Validation of micro-mechanical FFT-based simulations using High Energy Diffraction Microscopy on Ti-7Al
Abstract not provided
Tari, Vahid↗
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Exascale granular microstructure reconstruction in 3D volumes of arbitrary geometries with generative learning
Reconstructing 3D granular microstructures within volumes of arbitrary geometries from limited 2D image data is crucial for predicting the material properties, as well as performances of structural components accounting for material microstructural effects. We present a novel generative learning framework that enables exascale reconstruction of granular microstructures within complex 3D geometric volumes. Building upon existing transfer learning techniques using pre-trained convolutional neural networks (CNN), we introduce several key innovations to overcome the difficulties inherent in arbitrary geometries. Our framework incorporates periodic boundary conditions using circular padding techniques, ensuring continuity and representativeness of the reconstructed microstructures. We also introduce a novel seamless transition reconstruction (STR) method that creates statistically equivalent transition zones to integrate multiple pre-existing 3D microstructure volumes. Based on STR, we propose a cost-effective strategy for reconstructing microstructures within complex geometric volumes, minimizing computational waste. Validation through numerical experiments using kinetic Monte Carlo simulations demonstrates accurate reproduction of grain statistics, including grain size distributions and morphology. A case study involving the reconstruction of a 4-blade propeller microstructure illustrates the method’s capability to efficiently handle complex geometries. In conclusion, the proposed framework significantly reduces computational demands while maintaining high reconstruction quality, paving the way for scalable microstructure reconstruction in materials design and analysis.
36 MATERIALS SCIENCE↗
Size-dependent stochastic tensile properties in additively manufactured 316L stainless steel
Recent work in metal additive manufacturing (AM) suggests that mechanical properties may vary with feature size; however, these studies do not provide a statistically robust description of this phenomenon, nor do they provide a clear causal mechanism. Because of the huge design freedom afforded by 3D printing, AM parts typically contain a range of feature sizes, with particular interest in smaller features, so the size effect must be well understood in order to make informed design decisions. This work investigates the effect of feature size on the stochastic mechanical performance of laser powder bed fusion tensile specimens. A high-throughput tensile testing method was used to characterize the effect of specimen size on strength, elastic modulus and elongation in a statistically meaningful way. The effective yield strength, ultimate tensile strength and modulus decreased strongly with decreasing specimen size: all three properties were reduced by nearly a factor of two as feature dimensions were scaled down from 6.25 mm to 0.4 mm. Hardness and microstructural observations indicate that this size dependence was not due to an intrinsic change in material properties, but instead the effects of surface roughness on the geometry of the specimens. Finite element analysis using explicit representations of surface topography shows the critical role surface features play in creating stress concentrations that trigger deformation and subsequent fracture. The experimental and finite element results provide the tools needed to make corrections in the design process to more accurately predict the performance of AM components.
316L stainless steel↗
Effect of the scanning strategy on the formation of residual stresses in additively manufactured Ti-6Al-4V
During the laser-powder bed fusion (L-PBF) process, high laser intensities, short interaction times and highly localized heat input drive large thermal gradients that result in a state of high residual stresses. Generally, the residual stresses that develop during the L-PBF process can compromise the performance of the component. Up to now, the literature has indicated that the magnitude of the residual stresses can be affected by various process parameters. In this study, all process parameters such as laser power and speed are held fixed and the focus is solely on the effect of the laser scan strategy on the three-dimensional residual stress state of L-PBF metallic components. Four Ti-6Al-4V bridge shaped components were built using island and continuous scanning patterns parallel and offset 45° from the sample axes. High-energy X-ray diffraction was used to determine the residual stress field in each of the components. Two of them were re-measured after being partially removed from the build plate. The assumptions implicit in diffraction measurements of stress are reviewed and discussed in depth because the unique microstructure associated with L-PBF Ti-6Al-4V renders the validity of those assumptions uncertain. Specifically, additional data was collected and analyzed to evaluate the relationship between grain scale and macroscopic scale stresses. The observed residual stresses were large, ½ to ¾ of the yield strength, particularly the build direction stresses near the lateral edges of the bridges. Here in this work, the higher stresses were observed in the bridges built via the island scan strategies, chiefly near the edges of the parts.
