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Results for “AM Powder Characterization”

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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Effect of Magnesium Dopant on the Grain Boundary Stability of Nanocrystalline Aluminum Powders during Cryomilling

In this investigation, pure aluminum (Al) powders were cryomilled with and without magnesium dopants to study (a) the effect of cryomilling time on the crystallite size and (b) the effect of magnesium dopant on Al to achieve grain boundary stability. The cryomilling process was carried out using liquid nitrogen for different durations. The characterization of the cryomilled powders was carried out using scanning electron microscopy (SEM), transmission electron microscopy (TEM), and X-ray diffraction (XRD) to understand the particle morphology, crystallite size, and elemental composition. The results demonstrated that the size of the crystallites in both Al and Mg-doped Al powders reduces as the cryomilling duration increases. The results also indicated that the preferential segregation of Mg dopant at the grain boundaries of Al provides stability to the cryomilled powders at elevated temperatures. This article discusses the mechanism for the changes in crystallite size and the effect of the Mg dopant on the grain boundary stability in Al powders.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Synthesis, densification and characterization of ultra-fine W-Al2O3 composite powder

Highlights: • W-Al{sub 2}O{sub 3} ultrafine powder was prepared by hydrothermal synthesis. • Al{sub 2}(WO{sub 4}){sub 3} was a key process for forming nano-Al{sub 2}O{sub 3} coated W structure. • This coated structure inhibited the further growth of W particles. • Dispersed Al{sub 2}O{sub 3} particles improved obviously mechanical properties of W alloy. • Fracture mode changed into intergranular from transcrystalline with Al{sub 2}O{sub 3} addition. - Abstract: W-Al{sub 2}O{sub 3} composite powder was prepared via hydrothermal synthesis containing doping, annealing and reduction. The precursors WO{sub 3} and AlOOH were synthesized by the two sets of the hydrothermal reactions, respectively. The formation of Al{sub 2}(WO{sub 4}){sub 3} from these two precursors in an aqueous solution is a key process, which is beneficial to improve the mixing uniformity of final powder to a molecular level. During subsequent reduction, nano-Al{sub 2}O{sub 3} coated W particles were obtained, and inhibited the further deposition of reduced W atoms on the adjacent W particles, obtaining ultra-fine Al{sub 2}O{sub 3}/W composite powder. After sintering, the dense and fine-grained W-Al{sub 2}O{sub 3} alloy was obtained due to the high sintering activity of ultra-fine powder. Compared with the pure tungsten, the W-Al{sub 2}O{sub 3} alloy displays obvious higher values of both strength and plasticity especially when the Al{sub 2}O{sub 3} content is 2 wt%.

36 MATERIALS SCIENCE↗
DOE OSTI2021

In-Situ Characterization of Pore Formation Dynamics in Pulsed Wave Laser Powder Bed Fusion

Laser powder bed fusion (LPBF) is an additive manufacturing technology with the capability of printing complex metal parts directly from digital models. Between two available emission modes employed in LPBF printing systems, pulsed wave (PW) emission provides more control over the heat input compared to continuous wave (CW) emission, which is highly beneficial for printing parts with intricate features. However, parts printed with pulsed wave LPBF (PW-LPBF) commonly contain pores, which degrade their mechanical properties. In this study, we reveal pore formation mechanisms during PW-LPBF in real time by using an in-situ high-speed synchrotron x-ray imaging technique. We found that vapor depression collapse proceeds when the laser irradiation stops within one pulse, resulting in occasional pore formation during PW-LPBF. We also revealed that the melt ejection and rapid melt pool solidification during pulsed-wave laser melting resulted in cavity formation and subsequent formation of a pore pattern in the melted track. The pore formation dynamics revealed here may provide guidance on developing pore elimination approaches.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Syntheses and Characterization of Intermetallic Nanostructures Based on Mn

