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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

AMVOS: Additive Manufacturing Video Object Segmentation Dataset

This dataset provides labeled video frames from four additive manufacturing (AM) processes for video object segmentation (VOS) tasks. It contains 90 video segments comprising 900 individually annotated frames across five AM datasets: laser hot-wire directed energy deposition (LHW-DED), tungsten inert gas wire arc additive manufacturing (TIG-WAAM), plasma arc welding (PAW), visible-light polymer extrusion (visPolymer), and near-infrared polymer extrusion (irPolymer). Each video segment consists of 10 contiguous frames with corresponding pixel-level object instance annotations. Depending on the process, two of four object classes are labeled per frame: Melt Pool, Feed Wire, Nozzle, or Material. Raw frames are provided as .jpg files and annotations as palettized .png files. The dataset follows the directory structure of established VOS benchmarks (DAVIS, YouTube-VOS, MOSE), enabling direct integration into VOS model training and evaluation pipelines for foundation model fine-tuning, domain adaptation, or zero-shot performance benchmarking. Data was collected at Oak Ridge National Laboratory's Manufacturing Demonstration Facility.

Wetzel, Jon [ORNL]↗
DOE OSTI2023

Evaluation of Flaw Detection with SLDV Methods Before/After Mechanical Patch

This report provides a summary of the testing and the experiments to evaluate the utility of laser ultrasonic testing (UT) in detecting and characterizing defects on the surface of steel plates before and after the application of an engineered composite patch for crack repair. Included are the detection and characterization of defects from a section of welded plate material taken from the Sandia National Laboratories’ full-size mockup of a spent nuclear fuel (SNF) dry storage canister which had been pre-flawed and exposed to deliquescent sea salt conditions for 2 years. The information includes a review of previously reported metallurgical characterization, and new work on detailed surface characterization of the corrosion attack using laser UT.

36 MATERIALS SCIENCE↗
DOE OSTI2024

CHARACTERIZATION OF FATIGUE BEHAVIORS OF NOTCHED 316L DED AM SPECIMENS

ASME Codification of Additive Manufacturing • Integration of AM into ASME Codes and Standards • The ASME goal is to have AM requirements in ASME Code Cases preceding the 2025 Edition. • The ASME Special Committee on AM has drafted criteria for two Code Cases for Additive Manufacturing. • AM Construction of Pressure Equipment using the Direct Energy Deposition Process with Wire Feedstock. • Includes Gas Metal Arc Welding. • Time-independent material properties. • Status - Criteria endorsed by AM Committee. • AM Construction of Pressure Equipment using the Powder Bed Fusion AM Process. • Includes Laser and Electron Beam Energy Sources. • Austenitic and Nonferrous materials. • Time-independent material properties. • Status – Approval ballot circulating to the AM Committee.

Krentz, Timothy M.↗
DOE OSTI2024

In situ x-ray imaging to understand subsurface behavior during continuous wave laser drilling

A limited understanding regarding the underlying dynamics and mechanisms of material removal during continuous wave laser drilling has presented significant challenges in achieving precision and process control. Here, to address this, we employed high-fidelity, in situ synchrotron x-ray imaging to reveal previously unknown material behaviors during continuous wave laser drilling with power modulation. Our findings highlight that high-aspect ratio drill holes are achieved when the laser modulation frequency falls within the range of 8–12 kHz, provided that the laser average power and modulation amplitude levels meet the specified limits. Under these conditions, we identified a material removal mechanism driven by incremental accumulation of recoil pressure that gradually pushes material upward from deep within the substrate to the surface. This mechanism manifested as a low-frequency fluctuation in the vapor depression depth, resulting in periodic instances of material ejection. Furthermore, our study underscores that rapid expansion of the melt pool and the widening of the drill hole opening can impede effective material removal by redirecting energy from material ejection to increasing the melt pool size. This investigation contributes essential insights into the subsurface dynamics involved in the drilling of high-aspect ratio holes, furthering our fundamental understanding of this intricate process.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

FY23 Progress Report: SRNL Analysis of ICCWR LCM and WAMS data for Corrosion and Cracking

Algorithms for Machine Learning (ML) and data analysis for the 3013 Surveillance Program have been developed in an ongoing collaborative effort by the Savannah River National Laboratory (SRNL) and the University of South Carolina (USC). The objective of the algorithms is to automate the identification of corrosion and crack formation in the Inner Container Closure Weld Region (ICCWR) of the canister system used to store Pu-bearing material. Data for corrosion and cracking is collected from large binary files generated by a Laser Confocal Microscope (LCM), the Wide Area 3D Measurement System (WAMS), and in a recent proposal, by a Scanning Electron Microscope (SEM). The ML software uses the physical attributes in the data files (e.g., one or all of: height, color, and grayscale values as functions of position in a plane projection) to detect the presence of surface corrosion and cracking after being trained on similar data with the features to be detected labeled.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

