Results for “Processing” — Page 16

DOE OSTI2015

Optimization of processing temperature in the nitridation process for the synthesis of iron nitride nanoparticles

We have demonstrated an effective strategy on the nitridation process to synthesize ε-Fe{sub 3}N nanoparticles (NPs) from the zero valent iron NPs as a starting material. The transformation of iron into iron nitride phase was systematically studied by performing the nitridation process at different processing temperatures. The phase, crystal structure was analyzed by XRD. Morphology and size of the ZVINPs and ε-Fe{sub 3}N NPs were analyzed by field emission scanning electron microscope. Further, their room temperature magnetic properties were studied by using vibrating sample magnetometer and it revealed that the magnetic property of ε-Fe{sub 3}N is associated with ratio of Fe-N in the iron nitride system.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2017

AnalyzeThat: A Programmable Shared-Memory System for an Array of Processing-In-Memory Devices

Processing In Memory (PIM), the concept of integrating processing directly with memory, has been attracting a lot of attention since PIM can assist in overcoming the throughput limitation caused by data movement between CPU and memory. The challenge, however, is that it requires the programmers to have a deep understanding of the PIM architecture to maximize the benefits such as data locality and parallel thread execution on multiple PIM devices. In this study, we present AnalyzeThat, a programmable shared-memory system for parallel data processing with PIM devices. Thematic to AnalyzeThat is a rich PIM-Aware Data Structure (PADS), which is an encapsulation that integrally ties together the data, the analysis tasks and the runtime needed to interface with the PIM device array. The PADS abstraction provides (i) a key-value data container that allows programmers to easily store data on multiple PIMs, (ii) a suite of parallel operations with which users can easily implement data analysis applications, and (iii) a runtime, hidden to programmers, which provides the mechanisms needed to overlay both the data and the tasks on the PIM device array in an intelligent fashion, based on PIM-specific information collected from the hardware. We have developed a PIM emulation framework called AnalyzeThat. Our experimental evaluation with representative data analytics applications suggests that the proposed system can significantly reduce the PIM programming effort without losing its technology benefits.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2017

Mechanical characterization of parts produced by ceramic on-demand extrusion process

Not provided.

Materials Science↗

DOE OSTI2018

Evaluation of Simple Chemical Interactions in the Defense Waste Processing Facility (DWPF) Chemical Process Cell (CPC) Under the Glycolic Acid Flowsheet

This report describes results from testing developed for the increased understanding of simple chemical interactions relevant to the processing and vitrification of radioactive waste at the Savannah River Site (SRS) in Aiken, SC. This work is outlined in task 3 of the Technical Task Request X-TTR-S-00024, Rev. 0 and task 4 of the Task Technical & Quality Assurance Plan SRNL- RP-2014-01183 Rev. 0. The testing was conducted from May 2016 through February 2017 at the Aiken County Technology Laboratory (ACTL) and performed by Savannah River National Laboratory (SRNL) personnel. This testing involved the investigation of simple reactions and interactions of glycolic or nitric acids with combinations of sodium nitrite, manganese dioxide, mercuric oxide, and noble metals (silver, palladium, rhodium, and ruthenium). The aim of this testing was to better understand the reactions and chemical phenomena previously observed in the Sludge Receipt and Adjustment Tank (SRAT) cycle of the Chemical Process Cell (CPC) in the Defense Waste Processing Facility (DWPF).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Understanding Part to Part Variability During Directed Energy Deposition Processes Using In Situ and Ex Situ Process Characterization

The overall goal of this technical collaboration is the use of in situ and ex situ characterization techniques to understand part to part variability in Ti-6Al-4V parts fabricated using directed energy deposition (DED) process, and subsequently qualify parts fabricated using AM. The primary goal of the Phase-1 of this CRADA was to demonstrate the feasibility of capturing the above changes using a combination of high speed stereo imaging and in situ monitoring using two wavelength pyrometers. The in situ monitoring was then correlated using ex situ characterization performed using optical microscopy. The results from phase-1 clearly show that changes to the process and shielding gases have a significant impact on the geometric conformity of the build and the build layer height. The results from phase-1 show that in addition to using IR thermography as a tool to measure the temperature and gradients, we could use it to monitor the build topography and the layer height and use the information to develop closed loop control systems. The phase-1 results show that there is a narrow zone under which the process must operate in order to be “passively stable” or autocorrect for over building. In addition, the results demonstrate that when operated within this range the build autocorrects and there is a drastic reduction in the interlayer lack of fusion defect formation.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Historical Scaling Performance from Laboratory to Full Scale for The Defense Waste Processing Facility's Chemical Process Cell

