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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Evolution of dislocations during the rapid solidification in additive manufacturing

Materials processed by fusion-based additive manufacturing (AM) typically exhibit relatively high dislocation densities, along with cellular structures and elemental segregation. This representative structural feature significantly influences material performance; however, post-mortem microstructure characterizations of AM materials cannot capture the dynamic evolution of dislocations during the manufacturing process, thereby offering limited mechanism-based guidance for further advancing AM techniques and facilitating the qualification and certification of AM products. In this study, we conduct operando high-energy synchrotron X-ray diffraction experiments on wire-laser directed energy deposition of 316 L stainless steel. Through a unique configuration, our operando synchrotron experiments semi-quantitatively probe the dislocation density in solid phases and their dynamic changes during solidification and subsequent cooling. By integrating this advanced synchrotron technique with multi-physics simulation, in-situ neutron diffraction, and multi-scale electron microscopy characterization, our mechanistic study aims to elucidate the effects of rapid cooling and subsequent thermal cycling on the dislocation generation and evolution.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Electromagnetic levitation containerless processing of metallic materials in microgravity: rapid solidification

Space levitation processing allows researchers to conduct benchmark tests in an effort to understand the physical phenomena involved in rapid solidification processing, including alloy thermodynamics, nucleation and growth, heat and mass transfer, solid/liquid interface dynamics, macro- and microstructural evolution, and defect formation. Supported by ground-based investigations, a major thrust is to develop and refine robust computational tools based on theoretical and applied approaches. This work is accomplished in conjunction with experiments designed for precise model validation with application to a broad range of industrial processes.

42 ENGINEERING↗
DOE OSTI2024

Formation, chemical evolution and solidification of the dense liquid phase of calcium (bi)carbonate

Metal carbonates, which are ubiquitous in the near-surface mineral record, are a major product of biomineralizing organisms and serve as important targets for capturing anthropogenic CO 2 emissions. However, pathways of carbonate mineralization typically diverge from classical predictions due to the involvement of disordered precursors, such as the dense liquid phase (DLP), yet little is known about DLP formation or solidification processes. Using in situ methods we report that a highly hydrated bicarbonate DLP forms via liquid–liquid phase separation and transforms into hollow hydrated amorphous CaCO 3 particles. Acidic proteins and polymers extend DLP lifetimes while leaving the pathway and chemistry unchanged. Molecular simulations suggest that the DLP forms via direct condensation of solvated Ca 2+ •(HCO 3 – ) 2 complexes that react due to proximity effects in the confined DLP droplets. Furthermore, our findings provide insight into CaCO 3 nucleation that is mediated by liquid–liquid phase separation, advancing the ability to direct carbonate mineralization and elucidating an often-proposed complex pathway of biomineralization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Solidification cracking of laser melted commercial-purity tungsten

The high melting temperature of tungsten (W) makes it an attractive candidate for energy generation applications; however, its use is limited by its poor ductility at low temperatures. This limitation affects even melt-based additive manufacturing (AM) processes such as laser powder bed fusion (PBF-LB), with as-fabricated pure W exhibiting both longitudinal and transverse cracks. Metallurgical and processing factors that affect these cracks are still being explored. This work utilizes powderless single-tracks on pure W plates made over a range of power and velocity combinations in three unique PBF-LB setups: one with flowing argon, one with continuous vacuum, and an in situ high-speed synchrotron X-ray radiography setup. Each had different oxygen activities in their build environments. Longitudinal cracks with oxides appearing to exude from the crack were found for tracks deposited in a build environment with argon shield gas, while no such cracks were observed for builds conducted in vacuum. A calculation showed that direct oxygen ingress into the melt pool from the build environment is negligible when argon shield gas is present. Thus, incorporation of spatter is a likely mechanism for oxygen ingress into the melt pool. Radiography showed extensive keyholing, spatter generation, and crack formation at keyhole porosity. A heat transfer calculation showed the crack formation time was consistent with cooling below its ductile-to-brittle transition (DBT) temperature. This work identifies solidification cracking as a feasible mechanism in pure W beyond the well-known DBT related cracking.

