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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Rapid assessment of interfacial stabilization mechanisms of metastable precipitates to accelerate high-temperature Al-alloy development

Precipitate strengthened high-temperature alloys are currently used in safety-critical applications. Understanding precipitate stability and solute segregation mechanisms at high temperatures is key to designing high-strength alloys. Rapid in-situ approaches, therefore, are pivotal in accelerating the alloy design process. Hereby using the test case of a promising high-temperature Al-Cu-Mn-Zr alloy, we demonstrate the value of in-situ atom probe tomography coupled with in-situ transmission electron microscopy to reveal atomic-scale mechanisms that lead to the emergence of non-equilibrium solute segregation. Mn and Zr segregation at strengthening precipitate(θ’)-matrix interface increases the kinetic barrier for phase transformation thus retaining high-temperature strength.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A Novel Method for Preoperative Positioning of Total Ankle Replacement Using 3D Digital Model

Abstract Objective To establish a digital model of the ankle joint through 3D imaging technology and explore the preoperative placement of ankle replacement prostheses. Methods Computed tomography images of intact ankle joints from 54 cases in the outpatient and inpatient departments of our hospital were collected; according to the INBONE® total ankle system surgery process, the surgery model and surgical osteotomy were finished using MIMICS based on computer simulation method. The shortest distance was measured between the center point and the anterior, posterior, medial, and lateral, respectively, to ensure the precise position of the ankle replacement prosthesis by digital simulation surgery. The relationship between the two variables was analyzed by bivariate correlation analysis. Results The dataset of this study included 48 cases of the sub‐data set (26 males and 22 females) and included 27 cases of left ankle and 21 cases of right ankle. The average medial malleolar angle was 18.67°± 2.87°, the average amount of bone resection was 12.13 ± 1.86 cm 3 , the mid‐anterior distance was 1.72 ± 0.19 cm, the mid‐posterior distance was 2.00 ± 0.19 cm, the ratio of mid‐anterior to mid‐posterior was 0.87, the mid‐medial distance was 1.26 ± 0.17 cm, the mid‐lateral distance was 1.19 ± 0.16 cm, and the ratio of mid‐medial to mid‐lateral was 1.06. After osteotomy, the anteroposterior diameter was 3.73 ± 0.32 cm, the transverse diameter was 2.46 ± 0.27 cm, and the ratio of anteroposterior diameter to transverse diameter was 1.53. In the bottom view, the shape after osteotomy is rectangular. The mid‐anterior distance was strongly negatively correlated with age, the mid‐anterior distance and the amount of bone resection, the mid‐medial distance and the amount of bone resection, the mid‐lateral distance and the amount of bone resection, the mid‐lateral distance and the anteroposterior diameter, the anteroposterior diameter and the transverse diameter were all strongly positively correlated. Conclusion The projection point of the lower tibia centerline on the tibial horizontal osteotomy surface is located at a position slightly anterior to the midpoint of the transverse diameter after ankle arthroplasty. The rational positioning of the total ankle replacement is located at both a position slightly anterior to the midpoint of the transverse diameter and midpoint of the anteroposterior diameter, which can be used as a reference method before total ankle arthroplasty surgery.

Wu, Shi‐xun↗
DOE OSTI2022

Defect and satellite characteristics of additive manufacturing metal powders

Metal additive manufacturing (AM) requires high-quality metal powders to three-dimensionally (3D) print metallic components with complex and customizable geometries. The lack of quantification of AM metal powders creates quality control challenges for 3D printed components, increases the uncertainty of printing reliability and net cost of inspected and certified printed components, and reduces the recyclability of used powders. However, critical characteristics of AM metal powders that are decisive factors for the 3D printing process, such as internal porosity, contamination, and satellite feature, remain ambiguous. In this work, we developed a novel approach to 3D quantify key characteristics of AM metal powders down to individual particles by using high-resolution synchrotron x-ray computed tomography. Empowered by the penetrative capability of high-energy x-ray, internal porosity and contamination within as-atomized metal powders from high-entropy alloys to nickel-based superalloys were evaluated. Additionally, the newly-developed dispersion method enables the homogeneous separation of individual particles, and consequently, results in the implementation of 3D particle shape analysis. To resolve a major challenge of identification and quantification of satellite-feature particles in as-atomized AM metal powders, the satellite features were quantitated by modeling and analyzing the shape parameter of local thickness variance. Furthermore, the 3D analytical methods of particle assessment in this study can be applied to other materials systems like rock, food, and pharmaceutical particles, and provide insights for process optimization across powder metallurgy, concrete, food and pharmaceutical manufacturing, and AM industries.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Fracture Network Localization Preceding Catastrophic Failure in Triaxial Compression Experiments on Rocks