FY24 Progress Report: SRNL Analysis of ICCWR LCM and WAMS data for Corrosion and Cracking

Algorithms for Machine Learning (ML) and data analysis for the 3013 Surveillance Program have been developed in an ongoing collaborative effort by the Savannah River National Laboratory (SRNL) and the University of South Carolina (USC). The objective of the algorithms is to automate the identification of corrosion and crack formation in the Inner Container Closure Weld Region (ICCWR) of the canister system used to store Pu-bearing material. Data for corrosion and cracking is collected from large binary files generated by a Laser Confocal Microscope (LCM), the Wide Area 3D Measurement System (WAMS), or,in a recent proposal, by a Scanning Electron Microscope (SEM). The ML software uses the physical attributes in the data files (e.g., one or more of: height, color, and 16-bit grayscale values as functions of position in a plane projection) to detect signs of surface corrosion and cracking after being trained on similar data, with the features to be detected. Although the initial scope included screening for broader indicators of corrosion, e.g., pitting, identification of potential cracks was prioritized for the past several years at the request of program leadership. Labeled training data is essential to developing the ML algorithm, and enhancements to data labeling capability have been developed to address this essential precursor to application of ML routines. Efficient labeling is particularly important in view of the large volume of data required to train ML algorithms and the relative rarity of cracks in the ICCWR data set. The updated program will read binary data from either LCM, WAMS or SEM files, interrogate data attributes, facilitate user labeling of data for training ML algorithms, execute ML algorithms, output parameters from trained ML algorithms, report ML model accuracy with respect to labeled data, and generate graphical representations for various analyses. In FY24, hourglass neural networks (HNNs) that were initiated in FY22 were further developed and tested using available LCM data, and their performance was tested against that of the alternative U-Net Neural Network algorithm structure. HNNs along with previously developed Convolutional Neural Networks (CNNs) and Deep Neural Networks (DNNs) comprise a suite of ML tools for identification of cracks in the ICCWR

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

FY25 Progress Report: SRNL Analysis of ICCWR LCM and WAMS data for Corrosion and Cracking

Algorithms for Machine Learning (ML) and image analysis for the 3013 Surveillance Program have been developed in an ongoing collaborative effort by the Savannah River National Laboratory (SRNL) and the University of South Carolina (USC). The objective of the algorithms is to automate the identification of corrosion and cracks in the Inner Container Closure Weld Region (ICCWR) of the canister system used to store Pu-bearing material. Data for corrosion and cracking is collected from large binary files generated by a Laser Confocal Microscope (LCM), the Wide Area 3D Measurement System (WAMS), or, in a recent proposal, by a Scanning Electron Microscope (SEM). The ML software uses the physical attributes in the data files (e.g., one or more of: height, color, and 16-bit grayscale values as functions of position in a plane projection) to detect signs of surface corrosion and cracking after being trained on similar data with the features to be detected. Although the initial scope included screening for broader indicators of corrosion, e.g., pitting, the identification of potential cracks was prioritized for the past several years at the request of program leadership.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Material Characterization of Grade 91 Steel Welds using, Micro-resolution Ultrasonic Imaging System

Grade 91 (9Cr-1Mo-V) steel is a common structural material for fossil-fuel fired and nuclear power plants because of its creep strength and oxidation resistance at high temperatures. In this research, we studied the feasibility of correlating the high-resolution images obtained from the immersion ultrasonic imaging technique to microstructure regions in Grade 91 steel plate weldments. The high-resolution ultrasonic images presented in this paper were generated using a 20-MHz focused transducer as the transmitter, and a laser vibrometer as the receiver in the through transmission configuration to produce longitudinal and shear waves. This nondestructive evaluation (NDE) method was used to identify the Fusion Zone (FZ), Heat-Affected Zone (HAZ), and Base Metal (BM) regions of Grade 91 cold metal transfer (CMT) and flux core arc welds (FCAW). The ultrasonic imaging results were analyzed using beam propagation amplitudes and homogeneity, which in turn were used to relate the different microstructure regions of the FCAW and CMT welded samples. With this study, we were able to identify highly susceptible microstructures in the weld that could potentially promote creep type failures.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Power Density Distributions in Electron Beams

