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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Commodity Thermoplastic Elastomer-Enabled Templated Synthesis of Large-Pore Ordered Mesoporous Materials

Fabrication of ordered mesoporous materials (OMMs) has predominantly relied on templating-based methods. However, these methods are constrained by several limitations, especially the limited pore sizes attainable with commercially available surfactants used as structure-directing agents. To unlock the full potential of the OMMs, it is essential to develop synthetic strategies that facilitate the production of large-pore OMMs using scalable processes and cost-effective precursors. This work demonstrates the use of thermoplastic elastomer (TPE)-derived carbon replicas for synthesizing ordered mesoporous silica (OMS) and metal oxides (OMMOs) via precursor infiltration and template removal. The nanostructural evolution of the resulting inorganic materials was systematically investigated. Specifically, using tetraethyl orthosilicate (TEOS) as a silica precursor, this method can produce an OMS with relatively large pores. To establish the generalizability of this process, the fabrication approach was extended to other commercially available TPEs with varied chemical compositions and molecular weights while consistently resulting in ordered structures. Additionally, this synthetic strategy can be successfully applied to the production of OMMOs, including tin and titanium oxide matrix chemistries, yielding pore sizes of 16.0 and 19.2 nm, respectively. By developing a general method and using low-cost precursors, this work presents a scalable approach for fabricating large-pore OMMs with tunable pore textures and matrix chemistries.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Mesoscale simulation of granular materials under weak shock compaction–pore size distribution effects

This research established a systematic method to generate various pore-size distributions (PSDs) and studied the effect of PSDs on the shock compaction response of granular materials using two-dimensional mesoscale simulations under identical porosity. Simulations utilized various PSDs for three particle shapes (circle, ellipse, and square). Contacting particle configurations using three PSDs, characterized by spatially uniform distributed pores to heterogeneous distributed pores, and non-contacting particle configurations under a single case of PSD were tested. The PSD of generated particle sets was characterized using coordination number, mean diameter, and bimodality coefficient as statistical metrics. Mesoscale simulations showed that regardless of the conditions of pore distributions, shock compaction of granular materials consistently demonstrates a precursor, shock compaction front, and end. However, the shock compaction velocity of contacting particles was dependent on the PSDs despite the constant initial porosity. The compaction velocity was faster in particle configurations with relatively uniform pore distributions than in heterogeneous pore distributions, which our study demonstrated can be attributed to particle rearrangement during compaction. Circular-shaped particles had high sensitivity in shock compaction response to the various PSDs. Furthermore, a contacting particle configuration tended to propagate the shock compaction wave relatively faster than particles that were in a non-contact configuration. This study established the relative importance of considering PSD as a metric over the coordination number in studies of the shock compaction response of granular materials. Further, insights are provided on the evolving shock substructure to characterize the shock compaction response of granular materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The soil pore structure encountered by roots affects plant‐derived carbon inputs and fate

Summary Plant roots are the main supplier of carbon (C) to the soil, the largest terrestrial C reservoir. Soil pore structure drives root growth, yet how it affects belowground C inputs remains a critical knowledge gap. By combining X‐ray computed tomography with 14 C plant labelling, we identified root–soil contact as a previously unrecognised influence on belowground plant C allocations and on the fate of plant‐derived C in the soil. Greater contact with the surrounding soil, when the growing root encounters a pore structure dominated by small (< 40 μm Ø) pores, results in strong rhizodeposition but in areas of high microbial activity. The root system of Rudbeckia hirta revealed high plasticity and thus maintained high root–soil contact. This led to greater C inputs across a wide range of soil pore structures. The root–soil contact Panicum virgatum , a promising bioenergy feedstock crop, was sensitive to the encountered structure. Pore structure built by a polyculture, for example, restored prairie, can be particularly effective in promoting lateral root growth and thus root–soil contact and associated C benefits. The findings suggest that the interaction of pore structure with roots is an important, previously unrecognised, stimulus of soil C gains.

