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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Splat Quenching as a High Throughput Rapid Solidification Testing Method for Developing Additive Manufacturing Alloys

Splat quenching as a high throughput rapid solidification screening tool is evaluated. Samples were made using known alloys (SS316, IN625, Ti-5553) to evaluate and establish the microstructures for a variety of alloy systems as well as the predicted cooling rates. The samples are inductively heated and levitated prior to being struck between two platens that produce a high contact pressure and a thin sample resulting in cooling rates on the order of 10 6 to 10 7 K/s. Process parameters were evaluated with analytical models in addition to numerical simulations to provide an effect of process variables such as substrate material, melt superheat, and platen velocity on the resulting solidification. The splat thickness was found to be controlled by platen velocity, melt superheat, as well as the feedstock volume. The sample thickness is the key controlling factor for varying the average cooling rate experienced by the splat quenched sample. The splat quenching techniques can reach regions of rapid solidification space that meet and exceed laser and electron beam techniques across the sample. In conclusion, the results of the study provide a useful foundation in understanding the splat quenching technique and its potential as a low effort tool to explore rapid solidification effects on alloys.

Alloy Design↗
DOE OSTI2022

HEAT TRANSFER ASPECTS OF TWO PISTON SPLAT QUENCHING

This thesis investigates the heat transfer aspects of the two-piston splat quench system by modifying surface roughness and by using copper and stainless steel platens. In additive manufacturing, specifically selective laser melting (SLM), metal is subjected to a very rapid heating and cooling that produces cooling rates in the range from 105-106 °C/s. This rapid solidification produces microstructures that deviate far from equilibrium. Splat quenching is an experimental method that produces rapidly solidified structures under cooling rates that are comparable to those found in additive manufacturing. The splat quenching approach allows for more efficient testing of the rapid solidification behavior of a wide variety of alloys. In this thesis, two platen characteristics, surface roughness and material thermal conductivity, were examined to determine their role in controlling the heat transfer and the subsequent cooling rate during splat quenching of austenitic stainless steel 316L. To that objective, 5 surface finishes were produced using metallographic techniques, from 7046-203 Å Rms. Copper and 316L stainless steel platen material were used to reach different levels of thermal conductance. The combination of these 2 variables created 10 scenarios, which were examined using, backscatter imaging, secondary imaging, and electron back scatter diffraction. Cooling rates were estimated using cell sizing obtained through electrolytic etching and secondary imaging. This thesis determined that both surface modification and changes in material type had a statistically significant impact on the cell sizes observed. Where material type far outweighed surface roughness in its effect on cell size.

Roze, Jonathan↗
DOE OSTI2020

Microparticle impact-bonding modes for mismatched metals: From co-deformation to splatting and penetration

In this paper we present a comprehensive experimental campaign of high-velocity microparticle impacts with different combinations of particle and substrate materials to identify possible deformation regimes. Based on experimental observations of the impact sites, we identify three typical modes of behavior, namely, splatting, co-deformation, and penetration. We develop a theoretical framework to predict the operative bonding regime for a given particle/substrate combination, ranging from splatting and penetration at two extremes of a spectrum, and co-deformation in the center. We propose an impact ratio based on the materials’ properties, which can successfully quantify the spectrum. Co-deformation is expected when the ratio is around unity, while much larger or smaller ratios give rise to penetration and splatting, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Comparison of Solidification Structures and Submicroscale Cellular Segregation in Rapidly Solidified Stainless Steels Produced via Two-Piston Splat Quenching and Laser Powder Bed Fusion

Fusion-based additive manufacturing techniques leverage rapid solidification (RS) conditions to create parts with complex geometries, unique microscale/nanoscale morphological features, and elemental segregation. Three custom composition stainless steel alloys with varying chromium equivalence to nickel equivalence ratio (Cr eq /Ni eq ) between 1.53 and 1.95 were processed using laser powder bed fusion (LPBF) and/or two-piston splat quenching (SQ) to produce solidification rates estimated between 0.4 and 0.8 m/s. Both scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were utilized to collect high-resolution images, electron backscatter diffraction (EBSD) phase identification, and measure cellular segregation. Similar features were observed in both LPBF and SQ samples including phase and microstructure, nanoscale oxide particles, cell size, and segregation behavior. However, dislocation pileup was observed along the cell boundaries only in the LPBF austenite solidified microstructure. Targeted adjustment of the SQ feedstock Cr and Ni concentrations, within the ASTM A240 specification for 316L resulted in no observable impact on the cell size, oxide particle size, or magnitude of segregation. Also, the amount of Ni segregation in the ferrite solidified microstructures did not significantly differ, regardless of Cr/Ni eq or processing technique. Here, SQ is demonstrated as capable of simulating RS rates and microstructures similar to LPBF for use as an alternative screening tool for new RS alloy compositions.