Materials science↗
DOE OSTI2019

Numerical modeling of solid-cluster evolution applied to the nanosecond solidification of water near the metastable limit

Classical nucleation theory (CNT) is a promising way to predictively model the submicrosecond kinetics of phase transitions that occur under dynamic compression, such as the suite of experiments performed over the past two decades on the solidification of liquid water to the high-pressure ice VII phase. Myint et al. [Phys. Rev. Lett. 121, 155701 (2018)] presented the first CNT-based model for these types of rapid phase transitions, but relied on an empirical scaling parameter in their transient induction model to simulate the lag time that occurs prior to the onset of significant formation of ice VII clusters in the system. To build on that study, we model the liquid water–ice VII phase transformation using a numerical discretization scheme to solve the Zel’dovich–Frenkel partial differential equation, which is a fundamental CNT-based kinetic equation that describes the statistical time-dependent behavior of solid cluster formation. The Zel’dovich–Frenkel equation inherently accounts for transience in the nucleation kinetics and eliminates the need for the empirical scaling factor used by Myint et al. One major result of this research is that transience is found to play a relatively small role in the nucleation process for the dynamic-compression time scales of the liquid water–ice VII experiments being simulated. Instead, we show that it is possible to properly model the lag time using steady-state CNT by making small refinements to the interfacial free energy value. In conclusion, we have also developed a new dimensionless parameter that may be applied a priori to predict whether or not transient nucleation will be important in a given dynamic-compression experiment.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Quantitative probing of the fast particle motion during the solidification of battery electrodes

Synchrotron x-ray tomography represents one of the most powerful imaging techniques that can visualize the three-dimensional microstructural complexity with a high spatial resolution. To date, however, the temporal resolution of this technique has been handicapped by the intrinsic limitations in the data acquisition speed and the lack of a suitable data processing method. The present study aims to fundamentally resolve this challenge by implementing a data analysis method that is based on differentiating discrete tomography reconstruction from a continuous scan reconstruction. With this methodological development, we capture and quantify the particle motion during the solidification of battery electrodes and reveal the statistics of the dynamically evolving motion in the drying process, which has been challenging to resolve. We discover that the particle motion exhibits a strong dependence on its geometric location within a drying electrode. Our results also imply that the final electrode quality can be controlled by balancing the solvent evaporation rate and the particle mobility in the region close to the drying surface.

25 ENERGY STORAGE↗
DOE OSTI2019

Response of solidification cellular structures in additively manufactured 316 stainless steel to heavy ion irradiation: an in situ study

In-core or cladding structural materials exposed to heavy ion irradiation often suffer serious irradiation-induced damages. Introducing defect sinks can effectively mitigate irradiation-induced degradation in materials. Here, we investigated the radiation response of additively manufactured 316 austenitic stainless steel with high-density solidification cellular structures via in situ Kr ++ irradiation at 400°C to 5dpa. The study shows that the trapped dislocations along with the cellular walls can serve as effective defect sinks, thus reduce dislocation loop density compared with the conventional coarse-grained counterparts. This study provides a positive step for the potential applications of radiation-resistant, additively manufactured steels in advanced nuclear reactors.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Phase field model of uranium carbide solidification through a combined KKS and orientation field approach

A Phase Field model is developed combining the Orientation Field approach to modeling solidification with the Kim, Kim, Suzuki (KKS) method of modeling binary alloys. These combined methods produce a model capable of simulating randomly oriented second phase dendrites with discrete control of the solid-liquid interface energy and thickness. The example system of carbon (C) in a liquid uranium (U) melt is used as a test for the model. The formation of uranium carbide (UC) within a liquid U melt is simulated for isothermal conditions and compares well with experiments.

