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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Component Identification of Solid Biomass Fuels Using Reflected Light Microscopy: Interlaboratory Study 2

As nations transition toward sustainable energy systems, biomass has become a vital component of global energy portfolios. Derived from organic materials such as wood, agricultural residues, forestry byproducts, and organic waste, biomass is a renewable energy source with significant environmental and economic benefits. Responsible biomass energy production can improve waste management, reduce emissions of greenhouse gases, and mitigate environmental pollution. However, as the diversity of biomass-derived fuels increases, robust quality assessment methods are essential to ensure their efficiency, safety, and minimal environmental impact. Reflected light microscopy (RLM) is one such technique with the potential to complement conventional physico-chemical analyses by enabling a rapid identification of material constituents and impurities. To refine this methodology and evaluate the reproducibility of solid biomass component identification using RLM, an interlaboratory study (ILS) was conducted. The study involved the recognition of 58 components across 45 photomicrographs, with the participation of 65 scientists and students from 25 countries. The participants faced high difficulty identifying some of the marked components, and as a result, the percentage of correct answers ranged from 19.0 % to 98.3 %, with an average correct identification rate of 62.7 %. The most challenging aspects of the identification process included distinguishing between woody and non-woody (agro) biomass, accurately identifying petroleum-derived materials, and differentiating agro biomass from inorganic matter. The results suggest that while RLM is an important tool for characterizing solid biomass, further development of methodology guidelines and training are necessary to enhance its effectiveness. Future research should prioritize preparing detailed, image-rich, microscopic morphological descriptions of biomass fuel components, which could improve the accuracy and reliability of using RLM in biomass fuel characterization.

09 BIOMASS FUELS↗
DOE OSTI2021

Machine learning elastic constants of multi-component alloys

The present manuscript explores application of machine learning methods for determining elastic constants and other derived mechanical properties of multi-component alloys. Here, a number of machine learning models, including linear regression, neural network and random forest based models, are trained and tested on a dataset of binary alloys generated using density functional theory (DFT) calculations and spanning over a large number of elemental species in the periodic table. Starting with a wide range of simple and easily accessible compositionally-averaged elemental features, a correlation-based feature selection strategy was used to systematically down-select a set of most relevant features towards the prediction of the elasticity tensor components. The true predictive performance and the associated uncertainties of the models were established by testing on unseen data and bootstrapping, respectively. A single and pair-wise feature partial dependence analysis was performed to visualize the average property trends in the multi-dimensional feature space in order to further understand the achieved predictive performance. The utility of the trained model is further demonstrated by obtaining sufficiently accurate yet highly efficient approximations for bulk modulus, Young’s modulus, shear modulus and Poisson’s ratio for alloys beyond the binary space (i.e., two-component alloys) on which the model was originally trained. More importantly, we test and validate the predictive performance of the developed model directly against the experimentally measured elastic constants of technologically relevant multi-component alloys (such as, Ni- and Ti-based alloys). Finally, utility of such a data-enabled route is demonstrated by predicting the possible range of various elastic properties for vast composition space available within the five component Ni-Cr-Fe-Mo-W alloy system in a high-throughput manner.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The quest for efficient oxygenated fuels: Examining interactions between lubricant components and oxygenates

This work empirically evaluated oxygenated blendstock-lubricant compatibility using a novel but simple method. The reactivity or compatibility was evaluated via gas chromatograph equipped with a flame ionization detector (GC-FID) before and after heating for 2h at 150 °C, which would roughly mimic conditions encountered in the combustion chamber of an Spark Ignition (SI) or Compression-Ignition (CI) engine. Five oxygenate blendstocks spanning several functional groups and chain lengths (prenol, isoprenol, butyl acetate, isohexanol, polyoxymethylene dimethyl ethers) were evaluated in a base fuel with nine variations of lubricant components of controlled concentrations, including fully formulated commercial lubricants. Baseline comparative examples were also generated, to decouple the effect of the oxygenate on the mixture, by heating only the base fuel with the lubricant component. Results demonstrate the relative compatibility between noted lubricants and oxygenates in base fuel upon heating. This was illustrated by minimal to no changes in the GC-FID traces. However, reactions of several of the chosen lubricants, especially Molybdenum di (2-ethylhexyl) phosphorodithioate (Molyvan L) and zinc dialkyldithiophosphate (ZDDP), with prenol and polyoxymethylene dimethyl ethers blendstocks showed substantial side reactions compared to corresponding baseline examples. Control experiments without oxygenates but comprising the same lubricant components showed no change in the mixture with heating. We concluded the incompatibility is due to the oxygenate and not the components of the base fuel. This preliminary work is valuable in establishing trends as well as provide useful information when a new component is introduced in the fuel.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Wire-coil insert optimization for high-heat-load/flux synchrotron components

