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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Fungal colonization of plant roots is resistant to nitrogen addition and resilient to dominant species losses

Abstract Global change drivers, such as nitrogen (N) deposition and non‐random species extinctions, may shift interactions among aboveground and belowground communities. However, tightly coupled interactions between aboveground and belowground organisms may buffer ecosystems to global change. Here, we test how four years of organic and inorganic N addition and removal of a dominant plant species, Festuca thurberi , independently and interactively influences fungal colonization patterns and performance in a co‐dominant plant species, Helianthella quinquenervis . Surprisingly, we found N addition and Festuca removal had no measurable effects on the colonization of arbuscular mycorrhizal fungi (AMF) and dark septate endophyte ( DSE ) or the performance of Helianthella seedlings grown with field‐collected inoculum in a companion greenhouse experiment. However, the proximity of Helianthella to Festuca predicted fungal colonization: DSE colonization decreased by 1% for each cm of distance Helianthella was from Festuca , although the differences in fungal inoculum potential had no effect on Helianthella seedling survival or biomass. Our results suggest that plant–fungal interactions can be resistant to N addition and resilient to the loss of dominant plant species. Additionally, our results suggest that soil legacies, mediated through surviving symbiont communities or changes in soil properties, can shape ecosystem resistance and resilience to disturbance and perturbations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

An Extended Group Additivity Method for Polycyclic Thermochemistry Estimation

Automatic kinetic mechanism generation, virtual high-throughput screening, and automatic transition state search are currently trending applications requiring exploration of a large molecule space. Large-scale search requires fast and accurate estimation of molecules’ properties of interest, such as thermochemistry. Existing approaches are not satisfactory for large polycyclic molecules: considering the number of molecules being screened, quantum chemistry (even cheap density functional theory methods) can be computationally expensive, and group additivity, though fast, is not sufficiently accurate. Here, this paper provides a fast and moderately accurate alternative by proposing a polycyclic thermochemistry estimation method that extends the group additivity method with two additional algorithms: similarity match and bicyclic decomposition. It significantly reduces H f (298 K) estimation error from over 60 kcal/mol (group additivity method) to around 5 kcal/mol, C p (298 K) error from 9 to 1 cal/mol/K,and S(298 K) error from 70 to 7 cal/mol/K. This method also works well for heteroatomic polycyclics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Influence of Rare Earth Ce Additions on Microstructure and Mechanical Properties of Experimental Pipeline Steels

Herein, the effect of Ce additions ranging from 57 to 263 ppm is evaluated for an experimental pipeline steel. Compared to the Ce-free steel, progressive Ce additions result in a slightly refined microstructure, significantly improve transverse impact properties, and slightly increase strength. All these observations can be attributed to the gradual transformation of Mn sulfide and Mn–Si–Al oxide inclusions to Ce-containing oxide/sulfides. In particular, the inclusions consist exclusively of sub-5 μm spherical Ce 2 O 2 S particles upon near-stoichiometric additions of Ce, considering the oxygen and sulfur impurity level of the steel. In conclusion, the results suggest that Ce is a potentially promising alloying addition for next-generation pipeline steels by replacing overtly deleterious inclusions with potentially beneficial ones.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Comparison of the Effect of 2 at. % Additions of Nb and Ta on the 1100 °C Oxidation Behavior of Ni-6Al-(4,6,8) Cr Model Alloys

To continue improving alloy performance in harsh service environments, the development of alumina-forming nickel-based superalloys is essential. Current generations of these alloys heavily rely on the addition of refractory elements to enhance their mechanical properties at high temperatures; however, a systematic understanding of how such additions affect the overall oxidation behavior is still not well established, particularly from the standpoint of predicting the transition from internal to external alumina formation. The present work seeks to better understand the intrinsic effects that common minor additions of Ta and Nb have on the oxidation behavior of alumina-scale-forming γ-Ni model alloys. By combining a novel simulation approach with high-temperature oxidation experiments and advanced characterization techniques, the present study provides insightful details on the differing effects that 2 at. % addition of Ta and Nb have on the alumina scale formation of Ni-based alloys during 1100 °C oxidation.

