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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Protection against Chemical Warfare Agents and Biological Threats Using Metal–Organic Frameworks as Active Layers

The SARS-CoV-2 pandemic outbreak and the unfortunate misuse of toxic chemical warfare agents (CWAs) highlight the importance of developing functional materials to protect against these chemical and pathogen threats. Metal–organic frameworks (MOFs), which comprise a tunable class of crystalline porous materials built from inorganic nodes and organic linkers, have emerged as a class of heterogeneous catalysts capable of rapid detoxification of multiple classes of these harmful chemical or biological hazards. In particular, zirconium-based MOFs (Zr-MOFs) feature Lewis acidic nodes that serve as active sites for a wide range of catalytic reactions, including the hydrolysis of organophosphorus nerve agents within seconds in basic aqueous solutions. In addition, postsynthetic modification of Zr-MOFs enables the release of active species capable of reacting with and deactivating harmful pathogens. Despite this impressive performance, utilizing Zr- MOFs in powder form is not practical for application in masks or protective uniforms. To address this challenge, our team sought to develop MOF/fiber composite systems that could be adapted for use under realistic operating conditions to protect civilians, military personnel, and first responders from harmful pathogens and chemical warfare agents. Over the last several years, our group has designed and fabricated reactive and biocidal MOF/fiber composites that effectively capture and deactivate these toxic species. In this Account, we describe the evolution of these porous and reactive MOF/fiber composites and focus on key design challenges and considerations. First, we devised a scalable method for the integration of Zr-MOFs onto textile substrates using aqueous precursor solutions and without using pretreated textiles, highlighting the potential scalability of this method. Moving beyond standard textiles, we also developed a microbial synthesis strategy to prepare hierarchically porous MOF/bacterial cellulose nanofiber composite sponges that can both capture and detoxify nerve agents when exposed to contaminated gas flows. The mass loading of the MOF in the nanofibrous composite sponge is up to 90%, affording higher work capacities compared to those of textile-fiber-based composites with relatively lower MOF loadings. Next, we demonstrated that heterogeneous polymeric bases are suitable replacements for volatile liquid bases typically used in solution-phase reactions, and we showed that these composite systems are capable of effectively hydrolyzing nerve agents in the solid state by using only water that is present as humidity. Moreover, incorporating a reactive dye precursor into the composite affords a dual function sensing and detoxifying material that changes color from white to orange upon reaction with the byproduct following nerve agent hydrolysis, demonstrating the versatility of this platform for use in decontamination applications. We then created chlorine-loaded MOF/fiber composites that act as biocidal and reactive textiles that are capable of not only detoxifying sulfur-mustard-based chemical warfare agents and simulants but also deactivating both bacteria and the SARS-CoV-2 virus within minutes of exposure. Lastly, we synthesized a mixed-metal Ti/Zr-MOF coating on cotton fibers to afford a photoactive biocidal cloth that shows fast and broad-spectrum biocidal performance against viruses and Gram-positive and Gram-negative bacteria under visible light irradiation. Given the tunable, multifunctional nature of these MOF/fiber composites, we believe that this Account will offer new insights for the rational design and preparation of functional MOF/fiber composites and pave the way toward the development of next-generation reactive and protective textiles.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Quantitative 14 N NMR with Monte Carlo Uncertainty Analysis of Nitrate/Nitrite in Alkaline Nuclear Waste

While monitoring of nitrate and nitrite concentrations is important for managing corrosion in nuclear waste systems, existing analytical methods are hindered by turbidity, spectral interference, and delays from sample handling. Here, we demonstrate quantitative 14 N nuclear magnetic resonance (qNMR) spectroscopy as a direct, matrix-tolerant approach for nitrate and nitrite detection at natural abundance. Monte Carlo resampling was integrated into the workflow to quantify random error, establish precision–time tradeoffs, and separate noise-limited uncertainty from systematic bias arising from shimming, transmitter offset, or excitation pulse conditions. Quantification of nitrate and nitrite were validated in controlled alkaline matrix challenges and in 18-component Hanford-type simulants. These results establish 14 N qNMR as a practical, uncertainty-bounded tool for monitoring redox-active nitrogen species in chemically complex environments and provide a generalizable framework for quantitative analysis of quadrupolar nuclei.