Many synchrotron components require high levels of internal-flow, forced-convection heat transfer to minimize surface temperatures, thermal gradients, and thermally induced stress on high-power beam-interacting surfaces. Wire-coil inserts, physically similar to a common spring, are mechanically fitted inside of component cooling passages to optimize heat transfer performance. They are routinely used in Advanced Photon Source (APS) front end and beamline high-heat-load/flux components to significantly enhance convection heat transfer-up to 400% compared to plain open passages. This has the additional benefit of greatly reducing coolant flow requirements for these components. Using several cooling passage sizes, five different wire sizes, and a range of pitch values, an experimental investigation conducted at the APS has determined the average heat transfer coefficient and resulting pressure loss as a function of water flow rate for 65 different wire-coil inserts. Data from this study have been non-dimensionalized and generalized to yield relationships that can be used to determine the heat transfer performance and resulting pressure loss for any given wire-coil insert that may be used at the APS. Through data reduction, the wire-coil insert characteristic dimensions have also been optimized to yield the highest heat transfer enhancement while minimizing the coolant flow requirements. These generalized expressions for wirecoil inserts will be presented, and they can be used by scientists and engineers during the component design process to evaluate achievable heat transfer performance and associated pressure loss, aiding in the establishment of optimized operating parameters and cooling passage flow distribution schemes.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Performance of discontinuity-free components produced by additive turning computer aided manufacturing strategy

Computer aided manufacturing (CAM) techniques for directed energy deposition (DED) affect the material properties of the manufactured component based on the scan strategy used. In this study, we investigate the material characteristics of turning-style toolpath strategies to generate axisymmetric components with additive manufacturing (AM), referred to in this research as additive turning. This novel approach leverages existing CAM technology for turning, where the component rotates around a stationary cutting tool, to generate toolpath trajectories for DED with varying wall-thicknesses and controlled deposition angles. This strategy allows for entire components to be deposited in one continuous deposition, resulting in reduced cycle-time and improved material usage efficiency compared to conventional AM strategies where the beam is switched off at the end of every layer. Results from this study show that the use of additive turning can produce over 99 % dense components with less variation and anisotropy in texture and hardness, as well as a lower variation in elongation to failure when compared to conventional strategies. This research highlights that various CAM strategies could be deployed for AM to improve process efficiency or enable localized control over part performance.

36 MATERIALS SCIENCE↗
DOE OSTI2025

E3SM‐GCAM: A Synchronously Coupled Human Component in the E3SM Earth System Model Enables Novel Human‐Earth Feedback Research

Abstract Modeling human‐environment feedbacks is critical for assessing the effectiveness of climate change mitigation and adaptation strategies under a changing climate. The Energy Exascale Earth System Model (E3SM) now includes a human component, with the Global Change Analysis Model (GCAM) at its core, that is synchronously coupled with the land and atmosphere components through the E3SM coupling software. Terrestrial productivity is passed from E3SM to GCAM to make climate‐responsive land use and CO 2 emission projections for the next 5‐year period, which are interpolated and passed to E3SM annually. Key variables affected by the incorporation of these feedbacks include land use/cover change, crop prices, terrestrial carbon, local surface temperature, and climate extremes. Regional differences are more pronounced than global differences because the effects are driven primarily by differences in land use. This novel system enables a new type of scenario development and provides a powerful modeling framework that facilitates the addition of other feedbacks between these models. This system has the potential to explore how human responses to climate change impacts in a variety of sectors, including heating/cooling energy demand, water management, and energy production, may alter emissions trajectories and Earth system changes. Plain Language Summary Earth system models help us understand how humans are changing the climate. Currently, these models do not include human systems, so predetermined greenhouse gas, aerosol, and land use change data are input to these models. These data do not reflect human responses to changes projected by Earth system models. We have added a human component to an Earth system model to represent human responses to environmental change and calculate corresponding greenhouse gas and land use change data instead of using predetermined data. Including this human component changes projections of land use, land carbon storage, and regional climate. Key Points We have incorporated a novel, advanceable human component in an Earth system model to simulate human‐Earth feedbacks Including terrestrial productivity feedbacks from the Earth to the human systems affects land change, crop prices, carbon, and climate Regional effects of including terrestrial productivity feedbacks are greater than global effects because land change is the main driver