36 MATERIALS SCIENCE↗
The Trajectory of Additively Manufactured Titanium Alloys with Superior Mechanical Properties and Engineered Microstructures
Additive manufacturing (AM) plays a crucial role in the manufacturing and development of advanced materials including titanium alloys for engineering applications. During the last two decades, a great deal of effort has been devoted to print titanium parts with desired properties. However, due to presence of non-equilibrium/metastable phases, anisotropic microstructure, and various porosities in the printed titanium alloys, achieving an excellent combination of mechanical properties has been challenging. Here this review paper aims to provide a comprehensive overview of multiple post-process and in-process approaches to achieve enhanced strength-ductility combinations by microstructure engineering. Approaches such as addition of alloying elements/nucleants, multi-step post heat treatment, in-situ heat treatment, forced inter-pass cooling, in situ peening/rolling, hybridizing microstructure, high-intensity acoustic vibration, thermo-hydrogen refinement of microstructure, deliberately introducing lack of fusion defects with subsequent hot isostatic pressing are discussed in detail. Finally, we conclude by highlighting the challenges associated with each method and potential areas of improvement that can pave the way to develop reliable components with enhanced performance.
36 MATERIALS SCIENCE↗
Chemistry imaging and distribution analysis of rare earth elements in coal using LIBS and LA-ICP-MS instruments
Currently, demand for rare earth elements (REEs) increased significantly. Coal is actively evaluated as potential economic sources for extraction of REEs. Here, in this work, laser-induced breakdown spectroscopy (LIBS) was evaluated for rapid estimation of REEs content and their distribution in the natural coal samples. The results were compared with similar laser ablation–inductively coupled plasma–mass spectrometry (LA-ICP-MS) measurements. Thirteen coal samples (nine standard samples and five natural samples) were used in this study. Powder samples were pressed into pellets while coal chunks were directly ablated for data recording. Pellets of the powder standard samples were used to optimize the data acquisition system and then data recorded with this optimized system was used to identify the proper data acquisition and analysis models. After establishing the proper data acquisition system and analysis model using the standard samples, natural coal samples in powder form and their chunks were utilized to record LIBS and LA-ICP-MS spectra. Multivariate calibration models were developed using four of the natural samples, which were evaluated by predicting the REE content in the fifth sample. Principal component analysis was performed on the LIBS data obtained from the natural samples and it classified all the samples with high accuracy. Two-dimensional (2D) elemental mapping on coal chunk samples was also performed using both LIBS and LA-ICP-MS to study the distribution of REEs in the samples. The resulting elemental images and their correlations can be used to infer mineral distributions.
01 COAL, LIGNITE, AND PEAT↗
Design and characterization of a single-channel microwave interferometer for the Helicon Physics Prototype eXperiment
A heterodyne interferometer for measuring the plasma electron density in Helicon Physics Prototype eXperiment (HPPX) has been developed and characterized in the laboratory. The heterodyne-type interferometer uses a probing beam of 85 GHz and a reference beam of 85.7 GHz by using two Gunn oscillators for facilitating frequency modulation. The cutoff density for this frequency is 8.96 x 10 19 m –3 that is much higher than the nominal electron density of the HPPX plasmas. The maximum deflection angle due to the refraction effect is estimated to be 0.63° assuming a parabolic electron density profile, and the impact on the measurement is negligible for the plasmas with a size of 100 mm. Two identical HDPE lenses act as the vacuum windows, and the lenses working together with the transmitter and receiver horns, form a beam with the beam waist of about 20 mm located at the plasma center. The characterization results of the lens and the critical microwave components show good performance. The plasma electron density measurement results are in line with the expectation. Furthermore, the Signal to Noise Ratio (SNR) of the measurement is defined as SNR = 20lg($\bar{n}_{e}$/S), where $\bar{n}_{e}$ and S are respectively the average electron density and the standard deviation of the signal, and the SNR is 80 dB. Finally, this demonstrates the system's capability of providing a clear and detailed density resolution.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Thermal-shock experiments for separate-effects validation of UO 2 fuel fracture models