Graham, Trent R. [Pacific Northwest National Labor↗
DOE OSTI2026

Development of Data-Driven Models for Performance Prediction and Chemical Dosing of a Full-Scale Controlled Phosphorus Precipitation Reactor

This study evaluated the use of data-driven models to improve control of a struvite precipitation reactor that removes phosphorus from wastewater while producing a fertilizer product. The researchers developed predictive models for influent orthophosphate concentration, effluent orthophosphate concentration, and phosphorus removal using operational data from a full-scale MagPrex™ reactor at a water resource recovery facility in Denver, Colorado. Model predictions were used to recommend magnesium chloride dosing adjustments needed to achieve a target effluent phosphorus concentration. Several machine learning approaches were tested, with ridge regression providing the best predictions for influent orthophosphate concentration and phosphorus removal, and XGBoost providing the best predictions for effluent orthophosphate concentration. Simulation results indicated that the decision-support approach could correctly identify dosing adjustments in most cases and reduce chemical use. Full-scale implementation achieved lower accuracy due to changing operating conditions and limited historical data in some operating ranges. Here, the results demonstrate the potential of data-driven tools to support phosphorus recovery process control while also identifying practical limitations that affect deployment in full-scale systems.

42 ENGINEERING↗
DOE OSTI2020

NDX: Neutron Dose Rate Meters with Extended Capabilities

Particle accelerators, irradiation facilities, and nuclear power plants would benefit from using neutron dose rate meters featuring improved energy response covering full range of expected neutron energies, improved dynamic range of measured dose rates while providing the real-time data, and improved ability to operate in harsh radiation environments including heavy photon backgrounds and pulsed beams. The novel design of the neutron moderator for the NDX dose rate meter implements a layer of a Beryllium-loaded medium Z material which, similar to the earlier known WENDI detectors, allows the device to detect higher energy neutron flux and convert it to dose. Using Beryllium helps to fill the known dip in the response functions around 5-50 MeV. Optimized design parameter set, obtained using FLUKA Monte Carlo simulations, features the NDX moderator made of polyethylene embedding a layer of BeCu alloy inside, with the dose rate response constant within ±10% in the neutron energy range from about 100 keV to 500 MeV, and ±25% essentially in the full energy range above thermal. A new sensor technique implemented in the NDX is based on using the Ionization Chamber (IC) filled with 3He gas to capture the moderated neutron fluence, and includes a symmetric IC filled with regular 4He to evaluate the contributions due to the non-neutron ionizing radiation. Advantages of the method include large accessible dynamic range, relative insensitivity of the IC probes to photon radiation fields, and the ability to subtract their contribution. Two prototype NDX detectors were built, calibrated, and operated in various conditions at the CEBAF 12 GeV electron accelerator at JLab. The first results showed reliable neutron dose rate measurements in the presence of overwhelming photon radiation fields, and at practical high dose rate levels of up to approximately 10 Sv/h. Detector design, operation, first results, and further development plans are presented.

Degtiarenko, Pavel V.↗
DOE OSTI2024

Hydrogen Generation and Industrial Heat Opportunities for Nuclear Plants in the Gulf Coast

The United States (U.S.) nuclear-generation fleet stands as a critical national strategic asset, playing a pivotal role in achieving climate goals. Operating on light-water reactor (LWR) technologies, this fleet provides the largest share of U.S. carbon-free electrical generation, ensuring 24/7 clean-energy stability. With a proven track record of reliability while operating at high-capacity factors, consistently above 90%, the existing nuclear fleet serves as a cornerstone for sustainable energy. The Department of Energy’s (DOE’s) Light Water Reactor Sustainability (LWRS), Flexible Plant Operations and Generation pathway addresses U.S. nuclear power plant (NPP) grid integration challenges in the face of evolving energy landscapes. Research at Idaho National Laboratory (INL) highlights the potential synergy between high-temperature steam-electrolysis (HTSE) technology and nuclear steam and electricity during periods of high renewable grid penetration. Large-scale nuclear-integrated hydrogen production through HTSE presents significant potential for decarbonizing such energy-intensive sectors as oil refining, petrochemicals, ammonia, and fertilizers. The strategic advantage lies in the nuclear sector’s capability to deliver clean electrical and/or steam output during periods of low demand. Nuclear-produced hydrogen—with its ability to provide high-purity clean H 2 well below the national standard of 1 kg of CO 2 per kg of H 2 —represents a breakthrough methodology. This emphasizes the crucial role NPPs can fill in addressing the increasing need for clean hydrogen, establishing them as essential contributors to decarbonization. This report specifically delves into hydrogen-generation opportunities from the U.S. Gulf Coast region. This study aims to assess NPP capabilities for hydrogen production and to identify practical nearby industrial and pipeline-operator off-takers for nuclear-integrated hydrogen production as well as to present some specific case-study analysis showing the conditions under which nuclear hydrogen production and sale can be profitable. Also considered in this report is preliminary analysis of nuclear-heat opportunities accessible near Waterford NPP via transportation of hypothetical steam pipelines and heat-exchange equipment.

