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All sources NASA NTRS DOE OSTI

DOE OSTI2019

Computational Study of Short-Pulse Laser-Induced Generation of Crystal Defects in Ni-Based Single-Phase Binary Solid–Solution Alloys

Single-phase concentrated solid–solution alloys exhibit enhanced mechanical characteristics and radiation damage resistance, making them promising candidate materials for applications involving an exposure to rapid localized energy deposition. We use large-scale atomistic modeling to investigate the mechanisms of the generation of vacancies, dislocations, stacking faults, and twin boundaries in Ni, Ni 50 Fe 50 , Ni 80 Fe 20 , and Ni 80 Cr 20 targets irradiated by short laser pulses in the regime of melting and resolidification. The decrease in the thermal conductivity and strengthening of the electron–phonon coupling due to the intrinsic chemical disorder in the solid-solution alloys are found to have important implications on localization of the energy deposition and generation of thermoelastic stresses. The interaction of the laser-induced stress waves with the melting front is found to play a key role in roughening of the crystal–liquid interface and generation of dislocations upon the solidification. A common feature revealed in the structural analysis of all irradiated targets is the presence of high vacancy concentrations exceeding the equilibrium values at the melting temperature by about an order of magnitude. On the basis of the results of molecular dynamics simulations of solidification occurring at fixed levels of undercooling, the generation of vacancies is correlated with the velocity of the solidification front, and the processes responsible for creating the strong vacancy supersaturation are revealed. The suppression of the vacancy generation in the solid–solution alloys is also revealed and related to combined effect of enhanced vacancy mobility and higher energy of the vacancy formation in the alloy systems. The analysis of the first atomic shells surrounding the vacancy sites in Ni–Fe alloys uncovers the preference for the vacancy sites to be surrounded by Fe atoms and suggests that atomic-scale chemical heterogeneities may play an important role in defining the behavior and properties of the single-phase concentrated solid-solution alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Solidification cracking of refractory alloys: a computational and machine learning study to investigate composition-dependence for improved weldability and additive manufacturability

Large-batch numerical, CALculation of PHAse Diagrams (CALPHAD)-based solidification cracking calculations are performed and then analyzed with machine learning methods to generate models that relate chemistry of refractory alloys to cracking susceptibility. Kou’s solidification cracking index is used to study the refractory alloys including O, N, C binary mixtures with Mo, Ta, Nb, and W, the molybdenum-based TZM, Niobium-based C103, and Tantalum-based T111 and Ta-10 W, as well as hypothetical refractory ternary alloys. Findings strongly validate Kou’s Crack Susceptibility Index (CSI) against Varestraint test data for Nb- and Ta-based alloys, establishing CSI thresholds where refractory alloys with CSI < 15,000 K are likely weldable, CSI > 15,000 K are prone to cracking, and CSI > 25,000 K are likely unweldable (or unprintable). Furthermore, interstitial elements C, N, and O significantly increase crack susceptibility, with some existing material specifications coinciding with peak cracking susceptibility concentrations. Finally, machine learning-derived elemental potency factors enable rapid prediction of CSI from alloy chemistry for C103, TZM, Ta-10 W, and T-111 alloys. These results provide practical guidance for feedstock selection, powder reuse limits, and alloy specification amendments for welding and additive manufacturing applications.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Assessment of phase constitution on the Al-rich region of rapidly solidified Al-Co-Fe-Cr alloys

