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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

WholeTraveler Anonymized Data Phase 1

Phase 1 of the WholeTraveler Study data collection consisted of an online-only survey. This survey captured data on three categories of observable variation in the population relevant to transportation decisions. First, the survey collected traditional demographic data such as age, gender, income, and education level. Second, it collected data across personality, psychological, and preference categories. This included: 1. The "Big Five" inventory personality traits: openness to new experience, conscientiousness, extroversion, agreeableness, and neuroticism; 2. Risk and time preferences; and 3. Environmental preferences. Third, the survey collected data on historical behavior patterns including: 1. Adoption of (as well as interest in) new technologies or innovations (e.g., smartphones, PEVs, solar panels, adaptive cruise control [ACC]); 2. Car ownership history and current car ownership status; 3. Recent mode use across different time scales (e.g., previous week, previous month, previous year); and 4. Timing of major life events such as starting a family as well as overall lifecycle trajectory patterns. Data from Phase 1 and Phase 2 are linked by a unique respondent identifier. Anonymized versions of the Phase 1 and Phase 2 data are both available on Livewire.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Role of Computational Parameters on Predicting Self-Consistent Residual Stress and Distortion during Wire Arc Additive Manufacturing

Production of three-dimensional metallic parts through integration of an articulated robot and gas metal arc welding, also known as wire arc additive manufacturing (WAAM), can produce large-scale components with moderate geometrical complexity. This technology is particularly appealing due to its high deposition rates, scalability, and cost-effective feedstock compared to other AM processes. Despite its advantages, WAAM adoption is hindered by challenges in ensuring geometric conformity without extensive distortion, defect-free structures, and consistent mechanical properties. Finite element analysis (FEA) is often used to address the challenge of geometrical conformity. As the size of parts increases, the best practices for mesh size and temporal resolution known in the literature become computationally unviable. This research examined the effects of mesh and time-step resolutions during transient FEA of a large-scale (248 layers) metallic part. The impact of computational parameters on the thermal history, displacement, and residual stress distributions were evaluated. The results showed that predicted distortion was consistent across resolutions, while time-step length significantly affected predicted thermal history, and mesh size influenced residual stress distributions. To investigate this relationship further, directionally biased meshes were considered and analyzed. The results indicated that increasing mesh resolution perpendicular to the welding path yielded stress predictions that aligned closely with higher-resolution models while offering substantial computational savings. In conclusion, the significances of this research are related to verification and validation of WAAM models for widespread industrial adoption and pragmatic guidelines for optimizing computation parameters for balancing computational efficiency and predictive accuracy of residual stress and distortion.

Solsbee, Brandon [Univ. of Tennessee, Knoxville, T↗
DOE OSTI2026

On the Properties of Cosmological Ionization Fronts

We investigate the properties of cosmological ionization fronts during the epoch of reionization using the Cosmic Reionization on Computers simulations. By analyzing reionization timing maps, we characterize ionization front velocities and curvatures and their dependence on the density structure of the intergalactic medium (IGM). The velocity distribution of ionization fronts in the simulations indicates that while the barrier-crossing analytical model captures the overall shape in high-velocity regions, it fails to reproduce the low-velocity tail, highlighting the non-Gaussian nature of the IGM’s density field. Ionization front velocities are inversely correlated with local density, propagating faster in underdense regions and more slowly in overdense environments. Faster ionization fronts also lead to higher postionization temperatures, reaching a plateau at ∼2 × 10$^{4}$ K for velocities exceeding 3000 km s$^{−1}$. Examining curvature statistics further establishes a connection between ionization front structure and the normalized density contrast ν, with trends in overdense regions aligning well with barrier-crossing model predictions, while deviations appear in underdense environments due to model limitations. These results provide a detailed characterization of ionization front dynamics and their interaction with the underlying density field, bridging small-scale reionization physics with large-scale observables such as the 21 cm signal and the IGM’s thermal history.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Analytical Models of Frequency and Voltage in Large-Scale All-Inverter Power Systems