Plant Sciences↗
DOE OSTI2024

Fabrication of model ultrafiltration membranes with uniform, high aspect ratio pores

Here, in this manuscript, we report the facile fabrication of large-area model membranes with highly uniform and high aspect ratio pores with diameters <20 nm. These membranes are useful for fundamental investigations of separation by size exclusion in the ultrafiltration regime, where species to be separated from solution have dimensions of 1–100 nm. Such investigations require membranes with narrow pores and high aspect ratios such that the Hagen–Poiseuille equation is followed, enabling well-known models such as the hindered transport model to be evaluated and other affecting factors to be ignored. We demonstrate that the sub-20 nm pores in the membrane are of sufficiently high aspect ratio such that water flux through the membrane is consistent with the Hagen–Poiseuille equation. The fabrication relies on self-assembling block copolymers to form uniform, densely packed patterns with sub-20 nm resolution, sequential infiltration synthesis to convert the block copolymer in situ into a mask with adequate contrast to etch pores with an aspect ratio >5, and low-resolution photolithography to transfer the pattern over a large area into a silicon nitride membrane. Model membranes with narrow pore-size distribution fabricated in this way provide the means to investigate parameters that impact size-selective ultrafiltration separations such as the relationships between solute or particle size and pore size, their distributions, and rejection profiles, and, therefore, test the validity or limits of separation models.

Chen, Wen↗
DOE OSTI2021

Use of Gas Adsorption and Inversion Methods for Shale Pore Structure Characterization

The analysis of porosity and pore structure of shale rocks has received special attention in the last decades as unconventional reservoir hydrocarbons have become a larger parcel of the oil and gas market. A variety of techniques are available to provide a satisfactory description of these porous media. Some techniques are based on saturating the porous rock with a fluid to probe the pore structure. In this sense, gases have played an important role in porosity and pore structure characterization, particularly for the analysis of pore size and shapes and storage or intake capacity. In this review, we discuss the use of various gases, with emphasis on N2 and CO2, for characterization of shale pore architecture. We describe the state of the art on the related inversion methods for processing the corresponding isotherms and the procedure to obtain surface area and pore-size distribution. The state of the art is based on the collation of publications in the last 10 years. Limitations of the gas adsorption technique and the associated inversion methods as well as the most suitable scenario for its application are presented in this review. Finally, we discuss the future of gas adsorption for shale characterization, which we believe will rely on hybridization with other techniques to overcome some of the limitations.

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2024

Effects of Interactions Between Produced Formation Fluid and Rock Matrix on Pore Structure of Caney Shale, Southern Oklahoma

ABSTRACT: Rock-fluid interactions change properties of shales during exploitation. To investigate effects of rock-fluid interactions on pore structure of shales matrix after hydraulic fracturing, powder samples from two late Mississippian Caney Shale cores in the Ardmore Basin, southern Oklahoma, were used to react with formation produced fluid from the field in the batch reactor analysis. X-ray diffraction for mineralogy and Low-pressure nitrogen adsorption isotherms for pore structure were measured for original, after-7days, and after-30days samples. Results show that the samples consist mainly of quartz, followed by clay minerals, carbonates, and feldspar. The pore sizes of micropore (<2 nm) and mesopore (2-50 nm) increase 14%-233% due to dissolution of pyrite, feldspar, and carbonates after 7 days. Due to the transformation from smectite to illite and the increase of pore size, the specific surface area (SSA) decreases after 7-days interactions. After 30-days interactions, the micropore volume slightly increases and the mesopore and macropore volume decreases. Due to the decrease of pore size, the SSA of 30-days reacted samples increases correspondingly and is lower (for the clay-rich sample) or higher (for the calcareous sample) than that of the unreacted samples. Findings improve our understanding of dynamic alteration of shale properties during production. 1. INTRODUCTION Energy demand will continuously grow owing to the increasing global population as well as energy consumption (EIA, 2023). On the other hand, shale gas and oil reshaped the energy market in the United States, enabling the United States to become a net-export of natural gas country in 2017 (EIA, 2023). However, shale reservoirs are challenging tight formations that are still poorly understood in the extraction and production of hydrocarbons (Ross and Bustin, 2009; Curtis et al., 2012; Xiong et al., 2015, 2021a; Li Y. et al., 2016; Gong et al., 2019a; Benge et al., 2021; Awejori et al., 2022; Huang et al., 2022). One of the most challenging topics is the rock-fluid interactions post hydraulic fracturing and its subsequent impacts on the pore structures of fractured formation matrix.