We quantify the spatial distribution of fracture networks throughout six in situ X-ray tomography triaxial compression experiments on crystalline rocks at confining stresses of 5–35 MPa in order to quantify how fracture development controls the final macroscopic failure of the rock, a process analogous to those that control geohazards such as earthquakes and landslides. Tracking the proportion of the cumulative volume of fractures with volumes >90th percentile to the total fracture volume, ∑ v 90 / v t o t indicates that the fracture networks tend to increase in localization toward these largest fractures for up to 80% of the applied differential stress. The evolution of this metric also matches the evolution of the Gini coefficient, which measures the deviation of a population from uniformity. These results are consistent with observations of localizing low magnitude seismicity before large earthquakes in southern California. In both this analysis and the present work, phases of delocalization interrupt the general increase in localization preceding catastrophic failure, indicating that delocalization does not necessarily indicate a reduction of seismic hazard. However, the proportion of the maximum fracture volume to the total fracture volume does not increase monotonically. Experiments with higher confining stress tend to experience greater localization. To further quantify localization, we compare the geometry of the largest fractures, with volumes >90th percentile, to the best fit plane through these fractures immediately preceding failure. The r 2 scores and the mean distance of the fractures to the plane indicate greater localization in monzonite than in granite. The smaller mean mineral diameter and lower confining stress in the granite experiments may contribute to this result. Tracking these various metrics of localization reveals a close association between macroscopic yielding and the acceleration of fracture network localization. Near yielding, ∑ v 90 / v t o t and the Gini coefficient increase while the mean distance to the final failure plane decreases. Macroscopic yielding thus occurs when the rate of fracture network localization increases.

58 GEOSCIENCES↗
DOE OSTI2024

Materials Characterization: A Primer for Solid Phase Processing Applications

The Pacific Northwest National Laboratory (PNNL) undertook the Materials Characterization, Prediction, and Control (MCPC) Laboratory Directed Research and Development (LDRD) Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems produced via advanced manufacturing methods, such as solid phase processing, for use in national security and advanced energy applications (Smith 2021). As a two-year LDRD investment requiring focused research, the MCPC project applied only a subset of the wide range of available destructive and nondestructive characterization methods to provide data to the predictive modeling and data analytics tasks. The purpose of this report is to review a wide range of destructive and nondestructive characterization methods that are relevant in solid-phase processing (SPP) applications, but not necessarily applied in the MCPC Project as a guide to the planning of characterization activities in future research. Particular attention is given to measured characteristics that can correlate to other material characteristics, with a particular interest in nondestructive evaluation (NDE) that can be applied to samples obtained in the MCPC Project. Destructive examinations include tensile tests, optical and electron microscopy, micro-hardness, and residual stress tests. NDE tests include surface visual inspection, eddy current examination for cracks, 4-point potential drop, ultrasound, x-ray, and computed tomography.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Quantification of the Impact of Acidified Brine on Fracture-Matrix Transport in a Naturally Fractured Shale Using in Situ Imaging and Modeling

Understanding flow, transport, chemical reactions, and hydromechanical processes in fractured geologic materials is key for optimizing a range of subsurface processes including carbon dioxide and hydrogen storage, unconventional energy resource extraction, and geothermal energy recovery. Flow and transport processes in naturally fractured shale rocks have been challenging to characterize due to experimental complexity and the multiscale nature of quantifying continuum scale descriptions of mass exchange between micrometer-scale fractures and nanometer-scale pores. In this study, we use positron emission tomography (PET) to image the transport of a conservative tracer in a naturally fractured Wolfcamp shale core before and after the core was exposed to low pH brine conditions. Image-based experimental observations are interpreted by fitting an analytical transport model to fracture-containing voxels in the core. Results of this analysis indicate subtle increases in matrix diffusivity and a slightly more uniform fracture velocity distribution following exposure to low pH conditions. These observations are compared with a multicomponent one-dimensional reactive transport model that indicates the capacity for a 10% increase in porosity at the fracture-matrix interface as a result of the low pH brine exposure. This porosity change is the result of the dissolution of carbonate minerals in the shale matrix to low pH conditions. Further, this image-based workflow represents a new approach for quantifying spatially resolved fracture-matrix transport processes and provides a foundation for future work to better understand the role of coupled transport, reaction, and mechanical processes in naturally fractured rocks.

