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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A high-throughput approach for statistical process optimization in Laser Powder Bed Fusion

Process variability is inherent in metal additive manufacturing (AM). However, it is often overlooked in process optimization frameworks, constraining the understanding of process uncertainties and their influence on parameter selection. To address this, we present an integrated framework that combines high-throughput single-track experiments, GAN-based melt pool geometry extraction, robust statistical and machine learning modeling, and uncertainty-quantified process mapping. Process variability is characterized through single-track melt pool behaviors, and its influence on defect formation is systematically quantified to enable statistically guided process parameter optimization. This approach is demonstrated on Laser Powder Bed Fusion (L-PBF) of stainless steel 316L, effectively capturing the interplay between process parameters, melt pool variability, and defect probability. By integrating uncertainty quantification into process optimization, this study provides a structured methodology for addressing variability challenges in AM quality control, ultimately contributing to enhanced manufacturing reliability.

Laser Powder Bed Fusion↗
DOE OSTI2014

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing

Laser powder-bed fusion additive manufacturing of metals employs high-power focused laser beams. Typically, the depth of the molten pool is controlled by conduction of heat in the underlying solid material. But, under certain conditions, the mechanism of melting can change from conduction to so-called “keyhole-mode” laser melting. In this mode, the depth of the molten pool is controlled by evaporation of the metal. Keyhole-mode laser melting results in melt pool depths that can be much deeper than observed in conduction mode. In addition, the collapse of the vapor cavity that is formed by the evaporation of the metal can result in a trail of voids in the wake of the laser beam. In this paper, the experimental observation of keyhole-mode laser melting in a laser powder-bed fusion additive manufacturing setting for 316L stainless steel is presented. Finally, the conditions required to transition from conduction controlled melting to keyhole-mode melting are identified.

36 MATERIALS SCIENCE↗
DOE OSTI2026

X-ray observation of individual Ti-6Al-4V spherical powder particle impact in an in-situ operando laser directed energy deposition system

Understanding the particle capture mechanism in the laser directed energy deposition additive manufacturing process provides a foundation for improving productivity and reducing material loss. Capturing this phenomenon is challenging due to its highly transient time interval. To analyze the impact behavior of spherical Ti-6Al-4V powder, a custom laser directed energy deposition system was designed to control the deposition of individual particles. Synchrotron X-ray imaging at 24 kHz monitored the impact dynamics of individual powder particles. A multi-physics model based on the Smoothed-Particle Hydrodynamics scheme supported the analysis by providing the temperature and velocity fields of the molten pool. Results revealed that in laser directed energy deposition, surface tension forces dominated the powder–molten pool interaction. Hydrophobic Ti-6Al-4V powder particles had an equilibrium contact angle of 121 degrees with their molten state. Furthermore, Ti-6Al-4V powder particles required a high impact velocity (6 to 12 m/s) to transition from oscillation to submergence behavior. Lastly, oscillating powder particles that impacted near the location of the laser beam exhibited faster melting, highlighting the contribution of the laser beam to the melting mechanism. This work lays the foundation for investigations of powder particle impact in laser directed deposition and supports the validation of numerical models of powder–molten pool interactions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Geochemical advances in Arctic Alaska oil typing – North Slope oil correlation and charge history

The Arctic Alaska petroleum province is geologically and geochemically complex. Mixed hydrocarbon charge from multiple source rocks and/or levels of thermal maturity is common within an individual oil pool. Biomarker and chemometric statistical analyses were used to correlate twenty-nine oils to five oil families derived from: (1) Triassic Shublik Formation (calcareous organofacies), (2) Triassic Shublik Formation (shaly organofacies), (3) Jurassic Kingak Shale, (4) Cretaceous shale (pebble shale unit and Hue Shale), and (5) Paleogene shale (Canning Formation). Age-diagnostic and source-related oil biomarker parameters establish clear genetic relationships between the normal oil-window components and their putative source designations. However, application of diamondoid analyses reveals mixed-oil accumulations with postmature charge contributions (diamondoid-rich and biomarker-poor) in many oils. Most sampled reservoirs contain a predominant charge derived from a single oil-window source plus a minor contribution from one or more higher maturity source(s). Variations in source organofacies also are recognized in the Shublik, Kingak, and Cretaceous oil families. In some cases, oils from multiple pools within a single field display relatively homogeneous geochemical profiles, suggesting a common source and migration pathway. For example, oil from the significant Pikka discovery is inferred to originate mainly from the calcareous Shublik Formation. In other cases, variability among oils from multiple pools within a single field (e.g., Milne Point, Colville River, and Northstar) likely indicates a more complex source, migration, and charge history. The results of this study may be useful for anticipating the composition of oil charge in stratigraphic traps with low-permeability sandstone reservoirs, where oil gravity and other chemical parameters may influence economic viability.

