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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 559 records · Page 31
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Two-fluid simulations of galaxy formation

We investigate the formation of galaxies and larger structure with a simulation modeling two gravitationally coupled fluids representing dark matter and baryons. The baryon gas dynamics are calculated with a smoothed particle hydrodynamics (SPH) method, and the physics modeled includes thermal pressure, shock heating, and radiative cooling. We simulate a 16 Mpc periodic cube with 64(exp 3) particles in each fluid and 10% baryon mass fraction. We confirm, for the first time experimentally, disk formation as a natural consequence of hierarchical clustering in a large-scale cosmological environment. The majority of isolated galaxies exhibit centrifugally supported disks. A power-law relation between cold baryonic mass and maximum rotation velocity is found, M varies as nu(sub rot)(exp alpha) with alpha = 2.5 after correcting for differential numerical resolution. Both the spatial and velocity distributions of the simulated galaxies are biased with respect to the dark matter. A counts-in-cells analysis indicates that an unphysical degree of merging in the central cluster is likely responsible for the antibias signal in the correlation function. A robust, scale-dependent velocity bias is measured. The ratio of galaxy to dark matter pairwise velocity dispersions on a scale of 1 Mpc is 0.7. The amplitude is only mildly dependent on redshift or mass cutoff and scales with separation as r(exp 0.2). The degree to which these results depend on numerical parameters is discussed. Mass resolution plays a key role in controlling the resulting fraction of cold, dense baryons. The mass fraction associated with galaxies decreases by a factor of approximately greater than 3 when the mass per particle is increased by a factor 8. Photoionization and energy input from supernova will have to be included to determine more carefully the fraction of highly dissipated material and the characteristics of the stellar component of galaxies.

Evrard, August E.↗
NASA NTRS1998

Spacecraft Compartment Venting

At various time concerns have been expressed that rapid decompressions of compartments of gas pockets and thermal blankets during spacecraft launches may have caused pressure differentials across their walls sufficient to cause minor structural failures, separations of adhesively-joined parts, ballooning, and flapping of blankets. This paper presents a close form equation expressing the expected pressure differentials across the walls of a compartment as a function of the external to the volume pressure drops, the pressure at which the rates occur and the vent capability of the compartment. The pressure profiles measured inside the shrouds of several spacecraft propelled by several vehicles and some profiles obtained from ground vacuum systems have been included. The equation can be used to design the appropriate vent, which will preclude excessive pressure differentials. Precautions and needed approaches for the evaluations of the expected pressures have been indicated. Methods to make a rapid assessment of the response of the compartment to rapid external pressure drops have been discussed. These are based on the evaluation of the compartment vent flow conductance, the volume and the length of time during which the rapid pressure drop occurs.

Scialdone, John J.↗
NASA NTRS1994

A Fully Associative, Non-Linear Kinematic, Unified Viscoplastic Model for Titanium Based Matrices

Specific forms for both the Gibb's and complementary dissipation potentials are chosen such that a complete (i.e., fully associative) potential based multiaxial unified viscoplastic model is obtained. This model possesses one tensorial internal state variable that is associated with dislocation substructure, with an evolutionary law that has nonlinear kinematic hardening and both thermal and strain induced recovery mechanisms. A unique aspect of the present model is the inclusion of non-linear hardening through the use of a compliance operator, derived from the Gibb's potential, in the evolution law for the back stress. This non-linear tensorial operator is significant in that it allows both the flow and evolutionary laws to be fully associative (and therefore easily integrated) and greatly influences the multiaxial response under non-proportional loading paths. In addition to this nonlinear compliance operator, a new consistent, potential preserving, internal strain unloading criterion has been introduced to prevent abnormalities in the predicted stress-strain curves, which are present with nonlinear hardening formulations, during unloading and reversed loading of the external variables. Specification of an experimental program for the complete determination of the material functions and parameters for characterizing a metallic matrix, e.g., TIMETAL 21S, is given. The experiments utilized are tensile, creep, and step creep tests. Finally, a comparison of this model and a commonly used Bodner-Partom model is made on the basis of predictive accuracy and numerical efficiency.

