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At least 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Pumped-Storage Hydropower using Abandoned Underground Mines (PSH-AUM) as an Innovative Energy Storage Technology for Fossil-Integrated Systems

Pumped-storage hydropower (PSH) provides around 95% of all utility-scale energy storage in the U.S. and globally. Additional deployment of PSH is hampered by excessively long permitting and commissioning requirements and is constrained to locations for which natural topography provides suitable elevation relief between the upper and lower reservoirs (the ΔH challenge). The purpose of this research was to evaluate Pumped-Storage Hydropower using Abandoned Underground Mines (PSH-AUM) as a means to solve the ΔH challenge and initiate the commercialization pathway for a promising new energy storage technology. Four primary tasks were conducted: Screening and ranking of candidate sites for project development; multiphase reservoir modeling to evaluate mine performance; techno-economic analysis and preliminary designs for PSH-AUM systems integrated with fossil-fuel power units; and stakeholder engagement to identify pathways to commercialization of this new technology. Key results were achieved in each of the four primary tasks. Candidate site screening determined that nearly 10,000 underground mines were spatially locatable, of which more than 100 sites appear suitable for integration with existing fossil power plants that are expected to remain in longer-term operation. Mine reservoir models were developed using PNNL’s STOMP simulator and parameterized using candidate site data to evaluate interactions with the surrounding groundwater system and confirm the potential for some mines to accommodate inflows and outflows on the order of 100 m3/s over 8-hour durations (1.6 GWh system) without excessive aqueous pressures. Techno-economic analysis resulted in a project cost optimization scheme to identify key sensitivities and the development of preliminary designs that can minimize overall costs of deployment. Finally, stakeholder engagement with industry, state government, and local economic development leaders confirmed the viability of PSH-AUM as a promising new technology. Our Phase I project results suggest that PSH-AUM technology has a domestic market potential on the order of $100+ Billion with ample space for technology development to commercialization within the next decade.

13 HYDRO ENERGY↗
DOE OSTI2024

Science Area 1: Standard Award: Model-Data Fusion to Examine Multiscale Dynamical Controls on Snow Cover and Critical Zone Moisture Inputs (Final Report)

In many mountain watersheds of the world, seasonal snowpacks play an important role as natural reservoirs of water. Seasonal snowpacks accumulate water during cold, wet winter months that subsequently melts. Downstream communities depend on water from melting seasonal snowpacks to support agricultural, industrial, and municipal water needs. Rapidly melting snowpacks can also present a flooding hazard, particularly if snowpacks melt at rates faster than anticipated and where adequate reservoir capacity is unavailable to buffer river flows associated with melt. The spatial and temporal dynamics of snow accumulation and melt also play an important role in supporting upland ecosystems in mountain landscapes. Snowmelt provides soil moisture that enable terrestrial ecosystem productivity and exert control on soil microorganisms that play important roles in global carbon cycles. Climate warming is gradually decreasing the amount of precipitation in mountain watersheds arriving as snow, presenting potentially profound disruptions to mountain ecosystems, as well as downstream delivery of water. The overarching goal of this project was to understand how interactions between the near-surface atmosphere and surface topography control the input, accumulation, retention, and release of water from mountain snowpacks. Over a 5-year period, this project pursued an approach combining high-resolution regional climate modeling, satellite and airborne remote sensing data, and ground-based observations to develop and analyze benchmark datasets to address overarching science questions and hypotheses. Key products include a continuous, long-term, high spatiotemporal resolution (1 km/1 hr) dataset characterizing key climate variables in the Upper Colorado River Basin. The dataset included historical estimates of precipitation, temperature, humidity, solar and longwave radiation, and wind speeds. Additionally, the project developed a 20+ year long, 30 m spatial, daily temporal multi-sensor dataset characterizing snow presence/absence in the East/Taylor River watersheds in the Central Rocky Mountains of Colorado. The project supported training of 1 postdoctoral scholar, 1 Ph.D. student, and 1 M.S. student.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Approach and Model Used to Represent a Timeline Analysis for Security Design Enhancements