58 GEOSCIENCES↗
DOE OSTI2015

XCT analysis of the influence of melt strategies on defect population in Ti–6Al–4V components manufactured by Selective Electron Beam Melting

Selective Electron Beam Melting (SEBM) is a promising powder bed Additive Manufacturing technique for near-net-shape manufacture of high-value titanium components. However without post-manufacture HIPing the fatigue life of SEBM parts is currently dominated by the presence of porosity. In this study, the size, volume fraction, and spatial distribution of the pores in model samples have been characterised in 3D, using X-ray Computed Tomography, and correlated to the process variables. The average volume fraction of the pores (< 0.2%) was measured to be lower than that usually observed in competing processes, such as selective laser melting, but a strong relationship was found with the different beam strategies used to contour, and infill by hatching, a part section. The majority of pores were found to be small spherical gas pores, concentrated in the infill hatched region; this was attributed to the lower energy density and less focused beam used in the infill strategy allowing less opportunity for gas bubbles to escape the melt pool. Overall, increasing the energy density or focus of the beam was found to correlate strongly to a reduction in the level of gas porosity. Rarer irregular shaped pores were mostly located in the contour region and have been attributed to a lack of fusion between powder particles. - Graphical abstract: Display Omitted - Highlights: • Vast majority of defects detected were small spherical gas pores. • Gas bubbles trapped in the powder granules expand and coalesce in the melt pool. • Pores have been shown not to be randomly distributed. • Larger and deeper melt pools give more opportunity for gas to escape. • Minor changes to melt strategy result in significant reductions in pore population.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of laser rescanning on the grain microstructure of a selective laser melted Al-Mg-Zr alloy

Highlights: • Laser rescanning of a new Al-Mg-Zr alloy was investigated. • SLM of the Al-Mg-Zr alloy results in a duplex grain structure. • Rescanning of the alloy results in a refinement of the microstructure. - Abstract: The microstructures of alloys created via Additive Manufacturing (AM) can vary substantially from those present in cast or wrought products, due to the very rapid solidification associated with AM. While numerous studies have investigated the process-microstructure relationship of alloys created by Selective Laser Melting (SLM), few have investigated the effects of laser rescanning to alter the microstructure or take advantage of the rapid solidification conditions the process provides. This study investigates the effect of single- or multiple pass laser scanning upon the grain structure of Addalloy™, a new Al-Mg-Zr alloy strengthened via L1{sub 2} Al{sub 3}Zr precipitates. The bottom of the melt pools consisted of fine equiaxed grains (1.3 μm) that nucleated from primary Al{sub 3}Zr (100–400 nm) precipitates. The top of the melt pool consists of columnar grains (up to 40 μm long), consistent with lack of Al{sub 3}Zr nucleants due to Zr solute trapping from increased solidification velocities. Additional laser scanning (a second or third scan) reduces the amounts of columnar grains and increased the number equiaxed grains. The change is attributed to a shallower melt pool remelting the columnar grain region upon rescanning, due to reduced laser energy absorption and increased heat losses in the solid.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Interaction between laser radiation and metallic powder of 316L austenitic steel during selective laser melting