42 ENGINEERING↗
DOE OSTI2023

Investigation of the Effect of Chrome and Nickel Concentrations During Two-Piston Splat Quenching of Austenitic Stainless Steels

For solidification rates at or near equilibrium solidification conditions the effects of chrome (Cr) and nickel (Ni) on stainless steel solidification modes and microstructures are well detailed. However, fusion-based additive manufacturing (FBAM) processes that rely on faster, more rapid solidification rates call for a more in-depth understanding of the effects of rapid solidification on the solidification behavior and how these change with variations in alloy composition. Eleven custom stainless steel (SS) alloys with unique compositions based on 316L were made using targeted alloying element additions to generate feedstock with Cr/Ni eq ratios ranging from 0.9 to 2.1. Two-piston splat quenching (SQ) was used to produce rapid solidification conditions similar to those achieved in powder bed fusion processes in a fraction of the time and cost of traditional methods. Employing heat transfer simulations, SEM, TEM, and STEM characterization techniques, the SQ process was found to consistently produce solidification rates estimated to be between ~ 0.4 and 1.6 m/s. Five unique solidification microstructures were identified within the rapidly solidified SQ samples (primary austenite, massively transformed ferrite to austenite, primary austenite and massively transformed ferrite to austenite, primary ferrite, and primary ferrite and massively transformed ferrite to austenite). Both the primary ferrite solidification mode and primary ferrite phase were found to form at lower Cr/Ni eq values than previously predicted. SQ samples with compositions that were within the compositional specifications for 316L SS, an alloy which is commonly used in FBAM processes, demonstrated a wider range of potential solidification modes and microstructures that could form at rapid solidification rates than expected. Finally, by using SQ as a means to simulate rapid solidification conditions similar to those observed in FBAM processes, potential new alloy compositions can be screened faster and more cost effectively than purchasing and running test batches of the metallic powder.

36 MATERIALS SCIENCE↗
DOE OSTI2022

USE OF TWO-PISTON SPLAT QUENCHING TO INVESTIGATE & CHARACTERIZE THE IMPACT OF COMPOSITIONAL VARIATIONS ON RAPID SOLIDIFICATION MICROSTRUCTURES & SUB-MICROSCALE FEATURES IN STAINLESS STEEL ALLOY.

The objective of this dissertation was to use two-piston splat quenching (SQ) to investigate the impact of compositional modifications on the solidification and microstructure of rapidly solidified austenitic stainless steels (SS) and to demonstrate the ability of SQ to quickly and effectively simulate rapid solidification conditions similar to those found in powder bed fusion (PBF) additive techniques. PBF techniques like laser powder bed fusion (LPBF) are being implemented across a breadth of research and industrial applications to create parts with complex geometries and performance capabilities while pushing the current limits of processing conditions and understanding of material systems. In this work, SQ was used to experimentally produce rapid solidification in 20+ unique austenitic SS compositions with systematic variations of the chrome and nickel equivalency ratio (Cr/Nieq) through targeted compositional modifications. From the targeted change of Cr, Ni, and Mo concentrations in rapidly solidified SS alloys, the ferrite solidification mode was found to be the primary solidification mode at significantly lower Cr/Nieq than previously predicted for RS. Also, decreasing concentrations of Fe at a constant Cr/Nieq ratio (i.e., different Fe isopleths), or increased Mo concentrations at a constant Cr/Nieq ratio were found to suppress the ferrite to austenite massive transformation when compared to alloys with lower concentrations at the same Cr/Nieq. Using an established empirical relationship between cell size and cooling rate, the SQ technique was estimated to produce cooling rates between 106 and 108 K/s. Thermal gradients were extracted from 2-D heat transfer simulations of the SQ solidification event and used with these cooling rates to produce solidification rate estimates for SQ which were between 0.4-1.6m/s. The primary solidification mode was observed to be the determining factor in which elements segregated to the cell boundaries during RS, for which Cr and Mo were the main elements to segregate during primary austenite solidification and Ni during primary ferrite solidification. Finally, the solidification rates and conditions produced by SQ experiments resulted in similar microstructures, features, and microsegregation to what was found in LPBF samples of the same feedstock.

Hasenbusch, Zachary↗
DOE OSTI2026

3D Gaussian Splatting for Volume Compression

This codebase uses machine learning to train a collection of 3D Gaussian distributions to approximate scientific volume data. Because this collection uses less memory than the original dataset, it can be used as a compressed model of the original data for applications such as visualization.