Arnold, S. M.↗
NASA NTRSDate not supplied

Initial On-Orbit Spectral Calibration of the PACE Ocean Color Instrument

The NASA Plankton, Aerosol, Cloud, and ocean Ecosystem (PACE) mission Project Science Team has used Ocean Color Instrument (OCI) measurements of Fraunhofer lines in spectra of sunlight reflected by the solar diffuser and measurements of atmospheric absorption bands in cloudtop and ocean spectra to characterize the spectral calibration of OCI on orbit. Multiple lines have been analyzed for both the ultraviolet to visible (UVVIS, 340−607 nm) and visible to near-infrared (VISNIR, 597−897 nm) grating spectrographs. The spectrographs yield hyperspectral observations with 5 nm bandwidths and 0.625 nm sampling intervals. The on-orbit observations have been compared with the prelaunch spectral calibration of OCI performed by the Goddard Laser for Absolute Measurement of Radiance (GLAMR) during thermal vacuum testing to track any changes in the calibration since launch. The calibration analyzed the line positions and strengths for the Fraunhofer lines for each spectrograph by comparing the solar spectra measured by OCI with predicted solar spectra derived from the solar reference spectrum and the BRDF of the solar diffuser, convolved with the OCI relative spectral responses. The calibration also compared the line positions of the atmospheric absorption bands with the model transmissions used by the PACE Project. The line position comparisons show that the root mean square (RMS) spectral difference between the measured and predicted spectra is 0.15 nm, the average spectral shift is 0.062 nm, and the residual spectral dispersion over the wavelength range of the Fraunhofer lines is 0.17 nm. All three estimates of the spectral accuracy of OCI meet the instrument functional requirement of a spectral accuracy of 0.5 nm and are well within the 0.625 nm sampling interval of the data. The line strength comparisons between measured and predicted spectra are essentially the same. These results show that the spectral calibration of OCI on orbit has not drifted since the prelaunch calibration of OCI by GLAMR and that the on-orbit spectral calibration of OCI is stable over time. These results also provide a baseline for monitoring the future spectral performance of OCI on orbit.

Radiometric Calibration↗
DOE OSTI2020

Correlations between conduction electrons in dense plasmas

Most treatments of electron-electron correlations in dense plasmas either ignore them entirely (random phase approximation) or neglect the role of ions (jellium approximation). In this work, we go beyond both these approximations to derive a formula for the electron-electron static structure factor which properly accounts for the contributions of both ionic structure and quantum-mechanical dynamic response in the electrons. The result can be viewed as a natural extension of the quantum Ornstein-Zernike theory of ionic and electronic correlations, and it is suitable for dense plasmas in which the ions are classical and the conduction electrons are quantum-mechanical. Here, the corresponding electron-electron pair distribution functions are compared with the results of path integral Monte Carlo simulations, showing good agreement whenever no strong electron resonance states are present. We construct approximate potentials of mean force which describe the effective screened interaction between electrons. Significant deviations from Debye-Hückel screening are present at temperatures and densities relevant to high-energy density experiments involving warm and hot dense plasmas. The presence of correlations between conduction electrons is likely to influence the electron-electron contribution to the electrical and thermal conductivity. It is expected that excitation processes involving the conduction electrons (e.g., free-free absorption) will also be affected.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Floquet Spin Splitting and Spin Generation in Antiferromagnets

In antiferromagnetic spintronics, accessing the spin degrees of freedom is essential for generating spin currents and manipulating magnetic order, which generally requires lifting spin degeneracy. This is typically achieved through relativistic spin-orbit coupling or nonrelativistic spin splitting in altermagnets. Here, we propose an alternative approach: a dynamical spin splitting induced by an optical field in antiferromagnets. By coupling the driven system to a thermal bath, we demonstrate the emergence of steady-state pure spin currents as well as linear-response longitudinal and transverse spin currents. Crucially, thermal bath engineering enables a nonrelativistic Edelstein effect—the generation of a net spin accumulation—without relying on spin-orbit coupling. Furthermore, our results provide a broadly applicable and experimentally tunable route to control spins in antiferromagnets, offering new opportunities for spin generation and manipulation in antiferromagnetic spintronics.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS2012