Next-generation reactors will be able to use risk to inform and performance base the licensing of many aspects of the reactor, facility, and site design, including attributes of physical security. There are several factors related to security, including site topography, reactor design, and physical protection system components, to consider when designing the physical protection system into the overall facility design and plan of operation. With the versatility of advanced reactors, especially micro reactors, methods are needed to simplify and quickly evaluate potential timelines for designing a site configuration. This report describes an approach to generate qualitative and quantitative insights using a risk-informed simulation. The modeling process is described in detail, focusing on three aspects: (1) the facility mission time (the time required to control the plant until safe), (2) the attacker timeline (the time to potential sabotage), and (3) the response timeline (the time to counter the facility attack). The modeling capabilities also are extended to include facility physical phenomena such as thermal-hydraulics and heat transfer to capture realistic representation of dynamic changes to a facility. While the plant models and examples are hypothetical and do not represent a real facility, these modeling approaches could be used for future security-by-design engineering in advanced reactors. The outputs and insights from the modeling approach may be used to modify and optimize the security posture of a facility by efficiently making modifications to the model and seeing the overall impact from the modification. Lastly, use of the approach described in this report can also provide the technical basis for a physical protection program, describing how the facility and security strategy will cope with off-normal events.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Sensitivity of Near-Surface Variables in the RUC Land Surface Model in the Weather Research and Forecasting Model

In this study, we investigate the parametric sensitivity of near-surface variables, such as sensible heat flux, latent heat flux, ground heat flux, hub-height wind speed and land surface temperature, to the parameters used in the Rapid Update Cycle (RUC) land surface model (LSM) during a wintertime and summertime period. The model simulations are compared with observations collected from the second Wind Forecast Improvement Project (WFIP2) field campaign. The results suggest that parameters related to snow/ice and thermal processes can have significant impact on the simulated near-surface variables. Out of the 11 examined parameters, only 6 of them have considerable influences on the model behaviors and explain about 60 ~ 80 % of the estimated total variance of the simulated variables. In addition, the magnitude of the parametric sensitivity varies with season. For instance, parameters associated with snow/ice processes are dominant during the wintertime whereas those associated with thermal processes are more important during the summertime. Furthermore, the impact of the identified parameters on the simulated variables is highly related to the topography. There is a high degree of sensitivity to the parameter values over the slope region. This points out the importance of collecting field observations over steep areas to better quantity the appropriate values of key parameters. Overall, our findings provide a better understanding of the RUC LSM behavior associated with parameter uncertainties and can be used to improve the forecasting skill of land surface processes via calibration of the most uncertain model parameters.

17 WIND ENERGY↗
DOE OSTI2024

A multi-Physics Experiment for Low-Yield Nuclear Explosion Monitoring

A series of multi-physics experiments, referred to as Physics Experiment 1 (PE1) is underway at the United States’ Nevada National Security Site (NNSS). The PE1 series includes detonations of three underground chemical explosions in P-tunnel, with fully coupled (PE1 A), partially decoupled (PE1 D L ), and fully decoupled (PE1 B) emplacements. Canisters with gas tracers are imbedded in the explosives, and the tracers are released when the canister is destroyed by the detonation. A dedicated electromagnetic (EM) experiment (EMX) generates well-characterized EM signals at an underground location near the chemical explosive experiments. A series of atmospheric experiments (METEX, REACT, and METREX) release smoke and radioactive tracers around Aqueduct Mesa to test gas transport in complex topography. Each of the chemical explosive experiments includes a network of sensors to record seismic, acoustic, and electromagnetic waves, measurement of atmospheric conditions, and air sample collection for measurement of tracer concentration. EMX records EM signals underground and on the surface of Aqueduct Mesa. METEX, REACT, and METREX include measurement of atmospheric condition, as well as tracking smoke releases. REACT and METREX add low-level radioactive gas tracers to the atmospheric releases.

58 GEOSCIENCES↗
DOE OSTI2024

Nonsteady Load Responses of Wind Turbines to Atmospheric and Mountain-Generated Turbulence Eddies, With Impacts on the Main Bearing: A Validation Study