Measuring and controlling the power density distribution of electron beams used for welding is critical for producing repeatable welds and for transferring welding parameters between different machines. On any given machine, the power density distribution is controlled by defocusing the beam relative to its sharpest focused condition. However, measuring the power density distribution can be difficult due to the intense nature of welding beams and is further complicated by imperfect electron optics that can distort the beam, making it difficult to quantify. The enhanced modified Faraday cup (EMFC) diagnostic method was used here for beam analysis that utilizes computed tomography to reconstruct the beam’s power density distribution. These results were compared to the International Standards Organization (ISO) method for characterizing laser beams using a second-moment D4σ calculation. For ideal Gaussian-shaped beams, both methods would give the same result. However, for imperfect beams, the calculated D4σ diameter was shown to be about 25% larger relative to the FWe2 diameter measured by the EMFC due to the heavier weighting of data in the tails of the beam by D4σ. Finally, although both methods produce repeatable welds, it is important to understand the differences in the reported beam diameters, divergence angles, and beam parameter products when transferring parameters between machines.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Irradiation creep measurement and microstructural analysis of chromium nitride–coated zirconium alloy using pressurized tubes

Environmental barrier coatings for Zr-based materials are currently under development to reduce oxidation and embrittlement in light-water reactors. Chromium nitride is one such candidate for this application, particularly as accident-tolerant fuel cladding. However, quantifying the impact of coatings on the irradiation-induced creep of zircaloy (Zry) is critical as this mechanism often exceeds thermal creep rates under light-water reactor operating conditions and can be a limiting design characteristic. Additionally, examining irradiation effects in the microstructure at the coating interface is key to understanding the compatibility of the material system. Here, to accelerate the experimental measurement of irradiation creep and microstructure evolution in CrN-Zry, compact, pressurized creep tubes were fabricated and irradiated in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory. Miniature, thin-walled rodlets fabricated from annealed Zr-Sn barstock were coated with CrN using physical vapor deposition (PVD) to nominal thicknesses of 4 and 8 μm. Coated and uncoated rodlet specimens were internally pressurized and welded, generating nominal circumferential hoop stresses of 0, 90, or 180 MPa under 300°C irradiation conditions. Twelve specimens were measured diametrically prior to irradiation using a low-cost, automated, contactless laser profilometer developed for this work. Specimens were irradiated in sealed capsules for one 25-day HFIR cycle, accumulating approximately 1.8 $\times$ 10 21 n/cm 2 fast fluence (E n > 10 MeV). The irradiated samples were retrieved and remeasured using the same profilometry system in a shielded hot cell facility. Irradiation creep between specimens was compared using standard statistical tests and showed that both thicknesses of CrN coating had a negligible effect on the irradiation creep strain of the Zry material. Microstructure characterization of pre- and post-irradiated CrN-Zry specimens showed minimal changes due to irradiation but did show a substantial O-rich region at the Zry-CrN interface.

36 MATERIALS SCIENCE↗
DOE OSTI2020

ReaxFF Simulations of Laser-Induced Graphene (LIG) Formation for Multifunctional Polymer Nanocomposites

Irradiation of polymer films by a CO 2 infrared laser under ambient conditions converts the polymer into porous graphene or laser-induced graphene (LIG). In this work, we simulate the formation of LIG from five different commercially available polymers using reactive molecular dynamics. We determined that the molecular structure of the parent polymer has a significant effect on the final graphitic structure. CO is liberated during the initial part of the LIG formation process when the polymer is converted into an amorphous structure, while H 2 is evolved steadily as the amorphous structure is converted to an ordered graphitic structure. The LIG structure has out-of-plane undulations and bends due to a significant number of 5- and 7-member carbon rings present throughout the structure. We find that the simulated molecular structure compares well with recent experimental observations from the literature. We also demonstrate that the yield of LIG is higher in inert conditions, compared to environments with oxygen. Polybenzimidazole-derived LIG has the highest surface area and yield among the five polymers examined. These findings provide knowledge of LIG formation mechanisms that can be leveraged for bulk LIG applications such as sensors, electrocatalysts, microfluidics, and targeted heating for welding polymers.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Corrosion Resistance of 309L Stainless Steel Claddings on Carbon Steel Produced with Wire-Fed Directed Energy Deposition