Xiong, Fengyang↗
DOE OSTI2022

Synthesis and Characterization of Polymeric Pore Former Microspheres using Modified Polymer Resin

Porosity in polymer parts is often desired to improve mechanical properties. Individual pores must be small enough that bulk mechanical properties are retained but significant enough to reduce the density of the material. Filler materials can be incorporated into polymer matrices and subsequently removed to create voids. The materials used to create the voids are known as pore-formers. The present research aims to create spherical pores in a silicone matrix by inserting and removing core materials or fillers post-cure. A method was developed to incorporate pore formers into an uncured polymer resin and remove the materials from the matrix. Polyethylene Glycol (PEG) and Polylactic Acid (PLA) microspheres are created and incorporated into silicone matrices as pore formers. Microspheres with controllable size distributions are formed via ultrasonic spray pyrolysis and emulsion formation. Microspheres are removed from the matrix by solvent extraction and calcination. PLA microspheres were modified by hydroxyl addition to the surface to study their solubility in water. PEG-PLA block copolymers are also synthesized and investigated, comparing their physical and chemical properties to the monomers to identify whether the block copolymer microspheres will be more easily removable than their monomeric microspheres. Moreover, other properties including thermal stability, rheology, and mechanical response are studied. The present dissertation provides a comprehensive understanding of the synthesis and characterization of PEG and PLA-based pore formers, toward the future development of feedstock for additive manufacturing porous structures.

Damptey, Ransford↗
DOE OSTI2024

Tailorable Multi–Modular Pore–Space–Partitioned Vanadium Metal–Organic Frameworks for Gas Separation

Currently, few porous vanadium metal-organic frameworks (V-MOFs) are known and even fewer are obtainable as single crystals, resulting in limited information on their structures and properties. Here this work demonstrates remarkable promise of V-MOFs by presenting an extensible family of V-MOFs with tailorable pore geometry and properties. The synthesis leverages inter-modular synergy on a tri-modular pore-partitioned platform. New V-MOFs show a broad range of structural features and sorption properties suitable for gas storage and separation applications for C 2 H 2 /CO 2 , C 2 H 6 /C 2 H 4 , and C 3 H 8 /C 3 H 6 . The c/a ratio of the hexagonal cell, a measure of pore shape, is tunable from 0.612 to 1.258. Other tunable properties include pore size from 5.0 to 10.9 Å and surface area from 820 to 2964 m 2 g –1 . With C 2 H 2 /CO 2 selectivity from 3.3 to 11 and high uptake capacity for C 2 H 2 from 65.2 to 182 cm 3 g –1 (298K, 1 bar), an efficient separation is confirmed by breakthrough experiments. The near-record high uptake for C 2 H 6 (166.8 cm 3 g –1 ) contributes to the promise for C 2 H 6 -selective separation of C 2 H 6 /C 2 H 4 . The multi-module pore expansion enables transition from C 3 H 6 -selective to more desirable C 3 H 8 -selective separation with extraordinarily high C 3 H 8 uptake (254.9 cm 3 g –1 ) and high separation potential (1.25 mmol g –1 ) for C 3 H 8 /C 3 H 6 (50:50 v/v) mixture.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Micro- to nano-scale areal heterogeneity in pore structure and mineral compositions of a sub-decimeter-sized Eagle Ford Shale

Mineral and organic matter compositions & pore structures of fine-grained shale influence reservoir properties. To improve the understanding of spatial heterogeneity in core-sized samples, methods of microscale X-ray fluorescence (μXRF) mapping, (ultra-) small-angle x-ray scattering [(U)SAXS] and wide-angle X-ray scattering (WAXS) have been used to determine elemental, pore-structure variations at scales up to ~10 cm on two samples prepared at circular and rectangular orientations from a piece of Eagle Ford Shale outcrop in South Texas, USA. In addition, thin section petrography and field emission-scanning electron microscopy observations, X-ray diffraction (XRD), total organic carbon, and pyrolysis were utilized to investigate the potential spatial heterogeneity of pore types, mineral and organic matter compositions for cm-sized samples at both orientations. Overall, the siliceous-carbonate mineral contents in these two samples (8 cm×8 cm×0.08 cm and 5 cm × 8 cm × 0.08 cm, in terms of width×length×thickness) of carbonate-rich Eagle Ford Shale vary between laminations at mm scales. For the circular sample, porosity and specific surface area (SSA) variations range from 0.82 to 3.04% and 1.51 to 14.1 m 2 /g, respectively. For the rectangular sample, values for porosity and SSA vary from 0.93 to 2.50% and 3.95 to 10.8 m 2 /g. By analyzing six selected sub-samples on each of two samples with (U)SAXS and XRD techniques, nm-sized pores are mainly interparticle ones in the higher calcite regions, where the porosity is also relatively lower, while the lower calcite regions consist of both interparticle and intraparticle pore types with higher porosity. Lastly, the μXRF and (U)SAXS mappings are combined to generate porosity distribution maps to provide more insights about sample heterogeneity related to the laminations and fractures at our observational scales.