Highlights: • Single and multiple tracks on a loose bulk powder substrate were generated. • Understanding of the microstructure development during SLM was achieved. • Single tracks reveal a nearly symmetrical crystallography with elongated grains. • Multiple tracks show elongated grains perpendicular to the build direction. - Abstract: During selective laser melting (SLM), a complex heat state develops that leads to a characteristic crystallography and microstructure of the processed materials. Depending on the geometry of the processed part, most scan tracks of a new layer, so-called hatches, are located above a dense substrate or already solidified structures whereas others are located above loose powder. This is, inter alia, the case for overhanging structures. Attributable to the lower thermal conductivity of loose powder, temperature gradients and cooling rates of the melt pool differentiate in these areas, resulting in a different microstructural build-up. In this work, the microstructure and the crystallographic orientation of grade 316L austenitic stainless steel processed by SLM was investigated to understand the interaction between the laser radiation and the metallic powder during SLM-processing and to investigate the remelting of a track on a previous SLM-densified track. Single and multiple tracks on a loose bulk powder substrate, as well as single tracks on a dense substrate plate, were generated. A parameter study revealed that high energy densities are necessary to build continuous tracks on a loose bulk powder substrate. In addition, the amount of adhered particles, which are sintered on the fully melted and solidified tracks, is determined in comparison to the melted powder because the sintered particles strongly influence the surface roughness. To understand the microstructure development and, particularly, the influence of adjacent hatches during SLM-processing, investigations on the resulting microstructure and crystallographic orientation of a single track and two connected multiple tracks were carried out. During SLM processing of the tracks, the substrate plate and the solidified structures influence the temperature gradient and cooling rate of the melt pool, thus directionally solidified and elongated grains occur. Furthermore, the solidification is characterized by an epitaxial growth due to a distinct thermal gradient between the melt pool and the surrounding elements.

36 MATERIALS SCIENCE↗
DOE OSTI2017

In-situ characterization of laser-powder interaction and cooling rates through high-speed imaging of powder bed fusion additive manufacturing

We report detailed understanding of the complex melt pool physics plays a vital role in predicting optimal processing regimes in laser powder bed fusion additive manufacturing. In this work, we use high framerate video recording of Selective Laser Melting (SLM) to provide useful insight on the laser-powder interaction and melt pool evolution of 316 L powder layers, while also serving as a novel instrument to quantify cooling rates of the melt pool. The experiment was performed using two powder types – one gas- and one water-atomized – to further clarify how morphological and chemical differences between these two feedstock materials influence the laser melting process. Finally, experimentally determined cooling rates are compared with values obtained through computer simulation, and the relationship between cooling rate and grain cell size is compared with data previously published in the literature.

316 L stainless steel↗
DOE OSTI2019

On the evolution of microstructure and defect control in 316L SS components fabricated via directed energy deposition

To identify the critical issues that affect the evolution of microstructure during additive manufacturing, we investigated the influence of process parameters on the evolution of the dimensional and surface quality, microstructure, internal defects, and mechanical properties in 316L stainless steel (SS) components fabricated using laser engineered net shaping (LENS®), a directed energy deposition (DED) additive manufacturing (AM) technique. The results show that the accumulation of un-melted powder particles on the side walls of deposited sections can be avoided by selecting a laser under-focused condition. Moreover, we report that the variation of melt pool width is more sensitive to laser power than to the depth of the melt pool. The formation of a so-called “hierarchical” microstructure with cellular morphology is attributable to a combination of layer deposition and rapid solidification, which are characteristics of AM. Finally, we discuss microstructure evolution and defect formation, particularly the formation of multiple interfaces and the presence of un-melted powder particles and pores, in light of the dynamic convective fluid flow and rapid solidification that occur in the melt pool. X-ray computed tomography (X-CT) was used to precisely map the spatial distribution of pores in the DED components. The evolution of microstructure during DED is discussed in the context of related thermal phenomena in an effort to provide fundamental insight into the mechanisms that govern defect formation.