The nanocrystalline powders of Mn50Ni41Sn9 were prepared by ball milling using a PM 200-type RETSCH planetary ball mill. The morphological, microstructural, and structural characterizations of the nanostructured powders were carried out by scanning electron microscope, x-ray diffraction, first using the Williamson–Hall relation for the refinement of the diffraction peak profiles. The high-temperature thermal and magnetic properties of nanocrystalline alloy Mn50Ni41Sn9 were characterized at different temperatures using a vibrating sample magnetometer; differential scanning calorimetry was used to determine the transformation temperature and thermodynamic values in the Mn50Ni41Sn9 alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

NH3-SCR on Cu, Fe and Cu+Fe exchanged Beta and SSZ-13 catalysts: hydrothermal aging and propylene poisoning effects

Cu, Fe and Cu+Fe ion exchanged Beta and SSZ-13 catalysts were prepared by solution ion exchange using commercial NH4/Beta, and NH4/SSZ-13 that was prepared in-house. To study hydrothermal aging effects, Beta supported catalysts were aged hydrothermally at 700 C and SSZ-13 supported catalysts were aged at 750 C. In order to reveal the effects of Fe addition in the co-exchanged catalysts, these catalysts were characterized by means of powder X-ray diffraction (XRD), N2 adsorption-desorption, electron paramagnetic resonance (EPR), 27Al-nuclear magnetic resonance (27Al-NMR) and propylene coking followed with temperature programmed reaction (TPR), and further tested with standard NH3-SCR with and without the presence of propylene. Collectively, the catalyst characterizations and reaction testing indicated minor beneficial effects of Fe addition in Cu,Fe/Beta, where NH3-SCR activity, N2 selectivity and hydrothermal stability were all slightly improved. In contrast, Fe addition did not show apparent beneficial effects in low-temperature SCR for the Cu,Fe/SSZ-13 case. At elevated reaction temperatures, however, the presence of Fe indeed considerably improved NO conversion and N2 selectivity for the hydrothermally aged Cu,Fe/SSZ-13 catalyst in the presence of propylene. The authors from Pacific Northwest National Laboratory (PNNL) gratefully acknowledge the US Department of Energy (DOE), Energy Efficiency and Renewable Energy, Vehicle Technologies Office for the support of this work. The research described in this paper was performed in the Environmental Molecular Sciences Laboratory (EMSL), a national scientific user facility sponsored by the DOE’s Office of Biological and Environmental Research and located at PNNL. PNNL is operated for the US DOE by Battelle. The authors from East China University of Science and Technology acknowledge support from National Basic Research Program of China (2013CB933200), National Natural Science Foundation of China (21577035, 21577034), Commission of Science and Technology of Shanghai Municipality (15DZ1205305) and 111 Project (B08021). Aiyong Wang also gratefully acknowledges the China Scholarship Council for a Joint-Training Scholarship Program with PNNL.

Wang, Aiyong↗
DOE OSTI2018

Revealing particle-scale powder spreading dynamics in powder-bed-based additive manufacturing process by high-speed x-ray imaging

Powder spreading is a key step in the powder-bed-based additive manufacturing process, which determines the quality of the powder bed and, consequently, affects the quality of the manufactured part. However, powder spreading behavior under additive manufacturing condition is still not clear, largely because of the lack of particle-scale experimental study. Here, we studied particle-scale powder dynamics during the powder spreading process by using in-situ high-speed high-energy x-ray imaging. Evolution of the repose angle, slope surface speed, slope surface roughness, and the dynamics of powder clusters at the powder front were revealed and quantified. Interactions of the individual metal powders, with boundaries (substrate and container wall), were characterized, and coefficients of friction between the powders and boundaries were calculated. The effects of particle size on powder flow dynamics were revealed. Here, the particle scale powder spreading dynamics, reported here, are important for a thorough understanding of powder spreading behavior in the powder-bed-based additive manufacturing process, and are critical to the development and validation of models that can more accurately predict powder spreading behavior.