The formation of quasicrystalline approximants in rapidly solidified Al-Co-Fe-Cr alloys was investigated. Alloys of atomic composition Al{sub 71}Co{sub 13}Fe{sub 8}Cr{sub 8}, Al{sub 77}Co{sub 11}Fe{sub 6}Cr{sub 6} and Al{sub 76}Co{sub 19}Fe{sub 4}Cr{sub 1} were produced using melt spinning and arc melting methods and their microstructural characterization was carried out by X-ray diffraction, scanning electron microscopy and transmission electron microscopy. Up to the present there is no consensus in the literature regarding the formation of quasicrystalline phase or quasicrystalline approximants in the Al{sub 71}Co{sub 13}Fe{sub 8}Cr{sub 8} alloy. This work presents, for the first time, a detailed structural characterization of selected alloys in the Al-Co-Fe-Cr system close to the atomic composition Al{sub 71}Co{sub 13}Fe{sub 8}Cr{sub 8}. The results indicated the samples to be composed, mostly, by two intermetallic phases, which are quaternary extensions of Al{sub 5}Co{sub 2} and Al{sub 13}Co{sub 4} and are quasicrystalline approximants. Although the Al{sub 5}Co{sub 2} phase has already been reported in the Al{sub 71}Co{sub 13}Fe{sub 8}Cr{sub 8} alloy, the presence of the monoclinic Al{sub 13}Co{sub 4} is now identified for the first time in the as cast state. In the binary Al-Co system a quasicrystalline phase is known to form in a rapidly solidified alloy with composition close to the monoclinic and orthorhombic Al{sub 13}Co{sub 4} phases. This binary quasicrystalline phase presents an average valence electron per atom (e/a) between 1.7 and 1.9; thus, in addition to the Al{sub 71}Co{sub 13}Fe{sub 8}Cr{sub 8} alloy, the compositions Al{sub 77}Co{sub 11}Fe{sub 6}Cr{sub 6} and Al{sub 76}Co{sub 19}Fe{sub 4}Cr{sub 1} were chosen to be within the region of formation of the quaternary extension of the Al{sub 13}Co{sub 4} phase and also within the (e/a) of 1.7 to 1.9. However, no quasicrystalline phase is present in any of the studied alloys. The Al-Co-Fe-Cr system, around the compositions studied, is composed of quaternary extensions of Al-Co intermetallic phases, which present solubility of Fe and Cr at Co atomic sites. - Highlights: •The Al rich region of the AlCoFeCr system is studied concerning phase formation on rapidly solidified alloys. •The alloys were composed mostly by quaternary extensions of Al-Co intermetallic phases. •Al{sub 5}Co{sub 2} and Al{sub 13}Co{sub 4} were the major phases observed in the alloys and are approximants of a quasicrystalline phase. •No quasicrystalline phase was observed in the Al{sub 71}Co{sub 13}Fe{sub 8}Cr{sub 8} composition.

36 MATERIALS SCIENCE↗

NASA NTRS1986

Undercooled and rapidly quenched Ni-Mo alloys

Hypoeutectic, eutectic, and hypereutectic nickel-molybdenum alloys were rapidly solidified by both bulk undercooling and melt spinning techniques. Alloys were undercooled in both electromagnetic levitation and differential thermal analysis equipment. The rate of recalescence depended upon the degree of initial undercooling and the nature (faceted or nonfaceted) of the primary nucleating phase. Alloy melts were observed to undercool more in the presence of primary Beta (NiMo intermetallic) phase than in gamma (fcc solid solution) phase. Melt spinning resulted in an extension of molybdenum solid solubility in gamma nickel, from 28 to 37.5 at % Mo. Although the microstructures observed by undercooling and melt spinning were similar the microsegregation pattern across the gamma dendries was different. The range of microstructures evolved was analyzed in terms of the nature of the primary phase to nucleate, its subsequent dendritic growth, coarsening and fragmentation, and final solidification of interfenderitic liquid.