Low-order frequency response models for power systems have a decades-long history in optimization and control problems such as unit commitment, economic dispatch, and wide-area control. With a few exceptions, these models are built upon the Newtonian mechanics of synchronous generators, assuming that the frequency dynamics across a system are approximately homogeneous, and assume the dynamics of nodal voltages for most operating conditions are negligible, and thus are not directly computed at all buses. As a result, the use of system frequency models results in the systematic underestimation of frequency minimum nadir and maximum RoCoF, and provides no insight into the reactive power-voltage dynamics. This paper proposes a low-order model of both frequency and voltage response in grid-forming inverter-dominated power systems. The proposed model accounts for spatial-temporal variations in frequency and voltage behavior across a system and as a result, demonstrates the heterogeneity of frequency response in future renewable power systems. Electromagnetic transient (EMT) simulations are used to validate the utility, accuracy, and computational efficiency of these models, setting the basis for them to serve as fast, scalable alternatives to EMT simulation, especially when dealing with very large-scale systems, for both planning and operational studies.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Scaling neural simulations in STACS

Abstract As modern neuroscience tools acquire more details about the brain, the need to move towards biological-scale neural simulations continues to grow. However, effective simulations at scale remain a challenge. Beyond just the tooling required to enable parallel execution, there is also the unique structure of the synaptic interconnectivity, which is globally sparse but has relatively high connection density and non-local interactions per neuron. There are also various practicalities to consider in high performance computing applications, such as the need for serializing neural networks to support potentially long-running simulations that require checkpoint-restart. Although acceleration on neuromorphic hardware is also a possibility, development in this space can be difficult as hardware support tends to vary between platforms and software support for larger scale models also tends to be limited. In this paper, we focus our attention on Simulation Tool for Asynchronous Cortical Streams (STACS), a spiking neural network simulator that leverages the Charm++ parallel programming framework, with the goal of supporting biological-scale simulations as well as interoperability between platforms. Central to these goals is the implementation of scalable data structures suitable for efficiently distributing a network across parallel partitions. Here, we discuss a straightforward extension of a parallel data format with a history of use in graph partitioners, which also serves as a portable intermediate representation for different neuromorphic backends. We perform scaling studies on the Summit supercomputer, examining the capabilities of STACS in terms of network build and storage, partitioning, and execution. We highlight how a suitably partitioned, spatially dependent synaptic structure introduces a communication workload well-suited to the multicast communication supported by Charm++. We evaluate the strong and weak scaling behavior for networks on the order of millions of neurons and billions of synapses, and show that STACS achieves competitive levels of parallel efficiency.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Merger Response of Halo Anisotropy Properties

Anisotropy properties—halo spin, shape, position offset, velocity offset, and orientation—are an important family of dark matter halo properties that indicate the level of directional variation of the internal structures of halos. These properties reflect the dynamical state of halos, which in turn depends on the mass assembly history. In this work, we study the evolution of anisotropy properties in response to merger activity using the IllustrisTNG simulations. We find that the response trajectories of the anisotropy properties significantly deviate from secular evolution. These trajectories have the same qualitative features and timescales across a wide range of merger and host properties. We propose explanations for the behavior of these properties and connect their evolution to the relevant stages of merger dynamics. We measure the relevant dynamical timescales. We also explore the dependence of the strength of the response on time of merger, merger ratio, and mass of the main halo. These results provide insight into the physics of halo mergers and their effects on the statistical behavior of halo properties. This study paves the way toward a physical understanding of scaling relations, particularly to how systematics in their scatter are connected to the mass assembly histories of halos.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Induced microearthquakes predict permeability creation in the brittle crust

Predicting the evolution of permeability accurately during stimulation at the reservoir scale and at the resolution of individual fractures is essential to characterize the fluid transport and the reactive/heat-transfer characteristics of reservoirs where stress exerts significant control. Here, we develop a hybrid machine learning (ML) model to visualize in situ permeability evolution for an intermediate-scale (~10 m) hydraulic stimulation experiment. This model includes an ML model that was trained using the well history of flow rate and wellhead pressure and MEQ data from the first three stimulation episodes to predict average permeability from the statistical features of the MEQs alone for later episodes. Moreover, a physics-inspired model is integrated to estimate in situ fracture permeability spatially. This method relates fracture permeability to fracture dilation and scales dilation to the equivalent MEQ magnitude, according to laboratory observations. The seismic data are then applied to define incremental changes in permeability in both space and time. Our results confirm the excellent agreement between the ground truth and model-predicted permeability evolution. The resulting permeability map defines and quantifies flow paths in the reservoir with the averaged permeability comparing favorably with the ground truth of permeability.

