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At least 343 records · Page 19

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DOE OSTI2023

Process-dependent anisotropic thermal conductivity of laser powder bed fusion AlSi10Mg: impact of microstructure and aluminum-silicon interfaces

Purpose AlSi10Mg alloy is commonly used in laser powder bed fusion due to its printability, relatively high thermal conductivity, low density and good mechanical properties. However, the thermal conductivity of as-built materials as a function of processing (energy density, laser power, laser scanning speed, support structure) and build orientation, are not well explored in the literature. This study aims to elucidate the relationship between processing, microstructure, and thermal conductivity. Design/methodology/approach The thermal conductivity of laser powder bed fusion (L-PBF) AlSi10Mg samples are investigated by the flash diffusivity and frequency domain thermoreflectance (FDTR) techniques. Thermal conductivities are linked to the microstructure of L-PBF AlSi10Mg, which changes with processing conditions. The through-plane exceeded the in-plane thermal conductivity for all energy densities. A co-located thermal conductivity map by frequency domain thermoreflectance (FDTR) and crystallographic grain orientation map by electron backscattered diffraction (EBSD) was used to investigate the effect of microstructure on thermal conductivity. Findings The highest through-plane thermal conductivity (136 ± 2 W/m-K) was achieved at 59 J/mm 3 and exceeded the values reported previously. The in-plane thermal conductivity peaked at 117 ± 2 W/m-K at 50 J/mm 3 . The trend of thermal conductivity reducing with energy density at similar porosity was primarily due to the reduced grain size producing more Al-Si interfaces that pose thermal resistance. At these interfaces, thermal energy must convert from electrons in the aluminum to phonons in the silicon. The co-located thermal conductivity and crystallographic grain orientation maps confirmed that larger colonies of columnar grains have higher thermal conductivity compared to smaller columnar grains. Practical implications The thermal properties of AlSi10Mg are crucial to heat transfer applications including additively manufactured heatsinks, cold plates, vapor chambers, heat pipes, enclosures and heat exchangers. Additionally, thermal-based nondestructive testing methods require these properties for applications such as defect detection and simulation of L-PBF processes. Industrial standards for L-PBF processes and components can use the data for thermal applications. Originality/value To the best of the authors’ knowledge, this paper is the first to make coupled thermal conductivity maps that were matched to microstructure for L-PBF AlSi10Mg aluminum alloy. This was achieved by a unique in-house thermal conductivity mapping setup and relating the data to local SEM EBSD maps. This provides the first conclusive proof that larger grain sizes can achieve higher thermal conductivity for this processing method and material system. This study also shows that control of the solidification can result in higher thermal conductivity. It was also the first to find that the build substrate (with or without support) has a large effect on thermal conductivity.

Engineering↗

DOE OSTI2024

Phase separation during the direct powder bed fusion of SiC

Powder bed fusion (PBF) is an attractive additive manufacturing option for fabrication of SiC object with complex geometries. However, the density and microstructure controls remain a challenge. This study is aimed at understanding laser–SiC interactions, with emphasis on microstructure-processing relationships, to identify potential solutions for the process improvement. SiC tubes were fabricated by PBF of pure SiC powders without sintering additives. Further, comprehensive analysis by X-ray diffraction, Raman spectroscopy, and electron microscopy indicated that binding of SiC particles was achieved by incongruent melting of SiC to a Si/C mixture containing SiC micro- and nanocrystallites. The phase evolution under laser irradiation of SiC was explained by phase diagrams. This study uncovered the PBF SiC microstructure at different length scales and the relationship between the microstructure and the processing parameters.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Solid-State Sintering of Core-Shell Ceramic Powders Fabricated by Particle Atomic Layer Deposition