Tewari, S. N.↗

NASA NTRS1987

Undercooled and rapidly quenched Ni-Mo alloys

Hypoeutectic, eutectic, and hypereutectic nickel-molybdenum alloys were rapidly solidified by both bulk undercooling and melt spinning techniques. Alloys were undercooled in both electromagnetic levitation and differential thermal analysis equipment. The rate of recalescence depended upon the degree of initial undercooling and the nature (faceted or nonfaceted) of the primary nucleating phase. Alloy melts were observed to undercool more in the presence of primary Beta (NiMo intermetallic) phase than in gamma (fcc solid solution) phase. Melt spinning resulted in an extension of molybdenum solid solubility in gamma nickel, from 28 to 37.5 at. pct Mo. Although the microstructures observed by undercooling and melt spinning were similar, the microsegregation pattern across the gamma dendries was different. The range of microstructures evolved was analyzed in terms of the nature of the primary phase to nucleate, its subsequent dendritic growth, coarsening and fragmentation, and final solidification of interfenderitic liquid.

Tewari, S. N.↗

DOE OSTI2018

Ion Exchange Column Thermal Modeling: Prevention of Process Effluent Boiling - 18577

The Savannah River Site treats and disposes of legacy high-level waste, which resulted from 60 years of nuclear material production, medical research, and other nuclear related work. Complex mixtures of soluble and insoluble solids occupy tanks of which the South Carolina Department of Health and Environmental Control recognizes as the single largest environmental risk state-wide. The risk is reduced through removal, treatment, and solidification of decontaminated salt waste. Presently, SRS decontaminates the soluble salt component of the waste, a solution containing actinides and cesium, via implementation of the Actinide Removal Process and the Modular Caustic Side Solvent- Extraction Unit. Caustic solvent extraction is set to increase in scale by late 2018, with startup of the newly constructed Salt Waste Processing Facility. In conjunction with Salt Waste Processing Facility startup, Savannah River Remediation has been tasked by the Department of Energy to demonstrate modular ion exchange technology. The Tank Closure Cesium Removal project aims to demonstrate the feasibility of modular ion exchange processes for future Department of Energy applications. The Tank Closure Cesium Removal system is scheduled to begin operation in mid-2018. Dissolved salt solution, or influent, will be fed through a filter and ion exchange columns in lead-lag configuration, producing effluent. The effluent is fed to a separate high-level waste tank, for future disposition at Salt-stone Production Facility. Once the demonstration project is complete, the loaded ion exchange columns will be purged, dried, and placed in interim safe storage, awaiting final disposition. The ion exchange media selected for the Tank Closure Cesium Removal system is Honeywell UOP IONSIV{sup C} R-9120. The media is a prime candidate for separation of cesium from radioactive high-level waste. UOP R-9120{sup C} is inorganic and has high capacity, selectivity, and affinity for cesium. During operation, influent is fed to the ion exchange columns, contacting UOP R-9210{sup C} packed within the media vessel. Contact initiates loading of isotopes, and given ample time the solid phase (ion exchange media) and solution achieve thermodynamic equilibrium. UOP R-9120{sup C} is a prime candidate for separation of cesium and dissolved fission products. Although the properties of UOP R-9120{sup C} are favorable for separation, the same properties lead to accumulation of a heat source in the ion exchange bed. Cesium-137 and its daughter product, barium-137 m, generate a clear majority of heat (i.e. ∼ 94%). During operation salt solution flows through each column and transports heat from the ion exchange bed. Once operation is terminated, the effluent contained within the porous bed volume becomes essentially static. In the absence of engineering controls, the heat generated may boil the effluent. Rapid vaporization of aqueous salt solution would lead to bed over pressurization. Over pressurization and an associated release of high-level waste would result in adverse impacts to human health and the environment. This paper focuses on modeling the heat transfer associated with the Tank Closure Cesium Removal system ion exchange column. The model evaluates the maximum heat generation and the associated radionuclide loadings that prevent boiling within of the media vessel, under no flow conditions. A safety significant control, maintaining loadings less than the established loading limit ensures associated impacts to human health and the environment are prevented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Savannah River Remediation Liquid Waste Operations Lifecycle Savings through a Lean Business System at the Savannah River Site - 17245

