Results for “variable conductance” — Page 21

DOE OSTI2020

Management of Risk and Uncertainty Through Optimized Co-Operation of Transmission Systems and Microgrids with Responsive Loads (Final Report)

The evolution of the power system to the reliable, efficient and sustainable system of the future will involve development of both demand- and supply-side technology and operations. Ambitious national and state-level goals around the decarbonization of electricity relies on the integration of very high levels of renewable resources, most of which are variable and intermittent. The use of demand response is an ideal approach to counterbalance the intermittency of renewable generation and brings the consumer into the spotlight. Until recently, very little research had been conducted on the co-optimization of these two systems due to computational limitations. However, advances in computational capabilities, and the judicious use of decomposition methods and innovative approximation methods for high-dimension dynamic programming made this goal a viable objective for this project, leading to a fundamental shift in the ability to integrate and fully utilize demand-side resources. To this end, the modeling framework developed introduces a novel co-optimization framework, to include the operations of both the transmission and distribution systems (or microgrids) in operational decision making. This framework was used to analyze renewable and distributed generation along with responsive demand and to compare the capability of co-optimized systems to perform with higher levels of variable renewables. Results show that the use of a bi-level optimization approach is an appropriate structure, capable of co-optimizing a transmission system with multiple distribution systems and microgrids. While increasing the number of connected systems provides increasing flexibility for renewables integration this can also the economic benefits to the low-voltage subsystems with each additional system connected. Comparison of a traditional single-level decision structure with the co-optimization approach illustrates a reduction in overall system cost under co-optimization, while specific cost allocations to transmission and distribution systems are changed.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Neutron transport methods for multiphysics heterogeneous reactor core simulation in Griffin

Griffin is a reactor physics application based on the Multiphysics Object-Oriented Simulation Environment (MOOSE). This work discloses the methods, algorithms, and implementation for simulating heterogeneous reactor dynamics models. Griffin utilizes a discontinuous finite-element method with discrete ordinates (DFEM-S ) to discretize the field variable of the multigroup neutron transport equation. Multiphysics feedback is handled using two-step tabulated cross-section methodology. Feedback quantities are evaluated using the MOOSE-MultiApp system to couple various engineering phenomena, such as heat conduction and thermal fluids. The multiphysics DFEM-S system is solved using fixed-point iteration with a fully asynchronous parallel sweeper, unstructured coarse-mesh finite difference acceleration, and a multi-timescale improved quasi-static method scheme. The implementation is applied to a multiphysics microreactor model, with two transients: one initiated by a single heat-pipe failure and another by control drum rotation. Importantly, these examples demonstrate the ability of Griffin to tractably solve the neutron transport equation considering seven independent variables and feedback.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Design Optimization for Weighted Conduction Loss Minimization in a Dual-Active-Bridge-Based PV Microinverter

This manuscript presents a harmonic-superposition based frequency-domain approach for analysis and optimal design of a single-stage DAB-based DC-AC converter used in low-voltage DC to high voltage AC applications, such as PV microinverter. Specifically, two topological variations and correspondingly different modulation strategies involving up to four control variables (three phase shifts and switching frequency) are analyzed. Optimal trajectories of control variables are determined that result in minimized transformer RMS current at a given average power, while enforcing near-uniform ZVS. To make the design process holistic, an outer optimization loop is used to determine optimal values for the power transfer inductance (integrated as the transformer’s leakage inductance) and turns ratio, which minimize the weighted-average conduction loss contribution to the microinverter’s CEC efficiency. Based on the optimization analyses, a 400 W microinverter prototype is built and experimental results at one operating point are presented, achieving a measured efficiency of 92.8%.