An Alternative Inter-Satellite Calibration of the UMD HIRS OLR Retrievals

Outgoing Longwave Radiation (OLR) at the top-of-atmosphere (TOA) is a fundamental component of Earth's energy balance and represents the heat energy in the thermal bands rejected to space by the planet. Determination of OLR from satellites has a long and storied history, but the observational record remains largely fragmented with gaps in satellite measurements over the past three decades. Perhaps the most semi-continuous set of retrievals comes from the University of Maryland (UMD) algorithm that uses four HIRS (High Resolution Infrared Sounder) channels on the NOAA polar orbiting satellites to estimate OLR. This data set shows great promise in helping to bridge the discontinuous ERBS (Earth Radiation Budget Satellite) and CERES (Clouds and the Earth s Radiant Energy System) measurements. However, significant satellite inter-calibration biases persist with the present UMD data, principally outside the tropics. Difficulties relate to the combination of drift of the satellite equator crossing time through the diurnal cycle and changes in HIRS channel response function design. Here we show how an ad hoc recalibration of the UMD retrievals among the different satellites removes much of the remaining uncertainty due to diurnal drift of the satellite orbit. The adjusted HIRS data (using no other external information) show much better agreement with OLR from the European Center Interim Reanalysis (EC-Int), longer-term signals in the Global Energy and Water Cycle Experiment / Surface Radiation Budget (GEWEX/SRB) retrievals, and also agree well with ERBS and CERES OLR measurements. These results augur well for narrowing the uncertainties in multi-decadal estimates of this important climate variable.

Robertson, Franklin R.↗
DOE OSTI2022

Bio‐Based Piezo‐ and Thermoresistive Photocurable Sensing Materials from Acrylated Epoxidized Soybean Oil

Abstract Bio‐based photocurable polymers are increasingly in demand as environmentally friendly materials for advanced applications. Together with functional fillers, these represent a next step for the generation of functional and active smart materials, compatible with additive manufacturing technologies. Herein, acrylated epoxidized soybean oil (AESO) mixed with different amounts of reduced graphene oxide (rGO) up to 6 wt% in order to obtain UV‐curable piezoresistive and thermoresistive materials, is reported. It is shown that the addition of rGO to AESO hinders the curing process, but always maintains double bond conversions higher than 50%. Composites are characterized by a good dispersion of micrometric filler clusters. Further, the thermal stabilities are close to 300 °C and crosslinking degrees are above 1.75 mmol cm –3 . The Young modulus of the composites decreases with the addition of the rGO fillers, in particular for the higher filler contents, and electrical conductivities up to 0.13 S m –1 are obtained for the composites with the highest rGO content. UV‐curable composites with piezoresistive and thermoresistive responses suitable for applications are thus obtained, characterized by gauge factors around 26 for deformations up to 2% and maximum thermoresistive sensitivity of S = 0.43, values similar to the values obtained for petroleum‐based materials.

Mendes‐Felipe, Cristian↗
NASA NTRS1980

Space shuttle main engine digital controller

The controller provides responsive control of engine thrust and mixture ratio through the digital computer in the controller, updating the instructions to the engine control elements 50 times per second (every 20 milliseconds). Additionally, precise engine performance is achieved through closed loop control, utilizing 16 bit computation, 10 bit input/output resolution, and self calibrating analog-to-digital conversion. Engine reliability is enhanced by a dual redundant control system that allows normal operation after the first failure and a fail-safe shutdown after a second failure. The digital computer is programmable, allowing modification of engine control equations and constants by change of the stored program (software). The controller is packaged in a sealed, pressurized chassis with cooling provided by convection heat transfer through pin fins as part of the main chassis. The electronics are distributed on functional modules having special provisions for thermal and vibrational protection.