Because of the important role that fracture plays in the behavior of ceramic UO2 fuel in a nuclear reactor environment, fracture models are a major component of fuel performance codes. As with any aspect of fuel performance, it is crucial to validate these fracture models against experimental data; however, obtaining well-controlled data for conditions representative of a reactor environment is difficult. Quenching is proposed here as a relatively simple approach for using a laboratory environment to achieve conditions that approximate those of a reactor environment. In this paper, an experimental apparatus containing a single instrumented fuel pellet in a sealed section of copper tubing is developed. It is then applied to a series of seven experiments in which the apparatus is first heated to a high temperature (580-680°C) by immersion in a molten salt bath, then quenched in a cold bath (-10-4 °C). Development of these experiments was guided by numerical simulations, and post-test simulations were performed to aid in understanding the experimental behavior and assessing the accuracy of the predictions of fracture initiation and propagation. In addition, similar experiments were performed on solid copper rods to provide temperature-dependent heat transfer coefficients for use in simulations of these experiments. Here, this study demonstrates that quenching is a viable approach for generating thermal gradients representative of those in prototypical light-water reactor conditions at powers of about 5–10 kW/m. Fracture is expected to begin at these power levels, and moderate amounts of radial and axial cracking was observed in these quenching tests.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Helium-implantation-induced lattice strains and defects in tungsten probed by X-ray micro-diffraction
Tungsten is the main candidate material for plasma-facing armour components in future fusion reactors. Bombardment with energetic fusion neutrons causes collision cascade damage and defect formation. Interaction of defects with helium, produced by transmutation and injected from the plasma, modifies defect retention and behaviour. Here we investigate the residual lattice strains caused by different doses of helium-ion-implantation into tungsten and tungsten-rhenium alloys. Energy and depth-resolved synchrotron X-ray micro-diffraction uniquely permits the measurement of lattice strain with sub-micron 3D spatial resolution and ~10 -4 strain sensitivity. Increase of helium dose from 300 appm to 3000 appm increases volumetric strain by only ~2.4 times, indicating that defect retention per injected helium is ~3 times higher at low helium doses. This suggests defect retention is not a simple function of implanted helium dose, but strongly depends on material composition and presence of impurities. Conversely, analysis of W-1 wt% Re alloy samples and of different crystal orientations shows that both the presence of rhenium, and crystal orientation, have a comparatively small effect on defect retention. These insights are key for the design of armour components in future reactors where it will be essential to account for irradiation-induced dimensional change when predicting component lifetime and performance.
36 MATERIALS SCIENCE↗
A radiation tolerant light pulser for particle physics applications
A light emitting diode (LED) pulser has been developed that can be used for tests or calibration of timing and amplitude sensitivity of particle physics detectors. Here a comparative study is performed on the components and pulser output characteristics before and after application of 800 MeV protons and cobalt-60 gammas. This device is demonstrated to be tolerant to fluences up to 6.7 x 10 13 800-MeV-p/cm 2 and gamma doses up to 5 Mrad.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Asynchronous Two-Level Checkpointing Scheme for Large-Scale Adjoints in the Spectral-Element Solver Nek5000
Adjoints are an important computational tool for large-scale sensitivity evaluation, uncertainty quantification, and derivative-based optimization. An essential component of their performance is the storage/recomputation balance in which efficient checkpointing methods play a key role. We introduce a novel asynchronous two-level adjoint checkpointing scheme for multistep numerical time discretizations targeted at large-scale numerical simulations. The checkpointing scheme combines bandwidth-limited disk checkpointing and binomial memory checkpointing. Based on assumptions about the target petascale systems, which we later demonstrate to be realistic on the IBM Blue Gene/Q system Mira, we create a model of the expected performance of our checkpointing approach and validate it using the highly scalable Navier-Stokes spectralelement solver Nek5000 on small to moderate subsystems of the Mira supercomputer. In turn, this allows us to predict optimal algorithmic choices when using all of Mira. We also demonstrate that two-level checkpointing is significantly superior to single-level checkpointing when adjoining a large number of time integration steps. To our knowledge, this is the first time two-level checkpointing had been designed, implemented, tuned, and demonstrated on fluid dynamics codes at large scale of 50k+ cores.