36 MATERIALS SCIENCE↗
DOE OSTI2014

The Muon System of the Daya Bay Reactor Antineutrino Experiment

The Daya Bay experiment consists of functionally identical antineutrino detectors immersed in pools of ultrapure water in three well-separated underground experimental halls near two nuclear reactor complexes. These pools serve both as shields against natural, low-energy radiation, and as water Cherenkov detectors that efficiently detect cosmic muons using arrays of photomultiplier tubes. Each pool is covered by a plane of resistive plate chambers as an additional means of detecting muons. Design, construction, operation, and performance of these muon detectors are described. (auth)

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

High-speed synchrotron X-ray imaging of directed energy deposition of titanium: effects of processing parameters on the formation of entrapped-gas pores

Laser based directed energy deposition (DED) is a competitive method for repairing and remanufacturing metallic parts used in numerous industries including aerospace and biomedical. However, the numerous dynamic phenomena associated with the DED process often result in defects such as entrapped-gas pores, lack of fusion, and undesirable anisotropic properties. The entrapped-gas pore, being one of the most common issues, not only influences melt-pool dynamics but also reduces the fabrication quality and mechanical properties of parts fabricated by the DED process. To reduce and further understand this issue, the real-time observation of the pore formation process needs to be studied first. To directly observe the phenomena in the melt pool, high-speed techniques are needed because rapid solidification leads to rapid pore formation and movement. In-situ high-speed X-ray has been proven to be an effective method in investigating the melt pool dynamics and pore formation mechanisms in the laser powder bed fusion process, in which the fabrication process is quite different from that in DED. Here, the high-speed X-ray method is extended to study the formation of entrapped-gas pores. The real-time formation and quantitative analysis of pores under each set of processing parameters (particle velocity, laser power, and spot welding dwelling time of stationary laser) in the DED process are investigated. We found that the DED with a higher particle velocity (3.19 m/s) produced a smaller average pore size of 27.8 µm and a lower pore area fraction of 0.52%. The DED under lower laser power (156 W) generated a smaller average pore size of 20.3 µm and a lower pore area fraction of 1.94%. The shorter dwelling time (10 ms) benefited the decrease of both average pore size and pore area fraction.

Defect↗
DOE OSTI2021

Root exudates shift how N mineralization and N fixation contribute to the plant-available N supply in low fertility soils

Nitrogen (N) availability is a primary constraint to plant productivity, especially in marginal lands with inherently low fertility. Root exudates change with plant nutrient status, and are expected to affect the microbially-mediated N transformations (gross N mineralization vs N fixation) in low fertility soil (low soil organic matter). To explore this possibility, we sampled soils from two monoculture switchgrass (var. Cave-In-Rock) plot with and without N addition at two marginal land sites in Michigan, USA. In a two-week lab incubation, we quantified the effect of different root exudates on gross N mineralization and N fixation by adding simulated root exudates (carbohydrates, organic acids) at a rate of 100 μg C g –1 day –1 . On average, adding carbohydrates to low fertility soil increased the soil respiration by 254%, the dissolved organic carbon (DOC) by 366% and reduced dissolved organic N (DON) by 40%. In contrast, soils receiving organic acids had 159% more soil respiration, 163% higher DOC concentration and the DON concentration increased by 49%. Analysis of the C recovery in measured pools revealed that root exudates C inputs were nearly equivalent to the DOC, microbial biomass carbon (MBC), and soil respiration in sandy soil, but only 45–74% of the root exudate C was recovered in these pools in the sandy loam soil. This suggests that root exudate C may be adsorbed to mineral particles in the sandy loam soil. Soil treated with organic acids had higher gross N mineralization and N immobilization rates than soil with carbohydrates addition. Adding carbohydrates significantly increased the free-living N fixation rates, compared to organic acid addition. Changes in soil pH, and DON induced by root exudate addition had strong association with N transformation rates and N availability. Gross N mineralization produced more plant-available N than N fixation, as evidenced by higher inorganic N concentration in soils receiving organic acids than carbohydrates. Here, by quantifying how different root exudates affect the contribution of N mineralization and N fixation to the plant-available N pool in low fertility soils, this study enhances our understanding of the “C for N” exchange in the plant rhizosphere.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2012

The pyrimidine nucleotide carrier PNC1 and mitochondrial trafficking of thymidine phosphates in cultured human cells