Additive manufacturing (AM) tools are capable of applying overlay austenitic stainless steel (SS) claddings to carbon steel components. The benefits of this approach over arc welding include a smaller heat-affected zone, residual stress reduction, and material savings. In particular, wire-directed energy deposition is a suitable technique because of its low material cost and high rate of production compared to other AM methods. However, metallurgical variations in composition, phase fraction, and microsegregation can potentially influence the corrosion behavior of such claddings. In this work, 309L SS is clad on carbon steel substrates and electrochemical methods are used to measure their general and pitting corrosion resistance in simulated marine environments (3.5 wt% NaCl solutions). Two-layer claddings are fabricated with four laser powers to understand the effects of bulk chemical composition, austenite/δ-ferrite phase fractions, and individual phase compositions on corrosion behavior. The two-layer claddings are compared to a single-layer cladding, wrought 304 SS, and the carbon steel substrate for a comprehensive assessment of corrosion performance. The two-layer claddings are remarkably resistant to general corrosion in the 3.5 wt% NaCl environment because of their high Cr content (21.6 wt% to 23.3 wt% Cr). The single-layer cladding exhibits localized corrosion at unmixed Fe-rich peninsulas that originate at the dissimilar metal boundary and protrude into the first cladding layer. All two-layer claddings possess higher pitting corrosion resistance than wrought 304 SS, demonstrating their effectiveness as a corrosion-resistant barrier. Here, the pitting corrosion resistance is superior for claddings made with lower laser powers, due to low dilution and greater δ-ferrite contents.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Tensile Deformation of DED Graded IN718-René41 Superalloy at 650°C by in-situ Neutron Diffraction and Digital Image Correlation

A compositionally graded material comprised IN718 (718, γ'/γ" strengthened superalloy) and René41 (R41, a medium γ' strengthened superalloy) was fabricated using laser blown-powder directed energy deposition (DED/LB-M). Hot gas path components that require high and low temperature capabilities at different locations may benefit from such graded superalloy, potentially eliminating the use of welded or mechanically joined components and reducing cost. In the present work, microstructure and 650°C tensile behavior of 718-R41 graded superalloy in as-built and heat-treated states are investigated by Digital Image Correlation (DIC), in-situ neutron diffraction, coupled with conventional characterization techniques. The applied heat treatment generates static recrystallization and equiaxed grains in 718 rich compositions, while R41 rich compositions remain partially or un-recrystallized. Yield strengths of 718 and R41 sections in heat-treated state are comparable to wrought forms but the graded compositions show weakness. From neutron experiment, diffraction elastic constants and single crystal elastic constants are calculated, which show small difference between the as-built and heat-treated states and between the γ and γ' phases. Grain-level load transfer from the (220) grains to (200) grains is found to be composition dependent, and qualitatively agrees with DIC measured macroscopic yield strength. Within the (200) grains, the γ/γ' phases deform elastically until the γ phase yields and afterwards the γ' phase takes load from γ phase.

digital image correlation↗
DOE OSTI2022

Nondestructive Evaluation of Stress Corrosion Cracking in a Welded Steel Plate Using Guided Ultrasonic Waves

Stress corrosion cracking (SCC) had occurred in early-generation high-level nuclear waste tanks constructed by welding carbon steel. This paper describes an ultrasonic inspection system and its fundamental ability to detect and quantify the length of SCC on thick welded steel plates. The finite element method (FEM) was applied to simulate the welding process to estimate the welding residual stress field. Growth of stress corrosion cracks is driven by crack stress intensities exceeding the subcritical cracking threshold intensity. The subject plate was experimentally inspected with ultrasonic nondestructive evaluation (NDE) techniques to characterize the extent of SCC. The NDE system uses a piezoelectric transducer to generate guided waves in the thick steel plate, and a scanning laser Doppler vibrometer (SLDV) to measure multidimensional time–space wavefield data over a user-defined scanning area in the plate surface. The measured wavefield data can show wave interactions in a localized area in the plate due to the presence of the discontinuities of the SCC. To generate an inspection image that can precisely show the crack’s location and/or the dimension, the wavefield data are further processed to generate inspection image that maps the entire sample plate so the crack can be clearly identified in the plate while its length can be readily estimated. In conclusion, the ultrasonic test results for crack length agree well with the visually estimated length and are close to that predicted by the FEM for cracks in the weld residual stress field.