58 GEOSCIENCES↗
DOE OSTI2024

Effect of CO 2 on the water slip flow at silica surfaces for nanometer slit pores of talc

In our previous study, Molecular Dynamics (MD) simulated water flow with no dissolved gas in nanometer slit pores of the hydrophobic talc surfaces revealed a slip length of about 0.5 nm, which is close to the size of “water exclusion zone” but much less than experimental slip length. Atomic Force Microscopy (AFM) imaging confirmed the presence of pancake shape nanobubbles at the hydrophobic talc (001) surface (size from tens to hundreds of nanometers). The effect of CO 2 on water slip flow in talc nanopores is reported to reveal the importance of dissolved gas for confined fluid flow. MD simulated 7 nm CO 2 nanobubbles were found to attach and spread at the talc (001) surface, consistent with the AFM observation. Simulated CO 2 saturated water flow in the slit pores of talc (001) surfaces predicted the generation of CO 2 nanobubbles at the end of the slit pore, due to the stabilization of a CO 2 film at the talc (001) surfaces and a water barrier at the edge surfaces of talc. A “critical thickness” of about 1.5 nm was found for CO 2 nanobubbles to be stabilized at the end of the talc (001) surface. With 1.5 nm CO 2 nanobubbles at the talc (001) surface of a 6 nm slit pore, a water slip length of 1.8 nm was determined. Furthermore, the nanometer slit pore simulations with dissolved CO 2 in water revealed an increased slip length. It is expected that an increased slip length value would be found with an increased CO 2 film thickness.

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

Pore space partition of metal-organic frameworks for gas storage and separation

Pore space partition (PSP) concept is a synthetic design concept and can also serve as a structure analysis method useful for next-step synthetic planning and execution. PSP provides an integrated chemistry-topology-focused tool to design new materials platforms. While PSP is no less effective for making large-pore materials, the growing importance of small-molecule gas storage and separation for green-energy applications provides impetus for developing small-pore materials for which the PSP strategy is uniquely suited. Currently, the best embodiment of the PSP concept is the partitioned-acs (pacs) platform in which both fine or coarse adjustments to the building blocks have sparked a transformation of a prototype framework into a huge and continuously expanding family of chemically robust materials with controllable pore metrics and functionalities suitable for tailored applications. The pacs compositional diversity results from the platform’s intrinsic multi-module nature, geometric flexibility and tolerance towards individual module variations, and mutual structure-directing effects among various modules, all of which combine to enable the molecular-level uniform co-assemblies of chemical components rarely seen together elsewhere. Here, in this contribution, we present an overview of different pore space engineering methods and how different MOF materials have contributed to important advances in chemical stability, industrial gas storage and gas separation. In particular, we will focus on synthetic assembly of the pacs system, highlighting the differences of pacs materials from other MOF platforms and advantages of pacs materials in enhancing various MOF properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Unveiling stimulation fluid-driven alterations in shale pore architecture through combined interpretation of TD-NMR and multi-component gas adsorption

The hydraulic fracturing stimulation process can alter petrophysical and flow properties of the shale matrix in unconventional reservoirs. These alterations can result from interactions with native and exogenous fluids, and can be detrimental to reservoir productivity. Different experimental procedures have been proposed to study reactive processes and thereby understand the aforementioned interactions. Most published works do not consider the rock initial saturation with formation fluid, or the effect of organic matter (OM). To gain insights into these effects, two reactive experimental sets, differing in experimental conditions, were conducted. In the first set, at 125°C and 45 MPa, a stimulation fluid surrogate was put in contact with Baxter Shale samples, previously saturated and equilibrated with synthetic formation fluid. A baseline consisted of exposure to formation fluid exclusively. In the second set, at 0.08 MPa and 25°C, contact with stimulation fluid took place as in the first set. Two additional assays in this second set either skipped the initial formation fluid saturation or removed the OM, respectively. Petrophysical properties analyses, focused on the pore architecture, relied on the combined interpretation of gas adsorption and Time-Domain Nuclear Magnetic Resonance (TD-NMR). Results show that the presence of the formation fluid significantly restricts pore space accessibility to the stimulation fluid and mitigates the pore-architecture alteration to the macro-pore region. Mineral dissolution and precipitation dominate over surface or wettability alteration. Next, results suggest that the OM restricts accessibility to some pores. Ultimately, the equilibration process with synthetic formation fluid drives mainly surface alteration, unhindered by OM.