The properties of technical ceramics are highly dependent on their microstructure, which evolves during sintering. Sintering is the process by which ceramic parts are subjected to high temperatures to activate chemical diffusion and the consumption of porosity. During the initial stage of sintering, interparticle necks between neighboring particles form and subsequently increase in size, consuming porosity as the particle centers move closer together. To experimentally determine how this process depends on particle surface composition, particle atomic layer deposition (ALD) was used to deposit a thin film of amorphous aluminum oxide (Al2O3) onto yttria-stabilized tetragonal zirconia (3YSZ) particles, producing core-shell structured powders. The uniformity of the Al2O3 film was confirmed with transmission electron microscopy and energy dispersive spectroscopy. Scanning electron microscopy was used to observe microstructural evolution during sintering, and the dihedral angles of Al2O3 and 3YSZ grains were measured to determine the ratio of interfacial energies between the 3YSZ|3YSZ, 3YSZ|Al2O3, and Al2O3|Al2O3 interfaces. Analysis of the densification kinetics revealed that the initial stage of densification is dependent on the material at the surface of the particles (ie, the Al2O3 film) and is controlled by the diffusion of Al3+ cations through Al2O3. Once the Al2O3 film has coalesced, the sintering behavior is controlled by the densification of the core material (3YSZ). Thus, core-shell powders fabricated by particle ALD sinter by a two-step process where the kinetics are dependent on the material present at interparticle contacts.

alumina↗

DOE OSTI2020

Pressurization Analysis for Heating of a Screw Top Utility Can Loaded With Plutonium Oxide Powder by a 1273 K Fire

The documented safety analysis for the Savannah River National Laboratory (SRNL) evaluates the consequences of a postulated 1273 K fire in a glovebox. The radiological dose consequences for a pressurized release of plutonium oxide powder during such a fire depend on the maximum pressure that is attained inside the oxide storage containers. The oxide storage configuration selected for analysis is can/bag/can, comprised of oxide powder inside an 8.38 × 10 -6 m 3 stainless steel B vial inside 0.006 kg of polyethylene bagging inside a one-quart screw top utility can of the type commonly used to package solvents or rubber cements. To enable evaluation of the dose consequences, temperature and pressure transients have been calculated for exposure of a typical set of storage containers to the fire. The pressurization analysis credits venting to and from the B vial but does not credit venting or leakage from the can. Due to the low rate of venting from the B vial into the can gas space, the can pressure is nearly independent of the B vial pressure. Calculated maximum pressures are compared to the utility can burst pressure. In lieu of a structural analysis of the utility cans, burst pressures and leakage rates were measured using compressed nitrogen gas. The measured gauge burst pressure was 0.250 ± 0.043 MPa. The measured burst pressures are lower than the calculated maximum pressure due to fire exposure, indicating that the utility cans could burst during exposure to a 1273 K fire.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2023

Prediction of Substrate Distortion in Powder DED Using Finite Element Model

Abstract Leveraging the capabilities of both additive and subtractive manufacturing to repair tooling and other high value items can result in significant cost and time saving opportunities. However, when dimensional accuracy of the repaired component must be held within a specified tolerance, distortion of the component induced during repair can lead to an out of specification final component. This work presents simulation of a novel method to mitigate part distortion using sacrificial support structures. A blown powder directed energy deposition system was utilized for deposition of sacrificial support structures and clad surface depositions. Sacrificial support structures were deposited on the underside of the substrate with varying geometries prior to clad surface depositions. A finite element model was developed and verified using experimental results. The simulation and experimental control results were found to match within 6%. It has been shown that simulation can be used to predict effects of sacrificial support structures on substrate distortion in a blown powder directed energy deposition process.

Burl, Alan G.↗

DOE OSTI2025

PUMA:POWDER UTILIZATION MODELING APPLICATION

SF-25-084 PUMA a high performance modeling framework to simulate powder processing. It provides a scalable tool for manufacturers to simulate powder pre- and post-processing. The tool can predict the distortion, residual stress, and (for reactive processes) reaction completion fraction of complex parts after curing/debinding, sintering, and infiltration processes. These predictions are key metrics industry uses to optimize these processes to produce dense, defect-free, stable components.

HU, TIANCHEN (GARY)↗

DOE OSTI2020

Infrared Optical Constants from Pressed Pellets of Powders: I. Improved n and k Values of (NH4)(2)SO(4)from Single-Angle Reflectance