36 MATERIALS SCIENCE↗
DOE OSTI2023

In situ synchrotron X-ray diffraction analysis of ultrasonically assisted microstructure refinement during laser melting process

This work investigates the effect of ultrasonic treatment (UST) on the microstructure of AA4043 alloy during laser melting process. Here, the study utilizes in situ synchrotron X-ray diffraction (SXRD) and postmortem electron backscatter diffraction (EBSD) techniques to examine the ultrasonic grain refinement mechanism. The SXRD diffraction patterns exhibit higher continuity of major diffraction rings in the UST-test pattern, indicating a more refined grain structure. The presence of new diffraction spots in the post-test diffraction pattern with UST suggests the breakdown of epitaxial growth of columnar dendrites during solidification. Thermal profiles determined by analyzing the lattice parameter evolution show a faster cooling rate with UST. The inverse pole figures and aspect ratio distribution from EBSD reveal that the UST samples exhibit a refined, more equiaxed grain structure along the weld centerline. UST sample also develops more fine-sized low angle grain boundaries (LAGBs). These features offer better hot-cracking resistance in aluminum alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Energy Efficient Thermoplastic Composite Manufacturing

The objective of the project was to establish an effective and affordable method to lay-up and consolidate/join large thermoplastic composite aerospace structure with cycle times measured in minutes rather than hours. Composite airplane designs have proven efficient and effective however future potential product production rates are challenging what the current systems can efficiently produce due to material lay-down constraints and extended thermal cycle times. The ability to lay-up then rapidly heat, consolidate, and cool large complex composite structures plus very accurately tool them (i.e. matching CTE of composite materials) along with very precise thermal control is a difficult challenge. Current systems such as autoclave processing of thermoset materials require long cycle times due to method of heating and the large associated thermal masses. These extended cycle times inhibit the ability to meet higher rate production scenarios due to the need for multiple sets of equipment and tools. Thermoplastic composite materials were used to facilitate more rapid cycle times via the elimination of a need for a cure dwell at temperature. Also, utilized induction heating along with smart susceptors to enable the quick cycle times needed while providing precise intrinsic thermal control. The intrinsic control of the induction heating process via the smart susceptors along with the use of laser assisted fiber placement were the key innovations areas developed. The ability to rapidly heat and then precisely control the temperature of the consolidation component was paramount to the success of this project. It is this unique processing attribute coupled with the thermoplastic material characteristics along with rapid lay-up methods that are novel and advantageous. While many requirements and influencing factors decide the materials and processes utilized for future airplane construction, the forecast of accelerated production rates and the recent performance successes of composites in airplane construction provide an opportunity for this processing technology to have significant influence. During the course of this project a number of key accomplishments were completed. They are as follows: The needed laser assisted fiber placement capabilities have been developed and validated on a component of meaningful scale and complexity. Subsequently, a thermoplastic preform of the part scale-up part design was laser assisted fiber placed and made availalbe for consolidation. An induction consolidation system was sized, designed, and fabricated resulting in the full capability to consolidate the scale-up component. The tool for induction consolidating of the scale-up component was designed and fabricated. An aluminum pressure bladder was welded and formed for use as the pressurization membrane to perform the needed application of pressure on the part at temperature to achieve consolidation. The induction consolidation system consisting of the restraint, induction power supply, induction tool with integrated induction coils and smart susceptor liners, along with the aluminum bladder were successfully used to consolidate a large thermoplastic skin. The capability of accomplishing rapid heat-up rates and cool down rates for consolidation of large thermoplastic skins with precise thermal control and even pressure application at the consolidation temperature was validated. The general conclusion is that the use of induction consolidation with smart susceptors is an effective method to rapidly and efficiently consolidate large thermoplastic composite components and enable affordable high rate manufacturing of composites. More specific conclusions generated by this project are as follows: A restraint type induction consolidation system provides an affordable option over the standard press when using the induction consolidation processing method. Aluminum bladders can be formed to the complex shapes needed and supply uniform pressure for consolidation and co-consolidation of thermoplastic composite materials. Straightforward modifications can be made to existing fiber placement robotic systems to enable their use for thermoplastic lay-up applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Effect of processing parameters and strut dimensions on the microstructures and hardness of stainless steel 316L lattice-emulating structures made by powder bed fusion

In this study, we present the effects of input processing parameters and strut thickness (in square struts) on microstructure and properties in laser powder bed fusion additively manufactured stainless steel 316L lattice-emulating structures. Lattice-emulating X-structures with square cross-sections of 1.5, 1.0, and 0.5 mm were fabricated using three different parameter sets with varying power, speed, and therefore, linear energy density. Grain size and morphology were shown to be dictated by epitaxial growth, which was dependent on weld pool morphology. Additionally, grain size and morphology were shown to change across the thickness direction of the struts (from the bottom inclined surface to the top inclined surface). The spatial variation in grain size was reflected by changes in hardness through the thickness of each strut. The 0.5 mm struts exhibited more significant grain elongation in the strut direction and larger sub-grain solidification cell diameters than their thicker counterparts. The larger sub-grain solidification cell diameters in the 0.5 mm samples resulted in correspondingly lower hardness values when compared to samples of higher thicknesses.

36 MATERIALS SCIENCE↗