Previous computational and field experiments identify three characteristic time scales in the aerodynamic responses of utility-scale wind turbine loads to atmospheric boundary layer (ABL) turbulence: a 30-90 second time scale for the passage of high/low speed "streaks" through the rotor plane, the blade and rotor rotation time scales (approximately 1 to 5 seconds), and a sub-second time scale created by blade rotation through gradients within eddy coherent structure. In the current study we compare aerodynamic load responses from daytime ABL turbulence quantified with large-eddy simulation and a actuator line model of the NREL 5 MW wind turbine with analysis of field data from the NREL/GE 1.5 MW wind turbine 5 kilometers east of the Rocky Mountain Front Range in Colorado. In addition, we contrast the responses to the passage of the mountain-generated eddies embedded within the westerly winds with the ABL eddies embedded within northerly/southerly winds. These analyses are in context with the nonsteady forcing of the main bearing by the aerodynamic generation of nontorque bending moments on the main shaft. Potentially relevant to main bearing failure mechanisms, both computational and field data show that the magnitudes of turbulence-generated nontorque bending moments, that we show generate nonsteady force on the main bearing, are of order, and often larger than, torque (which underlies power). However, the temporal variations in these two responses are uncorrelated, implying that the aerodynamic mechanisms that drive power and main bearing response are fundamentally different. We find this to be the case in the field with both mountain-generated eddies (westerly winds) and ABL-generated eddies (northerly/southerly winds). Whereas the time and length scales are comparable, the mountain eddies were somewhat more energetic than the northerly/southerly ABL eddies. Interestingly, however, the fluctuations in nontorque bending moment that force the main bearing were found to be stronger when forced by the ABL eddies than the mountain eddies. The field studies validate the key results from the computational study and show even stronger response in the nontorque bending moment than in the computer simulations. In all cases, the torque and nontorque bending moments are temporally uncorrelated, torque and power are driven by time variations in rotor-averaged horizontal wind velocity and nontorque bending moments are driven by time changes in the degree of nonuniformity in the distribution of velocity over the rotor plane. Thus the results generalize the mechanisms underlying nonsteady aerodynamic forcing to classes of turbulence eddy types with strength of order or stronger than ABL eddies with transverse scale of order the wind turbine rotor. These include atmospheric turbulence eddies, topography-generated turbulence eddies and, by extension, impacts of turbine-wake-scale turbulence eddies on downstream wind turbine rotors.

17 WIND ENERGY↗
DOE OSTI2024

Optimizing DOE Opportunities to Research Land–Atmosphere Interactions in the U.S. Southeast (Workshop Report)

The southeastern United States (Southeast), with its complex and varied environments, is an area of tremendous economic, ecological, and societal importance to the country. The region is characterized by heterogeneous landscapes (i.e., geology and soil type) and a long history of human land use coupled with a warm temperature regime and high precipitation. As a result, soil erosion and deposition are pronounced, vegetation recovery is rapid, and human modification is extensive across the region. To better understand land–atmosphere interactions in this important and complex region, research communities supported by the U.S. Department of Energy’s Biological and Environmental Research (BER) program identified the Southeast as a priority region of interest. In fall 2024, the third Atmospheric Radiation Measurement Mobile Facility (AMF3), one of three mobile monitoring facilities designed to collect atmospheric and climate data from undersampled regions around the world, will begin operations in northwestern Alabama’s Bankhead National Forest (BNF). The AMF3-BNF 5-year deployment, from 2024–2029, will monitor the effects of feedbacks among aerosols, clouds, and precipitation on plant physiology and canopy-scale fluxes. It will also focus on scale aggregation to resolve the role of local forcing on larger-scale processes. To enable broader AMF3 involvement by the science community, the BER Environmental System Science (ESS) program organized the Southeast Land– Atmosphere Research Opportunities (SELARO) workshop in August 2023. The purpose was to identify gaps in scientific understanding of terrestrial processes in the Southeast (defined as states bounded by the Gulf of Mexico to the south, the Atlantic Ocean to east, the Mississippi River to the west, and extending through Tennessee and North Carolina to the north) and explore opportunities to use the AMF3-BNF deployment to coordinate and leverage research efforts across the region. Many parts of the Southeast have experienced repeated anthropogenic forcings. Farming, hunting, burning, and settlement of the region by Indigenous Peoples first shaped the distribution of plant communities, which in turn influenced European colonization patterns. Timber harvesting was common during the expansion of European settlements, and production forestry continues today. Agricultural production was extensive and then waned through the 20th century, creating a period of afforestation following agricultural abandonment. Today, many formerly agricultural landscapes are undergoing rapid urbanization and suburbanization. Overlying these patterns of anthropogenic land use are frequent disturbances from hurricanes, tornadoes, wildfires, drought, flooding, ice storms, and the occasional blizzard. An additional characteristic of the Southeast is its overall landscape complexity. Unlike the western United States, where broad expanses may share similar characteristics, Southeast topography, drainage patterns, vegetation, and development patterns vary widely across relatively small spatial scales (<1 km). This is due to the region’s underlying geology and soil development, species biodiversity patterns, and land ownership and use coupled with strong forces of erosion, weathering, and rapid plant growth in the warm, wet climate.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