Bair, Jacob L. (ORCID:0000000333273323)↗
DOE OSTI2021

Thermodynamic modeling of the Ti-Nb-Sn system and its preliminary applications in aging precipitation and solidification simulations

Abstract Gasping the thermodynamic and phase diagram of the materials being studied is essential for further guiding the development process, like composition design, heat treatment optimization and so on. Nb and Sn are common alloying elements in Ti-based biomedical alloys. In this work, the Ti-Nb-Sn system has been thermodynamically assessed based on experimental phase equilibria. A self-consistent thermodynamic description for the Ti-Nb-Sn system including two ternary compounds Ti 3 Nb 3 Sn 2 and Ti 3 NbSn has been obtained. Based on the comparison between the calculated and experimental phase equilibria, the reliability of the presently obtained thermodynamic description has been verified. The influence of Nb and Sn contents on the precipitation temperature and amount of hcp α -Ti phase in bcc β -(Ti, Nb) has been investigated based on thermodynamic calculations. Results show that the increase of Nb or Sn content in Ti-based alloys would significantly reduce the precipitation amount and transformation temperature of hcp α -Ti phase in bcc β -(Ti, Nb) and the influence of Nb content is more effective than that of Sn. The solidified phases in several as-cast alloys have been thermodynamically predicted based on Scheil solidification simulations. The presently developed thermodynamic description of the Ti-Nb-Sn system can serve as a sub-ternary one in the thermodynamic database for multicomponent Ti-based biomedical alloys.

Peng, Yingbiao↗
DOE OSTI2016

Solidification and Acceleration of Large Cryogenic Pellets Relevant for Plasma Disruption Mitigation

The technology for producing, accelerating, and shattering large pellets (before injection into plasmas) for disruption mitigation has been under development at the Oak Ridge National Laboratory for several years, including a system on DIII-D that has been used to provide some significant experimental results. The original proof-of-principle testing was carried out using a pipe gun injector cooled by a cryogenic refrig- erator (temperatures ~8-20 K) and equipped with a stainless steel tube to produce 16.5-mm pellets composed of either pure D 2 , pure Ne, or a dual layer with a thin outer shell of D 2 and core of Ne. Recently, significant progress has been made in the laboratory using that same pipe gun and a new injector that is an ITER test apparatus cooled with liquid helium. The new injector operates at ~5-8 K, which is similar to temperatures expected with cooling provided by the flow of supercritical helium on ITER. An alternative technique for producing/solidifying large pellets directly from a premixed gas has now been successfully tested in the laboratory. Also, two additional pellet sizes have been tested recently (nominal 24.4 and 34.0 mm diameters). With larger pellets, the number of injectors required for ITER disruption mitigation can be reduced, resulting in less cost and a smaller footprint for the hardware. An attractive option is longer pellets, and 24.4-mm pellets with a length/diameter ratio of ~3 have been successfully tested. Since pellet speed is the key parameter in determining the response time of a shattered pellet system to a plasma disruption event, recent tests have concentrated on documenting the speeds with different hardware configurations and operating parameters; speeds of ~100-800 m/s have been recorded. The data and results from laboratory testing are presented and discussed, and a simple model for the pellet solidification process is described.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Solidification Technologies for Radioactive and Chemical Liquid Waste Treatment - Final CRADA Report

This project, organized under DOE/NNSA's Global Initiatives for Proliferation Prevention program, joined Russian and DOE scientists in developing more effective solidification and storage technologies for liquid radioactive waste. Several patent applications were filed by the Russian scientists (Russia only) and in 2012, the technology developed was approved by Russia's Federal State Unitary Enterprise RADON for application throughout Russia in cleaning up and disposing of radioactive waste.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

High Temperature, High Pressure Equation of State: Solidification of Hydrocarbons and Measurement of Krytox Oil Using Rolling-Ball Viscometer Validation