58 GEOSCIENCES↗
DOE OSTI2021

Characterization of damage processes in Montney siltstone under triaxial compression using acoustic emission and diagnostic imaging

SUMMARY Crack nucleation and rock failure processes in a fine-grained siltstone (Montney Formation) under triaxial compression are investigated using combined diagnostic techniques, including ultrasonic-wave measurement, acoustic-emission (AE) monitoring, computed tomography (CT) scanning, and thin-section imaging. The sample displays a weak-to-moderate inherent seismic anisotropy and noticeable stress-induced anisotropy prior to failure. No AE event was detected until the applied axial stress reached 95 per cent of the peak value. The signal-to-noise ratio is relatively low, however, and detectable AE events are more diffuse than those observed in highly brittle rocks. The AE locations correlate with a shear fracture zone imaged by CT scanning. AE moment-tensor analysis reveals that events with larger relative magnitudes are characterized by high volumetric (tensile or compressive) components, and the initiation of the failure zone is dominated by combined shear-tensile (ST) failure. Stress inversion of the AE events with high tensile components is in good agreement with the known applied stress. Microscopic imaging of thin sections from the failed sample shows that the failure zone is an en echelon structure consisting of a major fracture with branching micro and minor cracks. This failure mechanism is consistent with a ST source mechanism and is interpreted to be associated with the fine granular structure and mineral composition of Montney siltstone.

Jia, Suzie Q. (ORCID:0000000326496190)↗
DOE OSTI2024

Advanced Instrumentation for Metal Additive Manufacturing

Laser powder bed fusion (LPBF) is the most widely used process for metal additive manufacturing (AM), particularly where complex geometries provide performance advantages unattainable with traditional manufacturing techniques. However, LPBF is highly sensitive to innate variability in both the powder spreading and fusion steps, often leading to defects such as pores that are difficult to detect yet significantly impair component mechanical properties and fatigue life. This thesis presents a range of novel instruments enabling both precise assessment of powder layer characteristics and in-situ thermal metrology of metal AM to advance the quality control of LPBF. First, leveraging a custom X-ray microscope and a radiation-transport model developed through this work, transmission X-ray imaging is used to study spreading of thin metal powder layers. Effective layer depth is directly mapped at a process-relevant size scale, surpassing optical techniques that can only estimate local deposition from layer surface topography. Layer packing density and quality are shown to be influenced by powder flowability and particle size relative to nominal powder layer thickness. Layer quality is additionally connected to the geometry of the spreading implement and its velocity. This technique and its presented findings enable pairing feedstocks with spreading strategies that create layers with consistent packing density and uniformity. Second, a twofold approach is employed to optically interrogate the laser fusion step of LPBF for observing signatures of defect formation. Aperture division multiplexing is conceptualized, providing for simultaneous laser delivery and high-fidelity infrared (IR) process monitoring through a common optic. In-situ microscopy at 50 μm spatial resolution and at mid-wave IR wavelengths is proven readily achievable with the first purpose-built optic of this type. Next, a bespoke imaging spectrometer, along with a temperature-emissivity separation technique, is used to retrieve accurate process temperatures over a 1000 K range. Data from these instruments are correlated to porosity as fine as 4.3 μm in two LPBF test artifacts, as verified using computed tomography (CT), establishing the viability of robust optically-based component qualification.

Penny, Ryan↗
DOE OSTI2024

On the instrument-dependent appearance of ion dissociation events in atom probe tomography mass spectra

The successful application of atom probe tomography (APT) relies on the accurate interpretation of the mass spectrum (i.e. m/z histogram) from a sample. Some materials yield mass spectra that are amenable to a straightforward peak assignment/ranging, however, there are many materials that produce mass spectra with features that defy simple interpretation. One such example is Ga 2 O 3 which yields mass spectra containing several broad and difficult to interpret features. Herein, we study the GaO 2+ → O 1+ + Ga 1+ dissociation and we explain how this dissociation process gives rise to broad and previously unassigned features in the mass spectrum. Trajectory simulations are performed for the dissociation reaction utilizing realistic electrostatic models and compared to experiments using commercially available straight flight and reflectron based local electrode (LE) APT instruments. It is shown that the appearance of these features is strongly dependent on the specific design of the time-of-flight (ToF) mass analyzer. Additionally, we explore how various experimental parameters can affect the appearance of the dissociation process in the one-dimensional (1D) mass spectrum and in the two-dimensional (2D) correlation histogram. While the focus of this work is on a particular dissociation process related to Ga 2 O 3 , the understanding gained in the course of these simulations and experiments should be applicable to the interpretation of dissociation processes in other materials.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Identifying build orientation of 3D-printed materials using convolutional neural networks

