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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Autonomous Satellite Command and Control through the World Wide Web: Phase 3

NASA's New Millenium Program (NMP) has identified a variety of revolutionary technologies that will support orders of magnitude improvements in the capabilities of spacecraft missions. This program's Autonomy team has focused on science and engineering automation technologies. In doing so, it has established a clear development roadmap specifying the experiments and demonstrations required to mature these technologies. The primary developmental thrusts of this roadmap are in the areas of remote agents, PI/operator interface, planning/scheduling fault management, and smart execution architectures. Phases 1 and 2 of the ASSET Project (previously known as the WebSat project) have focused on establishing World Wide Web-based commanding and telemetry services as an advanced means of interfacing a spacecraft system with the PI and operators. Current automated capabilities include Web-based command submission, limited contact scheduling, command list generation and transfer to the ground station, spacecraft support for demonstrations experiments, data transfer from the ground station back to the ASSET system, data archiving, and Web-based telemetry distribution. Phase 2 was finished in December 1996. During January-December 1997 work was commenced on Phase 3 of the ASSET Project. Phase 3 is the subject of this report. This phase permitted SSDL and its project partners to expand the ASSET system in a variety of ways. These added capabilities included the advancement of ground station capabilities, the adaptation of spacecraft on-board software, and the expansion of capabilities of the ASSET management algorithms. Specific goals of Phase 3 were: (1) Extend Web-based goal-level commanding for both the payload PI and the spacecraft engineer; (2) Support prioritized handling of multiple PIs as well as associated payload experimenters; (3) Expand the number and types of experiments supported by the ASSET system and its associated spacecraft; (4) Implement more advanced resource management, modeling and fault management capabilities that integrate the space and ground segments of the space system hardware; (5) Implement a beacon monitoring test; (6) Implement an experimental blackboard controller for space system management; (7) Further define typical ground station developments required for Internet-based remote control and for full system automation of the PI-to-spacecraft link. Each of those goals is examined in the next section. Significant sections of this report were also published as a conference paper.

Cantwell, Brian↗
DOE OSTI2016

On-chip generation and control of the vortex beam

A method to generate and control the amplitude and phase distributions of an optical vortex beam is proposed. By introducing a holographic grating on the top of a dielectric waveguide, the free space vortex beam and the in-plane guiding wave can be converted to each other. This microscale holographic grating is very robust against the variation of geometry parameters. The designed vortex beam generator can produce the target beam with a fidelity up to 0.93, and the working bandwidth is about 175 nm with the fidelity larger than 0.80. In addition, a multiple generator composed of two holographic gratings on two parallel waveguides is studied, which can perform an effective and flexible modulation on the vortex beam by controlling the phase of the input light. Our work opens an available avenue towards the integrated orbital angular momentum devices with multiple degrees of optical freedom, which can be used for optical tweezers, micronano imaging, information processing, and so on.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2016

On the Modeling of Wall Heat Flux Partitioning in Subcooled Flow Boiling

Accurate prediction of void distribution in reactor coolant channels at subcooled boiling conditions is an important factor in the analysis of the operating conditions of both pressurized water reactors (PWRs) and boiling water reactors (BWRs). Its importance arises from purely thermal-hydraulic considerations (thermal limits, CRUD formation, etc.) and the impact of void reactivity feedback on core neutronics. A mechanistic multidimensional model of subcooled boiling was originally developed by Kurul and Podowski. Whereas this model has been implemented in several commercial CFD codes and successfully used in computer simulations of flow and phase distributions in the coolant channels of light water reactor, additional new modeling aspects of forced-convection subcooled boiling heat transfer have been investigated in recent studies. The purpose of this paper is to formulate a modified model of wall heat flux partitioning, which allows for capturing and quantifying the effect of simultaneous evaporation and condensation at the heated wall on the net evaporation rate and wall temperature. The new model has been implemented in the NPHASE-CMFD code, numerically tested and validated against experimental data. A mechanistic wall heat flux partitioning model for subcooled flow boiling has been presented. This model has been combined with extensively tested models of interfacial mass, momentum and energy transfer terms. It turns out that the model predictions of the wall temperature and void fraction are in good agreement with the experimental data of reference. Future work will focus on the continuation of model validation against experimental data, and on extending its scope to include the phenomena governing departure from nucleate boiling. (authors)