In cycling cells cytosolic de novo synthesis of deoxynucleotides is the main source of precursors for mitochondrial (mt) DNA synthesis. The transfer of deoxynucleotides across the inner mt membrane requires protein carriers. PNC1, a SLC25 family member, exchanges pyrimidine nucleoside triphosphates in liposomes and its downregulation decreases mtUTP concentration in cultured cells. By an isotope-flow protocol we confirmed transport of uridine nucleotides by PNC1 in intact cultured cells and investigated PNC1 involvement in the mt trafficking of thymidine phosphates. Key features of our approach were the manipulation of PNC1 expression by RNA interference or inducible overexpression, the employment of cells proficient or deficient for cytosolic thymidine kinase (TK1) to distinguish the direction of flow of thymidine nucleotides across the mt membrane during short pulses with [{sup 3}H]-thymidine, the determination of mtdTTP specific radioactivity to quantitate the rate of mtdTTP export to the cytoplasm. Downregulation of PNC1 in TK1{sup -} cells increased labeled dTTP in mitochondria due to a reduced rate of export. Overexpression of PNC1 in TK1{sup +} cells increased mtdTTP pool size and radioactivity, suggesting an involvement in the import of thymidine phosphates. Thus PNC1 is a component of the network regulating the mtdTTP pool in human cells. -- Highlights: Black-Right-Pointing-Pointer Thymidine phosphates exchange between mitochondria and cytosol in mammalian cells. Black-Right-Pointing-Pointer siRNA-downregulation of PNC1 delays mitochondrial dTTP export in TK1{sup -} cells. Black-Right-Pointing-Pointer PNC1 overexpression accumulates dTTP in mitochondria of TK1{sup +} cells. Black-Right-Pointing-Pointer PNC1 exchanges thymidine nucleotides across the mitochondrial inner membrane. Black-Right-Pointing-Pointer PNC1 participates in the regulation of the mtdTTP pool supporting mtDNA synthesis.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Activity-Based Protein Profiling to Probe Relationships between Cytochrome P450 Enzymes and Early-Age Metabolism of Two Polycyclic Aromatic Hydrocarbons (PAHs): Phenanthrene and Retene

A growing body of literature has linked early life exposures to polycyclic aromatic hydrocarbons (PAH) with adverse neurodevelopmental effects. Once in the body, metabolism serves as a powerful mediator of PAH toxicity by bioactivating and detoxifying PAH metabolites. Since enzyme expression and activity varies considerably throughout human development, we evaluated infant metabolism of PAHs as a potential contributing factor to PAH susceptibility. Here, we measured and compared rates of phenanthrene and retene (two primary PAH constituents of woodsmoke) metabolism in human hepatic microsomes from individuals ≤21 months of age to a pooled sample (n = 200) consisting primarily of adults. We used activity-based protein profiling (ABPP) to characterize cytochrome P450 enzymes (CYPs) in the same hepatic microsome samples. Once incubated in microsomes, phenanthrene demonstrated rapid depletion. Best fit models for phenanthrene metabolism demonstrated either 1 or 2 phases, depending on the sample, indicating that multiple enzymes could metabolize phenanthrene. We observed no statistically significant differences in phenanthrene metabolism as a function of age, although samples from the youngest individuals had the slowest phenanthrene metabolism rates. We observed slower rates of retene metabolism compared to phenanthrene also in multiple phases. Rates of retene metabolism increased in an age-dependent manner until adult (pooled) levels were achieved at ~12 mo. ABPP identified 28 unique CYPs among all samples, and we observed lower amounts of active CYPs in individuals ≤21 months of age compared to the pooled sample. Phenanthrene metabolism correlated to CYPs 1A1, 1A2, 2C8, 4A22, 3A4, and 3A43 and activities and retene metabolism correlated to CYPs 1A1, 1A2, and 2C8 activities measured by ABPP and vendor-supplied substrate marker activities. These results will aid efforts to determine human health risk and susceptibility to PAHs exposures during early life.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Irreversible Trace Metal Binding to Goethite Controlled by the Ion Size