The advent of additive manufacturing (AM) processes brought with it intense research into various materials and manufacturing processes. At the same time, the need for validation of material properties, as well as study and forecasting of aging, has arisen. Modern imaging techniques, like X-ray computed tomography (XCT), are a convenient vehicle for such studies; however, the large datasets they produce require novel analysis techniques to efficiently extract critical information. Here, we present our work on developing a 3D extension of the ResNet architecture to distinguish between two build orientations of tensile bars produced by AM. Using only information from XCT, our method achieves a 99.3% correct classification at a misidentification of 1%.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Adsorption separation of heavier isotope gases in subnanometer carbon pores

Isotopes of heavier gases including carbon ( 13 C/ 14 C), nitrogen ( 13 N), and oxygen ( 18 O) are highly important because they can be substituted for naturally occurring atoms without significantly perturbing the biochemical properties of the radiolabelled parent molecules. These labelled molecules are employed in clinical radiopharmaceuticals, in studies of brain disease and as imaging probes for advanced medical imaging techniques such as positron-emission tomography (PET). Established distillation-based isotope gas separation methods have a separation factor ( S ) below 1.05 and incur very high operating costs due to high energy consumption and long processing times, highlighting the need for new separation technologies. Here, we show a rapid and highly selective adsorption-based separation of 18 O 2 from 16 O 2 with S above 60 using nanoporous adsorbents operating near the boiling point of methane (112 K), which is accessible through cryogenic liquefied-natural-gas technology. A collective-nuclear-quantum effect difference between the ordered 18 O 2 and 16 O 2 molecular assemblies confined in subnanometer pores can explain the observed equilibrium separation and is applicable to other isotopic gases.

36 MATERIALS SCIENCE↗
DOE OSTI2026

New developments in structure-property and amorphous materials research at the upgraded 16-BM-B Paris-Edinburgh press station at HPCAT

Beamline 16-BM-B of the High-Pressure Collaborative Access Team (HPCAT) at the Advanced Photon Source (APS) provides a Paris-Edinburgh press program to probe the structure and properties of crystalline and amorphous materials up to 12 GPa at room temperature or 7 GPa at 2000°C. During the recent APS upgrade, 16-BM-B undertook major improvements to its instrumentation and measurement techniques. The upgrade includes the addition of a 1.2 m horizontal “condenser” mirror and a new variable-sized collimation system, the combination of which decreases the acquisition time for energy dispersive X-ray diffraction measurements by a factor of 10 when compared to pre-upgrade measurements. The addition of a new Ge energy-sensitive detector and DANTE (XGLab) digital pulse processor allows for processing the increased diffraction counts with minimal deadtime. In addition to upgraded beamline components, new techniques are being developed for eventual release to the user community, including electrical resistivity and tomography measurements.

APS upgrade↗
DOE OSTI2020

We Know Where We Don't Know: 3D Bayesian CNNs for Credible Geometric Uncertainty

Deep learning has been successfully applied to the segmentation of 3D Computed Tomography (CT) scans. Establishing the credibility of these segmentations requires uncertainty quantification (UQ) to identify untrustworthy predictions. Recent UQ architectures include Monte Carlo dropout networks (MCDNs), which approximate deep Gaussian processes, and Bayesian neural networks (BNNs), which learn the distribution of the weight space. BNNs are advantageous over MCDNs for UQ but are thought to be computationally infeasible in high dimension, and neither architecture has produced interpretable geometric uncertainty maps. We propose a novel 3D Bayesian convolutional neural network (BCNN), the first deep learning method which generates statistically credible geometric uncertainty maps and scales for application to 3D data. We present experimental results on CT scans of graphite electrodes and laser-welded metals and show that our BCNN outperforms an MCDN in recent uncertainty metrics. The geometric uncertainty maps generated by our BCNN capture distributions of sigmoid values that are interpretable as confidence intervals, critical for applications that rely on deep learning for high-consequence decisions.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Computer-aided Veress needle guidance using endoscopic optical coherence tomography and convolutional neural networks