E3SM↗
DOE OSTI2023

Multiple emission components in the Cygnus cocoon detected from Fermi -LAT observations

Star-forming regions may play an important role in the life cycle of Galactic cosmic rays (CRs), notably as home to specific acceleration mechanisms and transport conditions. Gamma-ray observations of Cygnus X have revealed the presence of an excess of hard-spectrum gamma-ray emission, possibly related to a cocoon of freshly accelerated particles. We seek an improved description of the gamma-ray emission from the cocoon using ~13 yr of observations with the Fermi-Large Area Telescope (LAT) and use it to further constrain the processes and objects responsible for the young CR population. We developed an emission model for a large region of interest, including a description of interstellar emission from the background population of CRs and recent models for other gamma-ray sources in the field. Thus, we performed an improved spectro-morphological characterisation of the residual emission including the cocoon. The best-fit model for the cocoon includes two main emission components: an extended component FCES G78.74+1.56, described by a 2D Gaussian of extension r 68 = 4.4° ± 0.1° -0.1° +0.1° and a smooth broken power law spectrum with spectral indices 1.67 ± 0.05 -0.01 +0.02 and 2.12 ± 0.02 -0.01 +0.00 below and above 3.0 ± 0.6 -0.2 +0.0 GeV, respectively; and a central component FCES G80.00+0.50, traced by the distribution of ionised gas within the borders of the photo-dissociation regions and with a power law spectrum of index 2.19 ± 0.03 -0.01 +0.00 that is significantly different from the spectrum of FCES G78.74+1.56. An additional extended emission component FCES G78.83+3.57, located on the edge of the central cavities in Cygnus X and with a spectrum compatible with that of FCES G80.00+0.50, is likely related to the cocoon. For the two brightest components FCES G80.00+0.50 and FCES G78.74+1.56, spectra and radial-azimuthal profiles of the emission can be accounted for in a diffusion-loss framework involving one single population of non-thermal particles with a flat injection spectrum. Particles span the full extent of FCES G78.74+1.56 as a result of diffusion from a central source, and give rise to source FCES G80.00+0.50 by interacting with ionised gas in the innermost region. For this simple diffusion-loss model, viable setups can be very different in terms of energetics, transport conditions, and timescales involved, and both hadronic and leptonic scenarios are possible. The solutions range from long-lasting particle acceleration, possibly in prominent star clusters such as Cyg OB2 and NGC 6910, to a more recent and short-lived release of particles within the last 10–100 kyr, likely from a supernova remnant. The observables extracted from our analysis can be used to perform detailed comparisons with advanced models of particle acceleration and transport in star-forming regions.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Performance demonstration of vacuum microwave components critical for the operation of the ITER low-field side reflectometer

Final design studies in preparation for manufacturing have been performed for functional components of the vacuum portion of the ITER Low-Field Side Reflectometer (LFSR). These components consist of an antenna array, electron cyclotron heating (ECH) protection mirrors, phase calibration mirrors, and vacuum windows. Evaluation of these components was conducted at the LFSR test facility and DIII-D. The antenna array consists of six corrugated-waveguide antennas for simultaneous profile, fluctuation, and Doppler measurements. A diffraction grating, incorporated into the plasma-facing miter bend, provides protection of sensitive components from stray ECH at 170 GHz. For in situ phase calibration of the LFSR profile reflectometer, an embossed mirror is incorporated into the adjacent miter bend. Measurements of the radiated beam profile indicate that these components have a small, acceptable effect on mode conversion and beam quality. Baseline transmission characteristics of the dual-disk vacuum window are obtained and are used to guide ongoing developments. Preliminary simulations indicate that a surface-relief structure on the window surfaces can greatly improve transmission. The workability of real-time phase measurements was demonstrated on the DIII-D profile reflectometer. The new automated real-time analysis agrees well with the standard post-processing routine.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