The Defense Waste Processing Facility (DWPF) is planning to modify the chemical processing flowsheet by replacing formic acid with glycolic acid in the Chemical Process Cell (CPC) Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME). The replacement of formic acid with glycolic acid virtually eliminates the CPC’s largest flammability hazards, catalytic hydrogen and ammonia.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Adapting LEU-Modified Cintichem Process for Processing Up to 750 Grams of Uranium Targets

Argonne National Laboratory (Argonne) developed a low-enriched uranium (LEU)-modified Cintichem (LMC) process to enable production and purification of fission-produced molybdenum-99 (Mo-99) from LEU foil targets. This separation scheme starts with nitric acid (HNO 3 ) dissolution of irradiated LEU foil targets that yields an approximate final volume of 2 L. The dissolved uranium solution containing fission products, including Mo-99, is then treated by loading the solution on a titania-based recovery column to separate Mo-99 from bulk uranium. After several washing steps, Mo and other fission products are stripped from the titania column using sodium hydroxide (NaOH). The eluate is then acidified using nitric acid and subsequently processed for final purification using the LMC process. Uranium and most fission products are not adsorbed on the titania column but are eluted (i.e., removed using a solvent) during the wash steps; they can be purified and recycled into new uranium targets.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2022

Sparse Data Machine Learning Integration with Theory, Experiment and Uncertainty Quantification: Process-Structure-Property-Performance of Friction Deformation Processing

Computer vision and deep learning tools that advance the ability to establish processing-structure-property-performance (PSPP) relations are presented. The Bayesian binning method for image segmentation enables quantitative analysis of microstructural features in an automated way, while the analysis of shapes and relative orientation of these features reveals local deformation maps indicative of both, material flow and residual stresses due to materials processing. The deep learning method leads to the previous knowledge agnostic mapping of empirically observed microstructural zones in friction stir welding (FSW) process and synthetic microstructure generation capability that is statistically equivalent to experimentally collected data.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2013

Development of a Novel Gas Pressurized Process-Based Technology for CO2 Capture from Post-Combustion Flue Gases Preliminary Year 1 Techno-Economic Study Results and Methodology for Gas Pressurized Stripping Process

Under the DOE’s Innovations for Existing Plants (IEP) Program, Carbon Capture Scientific, LLC (CCS) is developing a novel gas pressurized stripping (GPS) process to enable efficient post-combustion carbon capture (PCC) from coal-fired power plants. A technology and economic feasibility study is required as a deliverable in the project Statement of Project Objectives. This study analyzes a fully integrated pulverized coal power plant equipped with GPS technology for PCC, and is carried out, to the maximum extent possible, in accordance to the methodology and data provided in ATTACHMENT 3 – Basis for Technology Feasibility Study of DOE Funding Opportunity Number: DE-FOA-0000403. The DOE/NETL report on “Cost and Performance Baseline for Fossil Energy Plants, Volume 1: Bituminous Coal and Natural Gas to Electricity (Original Issue Date, May 2007), NETL Report No. DOE/NETL-2007/1281, Revision 1, August 2007” was used as the main source of reference to be followed, as per the guidelines of ATTACHMENT 3 of DE-FOA-0000403. The DOE/NETL-2007/1281 study compared the feasibility of various combinations of power plant/CO2 capture process arrangements. The report contained a comprehensive set of design basis and economic evaluation assumptions and criteria, which are used as the main reference points for the purpose of this study. Specifically, Nexant adopted the design and economic evaluation basis from Case 12 of the above-mentioned DOE/NETL report. This case corresponds to a nominal 550 MWe (net), supercritical greenfield PC plant that utilizes an advanced MEAbased absorption system for CO2 capture and compression. For this techno-economic study, CCS’ GPS process replaces the MEA-based CO2 absorption system used in the original case. The objective of this study is to assess the performance of a full-scale GPS-based PCC design that is integrated with a supercritical PC plant similar to Case 12 of the DOE/NETL report, such that it corresponds to a nominal 550 MWe supercritical PC plant with 90% CO2 capture. This plant has the same boiler firing rate and superheated high pressure steam generation as the DOE/NETL report’s Case 12 PC plant. However, due to the difference in performance between the GPS-based PCC and the MEA-based CO2 absorption technology, the net power output of this plant may not be exactly at 550 MWe.