Rodriguez, Rafael↗
DOE OSTI2020

An experimental investigation of the effectiveness of Ar-CO 2 shielding gas mixture for the wire arc additive process

Wire arc additive manufacturing (AM) is the process by which a large, metallic structure is built layer-by-layer using a welding arc to melt a wire feedstock. A novel opportunity exists to alter the shielding gas composition to fabricate distinct geometrical features without altering the other AM parameters. In this paper, shielding gases with varied concentrations of Argon (Ar) and CO 2 was used to deposit three distinct geometric shapes (walls, infill, and overhang) using a wire-based additive manufacturing system utilizing the gas metal arc welding (GMAW) surface tension transfer (STT) process. Computer-aided design (CAD) models were sliced with a custom-built slicer, and the sliced algorithm was converted into optimal robotic toolpaths. A custom virtual instrument (VI) was built in LabVIEW to compare the temperature profiles on the surface during each deposition process. After each deposition, the geometric features were scanned, and the surface waviness value was evaluated. Tensile and Charpy impact coupons were extracted from the wall geometries in the longitudinal and transverse directions and tested. The results indicated that a higher CO 2 content produced higher melt pool temperatures to an extent, while lower contents of CO 2 resulted in a dimensionally accurate geometry. The data also indicated that the 2%/98% CO 2 /Ar blend produced scatter in tensile strength and the analysis of variance (ANOVA) shows significant difference. However, the intermediate range of CO 2 (5–10%) resulted in uniform tensile properties. Altogether, these results indicate that a 5%/95% CO 2 /Ar blend is the ideal shielding gas for lowering process temperatures and improving mechanical properties in wire arc additive manufacturing using the gas metal arc welding surface tension transfer process. Additionally, varying concentrations of Ar/CO 2 can be used within the same part in order to modify the local properties or process parameters such as strength, toughness, temperature, or dimensional features. This may improve overall manufacturing quality without sacrificing specific properties.

42 ENGINEERING↗
DOE OSTI2018

Sulfur-Reducing Additives Based on Aluminosilicates Al-SBA-15 and Al-SBA-16 for Cracking catalysts

Sulfur-reducing additives for fluid catalytic cracking (FCC) catalysts based on mesoporous aluminosilicates Al-SBA-15 and Al-SBA-16 were synthesized and characterized using FTIR spectroscopy, transmission electron microscopy, low-temperature N{sub 2} adsorption/desorption, and thermally programmed desorption of NH3. Catalytic experiments were performed using a commercial zeolite-containing FCC catalyst and the additives (10 wt.%). It was found that all synthesized materials were active for reducing sulfur in liquid catalytic cracking products. The S content in the liquid cracking products obtained using an additive of 3% La-Al-SBA-15/Al{sub 2}O{sub 3} (50:50) decreased by 36% as compared to the same parameter obtained using the commercial catalyst with no additive.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Investigation of Polypropylene-Montmorillonite Clay Nanocomposite Films Containing a Pro-degradant Additive

This paper investigates the performance of polypropylene (PP) incorporated with montmorillonite (MMT) nanoclay, maleic anhydride grafted PP (PP-g-MAH), and pro-degradant additive (TDPA®), which provides additional benefits of increasing biodegradability. A twin-screw extruder was used to compound PP, MMT, PP-g-MAH, and TDPA, and the extruded nanocomposite films were collected for testing, and their mechanical, thermal, barrier, oxo-biodegradability, and morphological properties were evaluated. Tensile test, differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), oxygen permeability test, soil burial test, X-ray diffraction (XRD), transmission electron microscopy (TEM), and scanning electron microscope (SEM) analysis were used to investigate these properties. Increasing MMT content from 1 to 3 phr increases tensile strength and Young’s modulus of the neat PP samples up to ca.45% and 27% respectively. Improvement of thermal properties for neat PP samples was observed by increasing MMT content from 1 to 3 phr. However, at 4 phr MMT content, both mechanical and thermal properties of nanocomposites dropped slightly. For soil buried samples, DSC and TGA results revealed significant changes in the thermal properties for PP samples containing TDPE additive compared to neat PP, clearly confirming the effectiveness of this TDPA additive in promoting oxo-biodegradation process of PP. Similarly weight loss evaluation result shows that about 4% weight loss for sample (PP/TD), which is PP and TDPA blend only, compared to neat PP. However, increasing MMT content from 1 to 4 phr slightly reduced weight loss of PP from 3.5 to 1.5%, respectively, for 6 month soil exposure period, which indicates that increasing MMT content was detrimental to the degradation process. For higher MMT content, the oxygen permeability of PP nanocomposites was decreased by 46% of the corresponding values for neat PP. The XRD and TEM results confirmed the exfoliation structure of the nanocomposites. The morphological change after soil burial test was studied using scanning electron microscopy (SEM).