In combination with other parameters, the real, n(?), and imaginary, k(?), components of the complex refractive index, = n + ik, can be used to simulate the optical properties of a material in different forms, e.g. its infrared spectra. But obtaining reliable values of the optical constants n/k for solid materials is challenging due to the lack of optical quality specimens, usually crystals, large enough to measure. An alternative to crystals is to press the powder into a uniform disk. We have produced pellets from ammonium sulfate, (NH4)2SO4, powder and derived the pellets’ n and k values via single-angle reflectance using a specular reflectance device in combination with a Fourier transform infrared spectrometer. The single-angle technique measures amplitude of light reflected from the material as a function of wavelength over a wide spectral domain; the optical constants are determined from the reflectance data using the Kramers-Kronig relationship. We investigate several parameters associated with the pellets and pellet formation and their effects upon delivering the most reliable n/k values. Parameters studied include pellet diameter, mass and density (void space), drying, grinding, sieving and particle size in the pellet formation, as well as pressing pressure and duration. Of these parameters, using size-selected mixtures of dried, small (< 100 µm) particles and pressing at = 10 tons for at least 30 minutes were found key to forming highly reflective samples. Comparison to two sets of previous literature n(?) and k(?) values obtained from crystalline (NH4)2SO4 both as crystal reflectance as well as extinction spectra of aerosols measured in a flow tube show reasonable agreement, but suggests the present values, as confirmed from two independent techniques, represent a substantial improvement for n/k values for (NH4)2SO4, also demonstrating promise to measure the optical constants of other materials.

Optical constants, index of refraction, single-ang↗

DOE OSTI2024

Spatiotemporally Registered In-Situ and Ex-Situ Datasets for Laser-based Blown Powder Directed Energy Deposition

This dataset is comprised of in situ sensing data collected during laser-based, blown powder directed energy deposition (DED) of Inconel 718 representing eight different printing conditions: (1) nominal, (2) +15% scan speed, (3) +12% laser power, (4) +42% powder feed rate, (5) +100% jerk limit, (6) +10% layer height, (7) +20% hatch spacing, (8) +20% carrier gas flow. All eight DED builds constructed an identical test coupon geometry consisting of geometric features representative of industrial print requirements (e.g., bulk deposition, thin walls, overhangs). In situ data consists of xyz-coordinates (100 Hz) and on-axis melt pool camera video (60 Hz), both of which have been temporally synchronized to spatially map the melt pool camera data. In addition, post-build X-ray computed tomography (XCT) data for each of the eight test geometries have been spatially registered to the recorded xyz-coordinates, allowing for comparisons between melt pool camera data and flaws identified in the XCT data.

additive manufacturing↗

DOE OSTI2021

Combining Spectroscopic Techniques to Determine the Optical Constants of Powdered Lactose

A method for deriving the optical constants (n/k) of organic powdered materials using pressed pellets in the mid-infrared spectral range is introduced that combines variable angle spectroscopic ellipsometry and transmission spectroscopy. The approach is applied to lactose, in which three different forms of pellets were pressed and measured: A pure lactose pellet and a mixed lactose/KBr pellet with a large analyte percentage were used for ellipsometric measurements, and a KBr transmission pellet with only a small analyte percentage were used for transmission measurements. The transmission data provide an initial set of oscillators and improve the spectral fitting of weak absorption features (k<0.01). Ellipsometric data for the pure and mixed pellets are then fit simultaneously to derive the final n/k values for lactose from 6000-400 cm-1. An alternative method just using the ellipsometric data from the mixed pellet and the transmission data is also presented and shows good agreement with the multi-sample analysis, providing a simpler method for powders that do not press easily into pure pellets. Finally, the derived optical constants are used to model the reflectance data, demonstrating a good match with the measured reflectance spectra if non-idealities are included.

Yokosuk, Michael O.↗

DOE OSTI2025

Real-time single-element-detection structured illumination optical metrology for laser powder bed fusion

Laser powder bed fusion (LPBF) is a type of metal additive manufacturing which could benefit from improved process monitoring to improve quality control. We demonstrate, for the first time to our knowledge, the coaxial monitoring of melt track formation in steel powder with spatial frequency modulation imaging (SPIFI), an enhanced-resolution imaging technique which uses a photodiode to record one-dimensional images. Using a custom live-display software and a high-speed SPIFI geometry, we offset the SPIFI field of view from the fusing beam to monitor different regions of the LPBF melt pool and surrounding area. This demonstrates the potential of SPIFI to monitor spatial features within the melt pool in real-time with increased data efficiency.

Hunter, Scott (ORCID:0009000886150312)↗

DOE OSTI2020

Implementing an aerosol dynamic shape factor for cerium oxide powder

The shape factor (X B ) of bulk powder CeO 2 (cerium oxide) particles is estimated to be X B = 1.34 (dimensionless). This is defined in relation to the measured aerated bulk density (0.91 g cm -3 , Hosokawa Micron, Summit NJ, 2018) of the CeO 2 powder. This information is used to determine the RRF (respirable release factor), and other parameters during drop test experiments of nuclear material storage containers at Los Alamos National Laboratory. The calculation is based on an experimental shape factor (X P = 2.66 dimensionless) for CeO 2 particles of the same (chain aggregate) morphology studied by other researchers. In that work, the shape factor was defined in terms of the maximum possible (compacted) density of CeO 2 material (7.13 g cm -3 ).

