Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “FEEDSTOCK”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Characterizing the Effect of Thermal Processing on Feedstock Al Alloy Powder for Additive Manufacturing Applications

Gas-atomized metallic powders are commonly used in additive manufacturing processes. Research has shown that, for certain AM techniques, the chemistry and microstructural properties of the feedstock powders significantly affect the properties of the consolidated material. Understanding the powder characteristics before use in additive manufacturing can lead to optimizing properties of additively manufactured materials as well as determining the recyclability of feedstock powders. This research studies the effect of various solution treatment processes on the characteristics and microstructural evolution of powder aluminum alloy 6061. Solution treatment times and temperatures were guided by thermodynamic and kinetic modeling. Light microscopy, scanning electron microscopy, and hardness were used to evaluate each condition in both two and three dimensions. Results indicate that the Mg{sub 2}Si present in the untreated condition dissolves after 60 min of solution treatment, while there are competing effects from the dissolution and concurrent growth of various Fe-containing phases. Additionally, it is shown that both granular and sub-granular structures exist in these rapidly solidified powders, and the sub-grains reorient themselves during solution treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Additive Manufacturing: Assessing Metal Powder Quality Through Characterizing Feedstock and Contaminants

The quality of powder feedstock for additive manufacturing (AM) metal powder bed fusion methods can significantly affect the quality of parts built from it. Particle size distribution (PSD) and shape factors influence flowability as well as the thickness and uniformity of each powder layer in the build box. For high-performance applications such as aerospace, medical, power generation and military, it becomes important to identify critical additional factors: the types, numbers and sizes of particulate contaminants that may be present in the powder. This is true for virgin, used and blended powders. Contaminants may be introduced during powder manufacture (e.g., ceramic insulation fragments from gas atomization equipment), handling (building insulation, talc) or possibly during the build process itself. Contaminants contained within a batch of powder can be physically built into an additive part when they are incorporated into the melt pool, and they can remain as discrete particulates or non-fused interfaces that act as stress concentrators. Their presence may decrease fatigue life by increasing the likelihood of fatigue crack initiation. This article describes three methods to rapidly and quantifiably characterize powder feedstock. (1) Computer-controlled scanning electron microscopy (CCSEM) provides quantitative size and shape parameters, as well as fine surface details from individual images on a particle-by-particle basis in large populations of powder. (2) Energy-dispersive spectroscopy (EDS) can be included, providing insights into variations within a batch of powder, as well as contaminant compositions. (3) For critical applications, the heavy liquid separation (HLS) method physically extracts low-density contaminants from a sample of powder metal down to part-per-billion detection limits to allow direct examination of contaminants and enhance identification and prevention of their sources. Altogether, these methods permit direct comparisons among powder metal samples. Better quantification of powder characteristics aids determination of suitability for end uses.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Correlations Between Powder Feedstock Quality, In Situ Porosity Detection, and Fatigue Behavior of Ti-6Al-4V Fabricated by Powder Bed Electron Beam Melting: A Step Towards Qualification

Ti-6Al-4V is the most studied alloy via electron beam melting (EBM) with regards to microstructure and mechanical behavior, but there have been no attempts to correlate in situ porosity detection and fatigue behavior. This is required for widespread adoption of EBM because conventional evaluation is often time-consuming and expensive. This study presents the use of near-infrared imaging to detect and quantify porosity in Ti-6Al-4V builds fabricated from different powder feedstocks and its correlation to their fatigue response. Finally, we report that, for identical processing parameters, the variability in powder feedstock causes variations in porosity and scatter in the respective fatigue response.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Standardization Gaps in Powder Feedstock Characterization and Establishing Acceptability for Reuse in Additive Manufacturing

Characterization techniques for powder feedstocks used in additive manufacturing (AM) have long been relied upon to describe the inputs to an AM workflow. However, functional gaps remain between tests to measure intrinsic and extrinsic properties with the direct performance within AM equipment. Furthermore, the common practice of reusing powder through multiple build cycles introduces effects and changes to feedstock performance that are otherwise difficult to measure quantitatively. Here, standardization and the development of new test methods have not kept pace with the rapid evolution of the AM industry and its reliance on highly coupled process-structure–property-performance relationships.