42 ENGINEERING↗
DOE OSTI2026

Dynamic Validation of CNN-Based Surrogate Models for Inverter-Based Resources in Open-Source Solvers

Traditionally, distribution system planning has focused on steady-state analyses, with limited consideration of dynamic behavior. However, as large or medium-scale inverter-based resources (IBRs), particularly grid-following (GFL) inverters in commercial or industry buildings, become more prevalent, understanding their dynamic impact is essential for grid planning and operation. This article presents an innovative deep-learning (DL)-approach using convolutional neural networks technique to model the GFL inverters. Developed from real grid-tied commercial IBR transient data, these dynamic DL models overcome proprietary constraints by requiring minimal knowledge of internal converter physics while maintaining high accuracy and flexibility. To demonstrate their applicability, the models were incorporated into GridLAB-D, an open-source, three-phase distribution analysis tool. This integration enables dynamic simulations of large-scale distribution networks with high IBR penetration stability analysis. Rigorous testing and validation, aligned with industry standards, confirmed the reliability and efficiency of this approach, paving the way for enhanced planning and operational assessments of modern power systems.

Deep-learning↗
NASA NTRS1993

Boundary-layer receptivity due to distributed surface imperfections of a deterministic or random nature

Acoustic receptivity of a Blasius boundary layer in the presence of distributed, 2D surface irregularities is investigated analytically. It is shown that, out of the entire spatial spectrum of the surface irregularities, only a narrow band of Fourier components can lead to an efficient conversion of the acoustic input at any given frequency to an unstable eigenmode of the boundary-layer flow. Random irregularities which are spatially homogeneous in nature, and also possess a continuous spectrum in the streamwise direction, lead to instability amplitudes that are intermediate to those caused by the periodic and isolated irregularities, respectively, being, in fact, of the same order as the geometrical mean of the amplitudes in the latter two cases. A physical explanation for these asymptotic scalings is given, in addition to providing an analytical expression for the expected value of the instability amplitude for an ensemble of statistically irregular surfaces with random phase distributions.

Choudhari, Meelan↗
DOE OSTI2018

Switching of Coercivity Process in MnBi Alloys

MnBi-based alloys represent an interesting choice for developing rare earth-free permanent magnets due to the high magnetocrystalline anisotropy of their characteristic low-temperature intermetallic phase (LTIP) with hexagonal structure. In this work, we discuss the switching of coercivity mechanism in MnBi alloys by modulation of their phase distribution and microstructure. As-cast MnBi alloys obtained by suction-casting technique exhibited LTIP interspersed within Bi- and Mn-rich areas. A noticeable coercivity field of 282 kA/m was observed. The coercivity mechanism for this alloy was explained in terms of the nucleation of reverse domains after saturation, by means of the Kronmüller equation, which incorporates the detrimental effect of microstructure defects through fitting parameters associated to reduced intrinsic magnetic properties at grain size boundaries, interfaces, and local demagnetizing fields. Subsequent annealing at 583 K for 24 h produced a marked reduction of coercivity (down to 16 kA/m), reflecting a switching of coercivity process from nucleation to pinning of domain walls. The key microstructural feature determining this variation is the formation/suppression of Bi-rich areas, which promotes the nucleation and growth of the initial MnBi intermetallic phase.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1994

Simulations of the effects of water vapor, cloud liquid water, and ice on AMSU moisture channel brightness temperatures