A 2-component blend of coconut oil-derived fatty acids as an oviposition deterrent against Drosophila suzukii (Drosophilidae: Diptera)

Abstract Coconut free fatty acid (CFFA), a mixture of 8 fatty acids derived from coconut oil, is an effective repellent and deterrent against a broad array of hematophagous insects. In this study, we evaluated the oviposition deterrent activity of CFFA on spotted-wing drosophila (SWD; Drosophila suzukii), a destructive invasive pest of berries and cherries, and identified bioactive key-deterrent compounds. In laboratory 2-choice tests, CFFA deterred SWD oviposition in a dose-dependent manner with the greatest reduction (99%) observed at a 20-mg dose compared with solvent control. In a field test, raspberries treated with 20-mg CFFA received 64% fewer SWD eggs than raspberries treated with the solvent control. In subsequent laboratory bioassays, 2 of CFFA components, caprylic and capric acids, significantly reduced SWD oviposition by themselves, while 6 other components had no effect. In choice and no-choice assays, we found that a blend of caprylic acid and capric acid, at equivalent concentrations and ratio as in CFFA, was as effective as CFFA, while caprylic acid or capric acid individually were not as effective as the 2-component blend or CFFA at equivalent concentrations, indicating the 2 compounds as the key oviposition deterrent components for SWD. The blend was also as effective as CFFA for other nontarget drosophilid species in the field. Given that CFFA compounds are generally regarded as safe for humans, CFFA and its bioactive components have potential application in sustainably reducing SWD damage in commercial fruit operations, thereby reducing the sole reliance on insecticides.

Entomology↗
DOE OSTI2026

Gram-positive bacterial cell wall components inhibit herpes simplex virus infection

The role of the mucosal microbiome in viral infections remains unclear. Genital herpes, caused by herpes simplex virus 1 and 2 (HSV-1 and HSV-2), is among the most prevalent sexually transmitted infections worldwide. Despite evidence linking vaginal Lactobacillus to protection against sexually transmitted viruses, the specific microbial components and mechanisms that mediate this defense are not well understood. Here, we show that multiple cell wall components from diverse gram-positive bacteria, including lactobacilli, inhibit HSV-1 and HSV-2 infection in cells and in a mouse model of genital herpes infection. Peptidoglycan (PG) and lipoteichoic acid (LTA), both major components of the gram-positive bacterial cell wall, significantly reduced HSV infectivity in vitro and improved survival and disease outcomes in mice. We further showed that Lactobacillus crispatus surface layer proteins SlpA and SlpB bind HSV-1 and inhibit infection. Antiviral effects of cell wall components were dose-dependent, relied on intact PG structure, and, in the case of PG and LTA, were independent of TLR2-mediated host signaling. Collectively, our findings identify a species-independent antiviral function for gram-positive bacterial cell wall components against HSV and suggest that the composition of the mucosal microbiome may play an underappreciated role in suppressing mucosal herpes infection in humans.

Adams↗
DOE OSTI2020

Glycosylation of hyperthermostable designer cellulosome components yields enhanced stability and cellulose hydrolysis

Biomass deconstruction remains integral for enabling second-generation biofuel production at scale. However, several steps necessary to achieve significant solubilization of biomass, notably harsh pretreatment conditions, impose economic barriers to commercialization. By employing hyperthermostable cellulase machinery, biomass deconstruction can be made more efficient, leading to milder pretreatment conditions and ultimately lower production costs. The hyperthermophilic bacterium Caldicellulosiruptor bescii produces extremely active hyperthermostable cellulases, including the hyperactive multifunctional cellulase CbCel9A/Cel48A. Recombinant CbCel9A/Cel48A components have been previously produced in Escherichia coli and integrated into synthetic hyperthermophilic designer cellulosome complexes. Since then, glycosylation has been shown to be vital for the high activity and stability of CbCel9A/Cel48A. Here, we studied the impact of glycosylation on a hyperthermostable designer cellulosome system in which two of the cellulosomal components, the scaffoldin and the GH9 domain of CbCel9A/Cel48A, were glycosylated as a consequence of employing Ca. bescii as an expression host. Inclusion of the glycosylated components yielded an active cellulosome system that exhibited long-term stability at 75 degrees C. The resulting glycosylated designer cellulosomes showed significantly greater synergistic activity compared to the enzymatic components alone, as well as higher thermostability than the analogous nonglycosylated designer cellulosomes. These results indicate that glycosylation can be used as an essential engineering tool to improve the properties of designer cellulosomes. Additionally, Ca. bescii was shown to be an attractive candidate for production of glycosylated designer cellulosome components, which may further promote the viability of this bacterium both as a cellulase expression host and as a potential consolidated bioprocessing platform organism.