14 SOLAR ENERGY↗

DOE OSTI2025

Demographic drivers of gut microbiome diversity

Abstract The gut microbiome plays a central role in orchestrating metabolic, immune, and neurological functions essential for human health. While extensive research has explored the effects of diseases and pathological conditions on gut microbiome composition, the influence of demographic factors remains underexplored, limiting our understanding of microbiome variations in disease states. This study addresses this gap by investigating the impact of demographic variables, including age, sex, and geography, on gut microbiome diversity in healthy individuals. Using the American Gut Project’s extensive dataset and the QIIME2 bioinformatics pipeline, we conducted a comprehensive analysis of microbial profiles across diverse demographic groups. Our results revealed significant age-related shifts in microbial richness and composition, and geographic location strongly influenced phylogenetic diversity. In contrast, sex exhibited limited impact on microbial diversity within healthy BMI ranges. These findings highlight the critical role of demographic factors in shaping gut microbiome diversity, providing a foundational framework to better contextualize disease-related microbiome variations and advance personalized healthcare approaches.

Biotechnology & Applied Microbiology↗

DOE OSTI2024

Fault Dataset Development for VAV Terminal Units: Damper and Airflow Sensor Faults

This report analyzes field data to understand the impact of faults in variable air volume (VAV) terminal units on building indoor conditions and heating, ventilation, and air-conditioning (HVAC) system operations. The Oak Ridge National Laboratory (ORNL) team conducted field tests at the commercial building test facility known as ORNL’s Flexible Research Platform (FRP) building. Two specific faults-damper malfunctions and airflow sensor inaccuracies- were implemented, as these are common faults in VAV terminal units and can significantly impact HVAC system performance by increasing energy consumption, causing occupant discomfort, and raising operational costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Strength and ductility of additively manufactured 316L stainless steel: Impact of neutron irradiation and data variability

Here, this article presents the mechanical properties of additively manufactured (AM) 316L stainless steel processed via the laser powder bed fusion (LPBF) method, focusing on the effects of neutron irradiation on mechanical properties and the variability in strength and ductility data. The rapid melting-solidification process and multiple heating-cooling cycles inherent in LPBF typically result in a fine, metastable microstructure with significant local variability. AM 316L builds of varying thicknesses were fabricated, and SS-J3 miniature tensile specimens were machined from six different locations. These specimens were irradiated with fast neutrons to doses of 2 and 10 dpa at target temperatures of 300 °C and 600 °C. Post-irradiation tensile tests were conducted at room temperature, 300 °C, and 600 °C. Compared to conventional 316L stainless steel, AM 316L exhibited higher initial strength but lower ductility. Irradiation at 300 °C caused significant hardening and prompt necking at yield, with limited uniform ductility, although embrittlement was not observed up to 10 dpa. While neutron irradiation, particularly at 600 °C, increased the variability in strength and ductility data, no clear dependence of mechanical properties on build thickness or sampling location was found—contrary to the conventional perception that AM materials may exhibit high property variability. Furthermore, we observed that the variability in property data for LPBF-processed 316L was relatively low compared to that of wrought 316L stainless steel. This reduced variability in AM 316L steel may be attributed to its highly metastable, stress-containing microstructure, which is discussed in the context of general tensile property variations.

Additively manufactured 316L stainless steel↗

DOE OSTI2020

Measuring Transverse Displacements Using Unmanned Aerial Systems Laser Doppler Vibrometer (UAS-LDV): Development and Field Validation

Measurement of bridge displacements is important for ensuring the safe operation of railway bridges. Traditionally, contact sensors such as Linear Variable Displacement Transducers (LVDT) and accelerometers have been used to measure the displacement of the railway bridges. However, these sensors need significant effort in installation and maintenance. Therefore, railroad management agencies are interested in new means to measure bridge displacements. This research focuses on mounting Laser Doppler Vibrometer (LDV) on an Unmanned Aerial System (UAS) to enable contact-free transverse dynamic displacement of railroad bridges. Researchers conducted three field tests by flying the Unmanned Aerial Systems Laser Doppler Vibrometer (UAS-LDV) 1.5 m away from the ground and measured the displacement of a moving target at various distances. The accuracy of the UAS-LDV measurements was compared to the Linear Variable Differential Transducer (LVDT) measurements. The results of the three field tests showed that the proposed system could measure non-contact, reference-free dynamic displacement with an average peak and root mean square (RMS) error for the three experiments of 10% and 8% compared to LVDT, respectively. Such errors are acceptable for field measurements in railroads, as the interest prior to bridge monitoring implementation of a new approach is to demonstrate similar success for different flights, as reported in the three results. This study also identified barriers for industrial adoption of this technology and proposed operational development practices for both technical and cost-effective implementation.