An ML-based terrestrial data fusion and augmentation framework to enable advanced understanding of the terrestrial carbon and water interactions

Soil moisture is essential to the terrestrial carbon and water cycles and land–atmosphere interactions. There are various types of soil moisture data, and each type has the distinct spatiotemporal strengths and limitations, depending on the diverse applications and retrieval methodologies of different data types (Li et al., in review; The PNNL-82151 FY23 Report). However, the limitations of different soil moisture data in terms of accuracy and spatiotemporal coverage hinder our ability to further understand the soil moisture dynamics across scales. To have a gap free soil moisture data product with a fine spatiotemporal coverage and vertical profiles, we train extreme gradient boosting (XGBoost) models by using (1) in-situ soil moisture measurements from the International Soil Moisture Network (ISMN), (2) soil moisture from the ECMWF reanalysis (ERA) at the 9 km and sub-daily spatiotemporal resolution, (3) the Daymet meteorological fields, and (4) data products that characterize surface conditions, including soil texture, organic content, topography, vegetation type, and rooting depth. We use the trained XGBoost models that have consistent performance across seven soil layers, i.e., 0–5 cm, 5–10 cm, 10–20 cm, 20–40 cm, 40–60 cm, 60–100 cm, and 100–200 cm, and the gridded model predictors to generate a soil moisture data at the 1 km and daily spatiotemporal resolution for the Continental United States (CONUS) from 2001–2020. This dataset can be broadly used for Earth system model benchmark, monitoring extreme weathers, making informed decisions regarding agriculture, water resource management, climate change mitigation, and ecosystem preservation.

58 GEOSCIENCES↗
DOE OSTI2025

University of Hawai‘i, Shallow Geothermal Resources: Energy Technology Innovation Partnership Project (Final Report)

Scientists at Lawrence Berkeley National Laboratory (Berkeley Lab) have teamed up with the University of Hawai‘i at Manoa (UH Manoa) through the U.S. Department of Energy’s Energy Technology Innovation Partnership Project to evaluate the technological and market feasibility of shallow geothermal heat exchanger (GHE) technology. UH requested this analysis to evaluate opportunities in building cooling, energy efficiency, and emissions reduction applications in Hawai‘i. UH has an abundance of geologic and geothermal data and is looking to the national labs’ expertise to execute this analysis. UH is also interested in investigating policy, regulatory, and business conditions advantageous for implementation of a pilot project and more broad deployment of this technology in Hawai‘i. In many locations around the world, the demands for heating and cooling are roughly balanced over the course of the year, so GHEs do not cause significant long-term changes in subsurface temperature. This is not the case in Hawai’i, where the demand for heating is very small, meaning that, over time, GHEs will add heat to the subsurface. If temperatures increase significantly, GHE systems will not work as designed. Regional groundwater flow has the potential to sweep heated water away from boreholes, thereby maintaining the functionality of the GHE system. Significant regional groundwater flow requires two things: a sufficiently large driving hydraulic head gradient (usually closely related to surface topography), and sufficient porosity and permeability to enable groundwater to flow in large enough quantities to enable near-borehole temperatures to be maintained at ambient values. Hawai‘i’s volcanic terrain offers ample surface topographic variation. The lava itself shows an extremely large range of porosity and permeability, so sites with large enough values of these properties must be selected. Numerical modeling of coupled groundwater and heat flow can be used to determine how large is large enough. Primarily, closed-loop systems have been investigated. Other options considered are open-loop systems and using cool seawater as the chilling source. Project work investigated the feasibility of GHE technology at two scales. At the island scale, GIS layers of various attributes relevant for GHE were combined to develop an overall favorability map for employing GHE in Hawai‘i. At the local scale, a hydrogeologic model for the subsurface component of a closed-loop system was developed for the Stan Sheriff Center at the UH Manoa campus. This site is considered promising because the rock below and immediately downgradient of the borefield is highly permeable, consisting of a subsurface karst system (limestone containing high-permeability open channels), which is underlain by a thick, high-permeability fractured basalt. Moreover, the site is near the base of the Ko‘olau Range, providing a large hydraulic head gradient. Thus, groundwater flow through the site is expected to be large, enabling efficient removal of heated groundwater. A full-GHE-system model of the site was also developed, with a simplified representation of the subsurface, in which groundwater flow is not considered and heat transfer is purely by conduction. Using the building cooling load data provided by UH, simulation results show that with groundwater flow present, a GHE can operate successfully for at least 10 years, but with no groundwater flow, the subsurface begins to heat up after only one year of operation, making the GHE unviable within 2-6 years. The team also developed a techno-economic model for this site to compare the cost of cooling using a GHE system with the costs of operating the current air-conditioning system. The GHE system is advantageous economically if favorable tax incentives and interest rates can be obtained.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

