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At least 127 records · Page 7

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DOE OSTI2020

Tailoring Surface Roughness Using Additive Manufacturing to Improve Internal Cooling

Abstract Surface roughness present on internal cooling channels produced with additive manufacturing has been previously shown to augment heat transfer and pressure loss to levels similar to traditionally cast turbulators. Given the ability of the surface roughness to improve the cooling performance of small cooling channels, the question arises on whether there is an optimal combination of random roughness features to maximize internal cooling performance. To investigate this question, test coupons with different surface roughness morphologies and magnitudes were manufactured by manipulating the parameters in the laser powder bed fusion additive manufacturing process. The coupons were tested to characterize the friction factor and Nusselt number of the cooling channels over a range of Reynolds numbers. Results showed that certain roughness combinations outperformed others, increasing the internal cooling performance of the channels. Additionally, manipulation of the performance using the process parameters allowed for reductions in build time, which could be useful for controlling component cost.

Engineering↗

DOE OSTI2022

The Dopamine Assisted Synthesis of MoO3/Carbon Electrodes With Enhanced Capacitance in Aqueous Electrolyte

A capacitance increase phenomenon is observed for MoO 3 electrodes synthesized via a sol-gel process in the presence of dopamine hydrochloride (Dopa HCl) as compared to α-MoO 3 electrodes in 5M ZnCl 2 aqueous electrolyte. The synthesis approach is based on a hydrogen peroxide-initiated sol-gel reaction to which the Dopa HCl is added. The powder precursor (Dopa) x MoO y , is isolated from the metastable gel using freeze-drying. Hydrothermal treatment (HT) of the precursor results in the formation of MoO 3 accompanied by carbonization of the organic molecules; designated as HT-MoO 3 /C. HT of the precipitate formed in the absence of dopamine in the reaction produced α-MoO 3 , which was used as a reference material in this study (α-MoO 3 -ref). Scanning electron microscopy (SEM) images show a nanobelt morphology for both HT-MoO 3 /C and α-MoO 3 -ref powders, but with distinct differences in the shape of the nanobelts. The presence of carbonaceous content in the structure of HT-MoO 3 /C is confirmed by FTIR and Raman spectroscopy measurements. X-ray diffraction (XRD) and Rietveld refinement analysis demonstrate the presence of α-MoO 3 and h-MoO 3 phases in the structure of HT-MoO 3 /C. The increased specific capacitance delivered by the HT-MoO 3 /C electrode as compared to the α-MoO 3 -ref electrode in 5M ZnCl 2 electrolyte in a −0.25–0.70 V vs. Ag/AgCl potential window triggered a more detailed study in an expanded potential window. In the 5M ZnCl 2 electrolyte at a scan rate of 2 mV s −1 , the HT-MoO 3 /C electrode shows a second cycle capacitance of 347.6 F g −1 . The higher electrochemical performance of the HT-MoO 3 /C electrode can be attributed to the presence of carbon in its structure, which can facilitate electron transport. Our study provides a new route for further development of metal oxides for energy storage applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

A combination interferometric and morphological image processing approach to rapid quality assessment of additively manufactured cellular truss core components

Advanced manufacturing (AM) processes such as laser powder bed fusion (LPBF) are increasingly capable of fabricating components with useful and unprecedented mechanical properties by incorporating complex internal bracing structures. From the standpoint of quality control and assessment, however, internally complex assemblies present significant build-verification challenges. Here we propose a hybrid approach to the inspection involving the application of computer-aided speckle interferometry (CASI) and morphological image processing as a rapid, inexpensive, and facile method for AM quality control. The described methodology has low capital equipment costs, is full-field and non-contact, can be used in an industrial setting, and has very low requirements in terms of operator training and expertise. Consisting primarily of the combination of image processing software with a simple optical system of variable sensitivity, the method is shown to be effective for inspection of a titanium honeycomb component subjected to differential pressure. Results are compared to those achieved with computed tomography (CT), immersion ultrasound testing (UT), and optical holographic interferometry. Here we propose several possible processing strategies for automated quality assessment based on this powerful hybrid approach.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Understanding the structural and morphological effects of synthesis route on NpO 2