42 ENGINEERING↗

DOE OSTI2020

Projected increase of the East Asian summer monsoon ( Meiyu ) in Taiwan by climate models with variable performance

Abstract The active phase of the East Asian summer monsoon (EASM) in Taiwan during May and June, known as Meiyu , produces substantial precipitation for water uses in all sectors of society. Following a companion study that analysed the historical increase in the Meiyu precipitation, the present study conducted model evaluation and diagnosis based on the EASM lifecycle over Taiwan. Higher and lower skill groups were identified from 17 Couple Model Intercomparison Project Phase 5 (CMIP5) models, with five models in each group. Despite the difference in model performance, both groups projected a substantial increase in the Meiyu precipitation over Taiwan. In the higher skill group, weak circulation changes and reduced low‐level convergence point to a synoptically unfavourable condition for precipitation. In the lower skill group, intensified low‐level southwesterly winds associated with a deepened upper level trough enhance moisture pooling. Thus, the projected increase in Meiyu precipitation will likely occur through the combined effects of (1) the extension of a strengthened North Pacific anticyclone enhancing southwesterlies; and (2) more systematically, the Clausius–Clapeyron relationship that increases precipitation intensity in a warmer climate. The overall increase in the Meiyu precipitation projected by climate models of variable performance supports the observed tendency toward more intense rainfall in Taiwan and puts its early June 2017 extreme precipitation events into perspective.

Tung, Yu‐Shiang↗

DOE OSTI2022

The value of in-reservoir energy storage for flexible dispatch of geothermal power

Geothermal systems making use of advanced drilling and well stimulation techniques have the potential to provide tens to hundreds of gigawatts of clean electricity generation in the United States by 2050. With near-zero variable costs, geothermal plants have traditionally been envisioned as providing “baseload” power, generating at their maximum rated output at all times. However, as variable renewable energy sources (VREs) see greater deployment in energy markets, baseload power is becoming increasingly less competitive relative to flexible, dispatchable generation and energy storage. Herein we conduct an analysis of the potential for future geothermal plants to provide both of these services, taking advantage of the natural properties of confined, engineered geothermal reservoirs to store energy in the form of accumulated, pressurized geofluid and provide flexible load-following generation. We develop a linear optimization model based on multi-physics reservoir simulations that captures the transient pressure and flow behaviors within a confined, engineered geothermal reservoir. We then optimize the investment decisions and hourly operations of a power plant exploiting such a reservoir against a set of historical and modeled future electricity price series. Further, we find that operational flexibility and in-reservoir energy storage can significantly enhance the value of geothermal plants in markets with high VRE penetration, with energy value improvements of up to 60% relative to conventional baseload plants operating under identical conditions. Across a range of realistic subsurface and operational conditions, our modeling demonstrates that confined, engineered geothermal reservoirs can provide large and effectively free energy storage capacity, with round-trip storage efficiencies comparable to those of leading grid-scale energy storage technologies. Optimized operational strategies indicate that flexible geothermal plants can provide both short- and long-duration energy storage, prioritizing output during periods of high electricity prices. Sensitivity analysis assesses the variation in outcomes across a range of subsurface conditions and cost scenarios.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

Temporal complementarity and value of wind-PV hybrid systems across the United States

Not Available

Harrison-Atlas, Dylan (ORCID:0000000252173355)↗

DOE OSTI2020

Mixed-Valent Copper Chalcogenides: Tuning Structures and Electronic Properties Using Multiple Anions