Characterization and Analytical Technique↗
DOE OSTI2015

Sweet Sorghum Juice and Bagasse as Feedstocks for the Production of Optically Pure Lactic Acid by Native and Engineered Bacillus coagulans Strains

Sweet sorghum is a bioenergy crop that produces large amounts of soluble sugars in its stems (3–7 Mg ha -1 ) and generates significant amounts of bagasse (15–20 Mg ha -1 ) as a lignocellulosic feedstock. These sugars can be fermented not only to biofuels but also to bio-based chemicals. The market potential of the latter may be higher given the current prices of petroleum and natural gas. The yield and rate of production of optically pure D-(-)- and L-(+)-lactic acid as precursors for the biodegradable plastic polylactide was optimized for two thermotolerant Bacillus coagulans strains. Strain 36D1 fermented the sugars in unsterilized sweet sorghum juice at 50 °C to L-(+)-lactic acid (~150 g L -1 ; productivity, 7.2 g L -1 h -1 ). B. coagulans strain QZ19-2 was used to ferment sorghum juice to d-(-)-lactic acid (~125 g L -1 ; productivity, 5 g L -1 h -1 ). Carbohydrates in the sorghum bagasse were also fermented after pretreatment with 0.5 % phosphoric acid at 190 °C for 5 min. Simultaneous saccharification and co-fermentation of all the sugars (SScF) by B. coagulans resulted in a conversion of 80 % of available carbohydrates to optically pure lactic acid depending on the B. coagulans strain used as the microbial biocatalyst. Liquefaction of pretreated bagasse with cellulases before SScF (L + SScF) increased the productivity of lactic acid. Here, these results show that B. coagulans is an effective biocatalyst for fermentation of all the sugars present in sweet sorghum juice and bagasse to optically pure lactic acid at high titer and productivity as feedstock for bio-based plastics.

09 BIOMASS FUELS↗
DOE OSTI2017

Conversion of a wet waste feedstock to biocrude by hydrothermal processing in a continuous-flow reactor: grape pomace

Wet waste feedstocks present an apt opportunity for biomass conversion to fuels by hydrothermal processing. In this study, grape pomace slurries from two varieties, Montepulciano and cabernet sauvignon, have been converted into a biocrude by hydrothermal liquefaction (HTL) in a bench-scale, continuous-flow reactor system. Carbon conversion to gravity-separable biocrude product up to 56 % was accomplished at relatively low temperature (350 C) in a pressurized (sub-critical liquid water) environment (20 MPa) when using grape pomace feedstock slurry with a 16.8 wt% concentration of dry solids processed at a liquid hourly space velocity of 2.1 h-1. Direct oil recovery was achieved without the use of a solvent and biomass trace mineral components were removed by processing steps so that they did not cause processing difficulties. In addition, catalytic hydrothermal gasification (CHG) was effectively applied for HTL byproduct water cleanup using a Ru on C catalyst in a fixed bed producing a gas composed of methane and carbon dioxide from water soluble organics. Conversion of 99.8% of the chemical oxygen demand (COD) left in the aqueous phase was demonstrated. As a result, high conversion of grape pomace to liquid and gas fuel products was found with residual organic contamination in byproduct water reduced to <150 mg/kg COD.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Replacing liquid fossil fuels and hydrocarbon chemical feedstocks with liquid biofuels from large-scale nuclear biorefineries

Liquid fossil fuels (1) enable transportation and (2) provide energy for mobile work platforms and (3) supply dispatchable energy to highly variable demand (seasonal heating and peak electricity). We describe a system to replace liquid fossil fuels with drop-in biofuels including gasoline, diesel and jet fuel. Because growing biomass removes carbon dioxide from the air, there is no net addition of carbon dioxide to the atmosphere from burning biofuels. In addition, with proper management, biofuel systems can sequester large quantities of carbon as soil organic matter, improving soil fertility and providing other environmental services. In the United States liquid biofuels can potentially replace all liquid fossil fuels. The required system has two key features. First, the heat and hydrogen for conversion of biomass into high-quality liquid fuels is provided by external low-carbon energy sources--nuclear energy or fossil fuels with carbon capture and sequestration. Using external energy inputs can almost double the energy content of the liquid fuel per unit of biomass feedstock by fully converting the carbon in biomass into a hydrocarbon fuel. Second, competing effectively with fossil fuels requires very large biorefineries—the equivalent of a 250,000 barrel per day oil refinery. This requires commercializing methods for converting local biomass into high-density storable feedstocks that can be economically shipped to large-scale biorefineries.