The availability of actinide standard materials for use in nuclear safeguard applications is critical, as is thorough characterization thereof. Although accurate trace element compositions and isotopic considerations are paramount for deployment of reference standards, structural characterization is also essential towards accurately describing the chemical form and potential matrix effects in candidate materials. Here, to this end, samples of NpO 2 were synthesized via a direct denitration (DD) method and probed with powder X-ray diffraction (PXRD), Raman spectroscopy, and scanning electron microscopy (SEM) for structural and morphological characterization and comparison with NpO 2 materials produced via modified direct denitration (MDD). PXRD confirmed the bulk identity of NpO 2 , and no additional phases were identified using this method. Analysis of Raman data collected using a 532 nm excitation wavelength indicates that samples are mostly phase pure; however, some variability in spectral features is observed. Analysis of additional spectroscopic data collected with a 785 nm excitation wavelength revealed variability in the relative intensity of spectral features. Raman spectroscopy indicates that the sample is primarily NpO 2 ; however, additional signals indicate possible structural disorder, oxidized species, or potential contributions from other Np phases. To further investigate the possibility of additional phase contributions within the sample of NpO 2 , Raman spectroscopic mapping was employed to examine the homogeneity of the sample produced via DD. From this analysis, we determined that despite variability in the intensity of Raman-active vibrational modes, consistent spectra are obtained throughout the area of the sample investigated. SEM images show aggregates with variable sizes and shapes, with rounded, primary particles possessing an average diameter of approximately 100 nm. Comparison of the results of these multimodal analyses to the literature indicates that the crystal chemical, spectroscopic, and microstructural properties of NpO 2 vary based on synthesis method, even if X-ray diffraction data indicate that the bulk phase is NpO 2 .

Direct denitration↗

DOE OSTI2023

Green Concrete with Glass Powder—A Literature Review

This paper represents a literature review of the effects of partially replacing cement with glass powder in concrete production, aiming to provide an enhanced elucidation of 78 published scientific articles between 2015 and 2023. Vigorous inclusion criteria were employed to accomplish this objective, such as focusing only on glass powder usage instead of cement, considering both conventional and unconventional concretes, and summarizing the physical, mechanical, durability, and morphological characteristics. It has been attempted not only to discuss the factors that contribute to similarities and differences but also to interpret associations and concerns as well as propose future research directions based on the identified gaps. The literature review reveals that using glass powder looks captivating and has higher mechanical and durability properties with environmentally friendly advantages simultaneously due to its filler and pozzolanic characteristics, especially in smaller sizes. The findings of this study are expected to promote sustainable and environmentally conscious practices beyond the current scope of research.

Hassani, Mohammad Sheikh↗

DOE OSTI2020

Unveiling 3D Morphology of Multiscale Micro-Nanosilver Sintering for Advanced Electronics Manufacturing by Ptychographic X-ray Nanotomography

The sintering processing–structure–property relationship of a multiscale silver materials is investigated: microparticles with nanofeatures, particularly on their three-dimensional (3D) morphology. The target application is to replace conventional lead-based solders in advanced electronic manufacturing. Unlike lead-based solders, silver powders are suited to satisfy increasingly demanding mechanical, electrical, and thermal requirements, meanwhile being free of health effect. Sintering the material at a low temperature and without applied pressure are desirable conditions, which results in a preferred use of silver nanoparticles, as nanofeatures have higher driving force to sinter with the decrease in particle size. However, nanosized powders present potential health/environmental effects. To address the trade-off between the benefits and shortcomings of nano-versus microparticles, this work studies a novel multiscale silver paste, namely micron-sized powders with nanosized features. To get quantitative 3D visualization of micro- and nanoscale features, ptychographic X-ray computed nanotomography is applied. The correlations between conditions (thermal aging, pressure, and substrate metallization), mechanical properties, and morphological parameters are established. Finally, using novel 3D X-ray nanoimaging technique, it is demonstrated that one can design multiscale materials while balancing complex demands required in advanced electronics manufacturing and research directions in materials design and characterization.