42 ENGINEERING↗
DOE OSTI2019

Mössbauer Studies and Magnetic Properties of Cubic CuFe{sub 2}O{sub 4} Nanoparticles

This study reports the preparation and characterization of nanocrystalline spinel powder of cubic copper ferrite nanoparticles (NPs) which have been fabricated via a cost-effective citrate sol–gel approach. The structural and morphological properties of the nanoparticles are analyzed by X-ray diffraction (XRD), Fourier transform spectroscopy (FT-IR), and scanning electron microscopy (SEM) whereas magnetic properties and Mössbauer analysis were performed using vibrating sample magnetometer (VSM) and Mössbauer spectra, respectively, and were characterized in detail. The empirical aim of this study is to perceive the transition phase of CuFe{sub 2}O{sub 4} as cubic symmetry which was confirmed by SEM images, and a couple of studies reported on the cubic structure of copper ferrite and discussed the magnetic properties. However, the present study gives the detailed information of the formation of cubic structure and magnetic behavior of the CuFe{sub 2}O{sub 4} cubic structure. X-ray diffraction measurements of resulting NPs show that the grain size of the particles is about 42.08 nm while SEM analysis showed that the particles have cubic nanostructured shapes with non-homogeneous sizes in around 80–100 nm. From {sup 57}Fe, Mössbauer parameters consist of one superparamagnetic doublet and superposition of four sextets. VSM result shows the enhanced superparamagnetic nature of the CuFe{sub 2}O{sub 4} NPs.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Transformations of Ti-5Al-5V-5Cr-3Mo powder due to reuse in laser powder bed fusion: A surface analytical approach

Reactive Ti-5Al-5 V-5Cr-3Mo (Ti5553) alloy feedstock powder is used in laser powder-bed fusion (LPBF). Due to the large quantity of powder necessary for LPBF, powder is reused numerous times under oxidizing environments. Transformations to the powder’s native surface oxide may impact the LPBF process and lead to deviations from expected behavior of printed parts. In this work, we present a multimodal characterization of new and reused powder by combining X-ray photoelectron spectroscopy (XPS), time-of-flight secondary ion mass spectrometry (ToF-SIMS), and transmission electron microscopy (TEM) of focused ion beam (FIB)-prepared cross sections of individual powder particles to understand how the surface oxide composition changes, grows, and becomes hydroxylated and hydrated due to reuse. We show that the native oxide film of Ti5553 powder is a hydroxylated mixed oxide composed of TiO 2 and Al 2 O 3 that grows from 5.6 +/- 0.7 nm to 8.3 +/- 1.1 nm due to reuse. Al oxide regions of the surface oxide become more hydroxylated during reuse in comparison to Ti oxide regions. This indicates that an outer oxide of pure TiO 2 may enhance recyclability of Ti5553 powder while the presence of Al oxides may decrease recyclability. Further characterization of surface transformations due to recyclability may eliminate unnecessary variation in LPBF.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A reduced-turbulence regime in the Large Helical Device upon injection of low-Z materials powders

Abstract Recently an improved confinement regime, characterized by reduced turbulent fluctuations has been observed in the Large Helical Device upon the injection of boron powder into the plasma (Nespoli et al 2022 Nat. Phys. 18 350–56). In this article, we report in more detail the experimental observations of increased plasma temperature and the decrease of turbulent fluctuations across the plasma cross section, on an extended database. In particular, we compare powders of different materials (B, C, BN), finding similar temperature improvement and turbulence response for the three cases. Modeling of the powder penetration into the plasma and of neoclassical electric field and fluxes support the interpretation of the experimental results. Additionally, we report evidence of the temperature improvement increasing with powder injection rates and decreasing for both increasing density and heating power. Though, plasma turbulence response varies depending on the initial conditions of the plasma, making it difficult to draw an inclusive description of the phenomenon.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

A review on experimentally observed mechanical and microstructural characteristics of interfaces in multi-material laser powder bed fusion

