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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Water Freezes at Near-Zero Temperatures Using Carbon Nanotube-Based Electrodes under Static Electric Fields

Although static electric fields have been effective in controlling ice nucleation, the highest freezing temperature ( T f ) of water that can be achieved in an electric field ( E ) is still uncertain. In this study, we performed a systematic study of the effect of an electric field on water freezing by varying the thickness of a dielectric layer and the voltage across it in an electrowetting system. Results show that T f first increases sharply with E and then reaches saturation at –3.5 °C after a critical value E of 6 × 10 6 V/m. Using classical heterogeneous nucleation theory, it is revealed that this behavior is due to saturation in the contact angle of the ice embryo with the underlying substrate. Finally, we show that it is possible to overcome this freezing saturation by controlling the uniformity of the electric field using carbon nanotubes. We achieve a T f of –0.6 °C using carbon nanotube-based electrodes with an E of 3 × 10 7 V/m. This work sheds new light on the control of ice nucleation and has the potential to impact many applications ranging from food freezing to ice production.

25 ENERGY STORAGE↗
DOE OSTI2022

An Investigation into the Effects of Swirl on the Performance and Emissions of an Opposed-Piston Two-Stroke Engine using Large Eddy Simulations

Opposed-piston two-stroke (OP-2S) engines have the potential to achieve higher thermal efficiency than a conventional four-stroke diesel engine. However, the uniflow scavenging process is difficult to control over a wider range of speed and loads due to its sensitivity to pressure dynamics, port timings, and port design. Specifically, the angle of the intake ports can be used to generate swirl which has implications for open and closed cycle effects. This study proposes an analysis of the effects of port angle on the in-cylinder flow distribution and combustion performance of an OP-2S using computational fluid dynamics engine. Large Eddy Simulation (LES) was used to model turbulence given its ability to predict in-cylinder mixing and cyclic variability. A three-cylinder model was validated to experimental data collected by Achates Power and the grid was verified using an LES quality approach from the literature. The model was used to simulate port angles from 12 to 29 degrees at constant pressure and temperature boundary conditions. Results indicated that the higher bulk swirl ratio generated by larger port angles tends to trap more internal residuals. This effect on the scavenging performance, combined with the larger trapped swirl ratio, also has a significant impact on the combustion performance in a two-stroke engine. It was concluded that there exists a tradeoff of efficiency and emissions that must be considered when increasing the port angle in a uniflow two-stroke engine. 1. Introduction Two-stroke engines were developed in the 1800s and are commonly used in practice today for lightweight power applications such as motorcycles or handheld power tools, as well as large-bore low speed engines for stationary power and marine applications. Two-stroke engines provide the distinct advantage of higher torque/power output but present challenges due to its coupled intake and exhaust process. Four-stroke engines have the benefit of using two full piston strokes to induct intake charge and to expel exhaust gases. Controlling the trapped charge composition in a twostroke engine via a scavenging process is crucial for reliable and efficient engine operation.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Strong Induced Circular Dichroism in a Hybrid Lead‐Halide Semiconductor Using Chiral Amino Acids for Crystallite Surface Functionalization

Abstract Chirality is a desired property in functional semiconductors for optoelectronic, catalytic, and spintronic applications. Here, introducing enantiomerically‐pure 3‐aminobutyric acid (3‐ABA) into thin films of the 1D semiconductor dimethylammonium lead iodide (DMAPbI 3 ) is found to result in strong circular dichroism (CD) in the optical absorption. X‐ray diffraction and grazing incidence small angle X‐ray scattering (GISAXS) are applied to gain molecular‐scale insights into the chirality transfer mechanism, which is attributed to a chiral surface modification of DMAPbI 3 crystallites. This study demonstrates that the CD signal strength can be controlled by the amino‐acid content relative to the crystallite surface area. The CD intensity is tuned by the composition of the precursor solution and the spin‐coating time, thereby achieving anisotropy factors ( g abs ) as high as 1.75 × 10 –2 . Grazing incidence wide angle scattering reveals strong preferential ordering that can be suppressed via tailored synthesis conditions. Different contributions to the chiroptical properties are resolved by a detailed analysis of the CD signal utilizing an approach based on the Mueller matrix model. This report of a novel class of chiral hybrid semiconductors with precise control over their optical activity presents a promising approach for the design of circularly polarized light detectors and emitters.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Building [U IV 70 (OH) 36 (O) 64 ] 4– oxocluster frameworks with sulfate, transition metals, and U V