Savannah River Remediation (SRR) was contracted by the U.S. Department of Energy (DOE) to manage its liquid waste project at the Savannah River Site. The liquid waste project is a unique, high hazard nuclear waste treatment and disposal facility consisting of 51 one million-gallon underground waste tanks, a solvent extraction processing unit, a vitrification facility for the highest radioactive waste, and a grout solidification and disposal facility for lower radioactive decontaminated salt solution. Our Project mission is to treat the nuclear waste and close the associated storage and treatment facilities, of which, 8 tanks have been closed to date. The Lean philosophy took root decades ago in the manufacturing sector and started with the work of W. Edwards Deming and his contemporaries. In more recent years the process has matured in the Toyota Production System and migrated into fields as diverse as services industries, health-care, and now the DOE complex. At SRR, a Lean business management system was adopted to address site inefficiencies, aging infrastructure concerns and budget constraints. With yearly escalation and flat budgets, continuous improvement is taking on a larger role - improving the work accomplished for each dollar. This paper focuses on the program results achieved to date, including the lifecycle savings identified through the Rapid Improvement Event (RIE) process. The RIE process is a Lean tool which creates a cross-functional team to analyze, develop and implement improvements for a given process. DOE-EM has recently emphasized the value of contractor's continuous improvement programs through their implementation of Plan of Action and Milestone (POAM): Goal 2 (Increase Efficiency/Improve Performance) Reduce EM Operations Cost in FY16. POAM Goal 2 was a FY 16 effort to achieve 5% cost savings across most programs. This past year's cost savings initiatives will likely become a trend as DOE and its contractors look to do more with less. In support of our own business objectives, as well as, DOE's motivation to improve efficiencies, SRR has held over one hundred formal Lean events and dozens of 5S events that have driven improvement across the Project, including tank closure and production facilities. These improvements have significantly reduced the time required to process material and achieve the overall goal of hazard reduction and tank closure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2003

First Post-Flight Status Report for the Microgravity Science Glovebox

The Microgravity Science Glovebox (MSG) was launched to the International Space Station (ISS) this year on the second Utilization Flight (UF2). After successful on-orbit activation, the facility began supporting an active microgravity research program. The inaugural NASA experiments operated in the unit were the Solidification Using a Baffle in Sealed Ampoules (SUBSA, A. Ostrogorski, PI), and the Pore Formation and Mobility (PFMI, R. Grugel, PI) experiments. Both of these materials science investigations demonstrated the versatility of the facility through extensive use of telescience. The facility afforded the investigators with the capability of monitoring and operating the experiments in real-time and provided several instances in which the unique combination of scientists and flight crew were able to salvage situations which would have otherwise led to the loss of a science experiment in an unmanned, or automated, environment. The European Space Agency (ESA) also made use of the facility to perform a series of four experiments that were carried to the ISS via a Russian Soyuz and subsequently operated by a Belgium astronaut during a ten day Station visit. This imaginative approach demonstrated the ability of the MSG integration team to handle a rapid integration schedule (approximately seven months) and an intensive operations interval. Interestingly, and thanks to aggressive attention from the crew, the primary limitation to experiment thru-put in these early operational phases is proving to be the restrictions on the up-mass to the Station, rather than the availability of science operations.

Baugher, Charles R., III↗

DOE OSTI2016

Effect of cooling rate and Mg addition on the structural evaluation of rapidly solidified Al-20wt%Cu-12wt%Fe alloy