Mitchell, W. T.↗
NASA NTRS2006

Ultra-lightweight, Low Scatter, Large Mirror Technology

A technique is being developed to fabricate a prototype lightweight composite mirror one meter in diameter. The mandrel, on which the composite mirror will be laid up, is an ultra low expansion quartz glass, TSG, whose thermal expansion coefficient, 10(exp -7)/ degC or less, is similar to that for the composite material itself. The mandrel surface will be super-polished to 6-8 A rms or better, resulting in ten times less scattered light in the visible region than is found in typical astronomical mirrors. We have shown experimentally that mandrel micro-roughnesses of this order can be successfully replicated on composite faceplates. The faceplate is very tough, and does not fracture like a thin glass faceplate. It will be supported by actuators alone, not by the edge of the mirror mount, to avoid non-uniform or non-symmetric influence functions. BOR developed actuators are designed for atmospheric correction, maintenance of optical figure, and minor tip tilt. They have a throw of a centimeter, can be controlled remotely, and have a response time of 1/2 msec. The piezoelectric part of the actuator operates in the 30-70 V range and the differential screw portion has a linearity of about +/-0.1 microns.

Bennett, H. E.↗
DOE OSTI2026

Effects of Concentration, Salinity and Temperature on the Conformations of Zwitterionic Poly(2-Vinylpyridine- N -Oxide) Chains in Semidilute Solutions Probed by Small-Angle X-Ray and Neutron Scattering

Polyzwitterions, composed of repeating units with equal numbers of anionic and cationic groups, have drawn considerable interest for applications ranging from antimicrobial coatings and antifouling membranes to low-friction interfaces, energy storage media, and actuators. A characteristic feature of many polyzwitterions is the anti-polyelectrolyte effect salt-induced chain expansion in aqueous solution a phenomenon often implicated in their functional behavior. In this study, we investigated the conformational behavior of poly(2-vinylpyridine-N-oxide) (P2VPNO) using smallangle X-ray and neutron scattering (SAXS and SANS). Small-angle X-ray scattering (SAXS) revealed that, in salt-free aqueous solution, P2VPNO adopts an expanded wormlike conformation stabilized by hydration. With increasing concentration, the chains contract due to screening of intrachain excluded-volume interactions, qualitatively consistent with de Gennes’ scaling predictions for neutral polymers. Small-angle neutron scattering (SANS) further demonstrated that P2VPNO exhibits the characteristic anti-polyelectrolyte response to added salt, as observed in many other polyzwitterions. At elevated temperatures, chain flexibility increases, leading to a shorter Kuhn length and reduced radius of gyration. Notably, however, salt-induced chain expansion persists, indicating that the anti-polyelectrolyte effect remains operative under elevated thermal conditions. These findings provide the first experimental evidence of scaling behavior in polyzwitterions, as well as the first observation of their altered antipolyelectrolyte response at elevated temperatures, offering new insights into the solution physics of this important class of polymers.

Conformation↗
NASA NTRS2011

Solid Rocket Booster (SRB) - Evolution and Lessons Learned During the Shuttle Program

The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Obsolescence issues occasionally required component recertification. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. Assembly and integration of the booster subsystems was a unique process and acceptance testing of reused hardware components was required for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.

Kanner, Howard S.↗
NASA NTRS2016

Mid and Thermal Infrared Remote Sensing at the Jet Propulsion Laboratory

The mid and thermal infrared (MTIR) for the Earth surface is defined between 3 and 14µm. In the outer solar system, objects are colder and their Planck response shifts towards longer wavelengths. Hence for these objects (e.g. icy moons, polar caps, comets, Europa), the thermal IR definition usually stretches out to 50µm and beyond. Spectroscopy has been a key part of this scientific exploration because of its ability to remotely determine elemental and mineralogical composition. Many key gas species such as methane, ammonia, sulfur, etc. also have vibrational bands which show up in the thermal infrared spectrum above the background response. Over the past few decades, the Jet Propulsion Laboratory has been building up a portfolio of technology to capture the MTIR for various scientific applications. Three recent sensors are briefly reviewed: The airborne Hyperspectral thermal emission spectrometer (HyTES), the ECOsystem Spaceborne Thermal Radiometer Experiment on Space Station (ECOSTRESS) and Mars Climate Sounder (MCS)/DIVINER. Each of these sensors utilize a different technology to provide a remote sensing product based on MTIR science. For example, HyTES is a push-brooming hyperspectral imager which utilizes a large format quantum well infrared photodetector (QWIP). The goal is to transition this to a new complementary barrier infrared photodetector (CBIRD) with a similar long wave cut-off and increased sensitivity. ECOSTRESS is a push-whisk Mercury Cadmium Telluride (MCT) based high speed, multi-band, imager which will eventually observe and characterize plant/vegetation functionality and stress index from the International Space Station (ISS) across the contiguous United States (CONUS). MCS/DIVINER utilizes thermopile technology to capture the thermal emission from the polar caps and shadow regions of the moon. Each sensor utilizes specific JPL technology to capture unique science. similar long wave cut-off and increased sensitivity. ECOSTRESS is a push-whisk Mercury Cadmium Telluride (MCT) based high speed, multi-band, imager which will eventually observe and characterize plant/vegetation functionality and stress index from the International Space Station (ISS) across the contiguous United States (CONUS). MCS/DIVINER utilizes thermopile technology to capture the thermal emission from the polar caps and shadow regions of the moon. Each sensor utilizes specific JPL technology to capture unique science.