induced seismicity↗
DOE OSTI2020

The Quantum Nature and Mass of the Neutrino. FY20 Annual Laboratory Continuation Progress Report

Over the last 100 years we have learned a much about the neutrino, but there remain interesting questions about this weakly interacting particle. In particular, at LLNL we are developing experiments to measure the mass and the quantum nature of the neutrino. The 2015 long range plan recommended tonne-scale neutrinoless double beta decay experiments as the top new project priority and this experiment will target the quantum nature of the neutrino. The LLNL team is motivated and focused on developing the best technology for this experiment which is a liquid xenon time project chamber called nEXO. On a longer time scale, LLNL is also developing technology to measure the neutrino mass with tritium decay experiments. Work on nEXO at LLNL started in 2015 with an LDRD and program development funds to develop the nEXO concept, publish sensitivity predictions, explore alternatives and risks, and to build a credible project team and this effort is on going. In addition, we received research funding from DOE-SC NP and LLNL manages pre-conceptual R&D for the nEXO collaboration a portion of which is executed at LLNL. The Project 8 effort is solely funded by LLNL LDRD, and ends this year. A second LDRD effort is focused on repurposing cyclotron radiation emission spectroscopy for eV-scale X-ray detection. This second effort, while separated from Project 8, still has scientific and technical commonalities with Project 8. The funding for this X-ray detection effort will continue for one more year. LLNL has a long history of building large projects, science projects and time projection chambers, but nEXO is in fact the first project of this scale that LLNL is prepared to lead for DOE-SC NP.We have the tools, skills, people and motivation to make nEXO a reality. The current program development dollars are used to prepare the nEXO concept for down select and CD1. These internal LLNL dollars pay for a number of things including project staff to organize the nEXO collaboration for the various reviews that lie ahead, to develop the draft plans and structure to manage the project as well as setting up an external advisory committee. The current LDRD is exploring alternatives that effect the risk profile as well as possible performance improvements. The DOE-SC NP base funding is targeted at simulation and analysis of the nEXO concept in preparation for the down select and refinement of the understanding of the detector as well as scientific effort on the large xenon test stand (LXTS) that will burn down one of the largest risks to the nEXO project. Lastly, LLNL is leading the pre-conceptual R&D effort and managing the funds for the nEXO collaboration. The results of this effort are reported elsewhere, but the scope of this executed at LLNL will be reported here and is primarily the engineering and construction of the LXTS experiment. The primary technical contribution of LLNL to the Project 8 concept is the formation and study of atomic tritium. Atomic tritium is necessary for Project 8 to reach the ultimate sensitivity. LLNL has considerable experience with tritium and is well suited for this crucial work. Although the focus of this work is strictly fundamental science, there has already been one significant spinoff to develop a new means to measure radio xenon in the air

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Diffstar: a fully parametric physical model for galaxy assembly history

We present Diffstar, a smooth parametric model for the in situ star formation history (SFH) of galaxies. The Diffstar model is distinct from traditional SFH models because it is parametrized directly in terms of basic features of galaxy formation physics. Diffstar includes ingredients for: the halo mass assembly history; the accretion of gas into the dark matter halo; the fraction of gas that is eventually transformed into stars, ϵ ms ; the time-scale over which this transformation occurs, τ cons ; and the possibility that some galaxies will experience a quenching event at time t q , and may subsequently experience rejuvenated star formation. We show that our model is sufficiently flexible to describe the average stellar mass histories of galaxies in both the IllustrisTNG (TNG) and UniverseMachine (UM) simulations with an accuracy of ~0.1 dex across most of cosmic time. We use Diffstar to compare TNG to UM in common physical terms, finding that: (i) star formation in UM is less efficient and burstier relative to TNG; (ii) UM galaxies have longer gas consumption time-scales, relative to TNG; (iii) rejuvenated star formation is ubiquitous in UM, whereas quenched TNG galaxies rarely experience sustained rejuvenation; and (iv) in both simulations, the distributions of ϵ ms , τ cons , and t q share a common characteristic dependence upon halo mass, and present significant correlations with halo assembly history. Finally, we conclude with a discussion of how Diffstar can be used in future applications to fit the SEDs of individual observed galaxies, as well as in forward-modelling applications that populate cosmological simulations with synthetic galaxies.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Optimal 1D Ly α forest power spectrum estimation – II. KODIAQ, SQUAD, and XQ-100