09 - BIOMASS FUELS↗
DOE OSTI2026

Higher-order interaction effects among operating conditions and feedstocks shape reactor microbiomes and fatty acid production profiles

Arrested anaerobic digestion (AAD) offers a promising route for producing fatty acids (FAs) from organic residues, yet optimal conditions for selectively generating medium-chain fatty acids (MCFAs) remain poorly defined. Here, we systematically evaluated the main and interaction effects of pH (5, 7, 9), feedstock (food waste, manure), temperature (35 and 45 °C), and inoculum source on microbiome composition and FA production. Anaerobic digester sludge and a novel bison rumen inoculum were compared. Significant higher-order interactions among operating parameters governed FA profiles and microbiome structure. Butyric acid production was driven by a three-way interaction among pH, feedstock, and temperature (p < 0.001), with maximum concentrations achieved in food waste reactors at pH 5.0 and 35 °C (1.2 ± 0.1 g L −1 with sludge and 1.1 ± 0.3 g L −1 with rumen). MCFA production exhibited significant four-way interactions (p < 0.1 to p < 0.001). At 45 °C and pH 5.0, inoculum source tuned MCFA selectivity: sludge favored pentanoic acid (0.4 ± 0.1 g L −1 ), whereas rumen favored hexanoic and heptanoic acids (up to 0.4 ± 0.2 g L −1 ). Manure reactors produced < 0.2 g L −1 MCFAs under all conditions. Genera, including Megasphaera, Prevotella, and Lactobacillus, were associated with production of specific MCFAs. PICRUSt2-based pathway predictions were consistent with MCFA production patterns and suggested a potential role for lactic acid–driven chain elongation pathways. This study provides insights into how interacting operating conditions shape AAD microbiomes, their FA profiles, and advances the trajectory of research aimed at engineering robust and controllable microbiomes for waste valorization.

09 BIOMASS FUELS↗
DOE OSTI2020

Binder jetting additive manufacturing of silicon carbide ceramics: Development of bimodal powder feedstocks by modeling and experimental methods

A limitation of binder jetting additive manufacturing is the low density of fabricated parts. Mixing powders with different sizes is a promising approach to increase powder bed packing density and, hence, printed part density. However, in previous studies mixed powder feedstock was prepared by trial and error method. In this research, both modeling and experimental methods were used to prepare the bimodal powder feedstocks. Analytical packing model was introduced for irregular powders. A bimodal powder was prepared by mixing two different-sized silicon carbide powders (i.e. coarse and fine) using ball mill, and their tap densities were measured. Silicon carbide plates were printed using the coarse and bimodal powders by a commercial binder jetting system. Results showed that the modeling method could predict the tap density of bimodal powders with high accuracy. The printed parts from bimodal powder achieved higher green densities than those from the unimodal powder.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Synthesis of nanograined zirconium diboride microsphere powder feedstock via emulsification of suspensions

Ceramic nanograined materials have desirable characteristics compared to their macroparticle counterparts but are rarely used in industrial applications due to issues with poor handleability and health hazards. Due to interparticle forces that become more dominant as the particle size decreases, it is difficult to use nanomaterials to fill dies, spread on surfaces, or flow through hoppers found in various manufacturing processes. In this work, we report a scalable gelcasting solution and unique emulsification process to create microspheres composed of nanoscale powders to enhance the flowability and handleability of nanomaterials. The gelcasting solution and emulsification process can be used with any nanoparticle composition that can be suspended in a liquid phase. This paper reports the effects of various parameters on zirconium diboride microsphere formation, such as surfactant content and mixing conditions. The microspheres maintain the nano-scale characteristics of the powder but improve its flowability by using cross-linked polyvinyl alcohol to combine irregularly shaped zirconium diboride nanoparticles with a particle diameter of 60 nm into larger spherical particles with a d 50 ~25 μm. This hierarchical feedstock engineering design combine the positive characteristics of materials across both length scales and improve the flowability of the feedstock from a Hausner Ratio of 1.56 to 1.19. The materials produced using this technique can be used in thermal plasma spray, die filling for hot pressing or spark plasma sintering, and binder jet printing applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Tire-derived carbon for catalytic preparation of biofuels from feedstocks containing free fatty acids

The utilization of waste feedstocks rich in free fatty acids (FFAs) improves biofuel production on the basis of economics and sustainability. However, converting these feedstocks to usable biofuel poses inherent problems in terms of the FFA to biofuel conversion yield and the catalyst lifetime. Here, we report novel ferric sulfate impregnated carbon derived from waste tires as highly active catalysts for FFA to biofuel conversion. Our approach takes advantage of facile synthesis methods involving sonication and dehydration processes to create materials that are useful for the efficient catalytic conversion of FFAs to advanced biofuels. Esterification of FFAs to fatty acid methyl esters was achieved at 65 °C and atmospheric pressure with >98% yield even in the presence of triglycerides. These catalysts maintained similar activity after four successive uses, which indicates that the active catalytic sites are effectively supported by the three-dimensional meso/microporous architecture of the tire-derived carbon.