A series of mixed-anion copper chalcogenides have been prepared using solid-state methods including ACu 4.2 TeS 2 (A = K, Rb, Cs), which adopt the KCu 4 S 3 structure type. The mixedanion motif has an expanded sublattice, relative to KCu 4 S 3 , that can accommodate additional Cu atoms at its interstitial sites that are unoccupied in the parent structure. The variable temperature transport shows that the materials are p-type metals with carrier densities on the order of 10 21 cm -3 and room-temperature electrical conductivity as high as 4000 S cm -1 . Band structures calculated using density functional theory corroborate the experimental data and indicate that the interstitial Cu atoms lower the carrier concentration and increase the Fermi level of the materials. The layered structure has Te and S atoms occupying unique sites within the ACu 4.2 TeS 2 structure, where relatively hard S 2- anions prefer Wyckoff positions where they can form energetically favorable acid-base interactions with hard alkali cations. The phenomenon is observed in the related K 3 Cu 8 Te 2 S 4 system, which also has a fully ordered layered structure. Here, we believe that the report provides new chemical guidelines for targeting ordered multianion structures, as well as a unique method for tuning the electronic properties of metallic chalcogenides.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Specific conductivity and salinity of the Parker River, PIE LTER, Plum Island Sound MA, August-November 2022

This dataset contains specific conductivity and calculated salinity data of Parker River water at a tidal brackish wetland dominated by Typha angustifolia at the upper estuary of the Plum Island Sound in Newbury, Massachusetts (MA) within the Plum Island Ecosystems Long Term Ecological Research site (PIE LTER). Measurements were taken to evaluate temporal changes in surface water salinity in high frequency to characterize boundary conditions of soil and plant responses to changes in salinity. A PVC pipe was installed in a low elevation spot in the creek bank so that the bottom of the pipe sat on the sediment surface allowing flushing with water during flooding. Raw measurements were collected using an Onset HOBO U24-002 Saltwater Conductivity/Salinity data logger. The specific conductance and salinity measurements were corrected and calculated respectively using Onset’s HOBOware software and reference specific conductivity measurements taken in tandem with the first and last points recorded by the HOBO sensor. These reference measurements were taken using a HACH HQ14D Portable Conductivity Meter. Because of the installation design, only data one hour before and after high tide are used. Metadata files Typha_ctd_salinity_dd.csv and Typha_ctd_salinity_flmd.csv contain detailed information on data variables, sampling and QA/QC methods, and site location.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Specific conductivity and salinity of the Parker River, PIE LTER, Plum Island Sound MA, March-November 2023

This dataset contains specific conductivity and calculated salinity data of Parker River water at a tidal brackish wetland dominated by Typha angustifolia at the upper estuary of the Plum Island Sound in Newbury, Massachusetts (MA) within the Plum Island Ecosystems Long Term Ecological Research site (PIE LTER). Measurements were taken to evaluate temporal changes in surface water salinity in high frequency to characterize boundary conditions of soil and plant responses to changes in salinity. A PVC pipe was installed in a low elevation spot in the creek bank so that the bottom of the pipe sat on the sediment surface allowing flushing with water during flooding. Raw measurements were collected using an Onset HOBO U24-002 Saltwater Conductivity/Salinity data logger. The specific conductance and salinity measurements were corrected and calculated respectively using Onset’s HOBOware software and reference specific conductivity measurements taken in tandem with the first and last points recorded by the HOBO sensor. These reference measurements were taken using a HACH HQ14D Portable Conductivity Meter. Because of the installation design, only data one hour before and after high tide are used. Metadata files Typha_ctd_salinity_dd.csv and Typha_ctd_salinity_flmd.csv contain detailed information on data variables, sampling and QA/QC methods, and site location.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Impact of the Earthquake Rupture on Ground-Motion Variability of the 24 August 2016 M w 6.2 Amatrice, Italy, Earthquake