36 MATERIALS SCIENCE↗

NASA NTRS1999

Monte Carlo Simulation of Nanoparticle Encapsulation in Flames

Gas-phase combustion (flame) synthesis has been an essential industrial process for producing large quantities of powder materials such as carbon black, titanium dioxide, and silicon dioxide. Flames typically produce simple oxides, with carbon black being the noted exception because the oxides of carbon are gaseous and are easily separated from the particulate matter that is formed during fuel pyrolysis. Furthermore, the powders produced in flames are usually agglomerated, nanometer-sized particles (nanoparticles). This composition and morphology is acceptable for many applications. However, the present interest in nanoparticles for advanced materials application has led to efforts to employ flames for the synthesis of unagglomerated nanoparticles (2 to 100 nm) of metals and non-oxide ceramics. Sodium-halide chemistry has proven to be viable for producing metals and non-oxide ceramics in flames. Materials that have been produced to date include Si (Calcote and Felder, 1993), TiN, TiB2, TiC, TiSi2, SiC, B4C (Glassman et al, 1993) Al, W, Ti, TiB2, AlN, and W-Ti and Al-AlN composites (DuFaux and Axelbaum, 1995, Axelbaum et al 1996,1997). Many more materials are possible. The main challenge that faces application of flame synthesis for advanced materials is overcoming formation of agglomerates in flames (Brezinsky, 1997). The high temperatures and high number densities in the flame environment favor the formation of agglomerates. Agglomerates must be avoided for many reasons. For example, when nanopowders are consolidated, agglomerates have a deleterious effect on compaction density, leading to voids in the final part. Efforts to avoid agglomeration in flames without substantially reducing particle number density and, consequently, production rate, have had limited success. Another critical challenge that faces all synthesis routes for nanopowders is ensuring that the powders are high purity and that the process is scaleable. Though the containerless, high temperature environment of a flame is excellent for producing high-purity simple compounds, ultrafine metals and non-oxide ceramic powders are inherently reactive in the presence of oxygen and/or moisture. Thus, the handling of these powders after synthesis poses a challenging problem. Impurities acquired during handling of nanoparticles have plagued the advancement of nanostructured materials technology.

Sun, Z.↗

DOE OSTI2024

On the measurement of shape: With applications to lunar regolith

With the renewed commitment from NASA and other commercial entities for a presence on the Moon, the importance of understanding the characteristics of lunar regolith and how to utilize it have become the target of increasing scrutiny. Much of what is known about lunar regolith was collected during and immediately after the Apollo program, however, analytical techniques and instrumentation have advanced in leaps and bounds in the subsequent decades. Specifically, dynamic image analysis systems have advanced to the point that millions of particles can have morphological characteristics automatically determined in relatively short time frames. Particle morphological data was collected on several lunar samples and a pair of widely used regolith simulants to ascertain the accuracy of these simulants and to explore statistical analysis methods of these large datasets. It is found that these morphology datasets can vary widely depending on the particle size of the particles, and simple averaging of the data skews the results heavily towards the numerically abundant size ranges, the fines. Different reporting methods are suggested to ameliorate these problems. When applied to the lunar regolith, the particles are noted to be less morphologically complex than initially suspected. Compared to the lunar material, the simulants are found to contain some more morphological variability and angular grains. Such difference is likely due to the wildly different comminution processes that these different powder systems are subjected to.

2D shape↗

DOE OSTI2022

A Flame Spray Process for Cathode Materials Manufacturing for Lithium Ion Batteries

Flame (combustion) processes are the most economic ones to produce fine powders and have been used to produce pigment titanium oxide and fused silica in large volumes. In this work a flame spray pyrolysis (FSP) process has been developed to make metal oxide powders for the positive electrode materials at low cost. In particular, the work was focused on making metal oxides of NMC materials with stoichiometric compositions and desired morphologies. Our FSP is a green chemical process employing low cost biomass precursors for the battery material manufacturing. The detailed results of the synthesis, characterization, and battery testing of the NMC powder materials will be presented.

25 ENERGY STORAGE↗

DOE OSTI2023

Effect of the filler morphology on the crystallization behavior and dielectric properties of the polyvinylidene fluoride‐based composite

Abstract Ceramic/polymer composites can be chemically stable, mechanically strong, and flexible, which make them candidates for electric devices, such as pressure or temperature sensors, energy storage or harvesting devices, actuators, and so forth. Depending on the application, various electrical properties are of importance. Polymers usually have low dielectric permittivity, but increased dielectric permittivity can be achieved by the addition of the ceramic fillers with high dielectric constant. With the aim to enhance dielectric properties of the composite without loss of flexibility, 5 wt% of BaTiO 3 ‐Fe 2 O 3 powder was added into a polyvinylidene fluoride matrix. The powder was prepared by different synthesis conditions to produce core/shell structures. The effect of the phase composition and morphology of the BaTiO 3 ‐Fe 2 O 3 core/shell filler on the structure and lattice dynamics of the polymer composites was investigated. Based on the results of the thermal analysis, various parameters of ceramic/polymer composites were determined. Differences in the phase composition and morphology of the filler have an influence on the formation of various polyvinylidene fluoride allomorphs and the degree of crystallinity. Furthermore, the dielectric performances of pure polyvinylidene fluoride and the polymer/ceramic composites were measured.