09 BIOMASS FUELS↗
DOE OSTI2021

Biomass pyrolysis devolatilization kinetics of herbaceous and woody feedstocks

Devolatilization kinetics were determined using a modified micropyrolyzer reactor for several biomass feedstocks: switchgrass, corn stover, red oak, and pine. Here, the micropyrolyzer was directly coupled to a flame ionization detector (FID) to track the release of volatiles from the biomass. Time series data from these experiments was analyzed to determine apparent devolatilization rates. Care was taken to assure the experiments were isothermal and kinetically limited calculating a Biot number less than 0.1 and pyrolysis numbers greater than 10, which simplifies the derivation of devolatilization rates. A single, first order reaction was able to model devolatilization rates at temperatures up to 500 °C. No correlation was found between the inorganic content of the biomass and its rate of devolatilization. Apparent activation energies were in the range of 54.9–88.4 kJ mol –1 . The rate coefficient at 500 °C was calculated as 1.90–5.14 s –1 for the four feedstocks.

09 BIOMASS FUELS↗
DOE OSTI2019

Fatigue of additive manufactured Ti-6Al-4V, Part I: The effects of powder feedstock, manufacturing, and post-process conditions on the resulting microstructure and defects

Additive manufacturing provides an appealing means to process titanium alloy parts with new levels of conformability, complexity, and weight reduction. However, due to the heating/cooling rates and heat transfer associated with directed energy source material processing, the as-built AM parts contain unique material and microstructural features. In order to confidently manufacture fatigue critical additive manufactured (AM) Ti-6Al-4V parts, a better understanding of the interrelationships between powder feedstock, AM processes, structure of the processed parts, their resulting mechanical properties, and their performance under realistic loadings is necessary. Part I of this two-part collection focuses on the powder-process-structure relationships and how powder feedstock, manufacturing, and post-processing conditions can affect the microstructure and defect features that ultimately contribute to the fatigue performance of Ti-6Al-4V parts. The material and physical phenomena inherent to the AM process of Ti-6Al-4V are discussed in detail and related to the phase composition/structure, grain morphology, surface characteristics, defect size/distribution, and post-process treatments available for AM parts. This investigation is the foundation for the structure-performance relationships that will be covered in detail in Part II.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Peak microhardness recovery via T6 heat treatment with extremely soft annealed Al7075 feedstock in additive friction stir deposition

With standard T6 heat treatments, precipitate-hardened alloys such as Al7075 and Al6061 fabricated using Additive Friction Stir Deposition (AFSD) method restore to noticeablely different peak mechanical properties. Previous research observed similar results but did not provide a viable solution. This study proposes a new processing strategy, namely enhanced plastic deformation by subjecting the Al7075 feedstock to annealed softening treatments. Specifically, by annealing the standard T651-Al7075 feedstock and deposition substrate (179 HV), their Microhardness were first degraded to its lowest state (80 HV), which is called a Soft-to-Soft system. For the Soft-to-Soft system subjected to AFSD, after undergoing appropriate T6 heat treatment, the microhardness of the AFSD 7075 alloy was restored to its peak value (183.1 ± 1.8 HV). The results indicate that this softening strategy can effectively reduce the non-strengthening phase in the AFSD matrix, thereby increasing the strengthening phase (η′ phase). This addresses the issue of traditional AFSD-prepared aluminum alloys being unable to achieve peak performance through T6 heat treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2026

The effect of varying powder feedstock chemistry and printing atmosphere on the microstructure of additively manufactured nickel-based ODS alloys: Role on stabilization of cellular structures vs. oxide dispersion formation