Here, the devastating 24 August 2016 M w 6.2 earthquake that struck Amatrice, Italy, marked the beginning of a prolonged seismic sequence dominated by three subsequent M w ≥6.0 events in the central Apennines region. The earthquake destroyed Amatrice’s historic center, claiming the lives of 299 individuals and causing widespread damage in the neighboring villages. The severity of the ground shaking, with a recorded maximum acceleration of 850 cm/s 2 on the east–west component at the Amatrice station, was far greater than the predicted acceleration based on the Italian ground-motion model (GMM). As pointed out by several investigations, the observed ground-motion amplitude and its spatial variability during the earthquake can be linked to specific rupture characteristics, including slip distribution and rupture directivity effects revealed by the observed data (Tinti et al., 2016; Pischiutta et al., 2021). In this study, we conducted physics-based 3D numerical simulations of ground motion for the Amatrice earthquake for frequencies up to 3 Hz. We employed a series of kinematic rupture models and a well-constrained local 3D velocity model incorporating surface topography. The kinematic rupture realizations were generated using multiscale hybrid and fully stochastic models, following the technique proposed by Graves and Pitarka (2016). We focused on assessing the sensitivity of near-fault ground-motion amplitudes to earthquake rupture characteristics, in particular, the spatial slip pattern. To evaluate the quality of our simulations, we employed goodness-of-fit measurements performed in comparisons of simulated and recorded ground motions. The simulated ground motions compare well with the recorded data and predictions from GMMs for Italy, ITA18 (Lanzano et al., 2019). However, we found that the simulated interevent ground-motion variability (randomness in the source process) of peak ground velocity, σ (PGV) is higher than the constant σ (PGV) predicted by conventional GMMs. Our simulations using several rupture scenarios demonstrate that the near-fault ground-motion amplification pattern is directly related to the slip distribution pattern.

3D Ground Motions Simulations↗

DOE OSTI2021

Defense Waste Processing Facility Nitric-Glycolic Flowsheet Chemical Process Cell Chemistry: Part 2