ABSTRACT We measure the 1D Ly α power spectrum P1D from Keck Observatory Database of Ionized Absorption toward Quasars (KODIAQ), The Spectral Quasar Absorption Database (SQUAD), and XQ-100 quasars using the optimal quadratic estimator. We combine KODIAQ and SQUAD at the spectrum level, but perform a separate XQ-100 estimation to control its large resolution corrections in check. Our final analysis measures P1D at scales k < 0.1 s km−1 between redshifts $z$ = 2.0–4.6 using 538 quasars. This sample provides the largest number of high-resolution, high-S/N observations; and combined with the power of optimal estimator it provides exceptional precision at small scales. These small-scale modes (k ≳ 0.02 s km−1), unavailable in Sloan Digital Sky Survey and Dark Energy Spectroscopic Instrument analyses, are sensitive to the thermal state and reionization history of the intergalactic medium, as well as the nature of dark matter. As an example, a simple Fisher forecast analysis estimates that our results can improve small-scale cut-off sensitivity by more than a factor of 2.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Quantifying Pore Morphology in Spray-Formed Tantalum Using X-ray Micro-computed Tomography

In order to establish quantitative process–structure–property relationships in thermal spray coatings, a robust framework for defining (micro)structural characteristics is needed. Here, we present a quantitative characterization of the three-dimensional morphology of porosity in spray-formed tantalum samples based on high-resolution X-ray micro-computed tomography. Using synchrotron facilities, we acquired dozens of high-resolution scans, enabling a statistically meaningful comparison across multiple samples, different regions within samples, and spray processes. We quantify the spatial distribution, size, and topology of porous inclusions, with a significant focus on variability across samples and different spray processes (plasma and cold sprayed), as well as sensitivity to image segmentation and resolution. Based on a typical segmentation, we report porosities ranging from 0.9 to 1.7 pct for all samples tested, with significant sensitivity due to image segmentation resulting in estimates as low as 0.6 pct and as high as 4.8 pct. For the complex pore space morphology observed in these materials, we argue that a conventional analysis based on identifying individual pores is not well suited, and propose an alternative approach based on morphological metrics with a rich history in porous media literature, such as spatial correlations, local pore thickness, and scale-dependent sub-sampling. Spatial correlations indicate anisotropic splat structures, but only mildly anisotropic pores. Various measures of pore size show a wide distribution of sizes, ranging from sub-micron to 10-micron length scales. Scale-dependent variations in porosity suggest that representative volumes of several hundred microns are required for convergence of morphological metrics, with larger volumes for cold-spray materials. This work provides a robust quantitative basis for describing three-dimensional pore structure in thermal spray coatings.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Evolutionary lineage explains trait variation among 75 coexisting grass species

Summary Evolutionary history plays a key role driving patterns of trait variation across plant species. For scaling and modeling purposes, grass species are typically organized into C 3 vs C 4 plant functional types (PFTs). Plant functional type groupings may obscure important functional differences among species. Rather, grouping grasses by evolutionary lineage may better represent grass functional diversity. We measured 11 structural and physiological traits in situ from 75 grass species within the North American tallgrass prairie. We tested whether traits differed significantly among photosynthetic pathways or lineages (tribe) in annual and perennial grass species. Critically, we found evidence that grass traits varied among lineages, including independent origins of C 4 photosynthesis. Using a rigorous model selection approach, tribe was included in the top models for five of nine traits for perennial species. Tribes were separable in a multivariate and phylogenetically controlled analysis of traits, owing to coordination of important structural and ecophysiological characteristics. Our findings suggest grouping grass species by photosynthetic pathway overlooks variation in several functional traits, particularly for C 4 species. These results indicate that further assessment of lineage‐based differences at other sites and across other grass species distributions may improve representation of C 4 species in trait comparison analyses and modeling investigations.