Uranium (IV) oxide clusters, colloids, and materials are designed and studied for 1) nuclear materials applications, 2) understanding environmental fate and transport of actinides, and 3) exploring the complex bonding behavior of open-shell f-elements. U IV -oxyhydroxsulfate clusters are particularly relevant in industrial processes and in nature. Recent studies have shown that counter-cations to these polynuclear anions differentiate rich structural topologies in the solid-state. Here we present nine different structures with wheel-shaped [U 70 (OH) 36 (O) 64 (SO 4 ) 60 ] 4- (U 70 ) linked into 1-dimensional and 2-dimensional frameworks with sulfate, divalent transition metals (Cr II , Fe II , Co II , Ni II ) and U V . Here, the small-angle X-ray scattering of these phases dissolved in butylamine reveals differing supramolecular assembly of U 70 clusters, controlled primarily by sulfates. However, observed trends in transition metal linking guide future design of U 70 -materials with different topologies. Finally, U 70 linking via U IV -O-U V -O-U IV bridges presents a rare example of mixed oxidation state uranium oxides without disorder.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Thickness dependence of piezo-bimorph adaptive mirror bending

A new generation of adaptive x-ray optics (AXO) is being installed on high-coherent-flux x-ray beamlines worldwide to correct and control the optical wavefront with sub-nm precision. These ultra-smooth mirrors achieve high reflectivities at glancing angles of incidence and can be hundreds of mm long. One type of adaptive x-ray mirror relies on piezoelectric ceramic strips which are segmented into channels and actuated to induce local, longitudinal bending, generating one-dimensional shape changes in the mirror substrate. A recently described mirror model uses a three-layer geometry with parallel actuators on the front and back surfaces of a thicker mirror substrate. By analogy to a solved problem in the thermal actuation of a tri-metal strip, we show that the achievable bending radius varies approximately as the square of the substrate thickness. We provide an analytic solution and simulate bending using a finite-element model.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Distinctive molecular configuration of nanostructured silica deposited at a glancing angle

Glancing-angle deposition (GLAD) produces nanostructured silica, showcasing form birefringence, an attractive alternative to traditionally used crystalline materials for polarization control. This work aims to enhance the understanding of its internal structure and associated defects in its native form and after laser processing. Our observations show, for the first time, that the GLAD silica exhibits a unique Raman signature that converges to a typical silica spectrum following laser melting. Defects were also investigated with fluorescence spectroscopy. The new insight provided by this work informs our understanding of this birefringent material and drives optimization of its performance in GLAD-based polarization control devices.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Architecture-Dependent Thin Film Self-Assembly of Star Polystyrene-poly(2-vinylpyridine) Block Copolymers

Controlling the orientation of nanostructured block copolymer (BCP) thin films is essential for their use in templating, transport, and pattern transfer. Conventional efforts mainly focus on adjusting enthalpic interactions between the blocks and interfaces, while entropic contributions are often overlooked. Here, we show that the morphology of BCP thin films can be precisely tuned by the architectural design of star BCPs. Specifically, we synthesized multiarm star BCPs with a polystyrene (PS) core and poly(2-vinylpyridine) (P2VP) corona, which exhibits a lamellar microdomain morphology. The entropic penalty associated with a parallel orientation of the microdomains to the substrate is controlled by varying the number of arms comprising the star BCPs, from 2-arms (triblock) to 3-arms and 4-arms. We systematically investigated the thin film morphology at different depths using grazing incidence small-angle X-ray and neutron scattering (GISAXS and GISANS), atomic force microscopy (AFM), water contact angle (WCA), and interference microscopy. The results show that 2-arm star BCPs show a parallel orientation, the 3-arm star BCPs form a uniform PS film at the air surface with a vertical orientation of the microdomains underneath, and the 4-arm star BCPs exhibit a parallel microdomain orientation at the air surface with mixed parallel and perpendicular microdomain orientation in the bulk. Additionally, we found that the inclination angle of microdomains at the edges of islands and holes, resulting from the incommensurability between film thickness and the characteristic period of the microdomain morphology, increases with a higher number of arms. This suggests a greater grain boundary tilt angle in the microdomains of star-shaped block copolymers (BCPs). When silicon substrates were modified with PS homopolymer, the selective interaction between substrate and core blocks promotes a parallel orientation for the 4-arm star BCPs. In conclusion, this work shows that control of arm number in star BCPs affords diverse BCP thin film morphologies, offering insights into the star BCP conformations in thin films across different depths.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Analysis of Line Distance Elements for Various Ibr Controllers and System Conditions