Dyken, Landon↗
DOE OSTI2024

Characterization of compositional variation and solidification condition on rapid solidification behavior of beta stabilized titanium

Rapid solidification (RS) is a field of study that has increased in importance due to the rise of additive manufacturing (AM) techniques. The breakdown of equilibrium at the solid-liquid interface results in an inability to use traditional solidification models that have been applied to great success in casting. As such, there is a current need for a high-throughput testing method to screen alloys at rapid solidification conditions without the significant cost for powder atomization. In this work, twin hammer splat quenching (SQ) is utilized and theoretically developed as a technique uniquely placed to test alloy systems for AM applications. Using analytical thermal spray models and numerical heat transfer simulations, the cooling rate and solidification conditions of splat quenching are compared across several parameters to evaluate the key parameters for generating cooling rates relevant to AM process. Once a framework for the cooling rates and relevancy of SQ are developed, SQ was used to process alloy compositions in the Ti5553 alloy space (AMS 7026) to study the formation of detrimental secondary phases occurring upon rapid quenching from the melt. A martensitic phase is found to occur at the lower end of the standard, but the composition listed in the standard were found to be safe. Finally, the rapid solidification behavior of Ti-5553 is evaluated by comparing splat quenching, laser welding, and plasma atomization that offer a wide window of solidification conditions. The segregation and solidification structure are analyzed and compared to models to provide a deeper understanding of the solidification behavior of beta stabilized titanium alloys.

Williamson, Christopher J.↗
DOE OSTI2021

Particle emission with identification from an atmospheric pressure plasma liquid interface

A conspicuous emission phenomenon of luminous particles from the liquid anode surface of an atmospheric pressure DC glow discharge is reported. The emission has been shown to occur when the plasma forms a pattern on the surface of the liquid electrolyte. Here, the spatial-temporal evolutions of the trajectories of emitted particles were studied using a high-speed imaging system. Particles were sampled in flight using a witness plate for analysis. Critical particle characteristics were examined using electron microscope technologies. The morphology of the resulting splats and compositions suggest that they are molten droplets with a great deal of structure, including evidence of nanoprecipitation. A theoretical model was employed to estimate the particle size from the measured splats, which provides a radius range within a hundred micrometers. This experiment leads to the postulation of a mechanism in which particle emission at the plasma liquid interface is likely driven by the Taylor cone effect.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Effect of pH on the Activity of Ice-Binding Protein from Marinomonas primoryensis

The ability of an ice-binding protein (IBP) from Marinomonas primoryensis (MpIBP) to influence ice crystal growth and structure in nonphysiological pH environments was investigated in this work. The ability for MpIBP to retain ice interactivity under stressed environmental conditions was determined via (1) a modified splat assay to determine ice recrystallization inhibition (IRI) of polycrystalline ice and (2) nanoliter osmometry to evaluate the ability of MpIBP to dynamically shape the morphology of a single ice crystal. Circular dichroism (CD) was used to relate the IRI and DIS activity of MpIBP to secondary structure. The results illustrate that MpIBP secondary structure was stable between pH 6 and pH 10. It was found that MpIBP did not interact with ice at pH=4 or pH=13. At 6=pH=12 MpIBP exhibited a reduction in grain size of ice crystals as compared to control solutions and demonstrated dynamic ice shaping at 6=pH=10. The results substantiate that MpIBP retains some secondary structure and function in non-neutral pH environments; thereby, enabling its potential utility in nonphysiological materials science and engineering applications.

antifreeze proteins↗
DOE OSTI2023

Quantifying Pore Morphology in Spray-Formed Tantalum Using X-ray Micro-computed Tomography

In order to establish quantitative process–structure–property relationships in thermal spray coatings, a robust framework for defining (micro)structural characteristics is needed. Here, we present a quantitative characterization of the three-dimensional morphology of porosity in spray-formed tantalum samples based on high-resolution X-ray micro-computed tomography. Using synchrotron facilities, we acquired dozens of high-resolution scans, enabling a statistically meaningful comparison across multiple samples, different regions within samples, and spray processes. We quantify the spatial distribution, size, and topology of porous inclusions, with a significant focus on variability across samples and different spray processes (plasma and cold sprayed), as well as sensitivity to image segmentation and resolution. Based on a typical segmentation, we report porosities ranging from 0.9 to 1.7 pct for all samples tested, with significant sensitivity due to image segmentation resulting in estimates as low as 0.6 pct and as high as 4.8 pct. For the complex pore space morphology observed in these materials, we argue that a conventional analysis based on identifying individual pores is not well suited, and propose an alternative approach based on morphological metrics with a rich history in porous media literature, such as spatial correlations, local pore thickness, and scale-dependent sub-sampling. Spatial correlations indicate anisotropic splat structures, but only mildly anisotropic pores. Various measures of pore size show a wide distribution of sizes, ranging from sub-micron to 10-micron length scales. Scale-dependent variations in porosity suggest that representative volumes of several hundred microns are required for convergence of morphological metrics, with larger volumes for cold-spray materials. This work provides a robust quantitative basis for describing three-dimensional pore structure in thermal spray coatings.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Influence of Molybdenum on Rapid Solidification Microstructure and Microsegregation in Primary Ferrite Solidified Stainless Steel