Johnson, William R.↗
NASA NTRS2020

Changing Physical Conditions and Lower and Upper Trophic Level Responses on the US Northeast Shelf

Sea surface temperature (SST), salinity, and chlorophyll concentration (CHL) have changed in the US Northeast Shelf ecosystem over recent decades. The changes in these parameters were distinctly marked by change points around the year 2012 resulting in a 0.83°C increase in SST, a 0.3 PSU increase in salinity, and decrease in CHL in excess of 0.4 mg m–3. Where temperature and salinity shifted in mean level around their respective change points, CHL declined in a more monotonic fashion. Modeled data suggest that the shift in CHL resulted in a greater contribution of pico- and nanophytoplankton and a decreased contribution of microphytoplankton to overall CHL. Complementary estimates of the contribution of different phytoplankton functional types suggest a diminished contribution of diatoms to the phytoplankton community. Hence, not only is there evidence of a decline in the overall primary production capacity of the ecosystem, but also evidence of a fundamental change in the size and quality of phytoplankton supporting food webs. Two ecosystem responses to the observed changes in SST, salinity, and CHL were analyzed. Both length and weight at age have declined for a number of species, and both measures of growth appear to be negatively associated with temperature and positively associated with CHL. Biomass of fish and macroinvertebrates has declined in recent years, with a decrease in pelagic species associated with a decrease in CHL, while the decline in demersal species was associated with an increase in temperature. Collectively, these ecosystem changes appear to be the result of the complex interactions of both thermal effects and changes at the base of the food web.

Kevin D. Friedland↗
DOE OSTI2022

Experimental Procedure and Results for Contact Thermal Conductance Measurements performed during FY 2021

Weapons Test Engineering groups at LANL are responsible for testing and simulating weapon assemblies and subassemblies in support of qualification and certification of nuclear weapon systems. The complex nature of the assemblies themselves coupled with the loading environments, gives rise to low confidence and high uncertainties in the interpretation of both experimental and simulated results. In an effort to reduce these uncertainties, a project was started at LANL to perform focused and systematic experiments combined with simulations to increase confidence in both arenas. A key goal of the work performed under the Delivery Environments (DE) Testbeds to Reduce Uncertainties in Simulations and Tests TRUST program, focuses on identifying and minimizing sources of uncertainty associated with experimental and computational techniques. Specifically, with the above as motivation, a measurement procedure was developed by MST-8 to perform thermal conductivity measurements on cylinders of both similar and dissimilar metallic systems as a function of loading conditions and varying material interface morphologies between these components.

36 MATERIALS SCIENCE↗
NASA NTRS2001

Absence of arterial baroreflex modulation of skin sympathetic activity and sweat rate during whole-body heating in humans