58 GEOSCIENCES↗
DOE OSTI2022

Bicontinuous substrates with reduced pore restriction for CO 2 -selective composite membranes

A substrate with bicontinuous structure is attractive for thin-film composite (TFC) membrane synthesis due to its high surface porosity and well-interconnected bulk morphology. In this study, the vapor-induced phase separation (VIPS) of the casting solution comprising water, 2-pyrrolidone, and polyethersulfone (PES) was studied. By tuning the water addition in the casting solution and water vapor exposure time, the optimized substrate exhibited a bicontinuous surface with a high porosity of 24.2% (or 216/µm 2 pore density), thereby mitigating pore restriction and showing a high CO 2 permeance of 2.94×10 5 GPU. Compared to the benchmark PES substrate with cellular surface pores and lower gas permeance, the use of the bicontinuous substrate led to a 12% increase in the CO 2 permeance of the TFC membrane. The mitigated pore restriction was further rationalized by a resistance-in-series model. The analysis of the lateral diffusion and substrate resistances indicates that an even higher surface pore density of the substrate is required to fully realize the potential of ultra-permeable, CO 2 -selective polymers in the TFC configuration. As a result, the scalability of the VIPS process was demonstrated by the roll-to-roll fabrication of the optimized bicontinuous substrate with a width of 21" and a length of >100'.

42 ENGINEERING↗
DOE OSTI2025

Belowground plant carbon and nitrogen exchange: plant-derived carbon inputs and pore structure formation

Belowground plant transfer of carbon (C) and nitrogen (N) can benefit soil ecosystems, increasing soil C gains and plant N availability, while improving soil pore structure. We explored such transfers among three plant species of North American prairie, where C and N were transferred from a grass (Panicum virgatum L., switchgrass (Sgrass)) to either a legume (Lespedeza capitata Michx., bush clover (Bclover)), a forb (Rudbeckia hirta L., black-eyed Susan (BSforb)), or a mixture of the two. The plants were grown either with/out direct root contact, thus allowing assessment of the relative contributions of fungal- and root-based transfer pathways. The Sgrass was labeled with 13 C and 15 N, and C and N transfers were assessed by measuring isotope enrichment of roots and aboveground biomass of neighboring plants. Soil inputs of plant-derived C and N were assessed by isotope analyses of the rhizosphere soil. X-ray computed tomography was used for pore structure analyses. Carbon transfer was much higher in the presence of direct/close root contact between source and recipient plants, yet N transfers appeared to be mainly fungal driven. Here, while C and N were readily transferred from Sgrass to other Sgrass and Bclover neighbors, transfers to BSforb were negligible. However, in a three species system, the presence of the legume enhanced C and N transfers to BSforb, suggesting non-additive influences of diverse plant community composition. The more plant-derived C and N was found in the rhizosphere of recipient plants, the greater C and N transfers through roots. Greater C and N transfers were associated with increases in 8–30 μm diameter pores and decreases in >150 μm pores. Summarily, diverse plant communities, especially those with legumes, increase C and N transfers, which then benefit soil C inputs and its protection via changes in pore structure.

13 CO 2 pulse labeling↗
DOE OSTI2021

A Pore‐Scale Investigation of Mineral Precipitation Driven Diffusivity Change at the Column‐Scale

Abstract Mineral precipitation affects the pore structure and thus transport properties of porous media. In this study, we investigated the pore‐scale dynamics of precipitation in diffusion controlled systems and the resulting impacts on the effective diffusivity, using a micro‐continuum reactive transport model. Forty two‐dimensional pore structures representing both idealized and realistic geometries were simulated with consideration of different precipitation scenarios and rates. A homogeneous nucleation scenario reproduced patterns observed in previous experimental study showing mixing‐induced precipitation, and a surface growth scenario captured the pattern for mineral precipitation on a substrate with the same or similar mineral structures. In all cases, local precipitation resulted in the reduction in the average porosity of the domain ( Φ ) until the cessation of diffusive transport and the termination of precipitation. The minimum porosity reached was referred to as the critical porosity ( Φ c ). The effective diffusivity ( D eff ) decreased with Φ and dropped sharply to effectively zero, that is, the critical effective diffusivity ( D eff c ), as Φ c was reached. These pore‐scale dynamics can be captured by a revised relationship that explicitly considers the critical porosity and the corresponding effective diffusivity, and the pre‐exponential coefficient and the exponent of the relationship varied with initial pore structure and the precipitation kinetics. Overall, the homogeneous nucleation scenario results in systematically larger Φ c and coefficients that give rise to a sharper decrease in diffusivity as Φ c is approached, compared to the surface growth scenario. The revised relationship was also implemented at continuum scale and used to examine column scale diffusivity change and reactions.