Chen, Shiaoguo↗

DOE OSTI2014

Liquefaction processes and systems and liquefaction process intermediate compositions

Liquefaction processes are provided that can include: providing a biomass slurry solution having a temperature of at least 300.degree. C. at a pressure of at least 2000 psig; cooling the solution to a temperature of less than 150.degree. C.; and depressurizing the solution to release carbon dioxide from the solution and form at least part of a bio-oil foam. Liquefaction processes are also provided that can include: filtering the biomass slurry to remove particulates; and cooling and depressurizing the filtered solution to form the bio-oil foam. Liquefaction systems are provided that can include: a heated biomass slurry reaction zone maintained above 300.degree. C. and at least 2000 psig and in continuous fluid communication with a flash cooling/depressurization zone maintained below 150.degree. C. and between about 125 psig and about atmospheric pressure. Liquefaction systems are also provided that can include a foam/liquid separation system. Liquefaction process intermediate compositions are provided that can include a bio-oil foam phase separated from an aqueous biomass solids solution.

09 BIOMASS FUELS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

Feasibility Study for Monitoring Actinide Elements in Process Materials Using FO-LIBS at Advanced spent fuel Conditioning Process Facility

Korea Atomic Energy Research Institute (KAERI) have been developing the design and deployment methodology of Laser- Induced Breakdown Spectroscopy (LIBS) instrument for safeguards application within the argon hot cell environment at Advanced spent fuel Conditioning Process Facility (ACPF), where ACPF is a facility being refurbished for the laboratory-scaled demonstration of advanced spent fuel conditioning process. LIBS is an analysis technology used to measure the emission spectra of excited elements in the local plasma of a target material induced by a laser. The spectra measured by LIBS are analyzed to verify the quality and quantity of the specific element in the target matrix. Recently LIBS has been recognized as a promising technology for safeguards purposes in terms of several advantages including a simple sample preparation and in-situ analysis capability. In particular, a feasibility study of LIBS to remotely monitor the nuclear material in a high radiation environment has been carried out for supporting the IAEA safeguards implementation. Fiber-Optic LIBS (FO-LIBS) deployment was proposed by Applied Photonics Ltd because the use of fiber optics had benefited applications of LIBS by delivering the laser energy to the target and by collecting the plasma light. The design of FO-LIBS instrument for the measurement of actinides in the spent fuel and high temperature molten salt at ACPF had been developed in cooperation with Applied Photonics Ltd. FO-LIBS has some advantages as followings: the detectable plasma light wavelength range is not limited by the optical properties of the thick lead-glass shield window and the potential risk of laser damage to the lead-glass shield window is not considered. The remote LIBS instrument had been installed at ACPF and then the feasibility study for monitoring actinide elements such as uranium, plutonium, and curium in process materials has been carried out. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Self-terminating etching processes for post-processing of 3D printed metal alloys

A process is provided to remove a selective amount of material from a metal part fabricated by additive manufacturing in a self-terminating manner. The process can be used to remove support structures and trapped powder from a metal part as well as to smooth surfaces of a 3D printed metal part. In one embodiment, selected surfaces of the metal part are treated to make the selected surfaces at least one of mechanically and chemically unstable. The unstable portion of the metal support can then be removed chemically, electrochemically, with a pressure differential, and/or through vapor-phase etching. In one embodiment, the metal part may comprise one or more of an aluminum alloy, a titanium alloy, and a copper alloy. The process can be used to modify any fluid or vapor-accessible regions and surfaces of a 3D printed metal part.

Hildreth, Owen J.↗

DOE OSTI2024

Integrated top-down process and voxel-based microstructure modeling for Ti-6Al-4V in laser wire direct energy deposition process

Laser-wire metal additive manufacturing (AM) is one of the ideal direct energy deposition (DED) processes for creating large-scale parts with a medium level of complexity. However, the DED process involves complex thermal signatures and wide length scales making the fabrication of realistic AM components and part qualification often reliant on experimental trial-and-error optimization. While experimental measurements over the full volume of a part are valuable and necessary, measuring the entire area of a part is significantly laborious and practically infeasible, particularly for large parts in terms of cost and rapid qualification. Therefore, in this work, we developed an effective thermal and microstructure modeling framework based on the Johnson–Mehl-Avrami-Kolmogorov (JMAK) and Koistinen & Marburger (KM) models through a top-down approach that considers plate distortion-affected thermal profiles. A voxel-by-voxel simulation method is used to predict individual phase fractions of Ti-6Al-4 V. The predicted results were validated through detailed metallurgical measurements. A combined voxel-by-voxel approach with a sparse data reconstruction technique produced a near-perfect reconstruction of the original data. This approach anticipates a significant reduction in data points and computation time and resources. Lastly, we conclude with potential extensions of this work to other modeling efforts.

36 MATERIALS SCIENCE↗