Polymer Science↗

DOE OSTI2025

Stirring and peristaltic pumping alter flow electrode particle size and morphology

Flowable carbon-based electrodes are widely studied in electrochemical systems for energy storage and water treatment. Most laboratory- and pilot-scale studies employ active mixing for slurry preparation and handling and use peristaltic pumps for slurry circulation. Magnetic stirring is the most prevalent mixing method at the laboratory scale, and the combination of magnetic mixing and peristaltic pumping is favored for convenience and compatibility with particulate suspensions. However, these methods can strongly affect particle size and morphology (and therefore cell performance). In this study, we evaluate how mixing and pumping influence particle degradation in two commonly used carbon materials: spherical carbon black (CB) beads and powdered activated carbon (AC). We performed 24 h stirring-only experiments using magnetic, orbital, and overhead stirring. Separately, we conducted 32 h circulation experiments using a commercial peristaltic pump. Particle morphology and size were analyzed using optical microscopy and laser diffraction. The initially spherical CB beads (~580 μm, 1.5 wt%) exhibit rapid and extensive breakdown under both peristaltic pumping and magnetic stirring. By comparison, AC particles (initially ~31 μm) tested at 1.5 and 15 wt% showed measurable size reductions of up to ~25 % under either stirring or pumping. In conclusion, these findings highlight the need to account for and quantify morphological changes caused by both stirring and pumping in the design and associated evaluation of flowable electrode systems.

Chemistry↗

DOE OSTI2024

Cellulose Nanofibrils Dewatered with Poly(Lactic Acid) for Improved Bio-Polymer Nanocomposite Processing

Cellulose nanofibrils (CNFs) have theoretically ideal properties for bio-based composite applications; however, the incorporation of these materials into polymers is made challenging by the strong binding of water to CNFs and the irreversible agglomeration of CNFs during drying. Previous methods used “contact dewatering”, wherein the addition of wood flour (WF) to CNFs facilitated the mechanical removal of water from the system via cold pressing, which showed potential in producing dried CNF fibrils attached to wood fibers for biocomposite applications. In this work, the viability of contact dewatering with poly(lactic) acid (PLA) powder for PLA/CNF composites was evaluated. The energy efficiency of dewatering, preservation of nanoscale CNF morphology, and mechanical properties were examined by mixing wet CNFs with pulverized PLA at various loading levels, pressing water out of the system, and compression molding and shear mixing composites for testing. The most impressive results from this dewatering method were the preservation of micron-to-nanoscale fibers with high aspect ratios in PLA-CNF composites; increased strength and modulus of 1.7% and 4.2%, respectively, compared to neat PLA; equivalent or better properties than spray-dried nanocellulose at similar loading levels; and an 11-194x reduction in drying energy compared to spray-drying CNFs.

Chemistry↗

NASA NTRS1987

Comparison of the tribological properties of fluorinated cokes and graphites

The friction, wear, endurance life, and surface morphology of rubbed (burnished) fluorinated graphite and fluorinated coke materials were studied. Two different coke powders, a graphitic carbon powder, and a graphite powder were fluorinated and then tribologically investigated. In addition, one of the coke powders was reduced in size before fluorinating to evaluate the effect of a finer particle size on the tribological properties. For comparison, graphite and coke powders which were not fluorinated were also tribologically evaluated. Elemental analysis by emission spectroscopy was performed on each sample to determine the impurity content and X-ray diffraction analysis was performed to determine the crystallinity. Coke was found to have very little lubricating ability, but fluorinated coke did possess good lubricating properties. However, the fluorinated graphite and fluorinated graphitic carbon (which gave equivalent results) gave superior results to those obtained with the fluorinated cokes. No tribological benefit was found for using small versus a larger particle size of coke, at least when evaluated as a rubbed film.

Fusaro, Robert L.↗

NASA NTRS1988

Comparison of the tribological properties of fluorinated cokes and graphites

Fusaro, Robert L.↗

NASA NTRS2010

Tailoring of Boehmite-Derived Aluminosilicate Aerogel Structure and Properties: Influence of Ti Addition

Aluminosilicate aerogels offer potential for extremely low thermal conductivities at temperatures greater than 900 C, beyond where silica aerogels reach their upper temperature limits. Aerogels have been synthesized at various Al:Si ratios, including mullite compositions, using Boehmite (AlOOH) as the Al source, and tetraethoxy orthosilicate as the Si precursor. The Boehmite-derived aerogels are found to form by a self-assembly process of AlOOH crystallites, with Si-O groups on the surface of an alumina skeleton. Morphology, surface area and pore size varies with the crystallite size of the starting Boehmite powder, as well as with synthesis parameters. Ternary systems, including Al-Si-Ti aerogels incorporating a soluble Ti precursor, are possible with careful control of pH. The addition of Ti influences sol viscosity, gelation time pore structure and pore size distribution, as well as phase formation on heat treatment.