Additive manufacturing (AM) is a revolutionary technology. One of the key AM categories, metal powder-based fusion processes, has many advantages compared to conventional methods for fabricating structural materials, such as permitting increased geometric complexity. While single material metal powder AM has advanced significantly in the past decade, multi-material AM is gradually attracting more attention owing to the recent breakthrough in multi-material feedstock delivery and the growing interest of fabricating functionally graded components. Multi-material AM offers an alternative route for applications that require location dependent material properties and high geometrical complexity. The AM community has invented several ways to achieve compositional gradients and discrete boundaries in two and three dimensions using mechanical spreading, nozzle-based, electrophotographic, and hybrid techniques. This article reviews the current state of laser powder bed fusion based multi-material AM of metals with focuses on the characteristics of the material interface as well as the properties and performance of the AM built functionally graded materials. We show the common challenges and issues related to material transitions, such as defects, segregation, phase separation, and the efficacy of some potential solutions including material and process optimizations. Additionally, this study evaluates the applicability and limitations of the existing testing standards and methods for measuring mechanical performance of functionally graded materials. Finally, we discuss mechanical testing development opportunities, which can help multi-material AM move towards higher technological maturity. In general, we find that the link between gradient microstructure and mechanical properties is not well understood or studied and suggest several mechanical tests that may better inform this knowledge gap.

42 ENGINEERING↗
DOE OSTI2021

A series of Rb 4 Ln 2 (P 2 S 6 )(PS 4 ) 2 (Ln = La, Ce, Pr, Nd, Sm, Gd) rare earth thiophosphates with two distinct thiophosphate units [P V S 4 ] 3- and [P IV 2 S 6 ] 4-

A series of rubidium rare earth thiophosphates with the formula Rb 4 Ln 2 (P 2 S 6 )(PS 4 ) 2 (Ln = La, Ce, Pr, Nd, Sm, and Gd) were synthesized using the high temperature molten flux crystal growth method utilizing a RbBr flux. Single crystals of all title compounds, as well as phase pure powders of the La-, Ce-, and Sm-containing compositions, were obtained. Single crystals of the title compounds were characterized by single crystal and powder X-ray diffraction for structure and phase identification. Rb 4 Ln 2 (P 2 S 6 )(PS 4 ) 2 crystallizes in the monoclinic crystal system adopting the P2 1 /n space group for the large rare earths (Ln = La, Ce, Pr) and the C2/c space group for the smaller rare earths (Ln = Nd, Sm, Gd). This Rb 4 Ln 2 (P 2 S 6 )(PS 4 ) 2 series is a rare example of thiophosphates containing both tetrahedral [P V S 4 ] 3– and dimeric [P IV 2 S 6 ] 4– thiophosphate units that, in this structural family, link corrugated rare earth sulfide chains into sheets. Here, the band gaps of the materials were determined from UV–Vis data and the fluorescence spectrum of Rb 4 Ce 2 (P 2 S 6 )(PS 4 ) 2 was collected. Optical band gaps were estimated to be 2.9 and 2.4 for the Nd and Sm analogues, respectively.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Enhancing Activity and Reducing Cost for Electrochemical Reduction of CO 2 by Supporting Palladium on Metal Carbides

Electrochemical CO 2 reduction reaction (CO 2 RR) with renewable electricity is a potentially sustainable method to reduce CO 2 emissions. Palladium supported on cost-effective transition-metal carbides (TMCs) are studied to reduce the Pd usage and tune the activity and selectivity of the CO 2 RR to produce synthesis gas, using a combined approach of studying thin films and practical powder catalysts, in situ characterization, and density functional theory (DFT) calculations. Notably, Pd/TaC exhibits higher CO 2 RR activity, stability and CO Faradaic efficiency than those of commercial Pd/C while significantly reducing the Pd loading. In situ measurements confirm the transformation of Pd into hydride (PdH) under the CO 2 RR environment. DFT calculations reveal that the TMC substrates modify the binding energies of key intermediates on supported PdH. As a result, this work suggests the prospect of using TMCs as low-cost and stable substrates to support and modify Pd for enhanced CO 2 RR activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Enhancing Activity and Reducing Cost for Electrochemical Reduction of CO 2 by Supporting Palladium on Metal Carbides