Donnelly, Ryan C.↗
DOE OSTI2025

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

Implementation of High Pressure Die Casting (HPDC) Aluminum (Al) body structures for high volume electrified vehicles (EV) to improve electric efficiency remains a key strategy within many original equipment manufacturer (OEM)s. In addition to high strength for safety requirements, superior Self-Piercing Riveting (SPR) performance is demanded for HPDC Al alloys to be compatible with high volume SPR joining. In this work, it is proposed to extend and validate an existing Contractor finite element multiscale macro-micro modeling approach to quantify the influence of the microstructure of HPDC alloys on the fracture strain/displacement under 3-point bend and clinch testing. The success of this work will allow to replace solution treatment stage with low energy consumption heat treatment (HT) processes, or to design new non heat treatable (NHT) HPDC Al alloys to eliminate HT requirements. Ultimately, this project will facilitate the application of HPDC Al alloys for super-large vehicle structures to significantly reduce vehicle weight, and thus improving energy efficiency. The purpose of this project is to extend and validate an existing finite element code, which is based on the Contractor developed macro-micro multi-scale modeling approach, to numerically simulate the three-point bending and clinch test and study the influences of material microstructural characteristics and phase properties on the rivetability. The macro-micro modeling approach begins with a sample scale model and identify the location, which is mostly prone to failure, the deformation history of the boundaries of that location calculated will be used to drive a microstructure-based sub-models where the material microstructure and microscale properties are considered. Using this approach, the wrap-bending failure for two Al alloys are correctly predicted for the first time. This will start with phase I effort of building a framework of macro-micro three point bending test and clinch test of Al10SiMgMn HPDC alloy in the as-cast and T7 heat treated conditions. Those results will then be validated with experimental test results. The phase II effort will involve the utilization of the knowledge learned in phase I to establish the quantitative correlation between the microstructure characteristics and the riveting performance, which will be further used to guide the optimization of HPDC Al alloy microstructure using heat treatment process to achieve sufficient rivetability to join large thin-wall HPDC alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Gate Set Tomography

Gate set tomography (GST) is a protocol for detailed, predictive characterization of logic operations (gates) on quantum computing processors. Early versions of GST emerged around 2012-13, and since then it has been refined, demonstrated, and used in a large number of experiments. This paper presents the foundations of GST in comprehensive detail. The most important feature of GST, compared to older state and process tomography protocols, is that it is calibration-free . GST does not rely on pre-calibrated state preparations and measurements. Instead, it characterizes all the operations in a gate set simultaneously and self-consistently, relative to each other. Long sequence GST can estimate gates with very high precision and efficiency, achieving Heisenberg scaling in regimes of practical interest. In this paper, we cover GST's intellectual history, the techniques and experiments used to achieve its intended purpose, data analysis, gauge freedom and fixing, error bars, and the interpretation of gauge-fixed estimates of gate sets. Our focus is fundamental mathematical aspects of GST, rather than implementation details, but we touch on some of the foundational algorithmic tricks used in the pyGSTi implementation.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Modeling Cosmic Reionization

The transformation of cold neutral intergalactic hydrogen into a highly ionized warm plasma marks the end of the cosmic dark ages and the beginning of the age of galaxies. The details of this process reflect the nature of the early sources of radiation and heat, the statistical characteristics of the large-scale structure of the Universe, the thermodynamics and chemistry of cosmic baryons, and the histories of star formation and black hole accretion. A number of massive data sets from new ground- and space-based instruments and facilities over the next decade are poised to revolutionize our understanding of primeval galaxies, the reionization photon budget, the physics of the intergalactic medium (IGM), and the fine-grained properties of hydrogen gas in the "cosmic web". In this review we survey the physics and key aspects of reionization-era modeling and describe the diverse range of computational techniques and tools currently available in this field.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Computational Investigation of Fuel Dispersal Phenomena during Large-Break Loss of Coolant Accident in Light-Water Reactors