09 BIOMASS FUELS↗
DOE OSTI2022

Network Uncertainty Quantification for Analysis of Multi-Component Systems

To impact physical mechanical system design decisions and realize the full promise of high-fidelity computational tools, simulation results must be integrated at the earliest stages of the design process. This is particularly challenging when dealing with uncertainty and optimizing for system-level performance metrics, as full-system models (often notoriously expensive and time-consuming to develop) are generally required to propagate uncertainties to system-level quantities of interest. Methods for propagating parameter and boundary condition uncertainty in networks of interconnected components hold promise for enabling design under uncertainty in real-world applications. These methods avoid the need for time consuming mesh generation of full-system geometries when changes are made to components or subassemblies. Additionally, they explicitly tie full-system model predictions to component/subassembly validation data which is valuable for qualification. These methods work by leveraging the fact that many engineered systems are inherently modular, being comprised of a hierarchy of components and subassemblies that are individually modified or replaced to define new system designs. By doing so, these methods enable rapid model development and the incorporation of uncertainty quantification earlier in the design process. The resulting formulation of the uncertainty propagation problem is iterative. We express the system model as a network of interconnected component models, which exchange solution information at component boundaries. We present a pair of approaches for propagating uncertainty in this type of decomposed system and provide implementations in the form of an open-source software library. We demonstrate these tools on a variety of applications and demonstrate the impact of problem-specific details on the performance and accuracy of the resulting UQ analysis. This work represents the most comprehensive investigation of these network uncertainty propagation methods to date.

42 ENGINEERING↗
DOE OSTI2022

Designing Cladded Components for High Temperature Nuclear Service: Part II—Design Rules

The challenge of using existing ASME Section III, Division 5, class A metallic materials for the construction of structural components of advanced reactors with corrosive coolants could be mitigated by allowing designers to use cladding to protect the base material from corrosion. However, the existing Section III, Division 5 rules provide no guidance on the evaluation of strain accumulation and creep-fatigue damage in cladded components. The availability of design rules for cladded components that do not require long-term clad material testing could promote the application of the cladding approach to accelerate the deployment schedule of these advanced reactor systems. To avoid long-term properties for the clad materials Part I of this work proposes two approximate design analysis methods for two types of clad materials—soft clads that creep much faster and have lower yield stress than the class A base material, and hard clads that creep much slower and have higher yield stress than the class A base material. The proposed analysis methods approximate the response of a soft clad by treating it as perfectly compliant and of a hard clad by treating it as linear elastic. Based on these approximate design analysis strategies this Part II develops a complete set of design rules for class A components cladded with either soft or hard clad materials. In conclusion, Part II discusses the reasoning behind the proposed design rules and uses example finite element analyses of representative reactor components to illustrate the use of these design methods.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Component Importance and Interdependence Analysis for Transmission, Distribution and Communication Systems

For critical infrastructure restoration planning, the real-time scheduling and coordination of system restoration efforts, the key in decision-making is to prioritize those critical components that are out of service during the restoration. For this purpose, there is a need for component importance analysis. While it has been investigated extensively for individual systems, component importance considering interdependence among transmission, distribution and communication (T&D&C) systems has not been systematically analyzed and widely adopted. In this study, we propose a component importance assessment method in the context of interdependence between T&D&C networks. Analytic methods for multilayer networks and a set of metrics have been applied for assessing the component importance and interdependence between T&D&C networks based on their physical characteristics. The proposed methodology is further validated with integrated synthetic Illinois regional transmission, distribution, and communication (T&D&C) systems, the results reveal the unique characteristics of component/node importance, which are strongly affected by the network topologies and cross-domain node mapping.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Sample problems for Section III, Division 5 design by inelastic analysis of Grade 91 components