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2019

Improvement of the Superconducting Properties of GdBa{sub 2}Cu{sub 3}O{sub 7-δ} with Nano-Sized Ferrite Addition

We have been investigating the effect of (CoFe{sub 2}O{sub 4}){sub x} and (ZnFe{sub 2}O{sub 4}){sub x} (x is the wt%) nano-sized ferrites on the superconducting (SC) properties of the high-T{sub c} SC compound GdBa{sub 2}Cu{sub 3}O{sub 7-δ} (Gd123) prepared by the conventional solid-state reaction technique. In this work, the magnetic hysteresis for pure Gd123 samples and samples added with nano-sized ferrites was measured using a superconducting quantum interference device (SQUID) magnetometer using a dc field up to 30,000 Oe. The magnetic J{sub c} was estimated using the extended Bean model. While a clear increase in J{sub c} values with the addition of (CoFe{sub 2}O{sub 4}){sub x} nano-sized ferrites is observed, a less clear positive effect on the J{sub c} values is observed with the addition of (ZnFe{sub 2}O{sub 4}){sub x} nano-sized ferrites. These results indicate an improvement of grain connectivity, decrease of voids between the grains, and decrease of porosity in Gd123 compound resulting from CoFe{sub 2}O{sub 4} addition consistent with the mechanical properties measured before. (CoFe{sub 2}O{sub 4}){sub x} nano-sized ferrite addition has thus resulted in an improvement in the SC properties of Gd123 high-T{sub c} SC compound making it more convenient for applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Improved Creep and Tensile Properties of a Corrosion Resistant Ni-Based Superalloy Using High Temperature Aging and Nb/Ta Additions

Resistance to creep deformation is essential for cast and wrought Ni-based superalloys in next generation energy systems due to the considerable exposure times required at the operating temperature. Here the amount of precipitate strengthening was increased in variants to Inconel alloy 725 (IN725), a corrosion resistant alloy, to improve its elevated temperature mechanical strength. Additions of Nb or Ta coupled with a high temperature aging (HTA) heat treatment promoted the formation of γ" precipitates and grain boundary phases which led to significant increases in time to failure. The HTA increased the creep life of various alloy formulations as compared to the standard aging heat treatment with a maximum improvement of 371%. The Nb and Ta additions lowered the minimum creep rate (MCR) and had a similar effect on increasing creep life. The positive effect of the additions was more pronounced when coupled with the HTA which employed a higher temperature in the first step of the heat treatment to promote precipitate phase formation. The Ti/Al ratio was used to design alloys with preferential formation of ' or γ" precipitates. Compact morphology precipitates were formed in the alloys with a low Ti/Al ratio. While a low Ti/Al ratio was primarily associated with lower MCRs, the effect on the creep life was less evident than that of the HTA. By using additions of Nb or Ta and a HTA heat treatment, the creep life of IN725 for testing at 973 K (700 °C) and 483 MPa was improved by up to 256%.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Novel Approach to Studying Influences of Na{sub 2}O and K{sub 2}O Additions on Viscosity and Thermodynamic Properties of BF Slags

Abstract:: The present work calculated the heat capacity, enthalpy change, and slag temperature of CaO–MgO–Al{sub 2}O{sub 3}–SiO{sub 2} slags after adding Na{sub 2}O or K{sub 2}O, and investigated the influences of Na{sub 2}O and K{sub 2}O on the slag viscosity under given temperatures and heat quantities. It was found that the slag viscosity decreases with the addition of Na{sub 2}O and tends to increase with K{sub 2}O additions at the same temperature. The heat capacity of the slag increases, while the enthalpy change decreases obviously with the increasing addition of Na{sub 2}O or K{sub 2}O. Under the constant heat quantity, an increase in content of Na{sub 2}O or K{sub 2}O of the slag leads to an appreciable increase in slag temperature, whereas the viscosity decreases significantly. Besides, the Na{sub 2}O or K{sub 2}O additions also help to stabilize the slag fluidity and lower energy consumption of blast furnace.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Ni Addition to Sn0.7Cu Solder Alloy on Thermal Behavior, Microstructure, and Mechanical Properties