During laparoscopic surgery, the Veress needle is commonly used in pneumoperitoneum establishment. Precise placement of the Veress needle is still a challenge for the surgeon. In this study, a computer-aided endoscopic optical coherence tomography (OCT) system was developed to effectively and safely guide Veress needle insertion. This endoscopic system was tested by imaging subcutaneous fat, muscle, abdominal space, and the small intestine from swine samples to simulate the surgical process, including the situation with small intestine injury. Each tissue layer was visualized in OCT images with unique features and subsequently used to develop a system for automatic localization of the Veress needle tip by identifying tissue layers (or spaces) and estimating the needle-to-tissue distance. We used convolutional neural networks (CNNs) in automatic tissue classification and distance estimation. In conclusion, the average testing accuracy in tissue classification was 98.53 ± 0.39%, and the average testing relative error in distance estimation reached 4.42 ± 0.56% (36.09 ± 4.92 μm).

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

3D analysis of TRISO fuel compacts via X-ray computed tomography

In this study, low-enriched uranium oxycarbide (LEUCO) and surrogate tristructural isotropic (TRISO)- coated-particle compacts with particle volumetric packing fractions of 25%, 40%, and 48% were imaged utilizing X-ray-computed tomography. Subsequent 3D image analysis identified and further quantified kernel size, sphericity, and observed porosity. In addition, the spatial distribution, coordination number, and kernel-nearest neighbors were analyzed and compared for the different packing fractions. Metrics such as observed porosity and sphericity enabled quantification and screening for abnormal kernels within TRISO compacts. Assessment of TRISO particle location confirmed and further quantified a non-uniform distribution of TRISO particles with the spatial distribution in the radial direction being roughly described as a dampened sinusoidal function. The amplitude and frequency of this non-uniform distribution increased with increasing packing fraction. Measured kernel-nearest neighbor distances indicated two regions along the radial surfaces of compacts where TRISO particles are more likely to be in intimate contact with one another. These regions were found: (1) at upper and lower faces of compacts (i.e., corners); (2) offset ~10% of a compact's length from the axial center near the exterior surface. Within these regions, small quantities of defective TRISO surrogate particles (48% packing fraction) and defective LEUCO TRISO particles (40% packing fraction) were found. No defective particles were found within 25% packing fraction LEUCO TRISO compacts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Additively manufactured Al-Ce-Ni-Mn alloy with improved elevated-temperature fatigue resistance

Here, the high cycle fatigue behavior of an additively manufactured (AM) Al-10.5Ce-3.1Ni-1.2Mn wt% alloy was evaluated at 350 °C. The measured fatigue strength of 50 MPa at this temperature is comparable to the most fatigue resistant wrought Al alloys (2618-T6 and 7079-T6) at 315 °C. Refinement of pore populations through advanced AM processing in the examined alloy led to oxide inclusions becoming dominant fatigue crack initiation sites. The distribution of microstructural features that determine crack initiation was measured by X-ray computed tomography and served as input to make fatigue strength model predictions with various methodologies. A Monte-Carlo based approach that was previously applied to predict the fatigue strength of cast aluminum alloys through pore size distributions yielded accurate predictions for the fatigue strength of this AM alloy. Given the tunability of defect distributions in AM alloys, the sensitivity of the Al-Ce-Ni-Mn alloy fatigue behavior to defect distributions and outstanding elevated-temperature fatigue resistance of this alloy; the results together suggest the possibility of a new generation of fatigue-resistant alloys produced by the additive manufacturing route.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of impurities on phase transformation and precipitation in a low-carbon steel

Impurity elements have been added to a commercial low carbon steel grade to simulate the levels that could arise as a result of increased scrap recycling during steel production. In this study, continuous cooling transformation (CCT) diagrams were constructed for the steels with varying levels of impurities, and it is shown that impurities suppress the phase transformation across a wide range of cooling rates. It was found that a step was formed in the start temperature curve, separating the reconstructive and displacive transformations. The influence of impurities on both the reconstructive transformation and displacive transformation are discussed. Additionally, Cu precipitates were observed using scanning transmission electron microscopy (STEM) in the highest impurity-containing steel after slow cooling (0.05°C/s), fast cooling (5°C/s) and interrupted cooling. It was found that the precipitation kinetics is in the following order: cementite within the secondary phase and cementite at secondary phase-ferrite interface> ferrite grain boundaries> ferrite grain matrix. Atom-probe tomography (APT) revealed Cu precipitates formed on the surface of cementite lamellae, but not within it. This work offers insights for the phase transformation control and precipitation regulation during the thermomechanical processing of low carbon steels containing impurity elements due to scrap recycling.

36 MATERIALS SCIENCE↗