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2020

CISME report on experiments with HMX powder, PBX 9501 prills, and heated PBX 9501

The ability to predict post-ignition explosive response is relevant to explosives safety, particularly weapons assembly/disassembly operations that must operate under a sufficiently conservative safety basis to meet risk mitigation criteria for inadvertent nuclear detonation (IND). In particular, hazard determinations hinge on whether the PBX 9501 main charge can ultimately attain detonation from an initial, non-shock, ignition stimulus. The CISME experiment uses a spherical explosive charge, which is thermally ignited in the center using a fiber-delivered infrared laser pulse. This ignition mechanism - i.e. a localized thermal hotspot - is representative of the ignition-causing insults typical in accident scenarios, including low-velocity impact, drop, skid, and punch events. In fiscal year 2018 CISME experiments were conducted with pristine PBX 9501 spheres, confined and unconfined. Sub-detonative, low-violence reactions were observed. Here we report experiments conducted since 2018. The explosive charge was varied: experiments were conducted with room temperature pour-density HMX powder and prills of PBX 9501, and heated, thermally damaged PBX 9501. Experiments were conducted in a confined configuration, with two 4 mm-thick stainless-steel hemispherical shells bolted around the sphere. Detonation, via DDT (deflagration-to-detonation transition) was observed in the 3-inch diameter powdered HMX and the 6-inch diameter heated and thermally-damaged PBX 9501 tests. No transition to DDT was observed in smaller diameters for those configurations, and no DDT was observed for pour-density prills of PBX 9501 of any diameter. The original test series demonstrated that the response of pristine, undamaged PBX 9501 to a central ignition is relatively benign. This new test series shows that increased porosity, lack of polymer binders and thermal damage can greatly increase the violence of the post-ignition response, up to and including detonation. These results bridge the explosive response of PBX 9501 from sub-detonative through detonation as a function of diameter and provide valuable test cases for modeling efforts that strive to capture the DDT threshold. By exploring explosive response in a more representative 3D geometry, we can also benchmark these new results to more plentiful DDT datasets generated from testing in 1D tube confinement (the historical test configuration)–the configuration upon which almost all DDT models were developed.

42 ENGINEERING↗

DOE OSTI2021

Non-destructive evaluation of specific surface area of porous powder systems using experimental and virtual air permeametry

The correlation of flow-permeable surface area (FSSA) of porous initiator powder to its performance is well-established. More specifically, with age, such powders tend to coarsen (i.e., lose surface area), with an accompanying deterioration in performance. Commercially available permeametry apparatuses, such as that from Fisher Scientific or a more modern version from Micromeritics suffers from a few drawbacks, including: (1) the need to work with a fixed mass equivalent of 1 cm 3 of solid material; (2) the need to re-compact the material to monitor aging effects (which can introduce unwanted errors in the derived results); (3) a superfluous design that involves a reference plug, and for the older Fisher Scientific model, the need to eyeball water meniscus height that can lead to inaccuracies; (4) calibrated and tested only for samples packed in cylindrical geometries.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Carbon Electrodes from Powder River Basin Coal Development of Competitive Supercapacitor Electrodes of Diverse Compositions from Coal Extract