The conversions of nitrite to nitrate, the destruction of glycolate, and the conversion of glycolate to formate and oxalate were modeled for the Nitric-Glycolic flowsheet using data from Chemical Process Cell (CPC) simulant runs conducted by Savannah River National Laboratory (SRNL) from 2011 to 2016. The goal of this work was to develop empirical correlation models to predict these values from measurable variables from the chemical process so that these quantities could be predicted a-priori from the sludge or simulant composition and measurable processing variables. The need for these predictions arises from the need to predict the REDuction/OXidation (REDOX) state of the glass from the Defense Waste Processing Facility (DWPF) melter. This report summarizes the work on these correlations based on the aforementioned data. Previous work on these correlations was documented in a technical report covering data from 2011-2015. This current report supersedes this previous report. Further refinement of the models as additional data are collected is recommended. The glass REDOX depends on the concentrations of nitrate and manganese (oxidants), and of glycolate, formate, oxalate, carbon, and antifoam (reductants) in the melter feed. The waste sludge contains nitrite, nitrate, manganese (Mn), and oxalate. Virtually all of the nitrite is converted to nitrate or NO+NO 2 +N 2 O gases in the CPC. The portion of the nitrite converted to nitrate increases the amount of nitrate in the sludge. The amount of glycolate in the final melter feed depends on the amount of the glycolic acid feed that is destroyed. Similarly, the amounts of formate and oxalate formed during the decomposition of glycolic acid are required. The material balance on carbon was found to not close in most cases. Generally, there was less carbon at the end of testing compared to the inputs. The most uncertain product variable was glycolate, so material balances were performed where the glycolate concentration was adjusted, usually upward, to close the balance. Correlation versus the original, as-measured, data was generally poor, but correlation against the material balance adjusted values was greatly improved. It was also shown that the correlation of the measured REDOX versus the predicted REDOX was much better when the material balance adjusted glycolate values were used. Three data series were primarily used during the regressions of the data; these series were 1) Sludge Batch 9 NG flowsheet simulant runs NG51-62 (SB9-NG); 2) Scaled Runs + Bounding Hydrogen Runs (SR+BH); and 3) Runs GN43-50 and 57 (43-50,57). The glycolate destruction was found to correlate with acid stoichiometry (AS), percent reducing acid (PRA), and for some data series, headspace to simulant volume ratio (HSV), mercury (Hg), and nitrate. Although glycolate destruction for pairs of data series (e.g., [SB9-NG] and [SR+BH]) were found to depend on HSV, the combination of all three data series was not found to have significant dependence on this variable. The best model for glycolate destruction depended on AS, nitrate, and Hg. This model predicted the product glycolate compositions of the data to within 92-106%. The conversion of glycolate to formate was high when noble metals and Hg were not present, with values up to 100%. When noble metals and Hg were present, this conversion ranged from zero to 7%, and was dependent on AS. Lower AS gave higher conversions to formate. The conversion to oxalate was found to depend on the AS and the initial concentration of nitrite. An alternative fit versus AS and the form of ruthenium (Ru) used is a possible alternative. This fit was somewhat less statistically significant. This second model predicts that more oxalate is formed when Ru-nitrosyl nitrate is used rather than Ru chloride. The conversion of glycolate to oxalate ranged from zero to 6%. The conversion of nitrite to nitrate depended primarily on AS and PRA, with HSV and Hg being significant when these variables were varied. For multiple series of data, nitrite was also needed to SRNL-STI-2017-00172 5HYLVLRQ viL distinguish between data series, and the effect of HSV became insignificant. The best model for nitrite to nitrate conversion depended on AS, PRA, nitrite, and Hg. The 95% confidence intervals on the predicted values of glycolate destruction, glycolate to oxalate conversion, and nitrite to nitrate conversion were used to determine the uncertainty in the predicted REDOX when starting with only the composition of the sludge, AS, and PRA. Using the 95% confidences on an individual value (that is the confidence in getting a particular value for one single test as opposed to what the mean would be for multiple tests), the uncertainty in the predicted REDOX was calculated. The uncertainty in the actual product composition glycolate, oxalate, formate, and nitrate concentrations translated to an uncertainty in the REDOX value of ±0.1,which is approximately the uncertainty claimed in the REDOX model itself.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Testing to Evaluate Processes Expected to Occur during MSR Salt Spill Accidents

Obtaining a license for a new nuclear reactor requires the identification and assessment of the potential consequences of specified accident scenarios, which are achieved using accident progression models. Those models need to be parameterized and validated using experimental data, but existing experimental data addressing processes relevant to molten salt reactor accidents are sparse. Specifically, experimental data that quantify the sensitives of important processes to the initial conditions of the spill, the ambient environment, and the containment features are needed to parameterize individual process models. Integrated experiments that simulate accident scenarios are also needed to provide data for model validation, but these experiments will require the use of proven methods to quantify the processes under evaluation. The overarching objectives of this work are to develop the methods for simulating the targeted processes, to determine the effectiveness of the methods in producing the data required for model development, to generate data that can be used to parameterize individual process models, and to provide key insights into the behavior of spilled molten salt that should be considered in models. Experimental methods were designed to quantify aspects of individual processes expected to occur during or after a molten salt spill accident that will affect the fate of spilled molten salt and the radionuclides within. These processes include 1) molten salt spreading and heat transfer, 2) molten salt flowing and freezing in tubing, 3) stainless steel corrosion kinetics in molten salt, and 4) molten salt splashing and aerosol generation. The initial tests described in this report were conducted using eutectic FLiNaK to demonstrate the test methods, the data that are generated, and the analyses of the data to derive values needed for modeling. The primary variables that were tested include initial salt temperature and the presence of volatile surrogate fission products (e.g., cesium and iodine). The developed methods are shown to be effective in quantifying the desired processes and can be applied to study more complex salt compositions of interest to molten salt reactor developers, a wide range of environmental conditions of interest to modelers, and additional variables relevant to salt spill accidents. The developed methods and insights gained from laboratory tests can also be incorporated in future large-scale integrated tests used to simulate molten salt spill accidents.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