The large-scale penetration of inverter-based resources in power systems has challenged protection engineers because of the different fault behaviors these sources provide compared to conventional generation systems. The main challenges include a low level of fault current magnitude, unpredictable angles of sequence currents, and lack of inertia that can lead to maloperation of conventional phasor-based protection elements. This paper presents a sensitivity analysis of transmission line distance protection elements during phase-to-ground and phase-to-phase faults for different inverter controllers and power system conditions. It also summarizes which line protection elements remain secure near IBR terminations and identifies the ones affected by the inverter-based response. The paper concludes by highlighting that regulating negative-sequence current injection during the fault aids correct protection decisions, but does not address the entire challenge. Finally, alternative protection elements to those affected by the inverter fault response are discussed.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Analysis of MHD stability and active mode control on KSTAR for high confinement, disruption-free plasma

Long-pulse plasma operation at high normalized beta, $β_N$, above the $\textit{n}$= 1 ideal MHD no-wall stability limit in KSTAR is presently limited by tearing instabilities rather than resistive wall modes. H-mode plasma operation during the recent KSTAR device campaign produced discharges having strong $\textit{m/n}$= 2/1 tearing instabilities at $β_N$ lower than the ideal MHD no-wall beta limit. The unstable tearing mode consequently reduced plasma confinement and toroidal plasma rotation significantly. We report the experiment confirmed that an extended duration of electron cyclotron heating (ECH) at the initial phase of the discharge plays a critical role in mode destabilization. To study destabilizing mechanisms that affect the mode growth, the stability of the observed tearing modes from plasmas with significantly different $β_N$ is computed by using the resistive DCON code and the M3D-C 1 code. Equilibrium reconstructions that include constraints from internal profile diagnostics, and computed fast particle pressure are used as input for reliable computation of stability. The classical tearing stability index, Δ', from resistive DCON is computed to be unstable when the island is fully saturated with large amplitude, while the unstable mode is not computed by M3D-C 1 . The modified Rutherford equation (MRE) describing the evolution of the island width has been constructed for KSTAR plasmas by using plasma parameters computed by the TRANSP code. The MRE model estimates a saturated island width corresponding to ~10% of the plasma minor radius for equilibrium at high $β_N$ 3 having a stable Δ' from the resistive DCON. In preparation for long-pulse plasma operation at higher beta utilizing increased plasma heating power, a resistive wall mode (RWM) active feedback control algorithm has been completed and enabled on KSTAR. To accurately determine the $\textit{n}$= 1component produced by RWMs, an algorithm has been developed that includes magnetic sensor compensation of the prompt applied field and the field from the induced current on the passive conductors. Use of multiple toroidal sensor arrays is enabled by modifying the sensor toroidal angles assumed in mode decomposition to include the effect of varied mode helicities in the outboard region where the mode measurement is made. This analysis on stability, transport, and control provides the required foundation for disruption prediction and avoidance research on KSTAR.

resistive wall mode (RWM)↗
DOE OSTI2022

Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

In Situ Ultra-Small- and Small-Angle X-ray Scattering Study of ZnO Nanoparticle Formation and Growth through Chemical Bath Deposition in the Presence of Polyvinylpyrrolidone

ZnO inverse opals combine the outstanding properties of the semiconductor ZnO with the high surface area of the open-porous framework, making them valuable photonic and catalysis support materials. One route to produce inverse opals is to mineralize the voids of close-packed polymer nanoparticle templates by chemical bath deposition (CBD) using a ZnO precursor solution, followed by template removal. To ensure synthesis control, the formation and growth of ZnO nanoparticles in a precursor solution containing the organic additive polyvinylpyrrolidone (PVP) was investigated by in situ ultra-small- and small-angle X-ray scattering (USAXS/SAXS). Before that, we studied the precursor solution by in-house SAXS at T = 25 °C, revealing the presence of a PVP network with semiflexible chain behavior. Heating the precursor solution to 58 °C or 63 °C initiates the formation of small ZnO nanoparticles that cluster together, as shown by complementary transmission electron microscopy images (TEM) taken after synthesis. The underlying kinetics of this process could be deciphered by quantitatively analyzing the USAXS/SAXS data considering the scattering contributions of particles, clusters, and the PVP network. A nearly quantitative description of both the nucleation and growth period could be achieved using the two-step Finke–Watzky model with slow, continuous nucleation followed by autocatalytic growth.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Optimizing conformance control for gas injection EOR in unconventional reservoirs