NitroNet: Smart System to Quantify Nitrous Oxide Emissions

Agricultural croplands are the largest anthropogenic source of nitrous oxide (N 2 O), the third most important greenhouse gas. Emissions are characterized by “hot spots” and “hot moments”, meaning emissions are highly heterogeneous in space and time. Emissions are driven by nitrification and denitrification processes which depend upon complex factors such as soil characteristics (type, compaction, pH, moisture, topography), management practices (fertilizer type and application, tillage, crop type, field history, irrigation), biogeochemistry (organic carbon, microbial composition), and meteorology (precipitation, temperature, and wind). For these reasons, quantifying cropland emissions by either measurements or modeling is extremely challenging with large uncertainties.

09 BIOMASS FUELS↗
DOE OSTI2026

A North Carolina Retrospective: Major Outage Event Trends & Hurricane Helene using TASTI-GRID

The impacts of Hurricane Helene in September of 2024 showed magnifying effects on the number of major power outages reported both during and after the catastrophic weather event. The affected areas on the western edge of North Carolina, particularly Buncombe County (Asheville), endured a disproportionate number of outage impacts than surrounding counties atop the Piedmont Plateau. In 2024, each of the counties with the highest frequency of major outage events received at least one category of FEMA Disaster Declaration following Hurricane Helene. While the storm’s impacts certainly skewed 2024’s yearly major outage frequencies, we use TASTI-GRID to identify existence resilience challenges in the years prior to 2024 that may have given way to understanding how geography, topography, population density and other factors have compounding effects on existing resilience challenges in Buncombe and Mecklenburg counties, specifically.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Methods for Assessing Opportunities for Ring Dam Pumped Storage Hydropower

There is growing interest in new pumped storage hydropower (PSH) deployment to provide a range of grid flexibility, reliability, and resiliency services under an evolving and uncertain future power sector. The National Laboratory of the Rockies develops open PSH resource assessment and cost modeling tools to help evaluate PSH deployment opportunities, and this report describes expansions to those tools to consider an additional PSH system configuration - ring-dam reservoirs built on flat topographical features that are constructed from roller-compacted concrete material. This reservoir type is common among current PSH proposals and requires new methods to identify sites with this reservoir geometry throughout the United States and characterize the associated dam cost. Cost characterization for ring dam reservoirs required collecting historical dam cost data for earthen, rockfill, and roller-compacted concrete dams and regressing equations that relate costs between alternative materials. The ring dam site identification algorithm follows a 5-step procedure to identify circular geometry reservoirs. Once ring dam reservoirs are identified, they are then paired with potential dry-gully reservoirs, and the full set of potential paired reservoirs is cost-optimized to produce a least-cost set of potential PSH sites with no overlapping reservoirs. The resulting analysis found 1,663 ring-dam to dry-gully systems in the contiguous United States that are lower cost than any overlapping dry-gully to dry-gully systems, 29 in Alaska, and none in Hawaii or Puerto Rico. These systems constitute 1.5 TW of capacity in the contiguous United States and nearly 29 GW in Alaska, demonstrating that under suitable topography and head, ring-dam systems can provide cost-effective PSH opportunities. The greatest density of these opportunities are found in the intermountain west where there are mesas and flat land at bases of mountain ranges, but continued work could incorporate additional site characteristics or consider more complex reservoir shapes to find additional PSH deployment opportunities.