Due to the widespread use and familiarity of austenitic stainless steels in many industries these alloys are often the first materials used when adapting new processing techniques. The rapid cooling and solidification rates that occur during fusion based additive manufacturing processes like powder bed fusion cause a fundamental shift in the solidification behavior of the material. While the effects that Cr and Ni have on the microstructure have been fairly well documented across a range of solidification conditions, the impact of alloying elements like Mo are not as well understood at rapid solidification rates. For this study, four custom stainless steel alloy feedstocks were made with targeted modification of the Cr and Mo concentrations to maintain a constant Cr/Ni eq ratio of ~1.7. Two-piston splat quenching was used to produce rapidly solidified samples and the solidification mode, phase, and cell size were investigated. Solidification rates were estimated to be between 0.4 and 1.5m/s. A comparison of the microsegregation and partitioning behavior of Cr, Ni and Mo in ferrite solidified material was also performed for the different alloy compositions. Variations of the Mo concentration between each feedstock showed no measurable influence on the solidification/cooling rates, solidification morphology, or the partitioning of Mo. Furthermore, higher concentrations of Mo were found to significantly increase the amount of ferrite phase in the microstructure by suppressing the ferrite to austenite massive transformation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

In situ and ex situ studies of anomalous eutectic formation in undercooled Ni–Sn alloys

Anomalous eutectic formation in undercooled Ni-Sn alloys was investigated by in situ X-ray diffraction and ex situ remelting and annealing experiments. Dynamic recrystallization and partial remelting of primary solids followed by repeated nucleation and growth of eutectic grains in the mushy zone were revealed by time-resolved X-ray diffraction. Ex situ experiments demonstrated that partial remelting of near-equilibrium solidified alloys of eutectic or near-eutectic composition can convert regular lamellar eutectic into anomalous eutectic, whereas high-temperature annealing of splat-quenched alloys of similar composition can convert eutectic or two-phase dendrites into anomalous eutectic. It is concluded that compared to ripening in solid-states, partial remelting of eutectic or two-phase dendrites in a mushy zone provides a more realistic mechanism for anomalous eutectic formation in undercooled solidification of Ni-Sn eutectic alloys. (C) 2020 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Crystal growth↗
DOE OSTI2022

Stress corrosion cracking mechanism of cold spray coating on a galvanically similar substrate

Here, the chloride-induced stress corrosion cracking (CISCC) mechanism of cold spray (CS) coating on a galvanically similar substrate is investigated. Arc welded 304L stainless steel (SS) specimens are loaded into four-point bend fixtures, cold sprayed with 304L SS, then immersed in boiling MgCl 2 . Interconnected porosity forms through crevice corrosion along CS splat boundaries, allowing corrosive species to penetrate through the CS layer. Nevertheless, the substrate is resistant to CISCC likely because of compressive stress introduced by peening during CS particle impacts. These findings underscore the importance of residual stress in the environmental degradation of CS coatings or repairs of engineering structures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

3D reconstruction and neural rendering for adversarial machine learning

While evasion attacks on computer vision systems have been widely studied, creating attacks that remain effective under significant changes in viewpoint continues to be challenging. Traditional approaches often rely on affine transformations of images, but these approaches degrade at larger perspective shifts and often produce unrealistic or ineffective perturbations. Recent methods use differentiable renderers to improve viewpoint robustness, but they typically depend on manually constructed 3D models. We introduce a semi-automated pipeline that generates physically printable and perspective-invariant adversarial patches using only a small set of 2D images. Our method integrates 3D reconstruction, neural rendering, adversarial patch optimization, and an object detection victim model into a unified workflow. We use 2D Gaussian Splatting for high fidelity mesh reconstruction and FlexPara for surface parameterization that produces texture maps suitable for patch editing. Together, these components form a fully differentiable pipeline in PyTorch3D that links texture modification to model outputs, enabling efficient optimization of patches that remain effective across many viewpoints. The complete process, from image capture to patch printing and physical evaluation, can be completed within a few hours. We demonstrate the effectiveness of the resulting patches through attacks on the YOLOv8 object detection model and discuss remaining challenges and opportunities for improving robustness and scalability.

Singhvi, Vivaan [ORNL] (ORCID:0009000586288221)↗