The present work examines the effect of Mg contents and cooling rate on the morphology and mechanical properties of Al{sub 20}Cu{sub 12}Fe quasicrystalline alloy. The microstructure of the alloys was analyzed by scanning electron microscopy and the phase composition was identified by X-ray diffractometry. The melting characteristics were studied by differential thermal analysis under an Ar atmosphere. The mechanical features of the melt-spun and conventionally solidified alloys were tested by tensile-strength test and Vickers micro-hardness test. It was found that the final microstructure of the Al{sub 20}Cu{sub 12}Fe samples mainly depends on the cooling rate and Mg contents, which suggests that different cooling rates and Mg contents produce different microstructures and properties. The average grain sizes of the melt spun samples were about 100–300 nm at 35 m/s. The nanosize, dispersed, different shaped quasicrystal particles possessed a remarkable effect to the mechanical characteristics of the rapidly solidified ribbons. The microhardness values of the melt spun samples were approximately 18% higher than those of the conventionally counterparts. - Highlights: •Quasicrystal-creating materials have high potential for applications. •Different shaped nanosize quasicrystal particles were observed. •The addition of Mg has an important impact on the mechanical properties. •H{sub V} values of the MS0, MS3 and MS5 samples at 35 m/s were 8.56, 8.66 and 8.80 GPa. •The volume fraction of IQC increases with increasing cooling rates.

36 MATERIALS SCIENCE↗

NASA NTRS2003

Data and Modeling of Dendrites Subject to A Step Change in Pressure (TDSE)

There is considerable interest in dendritic solidification because of the influence dendrites have in the determination of microstructure, and thereby in the physical properties of cast metals and alloys. Current theories and models of dendritic growth generally couple diffusion effects in the melt with the physics of the interface. Data and subsequent analysis prior of the tip growth speed and radii of thermal succinonitrile dendrites in the near-convection free, on-orbit, free-fall environment demonstrate that these theories yield predictions that are reasonably in agreement with the results of experiment. However, data and analysis for assessing the interfacial physics component of theory are not sufficiently detailed or definitive. To study fundamental aspects of dendritic interface stability, we are measuring and modeling the kinetics and morphology of dendrites as they evolve from one well-defined steady state at a pre-set supercooling, through a transient stage, to a different well-defined steady state. More specifically, we subject succinonitrile dendrites, growing under steady-state conditions, to a rapid change in pressure. This leads to a rapid change in thermal driving force from the corresponding change in both the equilibrium melting temperature due to the Clapeyron effect, and a change in the far-field temperature due to adiabatic temperature changes in the bulk liquid and solid. Subsequently, we observe transformations from a well-characterized initial state into a new steady-state. Initial data reveal that the dendrite tip velocity changes almost as fast as the pressure charges, while the tip radius changes occur more slowly, taking from 10 60 seconds depending on the size of the step change and the final supercooling. Computer modeling of this process shows both agreements and disagreements with the experimental data. In making these observations and measurements, we are gaining new understandings of interfacial dynamics and state-selection physics.

Koss, Matthew B.↗

NASA NTRS2003

Models of Mass Transport During Microgravity Crystal Growth of Alloyed Semiconductors in a Magnetic Field

Alloyed semiconductor crystals, such as germanium-silicon (GeSi) and various II-VI alloyed crystals, are extremely important for optoelectronic devices. Currently, high-quality crystals of GeSi and of II-VI alloys can be grown by epitaxial processes, but the time required to grow a certain amount of single crystal is roughly 1,000 times longer than the time required for Bridgman growth from a melt. Recent rapid advances in optoelectronics have led to a great demand for more and larger crystals with fewer dislocations and other microdefects and with more uniform and controllable compositions. Currently, alloyed crystals grown by bulk methods have unacceptable levels of segregation in the composition of the crystal. Alloyed crystals are being grown by the Bridgman process in space in order to develop successful bulk-growth methods, with the hope that the technology will be equally successful on earth. Unfortunately some crystals grown in space still have unacceptable segregation, for example, due to residual accelerations. The application of a weak magnetic field during crystal growth in space may eliminate the undesirable segregation. Understanding and improving the bulk growth of alloyed semiconductors in microgravity is critically important. The purpose of this grant to to develop models of the unsteady species transport during the bulk growth of alloyed semiconductor crystals in the presence of a magnetic field in microgravity. The research supports experiments being conducted in the High Magnetic Field Solidification Facility at Marshall Space Flight Center (MSFC) and future experiments on the International Space Station.