13 HYDRO ENERGY↗
DOE OSTI2026

TASTI-GRID: a holistic view of Florida's grid resilience opportunities

In December of 2025, the American Society of Civil Engineers updated Florida’s infrastructure grade to a ”C+” – reflecting overall investments in recent years. With the recommendation to further strengthen the electric grid and establish consistent building standards, extreme weather, aging infrastructure, and population in-migration are still compounding Florida’s grid vulnerabilities. Key challenges related to hurricane and other tropical & marine weather events are not unique to Florida. However, the state’s topography, location, demographics, and variation among rural and urban centers for tourism and industry, demonstrate the need for unique approaches to advancing critical infrastructure resilience, particularly for large concentrations of elderly residents or in areas of historic underinvestment. Florida’s grid asset advancements are credited with a reduction in average power outage durations. Yet, improvements since 2021 have set the stage for future resilience activities – as modernization efforts have greatly improved data collection – enabling better understanding of vulnerabilities and trends across counties and localities (particularly in Central Florida).

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Higrad/Firetec Wildfire Simulations

Wildfire behavior is a result of complex nonlinear interactions between a variety of physical processes and chemical reactions. Understanding the coupling between these components and the ways in which their interactions are influenced by their surrounding environment (e.g. winds, fuels, and topography) is a challenging undertaking. The IEEE SciVis 2022 Contest is focused on the visualization and analysis of simulations of wildfires.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Evaluation of Multi-Fidelity Soil Moisture Products Across the Continental United States

We have aggregated the most recent soil moisture datasets from a diverse range of sources, encompassing the Continental United States (CONUS). These sources encompass gridded data from remote sensing products, reanalysis products, machine learning-based projects, and land surface modeling products. Additionally, we have obtained and processed in-situ soil moisture observations from the International Soil Moisture Network. The collected datasets exhibit variations in both temporal and spatial resolutions. Among the 20 datasets, six are available at a spatial resolution of 0.25 degrees, while three are at a coarser spatial resolution of 25 km. To minimize spatial interpolation, we conducted data uncertainty evaluations at the 0.25-degree spatial resolution. For our data evaluations, we maintained a monthly temporal resolution, which effectively captures soil moisture seasonality and interannual variability. Our data processing strategy preserves the raw data and interpolated data at their original temporal resolutions. Datasets with higher temporal resolutions, including daily, three-hourly, and hourly datasets, are set aside for subsequent analyses. These analyses will delve into topics such as soil moisture changes and recovery during extreme weather events. Furthermore, we have processed auxiliary data to enhance our evaluation, leveraging tools such as Google Earth Engine. This includes incorporating topography data, land use land cover data, Köppen-Geiger climate classification, and more to provide a comprehensive assessment from multiple sources.

Li, Lingcheng↗
DOE OSTI2023

Global 1km Land Surface Parameters for Kilometer-Scale Earth System Modeling

Earth system models (ESMs) are progressively advancing towards the kilometer scale (k-scale). However, the surface parameters for Land Surface Models (LSMs) within ESMs running at the k-scale are typically derived from coarse resolution and outdated datasets. This study aims to develop a new set of global land surface parameters with a resolution of 1 km for multiple years from 2001 to 2020, utilizing the latest and most accurate available datasets. Specifically, the datasets consist of parameters related to land use and land cover, vegetation, soil, and topography. The new land surface parameters are tailored to meet the emerging needs of k-scale LSMs and ESMs modeling with significant implications for advancing our understanding of water, carbon, and energy cycles under global change. The data is published via PNNL DataHub.

Li, Lingcheng↗
DOE OSTI2024

On the Nature of Recoater Damage Powder Spreading Mechanics

Laser powder bed fusion (PBF-LB) additive manufacturing gained popularity for the creation of high mix, low volume parts for defense and commercial applications. Parts made via PBF-LB can be difficult to qualify due to their variation in performance, even within the same build. During the build process, regions of the PBF-LB recoater blade could be subject to damage by spatter or superelevation in the powder bed. As a result, the worn recoater can potentially cause spreading defects in the localized topography profile, which could in turn cause porosity or form deviations. These process concerns are not well understood for their criticality and subsequent impact on part quality. This study will investigate the mechanics of recoater damage through two experimental builds. Post-mortem inspection of the failure region will be conducted with laser line profilometry and will help propose a better understanding of the criticality of extreme recoater damage.

In-Situ Monitoring↗