The addition of Ni on lead-free solder alloys Sn0.7Cu was tested in this study. A small amount of Ni was added to the solder alloys to evaluate the thermal behavior, microstructure, and mechanical properties of the composite solders after sintering and isothermal aging for 3 days and then compared with the results of the binary Sn0.7Cu solder. The results indicated that the ultimate tensile strength and yield tensile strength changed when adding 0.25 wt.% of Ni. The tested results of the differential scanning calorimeter showed that the addition of Ni (such as 0.5 and 1 wt.%) could obviously increase the solidification temperature of Sn0.7Cu alloys in the cooling process. When the Ni content was increased to 0.25 wt.% in the ternary condition, which includes the Sn0.7Cu-xNi (x = 0, 0.1, 0.25, 0.5, and 1 wt.%) solder alloys for the indentation creep test, the minimum creep rate reached the maximum; however, the trend was reversed as the Ni content was higher than this level. In addition, the microstructure of Sn-0.7Cu-xNi solder alloys was obviously different with the eutectic Sn-0.7Cu solder, such that the Ni gradually accumulated in the (Cu, Ni){sub 6}Sn{sub 5} IMCs within the Ni-containing solder alloys. Additionally, this process refined the microstructure of the Sn-0.7Cu solder. The fracture surface of the eutectic Sn-0.7Cu solder revealed ductile fracture modes; however, there was no mixed ductile–brittle fracture mode occurred when the Ni content was in the range of 0-1 wt.%.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Ca and Sm Combined Addition on the Microstructure and Elevated-Temperature Mechanical Properties of Mg-6Al Alloys

In the present study, the microstructure and elevated-temperature mechanical properties of Mg-6Al, Mg-6Al-4Ca, Mg-6Al-4Sm and Mg-6Al-2Ca-2Sm alloys were investigated. The experimental results showed that the microstructure and elevated-temperature mechanical property of Mg-6Al alloy changed obviously with the different elements addition. By analyzing the results of optical microscope, x-ray diffraction analysis, scanning electron microscope, and transmission electron microscope, it could be determined that there was only Mg{sub 17}Al{sub 12} phase in Mg-6Al alloy, there were Al{sub 2}Ca and (Mg, Al){sub 2}Ca phases in Mg-6Al-4Ca alloy, there were Al{sub 2}Sm and Mg{sub 17}Al{sub 12} phases in Mg-6Al-4Sm alloy, and there were (Mg, Al){sub 2}Ca, Al{sub 2}Ca and Al{sub 2}Sm phases in Mg-6Al-2Ca-2Sm alloy. In addition, the addition of alloying elements including Ca and Sm, especially the composite addition, could significantly improve the tensile properties of Mg-6Al alloy. Compared to Mg-6Al alloy, the tensile strengths of Mg-6Al-2Ca-2Sm alloy at 448, 473 and 498 K were enhanced by 50.32, 87.92, and 94.99%, respectively. Furthermore, when the stretching temperatures were 448 and 473 K, the fracture pattern of Mg-6Al-2Ca-2Sm alloy was the mixture of intergranular fracture and trans-crystalline fracture. However, when the stretching temperature was 498 K, the fracture pattern of Mg-6Al-2Ca-2Sm alloy was the intergranular fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Characterization of Fe-6Si Soft Magnetic Alloy Produced by Laser-Directed Energy Deposition Additive Manufacturing