Abstract Electrochemical CO 2 reduction reaction (CO 2 RR) with renewable electricity is a potentially sustainable method to reduce CO 2 emissions. Palladium supported on cost‐effective transition‐metal carbides (TMCs) are studied to reduce the Pd usage and tune the activity and selectivity of the CO 2 RR to produce synthesis gas, using a combined approach of studying thin films and practical powder catalysts, in situ characterization, and density functional theory (DFT) calculations. Notably, Pd/TaC exhibits higher CO 2 RR activity, stability and CO Faradaic efficiency than those of commercial Pd/C while significantly reducing the Pd loading. In situ measurements confirm the transformation of Pd into hydride (PdH) under the CO 2 RR environment. DFT calculations reveal that the TMC substrates modify the binding energies of key intermediates on supported PdH. This work suggests the prospect of using TMCs as low‐cost and stable substrates to support and modify Pd for enhanced CO 2 RR activity.

Wang, Jiajun↗
DOE OSTI2019

A comprehensive investigation on the properties of nanostructured cerium oxide

The structural, optical, magnetic and electrical properties of cerium oxide (CeO{sub 2}) nanoparticles prepared by hydrothermal route are analyzed by subjecting them to characterization techniques such as Powder X-ray diffraction (PXRD), High resolution scanning electron microscope (HRSEM), High resolution transmission electron microscope (HRTEM), Energy Dispersive X-ray Analysis (EDAX), Fourier transform infra red spectroscopy (FTIR), Raman spectroscopy, Ultraviolet–Visible analysis, Vibrating sample magnetometer (VSM) analysis and Dielectric measurements. The PXRD, FTIR, Raman and EDAX analyses confirm the formation of CeO{sub 2} nanoparticles. The PXRD studies reveal that the cerium oxide nanoparticles have crystalline nature and have Face Centered Cubic structure. The average crystallite size, estimated using Scherrer formula, is 7 nm. The HRSEM and HRTEM images reveal that the CeO{sub 2} nanoparticles have spherical morphology with an average particle size of 23 nm. The optical band gap energy of the cerium oxide nanoparticles, calculated from UV–Vis studies, is 3.4 eV which could be due to the substantial concentration of Ce{sup 3+} ions in the ceria nanoparticles. The Ferromagnetic behavior of CeO{sub 2} at room temperature is implied from VSM studies. The Dielectric analysis divulge that the dielectric constant of cerium oxide nanoparticles decreases as the frequency and temperature increases. The electrical behaviour, activation energy and relaxation time of electrons of CeO{sub 2} nanoparticles are studied by plotting Nyquist plot, Arrhenius plot and Bode plot respectively.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2019

Characterizing the Effect of Thermal Processing on Feedstock Al Alloy Powder for Additive Manufacturing Applications

Gas-atomized metallic powders are commonly used in additive manufacturing processes. Research has shown that, for certain AM techniques, the chemistry and microstructural properties of the feedstock powders significantly affect the properties of the consolidated material. Understanding the powder characteristics before use in additive manufacturing can lead to optimizing properties of additively manufactured materials as well as determining the recyclability of feedstock powders. This research studies the effect of various solution treatment processes on the characteristics and microstructural evolution of powder aluminum alloy 6061. Solution treatment times and temperatures were guided by thermodynamic and kinetic modeling. Light microscopy, scanning electron microscopy, and hardness were used to evaluate each condition in both two and three dimensions. Results indicate that the Mg{sub 2}Si present in the untreated condition dissolves after 60 min of solution treatment, while there are competing effects from the dissolution and concurrent growth of various Fe-containing phases. Additionally, it is shown that both granular and sub-granular structures exist in these rapidly solidified powders, and the sub-grains reorient themselves during solution treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Enhancement of oxidative dehydrogenation over cerium-doped nickel niobium catalysts and analysis of batch-to-batch variability