Adjoints↗
srlife : A software tool for estimating the life of high temperature concentrating solar receivers. Part II – Ceramic receivers
As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat demands, high-temperature metallic materials, including nickel-based superalloys, face challenges in maintaining structural integrity. Advanced ceramics offer a promising alternative due to their superior high-temperature strength. However, accurately assessing the performance of ceramic components requires a fundamentally different approach from that used for metallic components. This Part II of a two-part paper describes the integration of ceramic statistical failure models within srlife – an open-source tool for predicting the life of high-temperature CSP receivers. These models account for the inherent variability in ceramic strength, as well as the effects of subcritical crack growth (SCG) under high temperature cyclic loads. Here, the paper includes an example problem that demonstrate the process of evaluating ceramic receivers using srlife. Part I details the life estimation process for metallic receivers (i.e. creep-fatigue life) along with input and output data structure, thermohydraulic analysis, and structural analysis. The complete tool is available as open-source software at https://github.com/srlife-project/srlife and can be installed via the PyPi package manager (https://pypi.org). By supporting both ceramic and metallic receiver analyses, srlife facilitates fair comparisons between competing metallic and ceramic designs, enabling accurate evaluations of plant efficiency and the economic benefits of ceramic solar receivers and other components.
High temperature ceramic receivers↗
Detecting DNA Methylation Using Surface-Enhanced Raman Spectroscopy
Among all of the epigenetic events that are responsible for various diseases such as cancer, lupus, and several birth defects, DNA methylation is one of the crucial ones. It occurs because of the alkylation of various bases. These modifications of genes carried through altered creations of proteins ultimately lead to various diseases. For example, a vital cause behind canine lymphoma is found to be DNA methylation in the guanine base. In this work, we analyzed the methylated and nonmethylated guanine structure with the assistance of surface-enhanced Raman spectroscopy and density functional theory (DFT). Because of their vulnerability for causing DNA methylation, the N7 and O6 positions of the guanine structure were the positions of interest with the addition of various adducts such as methyl, hydroxyethyl, and deuterated methyl groups. To distinguish the methylated samples from the nonmethylated ones, principal component analysis was performed, and the same analysis was used to distinguish their methylated positions and added adducts. The experimental results were then explained by structure optimization and frequency calculation of the molecules based on DFT calculations. To understand the charge distribution and detect the possible locations of alkylation of DNA bases, electrostatic potential, highest occupied molecular orbital, and lowest unoccupied molecular orbital for each of the molecules were analyzed, and the reactivity was discussed in the light of electronic structure calculations. The results presented in this study demonstrate a potential label-free technique to examine epigenetic modification of DNA.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Hygroscopic Metal-Complex Coated Metal Foam for Moisture Management
Moisture management for improving indoor air quality is critical for health and thermal comfort. Recently, the use of desiccant-coated heat exchangers (HXs) has emerged as a promising dehumidification approach to reduce energy consumption as compared with conventional vapor compression-based air dehumidification. The desiccant material is a key component of dehumidification performance. However, currently used desiccant materials have a low moisture uptake capability and require a high temperature for regeneration. The current study investigated the dehumidification performance of a metal-complex-based hygroscopic desiccant-coated metal foam HX. Furthermore, the results revealed that the desiccant-coated foams display increased hydrophilicity compared with the uncoated metal surfaces. Additionally, the desiccant coating had superior moisture absorption capability of more than 2 g/g desiccant , which is much higher than commonly used zeolite and silica gels. Wind tunnel experiments showed that the coating absorbs moisture from humid air and can be effectively regenerated at low temperatures. Additionally, the coating did not increase the pressure drop of the HX. Overall, the results of this study suggest that this desiccant-coated metal form can potentially be used for moisture management in the building sector.
Atmospheric chemistry↗
Resolving Nanoscopic and Mesoscopic Heterogeneity of Fluorinated Species in Battery Solid-Electrolyte Interphases by Cryogenic Electron Microscopy
The stability of lithium batteries is tied to the physicochemical properties of the solid-electrolyte interphase (SEI). Owing to the difficulty in characterizing this sensitive interphase, the nanoscale distribution of SEI components is poorly understood. Here, we use cryogenic scanning transmission electron microscopy (cryo-STEM) to map the spatial distribution of SEI components across the metallic Li anode. We reveal that LiF, an SEI component widely believed to play an important role in battery passivation, is absent within the compact SEI film (~15 nm); instead, LiF particles (100–400 nm) precipitate across the electrode surface. We term this larger length scale as the indirect SEI regime. On the basis of these observations, we conclude that LiF cannot be a dominant contribution to anode passivation nor does it influence Li+ transport across the compact SEI film. We refine the traditional SEI structure derived from ensemble-averaged characterizations and nuance the role of SEI components on battery performance.