Nickel-based alloys have a wide variety of structural applications due to their high corrosion resistance and mechanical strength which depend on solid solution strengthening, or the formation of oxides and/or intermetallic precipitation for their properties. In this study, the microstructure of six Ni–Cr–Y–Ti–Al powder batches designed for the production of oxide dispersion strengthened nickel were compared. These batches varied in chemistry and atomization technique used which included Gas Atomization Reactive Synthesis (GARS). The batches of powder were then consolidated via Additive Manufacturing (AM) Powder Bed Fusion using Laser Beam (PBF-LB) and characterized via transmission electron microscopy to elucidate the influence of powder feedstock (i.e. synthesis methodology and chemistry) on the PBF-LB microstructure. The study investigates (i) how the amount of yttrium and titanium additions in the powder feedstock and the addition of oxygen during the processing (through GARS) affect the microstructure of the powder itself and the AM printed microstructure, and (ii) how the control of oxygen addition in the printing atmosphere during the PBF-LB printing process itself is another important parameter for achieving the formation of the wanted oxide dispersion versus the stabilization of the cellular structure (often observed in AM processed alloys). Microstructural characterization of both powder particles and additively manufactured nickel alloys in this study provide important insights into the movement of yttrium within the material upon solidification, particularly along cell boundaries, and how yttrium behaves depending on alloy chemistry. When a threshold of yttrium content is reached within the system, yttrium consistently reacts to form an intermetallic along cell boundaries instead of forming oxide nanoparticles.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Fabrication of UO 2 -Mo composite fuel with enhanced thermal conductivity from sol-gel feedstock

In this study, fabrication of monolithic UO 2 and UO 2 -Mo composites from Mo metal powder feedstock and UO 3 spheres derived from internal gelation was explored. The addition of 10 vol% Mo as a secondary phase to UO 2 led to an increase of up to 30% in thermal conductivity compared to syntheses in which only pure UO 2 was used. Lastly, using coarse and fine Mo metal powder feedstock led to different microstructures, influencing the thermal conductivity of the resulting composites.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

The effect of caustic soda treatment to recover rare earth elements from secondary feedstocks with low concentrations

Caustic soda (NaOH) treatment has enhanced rare earth element (REE) extraction from monazite. Here, this study examined the effectiveness of caustic soda for RE-phosphates with lower concentrations for extraction from coal overburden, an alternative feedstock derived from mining waste. Pourbaix (Eh-pH) diagrams were constructed for La, Ce, Nd, Eu, and Y-PO 4 -H 2 O systems to understand the thermodynamics of NaOH-facilitated acid leaching for low-concentration RE-phosphates and oxides and to elucidate the difference in recoveries among individual REEs. The Eh-pH diagrams indicated that low crystallinity is beneficial for extraction. Nd was thermodynamically most favorable for the extraction process among the five elements examined, and Y was the least promising. Experiments were conducted using three Pennsylvania coal overburden samples to validate the effect of caustic soda on rare earth leaching. The experimental results showed that for NaOH (6 M), a leaching time of 2 h at 125 °C was sufficient to obtain twice the recovery values compared to those without the NaOH treatment. After implementing the caustic soda treatment, a high total REE recovery (>60%), especially for Nd and Pr, could be achieved with diluted HCl and more environmentally friendlier citric acid. The results were similar for both coarse and fine particles. This novel approach is likely to improve the feasibility of REE extraction from coal-associated feedstock in a more environmentally benign manner.

42 ENGINEERING↗
DOE OSTI2022

Process and feedstock driven microstructure for laser powder bed fusion of 316L stainless steel

Here in the pursuit of improving additively manufactured (AM) component quality and reliability, fine-tuning critical process parameters such as laser power and scan speed is a great first step toward limiting defect formation and optimizing the microstructure. However, the synergistic effects between these process parameters, layer thickness, and feedstock attributes (e.g. powder size distribution) on part characteristics such as microstructure, density, hardness, and surface roughness are not as well-studied. In this work, we investigate 316L stainless steel density cubes built via laser powder bed fusion (L-PBF), emphasizing the significant microstructural changes that occur due to altering the volumetric energy density (VED) via laser power, scan speed, and layer thickness changes, coupled with different starting powder size distributions. This study demonstrates that there is not one ideal process set and powder size distribution for each machine. Instead, there are several combinations or feedstock/process parameter ‘recipes’ to achieve similar goals. This study also establishes that for equivalent VEDs, changing powder size can significantly alter part density, GND density, and hardness. Through proper parameter and feedstock control, part attributes such as density, grain size, texture, dislocation density, hardness, and surface roughness can be customized, thereby creating multiple high-performance regions in the AM process space.

316L stainless steel↗