Ma, Nancy↗

DOE OSTI2017

Generation of nanocrystalline surface layer in short pulse laser processing of metal targets under conditions of spatial confinement by solid or liquid overlayer

The effect of spatial confinement by a solid or liquid overlayer on short pulse laser-induced surface microstructure modification is investigated in a series of large-scale atomistic simulations performed for Ag targets irradiated in the regime of melting and resolidification, below the thresholds for laser spallation and ablation. For Ag targets with free surfaces, the formation of a nanocrystalline region with random crystallographic grain orientation is observed under irradiation conditions leading to the generation of numerous sub-surface voids that slow down the solidification process. When no voids are generated, the resolidification produces grains misoriented with respect to the bulk of the target by just several degrees and separated from each other by low angle grain boundaries or dislocation walls. The presence of a liquid or solid overlayer suppresses nucleation of sub-surface voids, provides an additional pathway for cooling through the heat conduction to the overlayer, and facilitates the formation of nanocrystalline structure in a region of the metal target adjacent to the overlayer. Moreover, the stabilizing effect of the solid overlayer may result in an incomplete melting of metal in the vicinity of the interface, making it possible for grains growing from the interface to retain “memory” of the target orientation and to produce nanocrystalline interfacial region with small misorientation of grains with respect to the bulk of the target. In all simulations, the nanocrystalline layers generated by laser processing of single crystal Ag targets are characterized by a high density of stacking faults, twin boundaries, and point defects produced in the course of the rapid resolidification.

Chemistry↗

DOE OSTI2018

Microstructures, Martensitic Transformation, and Mechanical Behavior of Rapidly Solidified Ti-Ni-Hf and Ti-Ni-Si Shape Memory Alloys

In this work, the microstructure and mechanical properties of rapidly solidified Ti{sub 50−x/2}Ni{sub 50−x/2}Hf{sub x} (x = 0, 2, 4, 6, 8, 10, and 12 at.%) and Ti{sub 50−y/2}Ni{sub 50−y/2}Si{sub y} (y = 1, 2, 3, 5, 7, and 10 at.%) shape memory alloys (SMAs) were investigated. The sequence of the phase formation and transformations in dependence on the chemical composition is established. Rapidly solidified Ti-Ni-Hf or Ti-Ni-Si SMAs are found to show relatively high yield strength and large ductility for specific Hf or Si concentrations, which is due to the gradual disappearance of the phase transformation from austenite to twinned martensite and the predominance of the phase transformation from twinned martensite to detwinned martensite during deformation as well as to the refinement of dendrites and the precipitation of brittle intermetallic compounds.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Immobilization of Radioactive Materials Using Porous Iron Composite Media - 18582