Radiative transfer simulations are performed to determine how water vapor and nonprecipitating cloud liquid water and ice particles within typical midlatitude atmospheres affect brightness temperatures T(sub B)'s of moisture sounding channels used in the Advanced Microwave Sounding Unit (AMSU) and AMSU-like instruments. The purpose is to promote a general understanding of passive top-of-atmosphere T(sub B)'s for window frequencies at 23.8, 89.0, and 157.0 GHz, and water vapor frequencies at 176.31, 180.31, and 182.31 GHz by documenting specific examples. This is accomplished through detailed analyses of T(sub B)'s for idealized atmospheres, mostly representing temperate conditions over land. Cloud effects are considered in terms of five basic properties: droplet size distribution, phase, liquid or ice water content, altitude, and thickness. Effects on T(sub B) of changing surface emissivity also are addressed. The brightness temperature contribution functions are presented as an aid to physically interpreting AMSU T(sub B)'s. Both liquid and ice clouds impact the T(sub B)'s in a variety of ways. The T(sub B)'s at 23.8 and 89 GHz are more strongly affected by altostratus liquid clouds than by cirrus clouds for equivalent water paths. In contrast, channels near 157 and 183 GHz are more strongly affected by ice clouds. Higher clouds have a greater impact on 157- and 183-GHz T(sub B)'s than do lower clouds. Clouds depress T(sub B)'s of the higher-frequency channels by suppressing, but not necessarily obscuring, radiance contributions from below. Thus, T(sub B)'s are less closely associated with cloud-top temperatures than are IR radiometric temperatures. Water vapor alone accounts for up to 89% of the total attenuation by a midtropospheric liquid cloud for channels near 183 GHz. The Rayleigh approximation is found to be adequate for typical droplet size distributions; however, Mie scattering effects from liquid droplets become important for droplet size distribution functions with modal radii greater than 20 micrometers near 157 and 183 GHz, and greater than 30-40 micrometers at 89 GHz. This is due mainly to the relatively small concentrations of droplets much larger than the mode radius. Orographic clouds and tropical cumuli have been observed to contain droplet size distributions with mode radii in the 30-40 micrometers range. Thus, as new instruments bridge the gap between microwave and infrared to frequencies even higher than 183 GHz, radiative transfer modelers are cautioned to explicitly address scattering characteristics of such clouds.

Muller, Bradley M.↗
DOE OSTI2016

Modeling of Two-Phase Flow around Spacers with Mixing Vanes in Reactor Rod-Bundles

Reactor fuel rod bundles experience complex two-phase flow patterns that are governed by multiple interacting phenomena. Proper understand of the underlying flow hydrodynamics can point to potential hotspots within nuclear reactors. The structural supports, called spacer grids, have mixing vanes fixed to the trailing edges to enhance mixing and swirl within the flow. This is an added phenomenon that makes the flows even more complicated to model. As reactors can experience boiling conditions, it is important to understand how the spacer geometry affects local velocity and phase distributions in these geometries. This work represents a continuation of a study that has been focused on developing, testing, and validation of a consistent multidimensional model of dispersed bubbly flow along PWR coolant channels,. The proposed model has been implemented in the NPHASE-CMFD code the results of computer simulations have been compared to experimental results of Yloenen. One of the objectives of the current study has been to examine the effects of selected recent modeling improvements at RPI in NPHASE-CMFD as a part of the continuing model development and validation efforts. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1992

Boundary-layer receptivity due to distributed surface imperfections of a deterministic or random nature

Acoustic receptivity of a Blasius boundary layer in the presence of distributed surface irregularities is investigated analytically. It is shown that, out of the entire spatial spectrum of the surface irregularities, only a small band of Fourier components can lead to an efficient conversion of the acoustic input at any given frequency to an unstable eigenmode of the boundary layer flow. The location, and width, of this most receptive band of wavenumbers corresponds to a relative detuning of O(R sub l.b.(exp -3/8)) with respect to the lower-neutral instability wavenumber at the frequency under consideration, R sub l.b. being the Reynolds number based on a typical boundary-layer thickness at the lower branch of the neutral stability curve. Surface imperfections in the form of discrete mode waviness in this range of wavenumbers lead to initial instability amplitudes which are O(R sub l.b.(exp 3/8)) larger than those caused by a single, isolated roughness element. In contrast, irregularities with a continuous spatial spectrum produce much smaller instability amplitudes, even compared to the isolated case, since the increase due to the resonant nature of the response is more than that compensated for by the asymptotically small band-width of the receptivity process. Analytical expressions for the maximum possible instability amplitudes, as well as their expectation for an ensemble of statistically irregular surfaces with random phase distributions, are also presented.