1. Prior findings suggest that baroreflexes are capable of modulating skin blood flow, but the effects of baroreceptor loading/unloading on sweating are less clear. Therefore, this project tested the hypothesis that pharmacologically induced alterations in arterial blood pressure in heated humans would lead to baroreflex-mediated changes in both skin sympathetic nerve activity (SSNA) and sweat rate. 2. In seven subjects mean arterial blood pressure was lowered (approximately 8 mmHg) and then raised (approximately 13 mmHg) by bolus injections of sodium nitroprusside and phenylephrine, respectively. Moreover, in a separate protocol, arterial blood pressure was reduced via steady-state administration of sodium nitroprusside. In both normothermia and heat-stress conditions the following responses were monitored: sublingual and mean skin temperatures, heart rate, beat-by-beat blood pressure, skin blood flow (laser-Doppler flowmetry), local sweat rate and SSNA (microneurography from peroneal nerve). 3. Whole-body heating increased skin and sublingual temperatures, heart rate, cutaneous blood flow, sweat rate and SSNA, but did not change arterial blood pressure. Heart rate was significantly elevated (from 74 +/- 3 to 92 +/- 4 beats x min(-1); P < 0.001) during bolus sodium nitroprusside-induced reductions in blood pressure, and significantly reduced (from 92 +/- 4 to 68 +/- 4 beats x min(-1); P < 0.001) during bolus phenylephrine-induced elevations in blood pressure, thereby demonstrating normal baroreflex function in these subjects. 4. Neither SSNA nor sweat rate was altered by rapid (bolus infusion) or sustained (steady-state infusion) changes in blood pressure regardless of the thermal condition. 5. These data suggest that SSNA and sweat rate are not modulated by arterial baroreflexes in normothermic or moderately heated individuals.

Clinical Trial↗
NASA NTRSDate not supplied

Overview of Ablative TPS Modeling at NASA Ames

Over the past decade, NASA has invested in efforts to build predictive thermal protection system (TPS) material models from the micro-scale to the macro-scale. To complement the mission design cycle process and reduce the need for extensive testing, NASA is developing modeling and simulation tools that enable characterizing material properties and response to hot plasma experienced during atmospheric entry. Traditional material response and ablation modeling tools, such as the heritage code FIAT, and its multidimensional siblings, TITAN and 3dFIAT, are being complemented with newly developed software such as Icarus and PATO. Both of these programs are three-dimensional, finite-volume solvers that use unstructured meshes and 21st century programming paradigms to allow for efficient parallel simulations. FIAT and Icarus are also used for TPS sizing purposes. Today, these traditional tools are being supplemented with computational materials models at the atomistic level. The scales of interest range from computational chemistry (Density Functional Theory [DFT]), to atomistic simulations (Molecular Dynamics [MD]), to the microscale with the Porous Microstructure Analysis (PuMA) software that was recently awarded the 2022 NASA Software of the Year award. Finally, thermo-structural modeling is also of interest to the TPS Materials branch and done using commercial tools such as MSC MARC, MENTAT, NASTRAN and PATRAN. The present talk will also link the use of these computational tools to current NASA missions and projects associated with challenging and complex vehicles entries/reentries.

materials modeling↗
DOE OSTI2020

Origin of dislocation structures in an additively manufactured austenitic stainless steel 316L

In this experiment, the origin of dislocation structures in AM stainless steels was systematically investigated by controlling the effect of thermal stress through geometric constraints for the first time. Stainless steel 316L parts were produced in the form of “1D” rods, “2D” walls, and "3D" rectangular prisms to evaluate the effect of constraints to thermal expansion/shrinkage on the development of defect microstructures and to elucidate the origin of additively manufactured (AM) dislocation microstructures. Dislocation density, organization, chemical micro-segregation, precipitate structures, and misorientations were analyzed as a function of increasing constraints around solidifying material in 1D, 2D, and 3D components built using both directed energy deposition (DED) and powder-bed selective laser melting (SLM). In DED parts, the dislocation density was not dependent on local misorientations or micro-segregation patterns, but evolved from approximately ρ ⊥ = 10 12 m -2 in 1D parts to ρ ⊥ = 10 14 m -2 in 3D parts, indicating that it is primarily thermal distortions that produce AM dislocation structures. In DED 3D parts and SLM parts, dislocation densities were highest (ρ ⊥ ≈ 10 14 m -2 ) and corresponded to the formation of dislocation cells approximately 300-450 nm in diameter. Dislocation cells overlapped with dendrite micro-segregation in some but not all cases. The results illustrate that dendritic micro-segregation, precipitates, or local misorientations influence how the dislocations organize during processing, but are not responsible for producing the organized cell structures. Furthermore, this work shows that AM dislocation structures originate due to thermal distortions during printing, which are primarily dictated by constraints surrounding the melt pool and thermal cycling.

36 MATERIALS SCIENCE↗