High levels of nitrate (NO{sub 3}) derived from agriculture and naturally occurring radioactive materials (NORM), primarily uranium (U) and natural decay chain products that have been mobilized by the influx of oxygenated, high-alkalinity water, are a threat to shallow groundwater resources in California. Porous Iron Composite (PIC) materials were evaluated as a water treatment option in a series of batch experiments. While the use of Zero Valent Iron (ZVI) to address groundwater contaminated with NO{sub 3} or U has been demonstrated, the ability of PICs to chemically reduce and immobilize U and other associated contaminants in oxygenated alkaline groundwater where soluble uranyl-carbonate species dominate and high NO{sub 3} levels may compete for reductive capacity remain a concern. Additionally, ZVI materials have been used to immobilize other redox sensitive radionuclides (e.g., technetium-99 ({sup 99}Tc)) with limited success. Batch tests were conducted using an artificial groundwater surrogate (i.e., CAGW for California Groundwater) containing ∼ 100 mg L{sup -1} NO{sub 3}{sup -}, 200 mg L{sup -1} alkalinity, 100 μg L{sup -1} U, 100 μg L{sup -1} rhenium (Re) as a non-radioactive surrogate for the nuclear fission product technetium-99 ({sup 99}Tc), 100 μg L{sup -1} stable strontium (Sr) as a surrogate for radium (Ra) and the fission product strontium-90 ({sup 90}Sr), and 50 μg L{sup -1} arsenic (As), a common groundwater contaminant. Five gram samples of the PIC material were reacted with 200 mL of CAGW under two different atmospheric conditions to evaluate the impact of O{sub 2}. Batch tests were also conducted in the presence and absence of another oxidized species, NO{sub 3}. At specific time intervals, a small aliquot was collected from each batch treatment for chemical analysis (i.e., U, Re, As, Fe, NO{sub 3}, etc.) and the pH and ORP of the remaining suspension was measured. The PIC was effective at fully reducing NO{sub 3}{sup -} levels over the extended reaction time, even though the reactor pH quickly increased above 8.0 during equilibration. Soluble levels of U and Re decreased in a similar fashion to NO{sub 3}{sup -} in the presence and absence of O{sub 2}. Soluble As levels decreased more rapidly than other contaminants, but remained at ∼ 1 μg L{sup -1}. Very little nitrite (NO{sub 2}{sup -}) was detected in the batch tests, with NH{sub 4}{sup +} levels consistent with the amount of NO{sub 3}{sup -} reduced. Similar rates of immobilization for U, Re, and As were observed in the presence and absence of NO{sub 3}{sup -}. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Structural Dynamics in UV Curable Resins Resolved by In Situ 3D Printing X-ray Photon Correlation Spectroscopy

Additive manufacturing (AM) is a promising technique to rapidly produce polymeric materials into complex 3-dimensional (3D) geometries. While AM is widespread and relevant for a range of applications, implementation in industry has outpaced our fundamental understanding of polymer dynamics and structure development during the printing process. Characterization and quantification of such dynamics is necessary to optimize final material properties and design future materials and processes for 3D printing. Here, we utilize X-ray photon correlation spectroscopy (XPCS) to measure spatial and time-resolved, out-of-equilibrium dynamics during direct ink write (DIW) 3D printing. Specifically, we investigate the progression of structural dynamics in a dual cure (UV/thermal) nanocomposite during and directly after printing. As the filament is printed and cured in situ, the relaxation processes of the cross-linking network are measured through the dynamics of inorganic filler particles. The characteristic relaxation time of the dynamics is calculated through the intensity–intensity autocorrelation function g 2 and directly correlated to the printing process parameters, such as printhead velocity and UV light intensity. The time-resolved evolution of nanoscale dynamics follows a power-law dependence as the filament is cured. Additionally, bulk rheological characterizations reveal the macroscopic solidification of the resin, providing correlation of material properties across a wide range of length and time scales. Overall, the measurement of multiscale, out-of-equilibrium dynamics provides insight into the development of structure in polymer nanocomposite filaments during 3D printing and is used to further understand the influence of such parameters on the AM process.

36 MATERIALS SCIENCE↗

NASA NTRS1998

Interaction between Convection and Heat Transfer in Crystal Growth

Crystals are integral components in some of our most sophisticated and rapidly developing industries. Single crystals are solids with the most uniform structures that can be obtained on an atomic scale. Because of their structural uniformity, crystals can transmit acoustic and electromagnetic waves and charged particles with essentially no scattering or interferences. This transparency, which can be selectively modified by controlled additions of impurities known as dopants, is the foundation of modern electronic industry. It has brought about widespread application of crystals in transistors, lasers, microwave devices, infrared detectors, magnetic memory devices, and many other magnets and electro-optic components. The performance of a crystal depends strongly on its compositional homogeneity. For instance, in modern microcircuitry, compositional variations of a few percent (down to a submicron length scale) can seriously jeopardize predicted yields. Since crystals are grown by carefully controlled phase transformations, the compositional adjustment in the solid is often made during growth from the nutrient. Hence, a detailed understanding of mass transfer in the nutrient is essential. Moreover, since mass transfer is often the slowest process during growth, it is usually the rate limiting mechanism. Crystal growth processes are usually classified according to the nature of the parent phase. Nevertheless, whether the growth occurs by solidification from a melt (melt growth), nucleation from a solution (solution growth), condensation from a vapor (physical vapor transport) or chemical reaction of gases (chemical vapor deposition), the parent phase is a fluid. As is with most non-equilibrium processes involving fluids, liquid or vapor, fluid motion plays an important role, affecting both the concentration and temperature gradients at the soli-liquid interface.