Choudhari, Meelan↗
DOE OSTI2018

Micro-structural evolution during diffusion bonding of C-SiC/C-SiC composite using Ti interlayer

Highlights: • Formation of Ti{sub 3}SiC{sub 2} MAX phase in the joint of C-SiC composite • EBSD revealed three zone microstructure of the joint • Formation of a thin continuous layer of TiSi{sub 2} • The apparent shear strength of 19 MPa - Abstract: Diffusion bonding of C-SiC composite was achieved with Ti interlayer at 1500 °C for 3 h with the applied pressure of 20 MPa. The joined C-SiC composite showed the apparent shear strength of 19 MPa and the sample fractured away from the joint. The microstructure of joint consists of Ti{sub 3}SiC{sub 2} MAX phase, TiSi{sub 2} and TiC in which Ti{sub 3}SiC{sub 2} was the major phase. The distribution of phases in the microstructure of joint was categorized into three different zones based on electron backscattered diffraction (EBSD) results. The first zone consists of a thin continuous TiSi{sub 2} phase, which was followed by a thick zone of Ti{sub 3}SiC{sub 2} MAX phase. In the middle of the sample, a mix phase zone was found. The reaction mechanism was established for the evolution above microstructure of joined C-SiC composite.

36 MATERIALS SCIENCE↗
DOE OSTI2014

ARCHER{sub RT} – A GPU-based and photon-electron coupled Monte Carlo dose computing engine for radiation therapy: Software development and application to helical tomotherapy

Purpose: Using the graphical processing units (GPU) hardware technology, an extremely fast Monte Carlo (MC) code ARCHER{sub RT} is developed for radiation dose calculations in radiation therapy. This paper describes the detailed software development and testing for three clinical TomoTherapy® cases: the prostate, lung, and head and neck. Methods: To obtain clinically relevant dose distributions, phase space files (PSFs) created from optimized radiation therapy treatment plan fluence maps were used as the input to ARCHER{sub RT}. Patient-specific phantoms were constructed from patient CT images. Batch simulations were employed to facilitate the time-consuming task of loading large PSFs, and to improve the estimation of statistical uncertainty. Furthermore, two different Woodcock tracking algorithms were implemented and their relative performance was compared. The dose curves of an Elekta accelerator PSF incident on a homogeneous water phantom were benchmarked against DOSXYZnrc. For each of the treatment cases, dose volume histograms and isodose maps were produced from ARCHER{sub RT} and the general-purpose code, GEANT4. The gamma index analysis was performed to evaluate the similarity of voxel doses obtained from these two codes. The hardware accelerators used in this study are one NVIDIA K20 GPU, one NVIDIA K40 GPU, and six NVIDIA M2090 GPUs. In addition, to make a fairer comparison of the CPU and GPU performance, a multithreaded CPU code was developed using OpenMP and tested on an Intel E5-2620 CPU. Results: For the water phantom, the depth dose curve and dose profiles from ARCHER{sub RT} agree well with DOSXYZnrc. For clinical cases, results from ARCHER{sub RT} are compared with those from GEANT4 and good agreement is observed. Gamma index test is performed for voxels whose dose is greater than 10% of maximum dose. For 2%/2mm criteria, the passing rates for the prostate, lung case, and head and neck cases are 99.7%, 98.5%, and 97.2%, respectively. Due to specific architecture of GPU, modified Woodcock tracking algorithm performed inferior to the original one. ARCHER{sub RT} achieves a fast speed for PSF-based dose calculations. With a single M2090 card, the simulations cost about 60, 50, 80 s for three cases, respectively, with the 1% statistical error in the PTV. Using the latest K40 card, the simulations are 1.7–1.8 times faster. More impressively, six M2090 cards could finish the simulations in 8.9–13.4 s. For comparison, the same simulations on Intel E5-2620 (12 hyperthreading) cost about 500–800 s. Conclusions: ARCHER{sub RT} was developed successfully to perform fast and accurate MC dose calculation for radiotherapy using PSFs and patient CT phantoms.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Halogenated Dibenzo[ f , h ]quinoxaline Units Constructed 2D‐Conjugated Guest Acceptors for 19% Efficiency Organic Solar Cells