58 GEOSCIENCES↗
DOE OSTI2023

Precise Pore Engineering of fcu–Type Y–MOFs for One–Step C 2 H 4 Purification from Ternary C 2 H 6 /C 2 H 4 /C 2 H 2 Mixtures

The purification of C 2 H 4 from C 2 H 6 /C 2 H 4 /C 2 H 2 mixtures is of great significance in the chemical industry for C 2 H 4 production but remains a daunting task. Guided by powerful reticular chemistry principles, herein a systematic study is carried out to engineer pore dimensions and pore functionality of fcu-type Y-based metal–organic frameworks (Y-MOFs) through the construction of a series of eight new structures using linear dicarboxylate linkers with different length and functional groups. This study illustrates how delicate changes in pore size and pore surface chemistry can effectively influence the adsorption preference of C 2 H 6 , C 2 H 4 , and C 2 H 2 by the MOFs. Importantly, clear relations between pore size/pore surface polarity and C 2 adsorption selectivities of this series of MOFs are established. In particular, HIAM-326 built on a linker decorated with trifluoromethoxy group shows notably preferential adsorption of C 2 H 6 and C 2 H 2 over C 2 H 4 , with balanced C 2 H 2 /C 2 H 4 and C 2 H 6 /C 2 H 4 selectivities. Furthermore, this endows the compound with the capability of one-step purification of C 2 H 4 from C 2 H 6 /C 2 H 4 /C 2 H 2 ternary mixtures, which is validated by breakthrough measurements where high purity C 2 H 4 (99.9%+) can be obtained directly from the separation column. Its adsorption thermodynamics and underlying selective adsorption mechanisms are further revealed by ab initio calculations.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Uncovering acoustic signatures of pore formation in laser powder bed fusion

Abstract We present a machine learning workflow to discover signatures in acoustic measurements that can be utilized to create a low-dimensional model to accurately predict the location of keyhole pores formed during additive manufacturing processes. Acoustic measurements were sampled at 100 kHz during single-layer laser powder bed fusion (LPBF) experiments, and spatio-temporal registration of pore locations was obtained from post-build radiography. Power spectral density (PSD) estimates of the acoustic data were then decomposed using non-negative matrix factorization with custom $$\varvec{k}$$ k -means clustering (NMF $$\varvec{k}$$ k ) to learn the underlying spectral patterns associated with pore formation. NMF $$\varvec{k}$$ k returned a library of basis signals and matching coefficients to blindly construct a feature space based on the PSD estimates in an optimized fashion. Moreover, the NMF $$\varvec{k}$$ k decomposition led to the development of computationally inexpensive machine learning models which are capable of quickly and accurately identifying pore formation with classification accuracy of supervised and unsupervised label learning greater than 95% and 90%, respectively. The intrinsic data compression of NMF k , the relatively light computational cost of the machine learning workflow, and the high classification accuracy makes the proposed workflow an attractive candidate for edge computing toward in-situ keyhole pore prediction in LPBF.

36 MATERIALS SCIENCE↗
DOE OSTI2026

3D analysis of abnormal grain growth in calcia doped alumina in the presence of large pores

Abnormal grain growth has been previously found to increase with the inclusion of large pores (∼60 µm in diameter) in 80 ppm calcium doped alumina. However, the two-dimensional analysis could not accurately describe the proximity of the abnormal grains and pores to establish a correlation. This study uses laboratory-based diffraction contrast tomography and x-ray computed tomography to spatially map the pores and abnormal grains in 3D. A preference towards the formation of abnormal grains near large pores is found when compared to all potential sites. This finding supports that the pores may be a nucleation site for complexion transitions that promote abnormal grain growth. The growth of the abnormal grains in a subsequent heat treatment at 1600°C for 16 hrs was also studied. The elongation along the principal axes is similar for both small and large grains, again supporting that abnormal grain growth was facilitated by a complexion transition.

Abnormal grain growth↗