Hurwitz, Frances I.↗

DOE OSTI2024

Deep-Learning-Based Segmentation of Keyhole in In-Situ X-ray Imaging of Laser Powder Bed Fusion

In laser powder bed fusion processes, keyholes are the gaseous cavities formed where laser interacts with metal, and their morphologies play an important role in defect formation and the final product quality. The in-situ X-ray imaging technique can monitor the keyhole dynamics from the side and capture keyhole shapes in the X-ray image stream. Keyhole shapes in X-ray images are then often labeled by humans for analysis, which increasingly involves attempting to correlate keyhole shapes with defects using machine learning. However, such labeling is tedious, time-consuming, error-prone, and cannot be scaled to large data sets. To use keyhole shapes more readily as the input to machine learning methods, an automatic tool to identify keyhole regions is desirable. In this paper, a deep-learning-based computer vision tool that can automatically segment keyhole shapes out of X-ray images is presented. The pipeline contains a filtering method and an implementation of the BASNet deep learning model to semantically segment the keyhole morphologies out of X-ray images. The presented tool shows promising average accuracy of 91.24% for keyhole area, and 92.81% for boundary shape, for a range of test dataset conditions in Al6061 (and one AliSi10Mg) alloys, with 300 training images/labels and 100 testing images for each trial. Prospective users may apply the presently trained tool or a retrained version following the approach used here to automatically label keyhole shapes in large image sets.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

The laser powder bed fusion (LPBF) process utilizing a focused Gaussian-shaped beam faces challenges, including pore formation, melt pool fluctuation and liquid spattering. While beam shaping technology has been explored as a potential approach for defect mitigation, the beam-matter interaction dynamics during melting with shaped beams remain unclear. Here, we report the direct observation of ring-shaped beam-matter interaction dynamics, including pore formation, melt pool fluctuation and liquid spattering, and unveil defect mitigation mechanisms in ring-shaped beam laser powder bed fusion process. Here, we find that, by spatially manipulating incident laser rays, the ring-shaped beam controls keyhole morphology, thereby managing the distribution of the reflected rays. This manipulation can effectively eliminate the formation of an unstable cavity at the keyhole tip, stabilizing the keyhole and mitigating keyhole pores. This enhanced keyhole stability effectively reduces the melt pool fluctuation, the formation of liquid breakup induced spatters and liquid droplet colliding induced large spatters in the laser powder bed fusion process. Additionally, the high-energy forefront of the ring-shaped beam effectively melts the powder bed, reducing agglomeration liquid spatter in the laser powder bed fusion process. The discovered defect mitigation mechanisms may guide the design of beam shaping strategies for simultaneously increasing the quality and productivity of metal additive manufacturing.

Beam shaping↗

DOE OSTI2022

Critical differences between electron beam melted and selective laser melted Ti-6Al-4 V

Effective optimization of the production of Ti-6Al-4 V using AM requires a fundamental understanding of the relative importance of different microstructural features to the deformation and failure mechanisms, particularly features that vary between production methods. In this study, the tensile response and deformation mechanisms of electron beam melted (EBM) AM Ti-6Al-4 V material loaded in different orientations and produced using various powder sizes were compared to those of selective laser melted (SLM) AM Ti-6Al-4 V material. The density and morphology of pores, phase fractions, prior-β grains, and defect microstructures were evaluated using scanning electron microscopy, X-ray computed tomography, electron backscatter diffraction, and transmission electron microscopy before and after deformation. The results were used to evaluate the relative importance of each feature on strengthening, deformation, and failure initiation mechanisms. Results focused primarily on coarse-powder EBM materials indicated that phase distribution and defect density were most influential for determining material yield strength as well as maximum possible strain to failure. Porosity was lower overall in EBM Ti-6Al-4 V than in SLM, allowing for occasional increases in part strain to failure, but remained a limiting factor determining overall part ductility.

36 MATERIALS SCIENCE↗