Abstract Halogenation of Y‐series small‐molecule acceptors (Y‐SMAs) is identified as an effective strategy to optimize photoelectric properties for achieving improved power‐conversion‐efficiencies (PCEs) in binary organic solar cells (OSCs). However, the effect of different halogenation in the 2D‐structured large π‐fused core of guest Y‐SMAs on ternary OSCs has not yet been systematically studied. Herein, four 2D‐conjugated Y‐SMAs (X‐QTP‐4F, including halogen‐free H‐QTP‐4F, chlorinated Cl‐QTP‐4F, brominated Br‐QTP‐4F, and iodinated I‐QTP‐4F) by attaching different halogens into 2D‐conjugation extended dibenzo[ f , h ]quinoxaline core are developed. Among these X‐QTP‐4F, Cl‐QTP‐4F has a higher absorption coefficient, optimized molecular crystallinity and packing, suitable cascade energy levels, and complementary absorption with PM6:L8‐BO host. Moreover, among ternary PM6:L8‐BO:X‐QTP‐4F blends, PM6:L8‐BO:Cl‐QTP‐4F obtains a more uniform and size‐suitable fibrillary network morphology, improved molecular crystallinity and packing, as well as optimized vertical phase distribution, thus boosting charge generation, transport, extraction, and suppressing energy loss of OSCs. Consequently, the PM6:L8‐BO:Cl‐QTP‐4F‐based OSCs achieve a 19.0% efficiency, which is among the state‐of‐the‐art OSCs based on 2D‐conjugated Y‐SMAs and superior to these devices based on PM6:L8‐BO host (17.70%) and with guests of H‐QTP‐4F (18.23%), Br‐QTP‐4F (18.39%), and I‐QTP‐4F (17.62%). The work indicates that halogenation in 2D‐structured dibenzo[ f , h ]quinoxaline core of Y‐SMAs guests is a promising strategy to gain efficient ternary OSCs.

14 SOLAR ENERGY↗
DOE OSTI2023

Manipulation of Scattering Spectra with Topology of Light and Matter

Structured lights, including beams carrying spin and orbital angular momenta, radially and azimuthally polarized vector beams, as well as spatiotemporal optical vortices, have attracted significant interest due to their unique amplitude, phase front, polarization, and temporal structures, enabling a variety of applications in optical and quantum communications, micromanipulation, and super-resolution imaging. In parallel, structured optical materials, metamaterials, and metasurfaces consisting of engineered unit cells—meta-atoms, opened new avenues for manipulating the flow of light and optical sensing. While several studies explored structured light effects on the individual meta-atoms, their shapes are largely limited to simple spherical geometries. However, the synergy of the structured light and complex-shaped meta-atoms has not been fully explored. Here, in this paper, the role of the helical wavefront of Laguerre–Gaussian beams in the excitation and suppression of higher-order resonant modes inside all-dielectric meta-atoms of various shapes, aspect ratios, and orientations, is demonstrated and the excitation of various multipolar moments that are not accessible via unstructured light illumination is predicted. The presented study elucidates the role of the complex phase distribution of the incident light in shape-dependent resonant scattering, which is of utmost importance in a wide spectrum of applications ranging from remote sensing to spectroscopy.

42 ENGINEERING↗
DOE OSTI2024

A Difluoro‐Methoxylated Ending‐Group Asymmetric Small Molecule Acceptor Lead Efficient Binary Organic Photovoltaic Blend

Abstract Developing a new end group for synthesizing asymmetric small molecule acceptors (SMAs) is crucial for achieving high‐performance organic photovoltaics (OPVs). Herein, an asymmetric small molecule acceptor, BTP‐BO‐4FO, featuring a new difluoro‐methoxylated end‐group is reported. Compared to its symmetric counterpart L8‐BO, BTP‐BO‐4FO exhibits an upshifted energy level, larger dipole moment, and more sequential crystallinity. By adopting two representative and widely available solvent additives (1‐chloronaphthalene (CN) and 1,8‐diiodooctane (DIO)), the device based on PM6:BTP‐BO‐4FO (CN) photovoltaic blend demonstrates a power conversion efficiency (PCE) of 18.62% with an excellent open‐circuit voltage (V OC ) of 0.933 V, which surpasses the optimal result of L8‐BO. The PCE of 18.62% realizes the best efficiencies for binary OPVs based on SMAs with asymmetric end groups. A series of investigations reveal that optimized PM6:BTP‐BO‐4FO film demonstrates similar molecular packing motif and fibrillar phase distribution as PM6:L8‐BO (DIO) does, resulting in comparable recombination dynamics, thus, similar fill factor. Besides, it is found PM6:BTP‐BO‐4FO possesses more efficient charge generation, which yields betterV OC –J SC balance. This study provides a new ending group that enables a cutting‐edge efficiency in asymmetric SMA‐based OPVs, enriching the material library and shed light on further design ideas.