The global consumption of oil and gas continues to rise and has led to the search and recovery of petroleum sources from reservoirs exhibiting increasingly high-temperature, high-pressure conditions. For example, ultra-deep petroleum formations found at depths of approximately 5 km or more, can exhibit pressure and temperature values as high as 240 MPa (35,000 psi) and 533 K (260°C). The hydrocarbons produced from these ultra-deep formations experience significant decreases in temperature and pressure from reservoir to platform conditions. Hence, it is highly desirable to develop accurate equation of state models (EOS) and fluid properties databases that covers the entire temperature and pressure ranges associated with this process to promote the efficient, safe, and environmentally responsible production from these reservoirs at extreme conditions. Currently available databases and EOS models are generally limited to approximately 69 MPa and do not correlate accurately when extrapolated to the extreme environments associated with ultra-deep reservoirs where temperatures can reach as high as 533 K and pressures up to 240 MPa. Despite recent exploration and production of petroleum from ultra-deep formations, there are major gaps in the databases for pure and mixture density and viscosity of hydrocarbons. These are the most important fluid properties that enable accurate booking of reserves as well as the design of size and equipment to safely bring these fluids to the platform. The overall objective of this project is to develop methodologies to provide crude oil thermodynamic and transport properties—including density, viscosity, and phase composition— at extreme temperature and pressure conditions. The knowledge of these crude oil properties reduces uncertainties associated with deep drilling and promotes safer and reliable access to domestic energy resources. This report is an extension of work reported in our first Technical Report Series (TRS) released July 31, 2012: High Temperature, High Pressure Equation of State Density Correlations and Viscosity Correlations (Tapriyal et al., 2012). New experimental data were obtained by utilizing density cell and rolling-ball viscometer (both designed by our team) rated up to 533 K and 275 MPa. This report focuses on the solidification of hydrocarbons at elevated temperatures and pressures and

02 PETROLEUM↗
DOE OSTI2018

Homogeneous vs. Heterogeneous Nucleation Modes of Solidification at Strong Driving Force Conditions

We summarize and numerically estimate, in a simple form, the major relationship and parameters of classical nucleation theory (CNT) toward the problem of solidification under extreme conditions of large driving force. The effect of reduced quantities such as the interfacial free energy and chemical potential difference is explored under both heterogeneous and homogeneous modes of nucleation. It is shown when under strong driving force conditions, total homogeneous nuclei production within the bulk may exceed the production by heterogeneous nucleation sources.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Laser Intensity Profile Effects on the Solidification Microstructure of Ti-6Al-4V and Ti-5553

Traditional machining of Ti-6Al-4V and Ti-5Al-5Mo-5V-3Cr (Ti-5553) is challenging due to high chemical reactivity, adiabatic shear band formation, and material cost. Titanium is attractive because of its high tensile strength, low density, corrosion resistance, and ability to withstand extreme temperatures. Selective Laser Melting (SLM) is capable of manufacturing geometrically complicated parts at a lower expense. Exceptional tolerances can be obtained with properly tuned processing parameters. Alterations on scan parameters permit microstructure and melt pool control. Single track laser melting experiments were performed on Ti-6Al-4V and Ti- 5553 using elliptical intensity profiles. Results show that maintaining constant energy density but increasing power results in a melt pool failing to penetrate the substrate for Ti-5553. Increasing laser energy density increases melt pool width and can increase powder bed denudation. Comparing Ti64 and Ti-5553 microstructures contributes to a better understanding of rapid solidification in titanium.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Intensified Flue Gas Desulfurization Water Treatment for Reuse, Solidification, and Discharge