The dynamics of trace metals at mineral surfaces influence their fate and bioaccessibility in the environment. Trace metals on iron (oxyhydr)oxide surfaces display adsorption–desorption hysteresis, suggesting entrapment after aging. However, desorption experiments may perturb the coordination environment of adsorbed metals, the distribution of labile Fe(III), and mineral aggregation properties, influencing the interpretation of labile metal fractions. Here, in this study, we investigated irreversible binding of nickel, zinc, and cadmium to goethite after aging times of 2–120 days using isotope exchange. Dissolved and adsorbed metal pools exchange rapidly, with half times <90 min, but all metals display a solid-associated fraction inaccessible to isotope exchange. The size of this nonlabile pool is the largest for nickel, with the smallest ionic radius, and the smallest for cadmium, with the largest ionic radius. Spectroscopy and extractions suggest that the irreversibly bound metals are incorporated in the goethite structure. Rapid exchange of labile solid-associated metals with solution demonstrates that adsorbed metals can sustain the dissolved pool in response to biological uptake or fluid flow. Trace metal fractions that irreversibly bind following adsorption provide a contaminant sequestration pathway, limit the availability of micronutrients, and record metal isotope signatures of environmental processes.

58 GEOSCIENCES↗
DOE OSTI2025

Accumulation of Soil Microbial Necromass Controlled by Microbe–Mineral Interactions

Soil organic matter (SOM) is a key reservoir for global carbon (C), supporting soil fertility and influencing greenhouse gas emissions. Microbial residues, composed of dead cells and cellular fragments, are major contributors to SOM formation. Yet, mechanisms by which minerals enhance the accumulation of microbial residues remain poorly understood. Here, we used 13 C-labeled glucose in a year-long incubation to trace microbial residue in sandy and silty soils. Across both soils, approximately 89% of retained microbial 13 C was recovered in the fine (<53 μm) mineral-associated organic matter (MAOM) pool. Within this pool, the light MAOM fraction, enriched in poorly crystalline Fe minerals, held 4.3 times more 13 C than the heavy, phyllosilicate-dominated MAOM fraction, despite accounting for only 17.2% of the total MAOM mass and 12.3% of the total soil mass. Along with 13 C enrichment, the light MAOM fraction showed greater abundance of N-containing groups, e.g., (amides and amino groups), indicative of microbial-derived compounds like proteins and amino sugars. Fe oxides in light MAOM from both soils were spatially dispersed. Microbial residue accumulation was greater in finer-textured silty soil. These findings demonstrate that mineral composition and texture jointly regulate microbial necromass accrual, highlighting light MAOM as a key pool for enhancing soil C storage.

13C isotope labeling↗
DOE OSTI2018

Attributing the Carbon Cycle Impacts of CMIP5 Historical and Future Land Use and Land Cover Change in the Community Earth System Model (CESM1)

Historical global land use and land cover change (LULCC) emissions of 160 PgC represent a third of all human CO 2 emissions from 1850 to 2010. Future land management decisions will have large impacts on the global carbon cycle, with scenarios ranging from continued deforestation and wood harvest to mitigation scenarios that reduce total emissions through afforestation and conversion to bioenergy. Here we present a systematic assessment of Community Earth System Model (CESM1) Coupled Model Intercomparison Project phase 5 (CMIP5) historic and projection simulations, with and without LULCC. For the historical period, CESM produced a Net LULCC flux of 123 PgC to the atmosphere, removing 130 PgC from ecosystems while increasing wood product pools by 7 PgC. Historical LULCC fluxes were equally divided between conversion and wood harvest fluxes. For the Representative Concentration Pathway (RCP) 4.5 afforestation scenario CESM produced a Net LULCC flux of 53 PgC to the atmosphere, removing 58 PgC out of the ecosystem and increasing wood product pools of 5 PgC. The afforestation offsets the Direct LULCC flux of 153 PgC with a negative Indirect LULCC flux of 94 PgC. For the RCP 8.5 high LULCC scenario, CESM produced a Net LULCC flux of 211 PgC, removing 227 PgC from ecosystems and increasing wood product pools of 15 PgC. The LULCC of the future RCP scenarios was dominated by wood harvest fluxes, which is a process that was not included in many of the CMIP5 models. The analysis framework also allowed the attribution of Indirect and Prior LULCC fluxes that offset the Direct LULCC fluxes in many cases.

58 GEOSCIENCES↗