Recent demand for coal as a thermal energy source has decreased significantly and will likely continue to decrease as renewable sources of energy become more available and environmental concern and cost from burning coal makes it more costly than renewables. Given that Powder River Basin (PRB) coal in Wyoming has relatively low thermal energy, it is critical for Wyoming to employ coal in other capacities at the current energy transition period in history. Among many potential non-thermal applications, PRB coal can be utilized for membrane and electrode applications through the formation of carbon fibers. Coal-derived membranes can become low-cost, conductive membranes for use in electrodialysis separation processes. Carbon fiber derived electrodes have been shown be a cost-effective alternative to typical electrode materials that can meet or exceed the performance of current carbon electrode materials. In this talk, we demonstrate the manufacture of supercapacitor electrodes from Powder River Basin (PRB) coal-derived precursors. Specifically, PRB coal was treated in cheap solvents, partitioned into liquid extract and solid residue. An electropinning process has been developed that can convert either the liquid extract or the solid residue into carbon fiber mats. The electrospinning process is versatile with many tunable process parameters to achieve desirable physiochemical properties. For example, the coal residue can be manipulated by additional heat treatment, or by adding binders, salts, or surfactants to create a solution that can be electrospun into advanced carbon electrodes with desirable structural and surface properties. Similarly, some of the liquid extract (tar fraction) can be subsequently reacted with toluene diisocyanate to create resinous coal-derived polyurethane (PUs) as a spinnable ink. Carbon nanofiber mats made from our proprietary electrospinning process were further carbonized at temperature ranging from 700°C to 900°C before they are used as electrodes in supercapacitors. Galvanostatic charge-discharge (GCD) results show that the best performing PU fiber mats can deliver a specific capacitance of 604 F g -1 at the current density of 1 A g -1 . A carbon fiber mat from a different solvent extraction residue also delivered the specific capacitance of 508 F g -1 . These specific capacitance values are comparable to or better than commercial activated carbons, demonstrating the viability of manufacturing carbon nanofiber electrodes from coal without the use of a commercial polymer as binder in the spinning ink.

Cincotta, Robert↗

DOE OSTI2023

Characterizing PuO 2 Powder at Oak Ridge National Laboratory for the Multi-Lab Plutonium Process Signatures Campaign FY 2022

This report highlights the development of advanced analytical capabilities at Oak Ridge National Laboratory to characterize PuO 2 powder to support the Multi-Lab Plutonium Process Signatures Campaign in FY 2022. Two samples from a batch of 76 statistical precipitation runs were packaged and shipped from Pacific Northwest National Laboratory to Oak Ridge National Laboratory at the beginning of FY 2022. Techniques were used to characterize the sample, including powder X-ray diffraction, Raman spectroscopy, and diffuse reflectance spectroscopy. A brief description of each technique, the results and discussion, and future work are described in this report. Opportunities to expand current capabilities and include additional analytical capabilities for the next campaign will also be discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Measurements of emanation of Ar-37 and Ar-39 from irradiated rocks and powders

The emanation fraction of radionuclides has been highlighted as a known source of uncertainty in the estimation of radionuclide source signatures from underground nuclear tests and other nuclear activities, particularly in the case of activation products. A system was developed at Pacific Northwest National Laboratory to quantify the emanation fraction of argon from samples ranging in particle size from powder to small rocks. Seven materials, two powders and five rock types, were irradiated with fission spectrum neutrons and the emanation fraction of 37 Ar was measured. Additional measurements were made of the 39 Ar emanation for four of these materials.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Machine Learning Enabled Sensor Fusion for In-Situ Defect Detection in Laser Powder Bed Fusion

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. The current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques such as X-Ray Computed Tomography (XCT), which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. RTX Technologies Research Center (RTRC) has licensed ORNL’s Peregrine software package – a printer- and camera-agnostic data analytics tool designed specifically for detecting process anomalies using in situ data collected during powder bed printing. The goal of this project was to feed temporally rich, multi-modal sensor data, including visible light, integrated near infrared (NIR), and spatially mapped co-axial melt pool thermal emission data into Peregrine to enable detection of subsurface flaws. XCT data was used as ground truth training data to allow Peregrine’s deep learning algorithms to recognize anomalies in these complex data streams in both test artifacts and industrially relevant geometries. Completion of this program has seen the successful implementation of multi-modal, multi-layer sensor data footprints for training of machine learning models in Peregrine. Flaws detected in XCT data have been successfully detected directly from this in situ data footprint, and initial analyses of the in situ probability-of-detection has been conducted, showing performance levels commensurate with traditional non-destructive evaluation (NDE) methods. The in situ monitoring methodology was then applied to an industrially relevant component that was using post-build NDE, highlighting the utility of the proposed method for hard-to-inspect AM components. As a direct result of this program, two journal manuscripts [1], [2] have been published in Additive Manufacturing, with additional manuscripts planned following program completion.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder for Lithium-Ion Battery Anodes from Bulk Polyethylene Waste

Upcycling plastic waste into graphite can potentially be used to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing, and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create a stable carbon char, then be converted into a highly crystalline bulk graphite powder using a Fe-based catalytic process. The PE-derived graphite demonstrates excellent electrochemical performance as an anode material for lithium-ion batteries.

Gao, Yuan↗