Abstract Commercial electrical steels, Fe-Si alloys with < 4 wt.% Si, are inexpensive and efficient materials for electrical power conversion. Further efficiency improvements require increasing the silicon concentration to 6 wt.%, at which point the material becomes brittle and difficult to form by conventional rolling and sheet fabrication methods. Additive manufacturing stands to overcome challenges with commercial manufacturing techniques by leveraging near-net-shape fabrication. The wide array of process conditions provides additive manufacturing with increased flexibility, enabling control over the microstructure and mechanical properties. This work explores the microstructures and magnetic properties of ring-shaped Fe-Si alloys produced using concentric and cross-hatch tool paths on a laser-directed energy deposition additive manufacturing system. Concentric-built samples exhibit elongated grain structures while cross-hatch-built samples comprise lower aspect ratio grain structures. Thermal finite element analysis simulations model the stress conditions produced by the different scan path geometries. Microhardness measurements probe the mechanical properties as a function of anneal temperature, providing a qualitative understanding of the intergranular defect density. Soft magnetic properties measured under quasistatic and AC conditions show frequency- and microstructure-dependent coercivity and permeability. Finally, analysis of the core loss quantifies how the build strategies and thermal treatments influence efficiency in electrical power conversion applications. Understanding the influences of scan path geometry and thermal treatment provides a pathway towards application of additively manufactured soft magnetic materials.

Adamczyk, Jesse M.↗
DOE OSTI2019

Improvement of Methane Production from Sugar Beet Wastes Using TiO{sub 2} and Fe{sub 3}O{sub 4} Nanoparticles and Chitosan Micropowder Additives

An experimental study was performed to measure biogas production from sugar beet waste, which is, in fact, the chopped parts of the sugar beet not going through the sugar extraction process, at different additive concentrations. Medium molecular weight chitosan in microsize and TiO{sub 2} and Fe{sub 3}O{sub 4} nanoparticles were added to ten experimental reactors to investigate their effect on the anaerobic digestion process. Three different concentrations of 0.01, 0.04, and 0.12% w/w were used for each additive. Biogas production and methane content were compared with a control sample containing no additive. Adding chitosan in powder form did not help the process nor improved methanogenic activities. The results showed no effect on anaerobic digestion by the addition of TiO{sub 2} nanoparticles in the mentioned concentrations, whereas adding Fe{sub 3}O{sub 4} nanoparticles led to a slight increase in methane production and in volatile solid and total solid reduction. The maximum enhancement in methane and biogas production in the sample containing 0.04% Fe{sub 3}O{sub 4}, as compared with the control sample, reached 19.77% and 15.09%, respectively.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

Building blocks for a digital twin of additive manufacturing

Properties and serviceability of additively manufactured components are affected by their geometry, microstructure and defects. These important attributes are now optimized by trial and error because the essential process variables cannot currently be selected from scientific principles. A recourse is to build and rigorously validate a digital twin of the additive manufacturing process that can provide accurate predictions of the spatial and temporal variations of metallurgical parameters that affect the structure and properties of components. Key building blocks of a computationally efficient first-generation digital twin of laser-based directed energy deposition additive manufacturing utilize a transient, three-dimensional model that calculates temperature and velocity fields, cooling rates, solidification parameters and deposit geometry. The measured profiles of stainless steel 316L and Alloy 800H deposits as well as the secondary dendrite arm spacing (SDAS) and Vickers hardness measurements are used to validate the proposed digital twin. The predicted cooling rates, temperature gradients, solidification rates, SDAS and micro-hardness values are shown to be more accurate than those obtained from a commonly used heat conduction calculation. Finally, these metallurgical building blocks serve as a phenomenological framework for the development of a digital twin that will make the expanding knowledge base of additive manufacturing usable in a practical way for all scientists and engineers.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Structural integrity of additively manufactured stainless steel with cold sprayed barrier coating under combined cyclic loading