In the event of cladding rupture, which could occur in light water reactor fuel assemblies during a loss-of-coolant accident (LOCA), fuel particles, along with fission gases, can be expelled into the reactor core from the fractured fuel rod. This expulsion of fragmented fuel particles, referred as fuel dispersal, is the subject of investigation to evaluate the safety implications of increasing fuel burnup in light water reactors, with a specific focus on fuel fragmentation, relocation, and dispersal. Particle trajectories and the resulting mass distribution of the settled particles within the reactor pressure vessel can pose a long-term cooling challenge for the reactor core. The fuel dispersal phenomenon is significantly influenced by the ejection characteristics of the fuel fragments, as well as the size and shape of the cladding rupture and fuel rod depressurization history during LOCA transients. In this study, the transport of fuel particles within a scaled 5 × 5 lattice of a pressurized water reactor rod bundle geometry is modeled through a two-fluid Eulerian framework that treats the gas and solid phases as interpenetrating continua. The required boundary conditions are evaluated from the fuel performance code BISON in a postulated large-break LOCA scenario. The modeling framework considers solid fuel particles as granular matter, interacting with the gaseous dry steam phase and fission gases through the governing interfacial momentum and energy exchange between the gas and solid phases. The simulation results provide the volume fraction of the solids settled on the bottom surface of the fuel bundle, quantifying the deposition within the bundle geometry.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

On the halo-mass and radial scale dependence of the lensing is low effect

ABSTRACT The canonical Lambda cold dark matter (ΛCDM) cosmological model makes precise predictions for the clustering and lensing properties of galaxies. It has been shown that the lensing amplitude of galaxies in the Baryon Oscillation Spectroscopic Survey (BOSS) is lower than expected given their clustering properties. We present new measurements and modelling of galaxies in the BOSS LOWZ sample. We focus on the radial and stellar mass dependence of the lensing amplitude mismatch. We find an amplitude mismatch of around $35{{\ \rm per\ cent}}$ when assuming ΛCDM with Planck Cosmological Microwave Background (CMB) constraints. This offset is independent of halo mass and radial scale in the range Mhalo ∼ 1013.3−1013.9h−1 M⊙ and $r=0.1\!-\!60 \, h^{-1} \mathrm{Mpc}$ ($k \approx 0.05\!-\!20 \, h \, {\rm Mpc}^{-1}$). The observation that the offset is both mass and scale independent places important constraints on the degree to which astrophysical processes (baryonic effects, assembly bias) can fully explain the effect. This scale independence also suggests that the ‘lensing is low’ effect on small and large radial scales probably have the same physical origin. Resolutions based on new physics require a nearly uniform suppression, relative to ΛCDM predictions, of the amplitude of matter fluctuations on these scales. The possible causes of this are tightly constrained by measurements of the CMB and of the low-redshift expansion history.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

A detailed study of pre-heating effects in electron beam melting powder bed fusion process

Metal-based additive manufacturing processes, such as powder bed fusion with electron beam (PBF-EB) process, also referred to as electron beam melting (EBM), can produce high-density parts with minimal residual stresses due to the uniform and coherent preheating of the powder bed. However, understanding and controlling the multiple stages of preheating is required to enable the production of high-quality, consistent parts of various materials. This work presents a large-scale, multi-layer, three-dimensional numerical analysis focused on studying the preheating stages for predicting thermal history during the PBF-EB process. The model follows a continuous multi-stage cyclic process, that incorporates all the main stages of the PBF-EB process for 316 L stainless steel. This includes the gradual deposition of a new powder layer, the first and second preheating levels of the powder bed, and the energy deposition during melting (excluding the actual melt-pool behavior simulation). The model employs an adaptive time-scaling approach that automatically adjusts the energy deposition for each solution time-increment. This allows for localized changes in time-resolution over an otherwise computationally expensive multi-layer procedure. The material property variations are also taken into account, with an emphasis on the subtle irreversible changes in powder effective thermal conductivity after the two requisite preheating stages of the powder bed. This effect is studied using simplified conductivity models from the literature for partially sintered powder, validated by a dedicated experiment and numerical simulation. The large-scale model is then used to estimate the actual temperatures during first and second preheating levels for 316 L steel, which is not yet fully supported commercially for PBF-EB. Model predictions are corroborated by experiments, using and analyzing IR images, taken at the completion of each layer by the machine’s built-in infrared camera. The current model also incorporates a qualitative assessment for the effects of conductivity change during pre-heating, as well as evaluates the applicability of the time-scaling approach.

36 MATERIALS SCIENCE↗