Field observations have shown that interference between wells caused by connected fractures commonly exists in unconventional reservoirs. The well interference effect and conformance issues could lead to minimal enhanced oil recovery response (EOR) in actual operations if they are not properly controlled. A series of data analysis, modeling, and experimental activities were performed in this study to investigate the gas EOR strategies in the Bakken Formation. Employing the embedded discrete fracture modeling technology, a multiple-well, multiple-fracture model was developed to capture the well interference and conformance issues in the Bakken. The model made it possible to investigate the complex flow behavior between wells in the EOR (huff ‘n’ puff) processes. Alternative EOR and conformance control strategies using water and surfactant injections were studied to improve oil production performance based on experimental observations. Results showed that water injection could be used for conformance control in the Bakken because of its relatively low mobility compared to gas; however, water could also block oil flow around the conformance control wells because of the high interfacial tension between oil and water. Adding surfactant to the injection water is more effective for improving gas EOR performance since surfactant reduces the oil–water interfacial tension and contact angle effectively. Up to 9.4% more oil could be produced from the huff ‘n’ puff wells in 2 years of EOR operations when rich gas was injected at only 3 MMscf/d with 6000 psi of surfactant injection in the offset wells for conformance control.

42 ENGINEERING↗
DOE OSTI2020

Transport of coexisting Ni-Cu sulfide liquid and silicate melt in partially molten peridotite

Transport of coexisting sulfide and silicate melts in partially molten peridotite contributes to the redistribution of chalcophile elements within the upper mantle as well as the genesis of magmatic Ni-Cu sulfide deposits, but has not been investigated systematically. Using laboratory experiments, theoretical calculations, and X-ray synchrotron microtomography, this study documents the topology and considers controls on the extraction of two immiscible liquids during partial melting of mantle peridotite. Under hydrostatic conditions, the measured dihedral angle at silicate melt-mineral-mineral junctions is 13.7–21.3°. Silicate melt is distributed along grain edges forming incompletely interconnected melt channels that disconnected by some dead ends at melt fractions ~7–9 vol%. Application of theoretically predicted permeability (k ~10 -14 -10 -16 m 2 ) permits estimation of the extraction velocity of silicate melt of 0.7-11.1 μm/day within a single interconnected melt channel. In the absence of silicate melt, isolated sulfide droplets (3.77 vol%) show a sulfide-olivine-olivine dihedral angle of 91.5–101.3°. However, in the presence of silicate melt, sulfide droplets (average size ~2.53±2.14μm, 1σ) are partially surrounded by silicate melt and stranded in triple junctions or melt pockets due to the limitation of the smallest dimension (0.3μm) of melt channels. Thus, the extraction of sulfide liquid is highly restricted by these dead ends and the smallest dimension of melt channels during porous flow of silicate melt. In contrast, during large-strain shear deformation (strain ~1.6–2.5), initially stranded sulfide droplets were elongated and extracted with silicate melt into liquid-rich sheets with a length of several hundred microns, constantly oriented at 14.3±4.5°to the shear plane and antithetic to the shear direction. The angle is lower than that (18-30°) of those sheets containing sulfide liquid only, indicating that silicate melt dominates liquid-rich sheets. Driven by stress, silicate melt-dominated liquid-rich sheets open the appropriately oriented grain boundaries between silicate minerals, thus providing an efficient pathway for the extraction of sulfide liquid during deformation. When such sheet-like channels remain open, sulfide droplets (> millimeter-scale) can be potentially mobile through high strain domains of the upper mantle, contributing to the addition of chalcophile elements and the fertilization of the lithospheric mantle.

high P-T experiment↗
DOE OSTI2020

Shear strength and permeability of the cement-casing interface

Here, the shear strength and hydraulic permeability of the interface between well cement and casing was investigated using a triaxial direct shear apparatus. For the first time, these experiments provide measurements under controlled stress conditions with fluid flow measurements along the interface. The low cohesion (1.1 ± 1.1 MPa) and the high friction angle (43.4 ± 2.0°) indicates that the shear strength of the interface is provided by friction. This implies that the state of stress of the cement is critical to well integrity. The hydraulic aperture of the undamaged cement-steel samples was 6.8 ± 1.0 microns. Shear damage to the interface caused a decrease (-20 %) in hydraulic aperture for samples aged up to 1 month, and an increase (+300 %) for samples cured for two years. We performed numerical simulations to estimate the leakage potential from a carbon storage operation. This model predicts negligible leakage amounts (47 tonnes) in a shear-damaged well for the modeled injection of ~1.26 million tonnes of CO 2 . Thus, our measurements indicate that the cement-casing interface is not a significant leakage pathway in its intact or damaged state, and that shear-driven failure scenarios for this interface are not a significant risk to CO 2 storage security.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Self-Assembled Solute Networks in Crowded Electrolyte Solutions and Nanoconfinement of Charged Redoxmer Molecules