Nickel based catalysts are inexpensive and efficient for use in the oxidative dehydrogenation of ethane. NiO doped with niobium and cerium shows increased ethylene production. Small amounts of Ce doped onto a NiNb catalyst led to increased Ni activity. The catalyst that had the highest ethylene production rate per g of catalyst had 1 atom% Ce, 86 at% Ni, and 13 at% Nb (1CeNiNb) while, if surface area is incorporated into the calculation, the catalyst that had the highest ethylene production rate per m 2 was the 0.5CeNiNb catalyst. The ethylene production rates of these Ce-containing catalysts are 27 %-127 % higher than those with NiNb alone previously reported in the literature. Here, to fully understand how cerium affects the NiNb catalyst, the Ce content and effect on active sites has been fully characterized over multiple batches. In doing this, light has been shed on batch-to-batch variability. Characterization techniques such as powder X-ray diffraction, hydrogen temperature programmed reduction, X-ray photoelectron spectroscopy, synchrotron X-ray absorption spectroscopy, and methanol adsorption were used.

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

Effect of amine type on acidic toxic gas adsorption at ambient conditions on modified CuBTC

We report two amine-modified copper-based Metal Organic Frameworks (MOF (CuBTC)) of different surface chemical and textural features were synthesized and used as adsorbents of acidic toxic gases (NO 2 and H 2 S) in both moist (71% relative humidity (R.H.)) and dry conditions. The initial and exhausted samples were characterized by nitrogen adsorption, powder X-ray diffraction, scanning electron microscopy, thermal gravimetric analysis and Fourier transform infrared spectroscopy. The addition of melamine prevented full growth of CuBTC crystals and resulted in amorphous-like particles with sizes less than 200 nm. The material was non-porous with a small surface area. When urea was used as an amine source, the resulting particles maintained the overall octahedral shape of the parent CuBTC MOF and the material was more porous than the parent MOF. While the urea-modified CuBTC sample performed well as an NO 2 adsorbent in the presence of moisture, the reactivity of the melamine-modified sample and its physical properties provided a favorable environment for the removal of H 2 S. The incorporation of amines into the MOF structure also resulted in surface defects /open copper sites that favored the removal of toxic gases in dry conditions. The reactivity of the adsorbents with toxic gases was demonstrated by the changes in the adsorbent colors, in texture, and in surface chemistry (organic salts, complexes, sulfides and nitrates were formed).

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

Diatom influence on the production characteristics of hydrate-bearing sediments: Examples from Ulleung Basin, offshore South Korea

The Ulleung Basin Gas Hydrate field expeditions in 2007 (UBGH1) and 2010 (UBGH2) sought to assess the Basin's gas hydrate resource potential. Coring operations in both expeditions recovered evidence of gas hydrate, primarily as fracture-filling (or vein type) morphologies in mainly silt-sized, fine-grained sediment, but also as pore-occupying hydrate in the coarser-grained layers of interbedded sand and fine-grained systems. A commonality across many of these occurrences is the presence of diatoms in the fine-grained sediment. Here we tested fine-grained sediment (median grain size <12.5 μm) associated with hydrate occurrences at four UBGH2 sites (UBGH2-2-2, UBGH2-3, UBGH2-6 and UBGH2-11) to investigate potential impacts of diatoms on efforts to extract methane from hydrate, or to tap hydrocarbon reservoirs beneath hydrate-bearing sediment. Two key considerations are: the extent to which diatoms control sediment mechanical properties, and the extent to which pore-water freshening, which occurs as gas hydrate breaks down during resource extraction, alters the diatom control on sediment mechanical properties. We conducted experiments to measure sediment index properties, sedimentation behavior and compressibility to address these considerations. We relied on scanning electron microscope (SEM) imagery and X-ray powder diffraction (XRD) to characterize the sediment mineralogy. Our high-level findings are that at the ~20–45% (by volume) diatom concentrations observed at these UBGH2 sites, sediment compressibility increases with diatom content, but diatoms only appear to increase porosity and permeability at the highest diatom concentration (~45%). Our measurements suggest in situ compression indices of 0.35–0.55 and permeabilities on the order of 0.01milliDarcies (1 × 10 -17 m 2 ) can be anticipated at these sites. Importantly, these properties are not expected to vary significantly upon pore water freshening that accompanies gas hydrate dissociation during production.

58 GEOSCIENCES↗