Source record↗

NASA NTRS2021

Magma Ocean Evolution of the TRAPPIST-1 Planets

Recent observations of the potentially habitable planets TRAPPIST-1 e, f, and g suggest that they possess large water mass fractions of possibly several tens of wt% of water, even though the host star’s activity should drive rapid atmospheric escape. These processes can photolyze water, generating free oxygen and possibly desiccating the planet. After the planets formed, their mantles were likely completely molten with volatiles dissolving and exsolving from the melt. In order to understand these planets and prepare for future observations, the magma ocean phase of these worlds must be understood. To simulate these planets, we have combined existing models of stellar evolution, atmospheric escape, tidal heating, radiogenic heating, magma ocean cooling, planetary radiation, and water-oxygen-iron geochemistry. We present Magm Oc, a versatile magma ocean evolution model, validated against the rocky Super-Earth GJ 1132b and early Earth. We simulate the coupled magma ocean-atmospheric evolution of TRAPPIST-1 e, f, and g for a range of tidal and radiogenic heating rates, as well as initial water contents between 1 and 100 Earth oceans. We also reanalyze the structures of these planets and find they have water mass fractions of 0–0.23, 0.01–0.21, and 0.11–0.24 for planets e, f, and g, respectively. Our model does not make a strong prediction about the water and oxygen content of the atmosphere of TRAPPIST-1 e at the time of mantle solidification. In contrast, the model predicts that TRAPPIST-1 f and g would have a thick steam atmosphere with a small amount of oxygen at that stage. For all planets that we investigated, we find that only 3 ́5% of the initial water will be locked in the mantle after the magma ocean solidified.

Exoplanets↗

DOE OSTI2022

Transformational Challenge Reactor – On the Application of Design for Additive Manufacturing (DfAM) Techniques to the Conception of Nuclear Core

Additive manufacturing (AM) technologies are radically changing the way objects are designed and manufactured. They allow building by deposition and solidification of material layer by layer, enabling the possibility to create simple and complex features alike, almost seamlessly. Generally, the design optimization process requires to define objectives, design variables and constraints. Additive manufacturing does not challenge this process per se but does allow designers to completely redefine the constraints space as the ones originating from fabrication can be considerably relaxed compared to more “traditional” manufacturing. Thus, design optimization becomes naturally far more responsive to the actual physics being solved and considerably less influenced by fabrication limitations, leading to dramatically different designs. To take advantage of these new opportunities, so-called Designing for Additive Manufacturing (DfAM) techniques are emerging. Development of design techniques specifically tailored for additive manufacturing is warranted because, considering AM, the design space is typically considerably larger than with traditional manufacturing. The ability to explore the design space efficiently is of paramount importance for designers. This study proposes to investigate and apply some of these DfAM techniques to the conception of nuclear core. The goal being to assess if these new methods can be applied to core design and if core design could benefits from additive manufacturing technologies. After a brief investigation on the pertinence of some DfAM techniques for core design, algorithms are proposed and a workflow is established to carry neutronics and steady-state thermal-hydraulics analyses. To diminish the work load, the workflow has been automated using python modules. These modules allow the rapid creation of input files, post-treatment of output files and visualization. To test the pertinence of the proposed workflow, three test cases have been investigated: a research and test reactor, a micro-reactor and a space propulsion reactor. These test cases offered a variety of objectives, constraints and operating conditions. It is observed that the proposed workflow is capable of converging quickly and efficiently to valid design solutions. It is then concluded that DfAM techniques can be applied to core design.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