Redoxmers are electrochemically active organic molecules storing charge and energy in electrolyte fluids circulating through redox flow batteries (RFBs). Such molecules typically have solvent-repelling cores and solvent-attracting pendant groups introduced to increase solubility in liquid electrolytes. These two features can facilitate nanoscale aggregation of the redoxmer molecules in crowded solutions. In some cases, this aggregation leads to the emergence of continuous networks of solute molecules in contact, and the solution becomes microscopically heterogeneous. In this study, we used small-angle X-ray scattering (SAXS) and molecular dynamics modeling to demonstrate formation of such networks and examine structural factors controlling this self-assembly. We also show that salt ions become excluded from these solute aggregates into small pockets of electrolytes, where these ions strongly associate. This confinement by exclusion is also likely to occur to charged redoxmer molecules in a “sea” of neutral precursors coexisting in the same solution. Here, we demonstrate that the decay lifetime of the confined charged molecules in such solutions can increase several fold compared to dilute solutions. We attribute this behavior to a “microreactor effect” on reverse reactions of the confined species during their decomposition.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Sidelobe modeling and mitigation for a three mirror anastigmat cosmic microwave background telescope

Telescopes measuring cosmic microwave background (CMB) polarization on large angular scales require exquisite control of systematic errors to ensure the fidelity of the cosmological results. In particular, far-sidelobe contamination from wide angle scattering is a potentially prominent source of systematic error for large aperture microwave telescopes. Here we describe and demonstrate a ray-tracing-based modeling technique to predict far sidelobes for a three mirror anastigmat telescope designed to observe the CMB from the South Pole. Those sidelobes are produced by light scattered in the receiver optics subsequently interacting with the walls of the surrounding telescope enclosure. After comparing simulated sidelobe maps and angular power spectra for different enclosure wall treatments, we propose a highly scattering surface that would provide more than an order of magnitude reduction in the degree-scale far-sidelobe contrast compared to a typical reflective surface. Finally, we conclude by discussing the fabrication of a prototype scattering wall panel and presenting measurements of its angular scattering profile.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

6D Simulations of PIP-II Booster Injection

The PIP-II superconducting linac will deliver 2 mA average H⁻ beam current at 800 MeV to the existing Booster synchrotron over a period of 0.55 ms (285 turns). As a result, the injected beam power will quadruple to 17 kW. Safe operation at the increased beam power implies careful attention to the origin, magnitude, and distribution of both controlled and uncontrolled losses. Uncontrolled losses are due to neutral ions in excited states stripped in downstream magnets and large angle scattered protons from parasitic foil hits. The relative magnitudes of these loss mechanisms is used to determine the optimal foil thickness. A transverse painting scheme involving closed orbit motion will be used to mitigate space charge effects and minimize parasitic foil hits. Using a detailed full 6D simulation of the injection process, we compute large angle scattering losses and compare results to back of the envelope estimates. We investigate possible impact of space charge on the emittance and beam distribution both during and at the conclusion of the injection period.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Interest in multi-axis additive manufacturing has grown significantly in recent years due to associated benefits that range from improved quality to support for greater geometric complexity. A method of 5-axis Laser Hot-Wire Directed Energy Deposition is developed and demonstrated in this study using an 8-axis industrial robot, comprised of a 6-axis serial link robot and a 2 degree-of-freedom positioner. Coordinated 5-axis motion is used to print Ti-6Al-4V objects predominantly through build plate rotation. Methods of slicing and toolpath generation are presented, including the use of an alternating toolpath direction philosophy and the manipulation of the CAD model surface normal vectors for determining the required build plate tilt angles for maintaining consistent deposition orientations relative to gravity. Another objective of the study was to determine the limits of conventional slicing and layer height control techniques for printing geometries with significant unsupported overhangs. A comparison is made between the behavior of normal and conformal bead alignment in this regard, and the performance of the layer height controller is reported as it relates to process stability and the limits of printing overhang geometries. Unsupported overhangs were successfully printed at 35° without build plate tilt and 45° with build plate tilt. Toolpath velocity and net-shape printing performance are reported as well, with 3D scans of the printed surfaces used for net-shape characterization. In all, the printing of three geometries is presented, including the overhang geometry, a 5-axis toolpath geometry, and a large-scale, multi-bead demonstrator part, which exceeded 500 mm in height and weighed 44 kg (97 lbs).

36 MATERIALS SCIENCE↗