Chemistry↗
DOE OSTI2025

Correlated X‐Ray and Electron Microscopies of a Single Biphasic GaAs Nanowire

Engineering the properties of semiconductors by changing their crystalline phase is a technologically and economically relevant alternative to doping using foreign elements, with strong potential for photonic and electronic applications. Although major advances have been reported recently for crystal‐phase engineering of III‐V and group IV semiconductor nanowires, interfacing two mismatched crystalline phases in a nanostructure induces several deformation mechanisms, which remain largely unexplored. Here, using state‐of‐the‐art synchrotron X‐ray nanobeam diffraction and transmission electron microscopy, subtle twisting and bending is unveiled within an individual GaAs nanowire containing cubic and hexagonal segments. Their role is discussed in accommodating the inter‐reticular spacing fluctuations, and their variations are correlated to the nanoscale phase distribution and to the effect of the NW support. This study brings direct evidence of a complex combination of deformation mechanisms in biphasic nanowires, which opens a new path to tune the nanowire properties with appealing perspectives for device engineering in nanophotonics and nanomechanics.

III-V semiconductors↗
DOE OSTI2022

Effect of post-extrusion heat treatment on mechanical property of aluminum alloy 2024 tube produced using Shear Assisted Processing and Extrusion (ShAPE)

The present work deals with the Shear Assisted Processing and Extrusion (ShAPE) of aluminum alloy 2024 tubes and mechanical property optimization via post extrusion heat treatments (T3510 and T8510). The ShAPE process enables extruding AA2024 at an extrusion speed of 7.4 m/min and extrusion temperature of 480 °C, which is otherwise beyond the extrudability limit of this alloy using conventional extrusion techniques. The ultimate tensile strength reaches 466 MPa for ShAPE+T3510 condition and 503 MPa for ShAPE+T8510 condition, both of which exceed the corresponding ASTM/ASM (minimum/typical) values for the studied tube geometry. The yield strength reaches 382 MPa for ShAPE+T3510 condition and 481 MPa for ShAPE+T8510 condition, both of which surpass any reported values in the literature or the highest industrial values. In addition, the ductility of AA2024 tube fabricated from ShAPE+T3510 or ShAPE+T8510 are evidently improved by the grain size refinement, second phase refinement, and enhanced uniformity in second phase distribution due to the severe plastic deformation of ShAPE process.

Shear Assisted Processing and Extrusions (ShAPE), ↗
DOE OSTI2018

Wave Diagnostics and Forcing

Physical possibilities of remote diagnostics and manipulation with the state of the propagation medium by the methods of wave tomosynthesis are considered. This refers to the electromagnetic and acoustic waves as well as waves of other nature. Important are multi-position measurements with retention of phase information at each point of the medium that allows the technology of synthesizing a wide aperture with focusing to be implemented. Processing of wave projections of hidden objects makes it possible to restore their three-dimensional images. In this way, the effect of multiple wave re-reflections is reduced. In addition, the tomographic approach allows one to manipulate with the properties of the media being sounded. Thus, an increase in the radiation power at a chosen focusing point causes hyperthermia that can be used, for example, to treat oncological diseases. And creation of a minimum field and a preset phase distribution in certain regions of the medium opens the possibility of control over the motion of microparticles being trapped. The last circumstance is important, for example, for targeted delivery of medical preparations in medicine.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

A High-Throughput Method to Define Additive Manufacturing Process Parameters: Application to Haynes 282

This paper demonstrates how an analytical and experimental method can be used to rapidly define the 45 additive manufacturing settings for a new alloy where the process parameters were previously unknown. A nickel-based superalloy, Haynes 282, was chosen for the analysis. An experimental matrix of focused processing parameters was predicted with a dimensionless number and 100 samples were printed using the Selective Laser Melting technique. High-throughput measurements validated the predicted process conditions needed to achieve desired density and hardness. The whole process was completed in 16 hours. The new technique was confirmed with analytical processing maps adopted by the metal additive manufacturing community. With the predicted set of process parameters, microstructural characterizations and tensile testing were used to confirm the predictions. The resultant as-fabricated microstructures have refined length scales of both microsegregation and secondary phase distributions. As a result, the mechanical properties were comparable within the predicted processing window and exhibited high strength and high ductility.

Laser Material Processing↗