This report works through two sample design analyses of representative Grade 91 components using the ASME Boiler & Pressure Vessel Code Section III, Division 5, Appendix HBB-T rules for the strain and deformation and creep-fatigue design criteria using a design by inelastic analysis approach. The component geometries and loadings were selected to span a wide variety of potential applications. The sample components are an endplate geometry, which is fairly representative of typical pressure vessel construction, and a core block, representing a critical component in a heat pipe microreactor, which has a complicated geometry and complex thermal stress history. These sample problems serve several functions. First, they are complete worked examples of how to apply the current design by inelastic analysis rules. Second, they serve as test cases to evaluate the current rules and provide feedback on how they could be optimized to deal with complicated component geometries or to be better automated in modern finite element analysis software. Finally, the analysis here uses an inelastic constitutive model for Grade 91 developed by Argonne National Laboratory and proposed for inclusion in the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules as a reference constitutive model. Using this constitutive model in the sample problem analyses tests the model in the context of the ASME Code rules. The final conclusions of this report are that the material model and the current Code rules are satisfactory, but that the Code rules could be optimized to simplify automation and reduce over conservatism. Future work should address the specific optimization topics discussed in this report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Design rules for 316H nuclear components cladded with nickel or tungsten

The existing Class A metallic materials qualified in the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules for high temperature nuclear reactors are not ideally suited for long term molten salt corrosion resistance in high temperature molten salt reactors. Potentially, corrosion or corrosion driven environmentally assisted cracking could limit the design life of structural components in molten salt reactors. A solution to this limitation is the use of cladded components – overlay the Class A material with a thin layer of some non-qualified, corrosion-resistant material. However, this necessitates the development of design methods for cladded components that do not require long-term testing of clad materials in order to support the near-term deployment of molten salt reactors. This report develops such a methodology along with a complete set of rules presented in a format compatible with an ASME nuclear Code Case. These design rules are for 316H Class A components cladded with either nickel or tungsten. The report also discusses the development of a set of general criteria for selecting clad materials beyond the specific 316H/tungsten and 316H/nickel systems and general acceptance tests for checking the mechanical integrity of the clad/base metal interface. Finally, the report includes a set of fully-documented sample problems detailing the application of the rules to high temperature cladded components

36 MATERIALS SCIENCE↗
DOE OSTI2021

Low Cost HIP Fabrication of Advanced Power Cycle Components and PM/Wrought Inconel 740H Weld Development (Final Technical Report)

The objective of this Phase 1 project is to demonstrate the feasibility of structures and components for advanced fossil energy power cycle by fusion welding powder metallurgy (PM) based near net shape (NNS) hot isostatic pressing (HIP) Nickel superalloy Inconel 740H (IN740H) components to wrought IN740H components. The outcome of the project includes a prototype pipe elbow demonstration of the NNS HIP process using IN740H powder, an initial assessment of IN740H PM/wrought weldability, and a manufacturing and capital cost analysis of IN740H NNS HIP components for advanced ultra-super critical steam (AUSC) power plants. The anticipated value proposition of NNS HIP manufacturing is ~50% cost reduction of large complex components in AUSC or super-critical carbon dioxide (sCO2) power cycles. This document is a final technical report for the project, covering efforts conducted from October 2019 to June 2021.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Electrical-Discharge-Machining Contamination Removal from Metal Additively Manufactured Components

The use of an electrochemical dissolution process is shown to remove the recast layer contamination from the surfaces of electrical-discharge-machining cut components, as well as the interior exposed surfaces of the structure. The solution chemistry, cell potential, and exposure time are all relevant interdependent variables. Optimization of the electrode geometry should be made for each type of component. For the case of Cu-Zn recast contamination of 300-series alloy components, surface composition analysis indicates that complete electrochemical dissolution is achieved using a dilute solution of nitric acid (HNO 3 ). For example, electrochemical dissolution of the Cu-Zn recast is accomplished at 1.2 V cell potential using a 20% nitric solution and an exposure time of 4 h. The use of a nitric acid bath was specifically chosen since it’s chemically compatible and will not degrade the host alloy or the component. In sum, an electrochemically driven dissolution process can be tailored to remove of the recast contamination without affecting the integrity of the host component structure and its dimensional tolerances.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