25 ENERGY STORAGE↗
Bottom-up design of de novo thermoelectric hybrid materials using chalcogenide resurfacing
Hybrid organic/inorganic thermoelectric materials based on conducting polymers and inorganic nanostructures have been demonstrated to combine both the inherently low thermal conductivity of the polymer and the superior charge transport properties (high power factors) of the inorganic component. While their performance today still lags behind that of conventional inorganic thermoelectric materials, solution-processable hybrids have made rapid progress and also offer unique advantages not available to conventional rigid inorganic thermoelectrics, namely: (1) low cost fabrication on rigid and flexible substrates, as well as (2) engineering complex conformal geometries for energy harvesting/cooling. While the number of reports of new classes of viable hybrid thermoelectric materials is growing, no group has reported a general approach for bottom-up design of both p- and n-type materials from one common base. Thus, unfortunately, the literature comprises mostly of disconnected discoveries, which limits development and calls for a first-principles approach for property manipulation analogous to doping in traditional semiconductor thermoelectrics. Here, molecular engineering at the organic/inorganic interface and simple processing techniques are combined to demonstrate a modular approach enabling de novo design of complex hybrid thermoelectric systems. Here, we chemically modify the surfaces of inorganic nanostructures and graft conductive polymers to yield robust solution processable p- and n-type inorganic/organic hybrid nanostructures. Our new modular approach not only offers researchers new tools to perform true bottom-up design of thermoelectric hybrids, but also strong performance advantages as well due to the quality of the designed interfaces. For example, we obtain enhanced power factors in existing (by up to 500% in Te/PEDOT:PSS) and novel (Bi 2 S 3 /PEDOT:PSS) p-type systems, and also generate water-processable and air-stable high performing n-type hybrid systems (Bi 2 Te 3 /PEDOT:PSS), thus highlighting the potency of our ex situ strategy in opening up new material options for thermoelectric applications. Finally, this strategy establishes a unique platform with broad handles for custom tailoring of thermal and electrical properties through hybrid material tunability and enables independent control over inorganic material chemistry, nanostructure geometry, and organic material properties, thus providing a robust pathway to major performance enhancements.
36 MATERIALS SCIENCE↗
Systematic characterization of selenium speciation in coal fly ash
Millions of tons of coal fly ashes (CFAs) are produced annually during coal combustion in the U.S., which are commonly beneficially used in the concrete industry or disposed of in ash ponds. CFAs contain trace amounts of a range of toxic heavy metals including selenium (Se). Because the toxicity of Se is dependent on its speciation, investigating Se speciation in CFAs as affected by coal source and combustion conditions can help understand the related environmental and human health impacts during disposal or beneficial reuse. In this study, a set of representative CFA samples were characterized for Se speciation using synchrotron X-ray absorption spectroscopy (XAS) and micro-X-ray fluorescence spectromicroscopy (μ-XRF/XAS). Se-containing particles were highly heterogeneous, and individual particles might contain multiple oxidation states including Se(0), Se(IV), and Se(VI). Principal component analysis was performed for sample characteristics including Al 2 O 3 , SiO 2 , CaO, FeO, loss on ignition, average particle size, Se concentration, and Se oxidation state. Selective catalytic reduction (SCR), which is used to limit nitrogen oxide (NO x ) emissions during coal combustion, was found to be associated with the presence of reduced Se oxidation states, with up to 90% Se(0) observed in samples with SCR. Alongside SCR, FeO content may also influence Se speciation.
01 COAL, LIGNITE, AND PEAT↗
Solvent polarity and nanoscale morphology in bulk heterojunction organic solar cells: A case study
Organic bulk heterojunction solar cells were fabricated under identical experimental conditions, except by varying the solvent polarity used for spin coating the active layer components and their performance was evaluated systematically. Results showed that presence of nitrobenzene-chlorobenzene composition governs the morphology of active layer formed, which is due to the tuning of solvent polarity as well as the resulting solubility of the P3HT:PCBM blend. Trace amount of nitrobenzene favoured the formation of better organised P3HT domains, as evident from conductive AFM, tapping mode AFM and surface, and cross-sectional SEM analysis. The higher interfacial surface area thus generated produced cells with high efficiency. But, an increase in the nitrobenzene composition leads to a decrease in cell performance, which is due to the formation of an active layer with larger size polymer domain networks with poor charge separation possibility.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