The goal of this final project report is to summarize the work conducted on project DE-FE0031555. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Center for Applied Energy Research (UK CAER) (Recipient) developed a hybrid electrochemical-membrane technology for treating wet flue gas desulfurization (WFGD) blowdown from coal-fired power generation plants that (1) removes government-regulated species and total suspended solids (TSS) via electrocoagulation with solid/liquid separation to avoid further treatments by a biological method specifically for selenium, and (2) reduces total dissolved solids (TDS) in a nanofiltration unit to promote water recycle and reduce freshwater intake. Additional technological configurations were pursued, including (1) nanofiltration combined with zeolite dewatering for a near-zero liquid discharge (ZLD) scenario, and (2) polishing discharge from zeolite dewatering using capacitive deionization (CDI) with 90+% salt rejection to produce water with less than 100ppm TDS for more beneficial use. Project results verified that UK CAER’s hybrid approach addressed the complexities of WFGD blowdown with simplified unit operation at relatively low capital investment by demonstrating: (1) an effective in-situ generated solid sorbent material, green-rust (GR), that specifically removes regulated dissolved species in WFGD blowdown, including selenium, arsenic, and nitrates; (2) a low-cost, high flux nanofiltration treatment that removes both monovalent and divalent species at >80% rejection to adequately provide water recycle and extend the life of FGD equipment by mitigating chloride aided pitting corrosion mechanisms; and (3) a solidification and stabilization process using pozzolanic agents that retain regulated species and satisfy the Resource Conservation and Recovery Act (RCRA) leachate requirements. UK CAER proved electrocoagulation with GR to be an intensified solution for effluent limit guidelines (ELG), and based on preliminary techno-economic analysis (TEA), in comparison to DOE’s Case 1 for Biological Wastewater Treatment that had a purchased equipment cost (PEC) of $\$$5.26 million and a Total plant cost (TPC) of $\$$30.0 million, the EC process had a PEC of $\$$2.67 million and the TPC of $\$$17.0 million. While the electricity consumption for Case 1 was 53 kW, it was 110 kW for the EC process due to dissolving iron for a three-stage reaction design. However, electricity consumption for the EC process could be significantly reduced by adopting a counter-current reactor design for at least a 6-stage chemical reaction operation.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Probing the solidification of quasicrystals via joint experiment and simulation (Final Report)

Quasicrystals (QCs) possess long-range positional order but non-crystallographic orientational order. Their classically ‘forbidden’ symmetry has long attracted the interest of scientists worldwide. Despite their frequent observation in both metal alloys and soft matter structures in the 35 years since their discovery, little is known about how QCs evolve from a liquid, amorphous, or crystalline precursor. In this project, we sought to resolve the enigma of QC self-assembly through a combined experimental and computational program. The Shahani group employed in situ electron and synchrotron X ray imaging to peer into the growth dynamics of QCs in a liquid, covering a broad range of length scales and solidification pathways. Glotzer's team developed new simulation models incorporating phasonic defects — which are unique to quasicrystals — and used this model to investigate two grains growing together, closely mimicking the experimental conditions. While QCs remain exceptional structures, most compounds in the realm of intermetallics adopt non-trivial geometries. In fact, only around 6% of phases are comprised of the simplest sphere packings that researchers so readily associate with metals. State-of-the-art knowledge of phase transformations at the outset of this collaborative project did not encompass the remaining 94% of intermetallic compounds that possess complex and aperiodic structure types. Therefore, we expect that outcomes from this project will have immediate and profound impact on synthesis and processing science: our efforts will be used to not only explain the growth dynamics of QCs but also complex intermetallics more broadly.

36 MATERIALS SCIENCE↗
DOE OSTI2023

An Implicit Approach to Phase Field Modeling of Solidification for Additively Manufactured Alloys [Slides]

We are leveraging modern algorithms and computational science to provide a route to predictive simulation of microstructure evolution on emerging exascale architectures. We are utilizing the fastest supercomputers in the world for modeling and simulation of microstructure evolution for generation of data under AM conditions. Solidification conditions in AM can be tailored for the reliable design of materials to specific performance requirements. Developing computational tools to further characterize alloys and correlate the processing-structure-properties-performance (PSPP) relationship.

36 MATERIALS SCIENCE↗