-free components by metal 3D printing is a major hurdle for widespread commercial adoption. This project resolved important dynamics in laser powder bed fusion including the identification of plasma formation mechanisms, transitions between laser-induced melting modes and stochastic precursors to defect formation. These findings were realized through implementation of electronic sensing diagnostics into an existing testbed system and harnessing capabilities developed for the time dependent analysis of laser powder bed fusion datasets. Importantly, the results advance our understanding of laser-material interactions and reveal that detection of thermionic emission can also resolve information critical to optimization of the laser powder bed fusion fabrication process. The findings are critical for advancing our fundamental understanding of the laser powder bed fusion process and can help assure the requisite fidelity of fabricated components.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A Bezier Curve Informed Melt Pool Geometry to Model Additive Manufacturing Microstructures Using SPPARKS

Additive manufacturing is a transformative technology with the potential to manufacture designs which traditional subtractive machining methods cannot. Additive manufacturing offers fast builds at near final desired geometry; however, material properties and variability from part to part remain a challenge for certification and qualification of metallic components. AM induced metallic microstructures are spatially heterogeneous and highly process dependent. Engineering properties such as strength and toughness are significantly affected by microstructure morphologies resulting from the manufacturing process Linking process parameters to microstructures and ultimately to the dynamic response of AM materials is critical to certifying and qualifying AM built parts and components and improving the performance of AM materials. The AM fabrication process is characterized by building parts layer by layer using a selective laser melt process guided by a computer. A laser selectively scans and melts metal according to a designated geometry. As the laser scans, metal melts, fuses, and solidifies forming the final geometry in a layerwise fashion. As the laser heat source moves away, the metal cools and solidifies forming metallic microstructures. This work describes a microstructure modeling application implemented in the SPPARKS kinetic Monte Carlo computational framework for simulating the resulting microstructures. The application uses Bzier curves and surfaces to model the melt pool surface and spatial temperature profile induced by moving the laser heat source; it simulates the melting and fusing of metal at the laser hot spot and microstructure formation and evolution when the laser moves away. The geometry of the melt pool is quite flexible and we explore effects of variances in model parameters on simulated microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of powder layer thickness on the microstructural development of additively manufactured SS316

By Increasing the powder layer thickness we could increase material deposition rates and reduce build times during laser powder bed fusion (LPBF). However, increasing the powder layer thickness could also negatively affect the local melting and subsequent microstructure of the printed material. This study systematically investigated, for the first time, the defect evolution and microstructural changes of LPBF stainless steel 316 (SS316) processed by using various powder layer thicknesses of 40, 80, and 120 μm while also varying the laser dwell time for the pulsed laser. Through image analysis, the pore density was found to increase with increasing powder layer thickness, particularly when the dwell time was too high or too low. The maximum achievable density (>99%) was found over a wide processing window when using the smallest powder layer thickness of 40 μm between dwell times of 60 and 100 μs. Increasing the powder layer thicknesses to 80 and 120 μm resulted in maximum densities of 98.7 and 96.8%, respectively, but the window for acceptable laser dwell times that could achieve these densities narrowed considerably. A microstructural analysis of the melt pools was performed to measure the melt pool depths and widths, both of which increased with increasing dwell time. However, increasing the powder layer thickness did not affect the melt pool depth and only minorly affected the width. A sub-grain cellular structure distinguished the melt pool boundaries. The cell size increased with increasing dwell time and decreasing powder layer thickness. Moreover, the cell size was used to calculate a cooling rate that had a magnitude of 10 7 K/s and increased with increasing powder layer thickness.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Texture Analysis of Inconel 718 with Different Modes During Single-Track Laser Surface Re-Melting

An in-depth understanding of the texture formation in melt pools allows for the modification of the surface layer microstructure and corresponding material properties, providing an opportunity to integrate laser surface re-melting into metal additive manufacturing. This study investigates crystallographic texture formation at different cooling rates in single melting tracks on the Inconel 718 (IN718) plate produced by laser surface re-melting. The cooling rate varies from 2.31 × 10 5 °C/s to 9.56 × 10 5 °C/s with the increase in scanning rates from 400 mm/s to 1200 mm/s, measured by recently developed real-time temperature monitoring of melt pools. Columnar grains are dominant, with distinct crystallographic textures forming in the melt pools. At a slower scanning speed, the keyhole mode shows three different textures forming at different depths (crystallographically layered structure), while, at a faster scanning speed, the conduction mode shows only random grain orientation. There are no pores/voids detected, and the columnar grain morphology and columnar grain width (8.6 μm to 12.4 μm) follow the analysis framework in terms of thermal gradient and solidification rate analysis. This implies that laser surface re-melting provides the potential to modify the surface structure from a random grain orientation to a crystallographically layered structure.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Thermal and magnetic evolution of a crystallizing basal magma ocean in Earth's mantle

We present the thermochemical evolution of a downward crystallizing basal magma ocean (BMO) overlying the liquid outer core and probe its capability to dissipate enough power to generate and sustain an early dynamo. Furthermore, a total of 61 out of 112 scenarios for a BMO with imposed, present-day heat flux, Q BMO , values of 15, 18, and 21 TW and radiogenic heat, Q r , values of 4, 8, and 12 TW fully crystallized during the age of the Earth. Most of these models are energetically capable of inducing magnetic activity for the first 1.5 Gyrs, at least, with durations extending to 2.5 Gyrs; with final core-mantle boundary (CMB) temperatures of 4400 ±500 K-well within current best estimates for inferred temperatures. None of the models with Q BMO = 12 TW achieved a fully crystallized state, which may reflect a lower bound on the present-day heat flux across the CMB. BMO-powered dynamos exhibit strong dependence on the partition coefficient of iron into the liquid layer and its associated melting-point depression for a lower mantle composition at near-CMB conditions-parameters which are poorly constrained to date. Nonetheless, we show that a crystallizing BMO is a plausible mechanism to sustain an early magnetic field.

58 GEOSCIENCES↗
DOE OSTI2023

Melt-Processed Halide Perovskite Thin Films from a Two-Dimensional Ruddlesden–Popper Phase Precursor

While halide perovskite thin films have enormous potential for photovoltaics and other optoelectronics, the use of environmentally hazardous solvents during their deposition and processing poses a barrier to their commercialization. In this work, we demonstrated the deposition of melt-processable precursors and subsequent transformation into halide perovskite thin films without using environmentally hazardous solvents. We melted the wide-bandgap layered perovskites [(C 6 H 5 CH(CH 3 )CH 2 NH 3 ) 2 PbI 4 :β-Me-PEA 2 PbI 4 ] at ~210 °C and blade coated them into films. The β-Me-PEA 2 PbI 4 films were subsequently transformed to perovskite-phase methylammonium or formamidinium lead iodide films using a cation-exchange process in an alcohol-based solvent. Lastly, we demonstrate the potential and limitations of a completely solvent-free approach that uses solid-state transformation of a β-Me-PEA 2 PbI 4 film. As a result, this work represents a substantial step toward eliminating environmentally hazardous solvents and enables inexpensive industrial-scale liquid-phase deposition processes that do not require expensive systems for handling and disposing of environmentally hazardous solvents.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