Integration of metal additive manufacturing (AM) and cold spray (CS) technologies provide an unprecedented opportunity to manufacture coated material systems with complex geometrical features. The application of these material systems in functionally critical components requires adequate structural integrity, particularly in the presence of cyclic loading. This article researches the multiaxial fatigue (axial-torsional cyclic loading) behavior of a coated material system consisting of 15Cr-5Ni precipitation-hardening stainless steel (15-5 PH SS) substrate additively manufactured by direct metal laser sintering with a layer of chromium carbide nickel (CrC-Ni) barrier coating deposited by CS. The influence of AM and CS-induced residual stresses on fatigue performance of test specimens was thoroughly studied. Additionally, the effect of surface roughness and processes induced defects were considered to explain the crack growth mechanism. Stresses assessed by synchrotron X-ray diffraction indicated a substantial accumulation of residual stresses, particularly in the outer surface of the as-fabricated 155 PH SS specimens. The state of residual stress was changed notably following the deposition of CrC-Ni coating in the axial, hoop, and radial directions of the fatigue test specimen. Also, CS deposition of CrC-Ni coating caused significant improvement in the surface quality of the additively manufactured components. Fatigue test results indicated, CS deposition of CrC-Ni substantially enhances the fatigue life of the AM-produced 15-5 PH SS substrate in all loading conditions, particularly in the high cycle fatigue regime. The improvement in the fatigue life of the specimens with coating was associated with a reduction in equivalent residual stress at the substrate surface and improvement in the specimens' surface condition (i.e., reduced surface roughness). The fractographic analysis of the specimen indicated the cracks tend to initiate in the surface of both as-fabricated and cold-sprayed specimens. However, the mechanism of crack growth changed notably following the deposition of CrC-Ni coating. The cracks tended to propagate in the planes parallel or with a small deviation from the build layers of the AM-produced specimens. On the other hand, deposition of CrC-Ni coating increased the deviation of crack growth plane from the build layers of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Structural stability of thin overhanging walls during material extrusion additive manufacturing of thermoset-based ink

Recent developments have enabled material extrusion additive manufacturing of thermoset-based composite inks on the large scale. In addition, printing out-of-plane components is of broad interest to the polymer material extrusion community. Here, we address some of the challenges associated with both large-scale and out-of-plane thermoset material extrusion additive manufacturing by studying the height at which thin overhanging walls collapse. Walls at a range of overhang angles were printed until they collapsed. An optical camera captured the profile of each wall throughout the print, allowing the collapse height to be identified and the geometric fidelity to the programmed angle to be evaluated. Using previously measured rheological properties, predictive models were generated to approximate the collapse height and profile of the deflected walls. First, an analytical model was created to predict the height at which the walls would yield. The analytical model assumes the walls exhibit a perfectly linear profile; however, experiments proved this assumption to be false. Therefore, a finite element simulation was developed to account for the elastic deflection that occurs during printing. The finite element simulation predicts both the yield height and the deflected profile after the deposition of each layer. For the properties of the thermoset ink used here, the yield height predicted by the analytical model and finite element simulation are virtually identical. These predictions match experimental data reasonably well, but minor errors are observed. Accounting for the fully plastic moment appears to explain the small mismatch between experimental data and predictions. Additionally, the finite element simulation provides an excellent prediction of the deflected profile before the wall begins to collapse. Finally, by demonstrating that the collapse height and deflected profile of thin overhanging walls can be predicted, this work illustrates how the soft viscoelastic properties of thermoset-based composite inks limit the scale of a key feature required to print some nonplanar components. It also provides a basis to tailor in-process curing systems to suppress deflection and collapse of thin overhanging walls.

36 MATERIALS SCIENCE↗
DOE OSTI2022

In situ laser profilometry for material segmentation and digital reconstruction of a multicomponent additively manufactured part

In addition to its ability to produce geometrically complex parts, additive manufacturing offers a unique opportunity to collect data about a component while it is being fabricated. However, there has only been limited effort to characterize parts morphologically and compositionally in situ. In this article, we present a layer-by-layer, laser profilometry-based in situ characterization technique as a method to digitally reconstruct a multi-material part. Data collected by the laser profilometer yields height maps and grayscale images which are voxelized using purpose-built software to volumetrically reconstruct the part. Additionally, the same part was also analyzed using X-ray computed tomography (CT) which was not able to resolve the different compositional regions within the part, but captured the filament morphology. The part was then bisected to compare the digital reconstruction to the actual part morphology and composition. Overall, the digital reconstruction was in good agreement with both the CT and bisected images. Deviations between the digital reconstruction and the CT/bisected images are likely the result of image segmentation settings or material shifts after data was collected. The in situ characterization method demonstrated here sets the stage for real time process monitoring and paves the way for additively manufactured parts that are “born qualified.”

36 MATERIALS SCIENCE↗