08 HYDROGEN↗
DOE OSTI2020

A Hybrid Deep Learning Approach to Cosmological Constraints from Galaxy Redshift Surveys

We present a deep machine learning (ML)–based technique for accurately determining σ g and Ω m from mock 3D galaxy surveys. The mock surveys are built from the AbacusCosmos suite of N -body simulations, which comprises 40 cosmological volume simulations spanning a range of cosmological parameter values, and we account for uncertainties in galaxy formation scenarios through the use of generalized halo occupation distributions (HODs). We explore a trio of ML models: a 3D convolutional neural network (CNN), a power spectrum–based fully connected network, and a hybrid approach that merges the two to combine physically motivated summary statistics with flexible CNNs. We describe best practices for training a deep model on a suite of matched-phase simulations, and we test our model on a completely independent sample that uses previously unseen initial conditions, cosmological parameters, and HOD parameters. Despite the fact that the mock observations are quite small (~0.07 h -3 Gpc 3 ) and the training data span a large parameter space (six cosmological and six HOD parameters), the CNN and hybrid CNN can constrain estimates of σ g and Ω m to ~3% and ~4%, respectively.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

HANDBOOK BEST PRACTICES FOR ORGANIZING PUBLIC E WASTE COLLECTION EVENTS Indoor and Outdoor Settings

This handbook was created to share best practices of organizing public e-waste collection events in the United States. The steps and checklists outlined in this handbook have been drawn from Sunnking’s decade’s long experience of organizing large scale outdoor collection events in New York. These practices have been verified by INL and ECyclers of Idaho to work well for both indoor and outdoor events in Idaho at a smaller scale. Understanding that the local conditions vary significantly, we have compiled key deciding factors to share in this handbook. We hope that by following these steps, you will succeed in organizing your own events. Although e-waste events typically require careful logistics planning due to the nature of the materials, the experience is very rewarding to bring the community together.

Collection Event↗
DOE OSTI2022

Unveiling mechanism of surface-guided platinum nanowire growth

We report surface-guided growth of non-planar nanowires on functional substrates offers the new opportunity to precisely control their diameter, length, density and alignment, which will greatly benefit their direct integration into practical devices for large-scale applications. However, control of noble metal nanowires growth and arrangement remains a great challenge, and the mechanistic understanding is still limited. Herein, we choose Pt as a model material system to study the synthesis conditions required to control the in situ growth of aligned Pt nanowires on flat titanium substrate via a one-step and room-temperature green chemical synthesis process in aqueous solution. Most importantly, it is for the first time discovered that ordered nanoarrays and self-assembled nanoflowers can be directly grown on flat Ti substrate by merely adjusting the reaction times, without use of any soft/hard templates, surfactants and organic solvents. The proposed surface-guided growth mechanisms for nanoarray and nanoflower formation in this study may shed light on understanding of oriented arrangement/assembly of one-dimensional Pt nanowires into desirable morphologies for a variety of practical device applications.

Pt nanoflower↗
DOE OSTI2021

Optimizing Vehicle Fleet and Assignment for Concentrating Solar Power Plant Heliostat Washing

Concentrating solar power central-receiver plants use thousands of sun-tracking mirrors, i.e., heliostats, to reflect sunlight to a central receiver, which collects and uses the heat to generate electricity. Over time, soiling reduces the reflectivity of the heliostats and, therefore, the efficiency of the system. Current industry practice sends vehicles to wash heliostats in an ad hoc fashion. We present a mixed-integer nonlinear program that determines wash vehicle fleet size, mix, and assignment of wash crews to heliostats to minimize the sum of (i) the revenues lost due to heliostat soiling, (ii) the costs of hiring wash crews and operating the vehicles, and (iii) the costs of purchasing wash vehicles. We establish conditions for convexity of the objective function, and then propose a decomposition method that enables near-optimal solutions to the wash vehicle fleet sizing and assignment problem on the order of a couple of minutes. Furthermore, these solutions yield hundreds of thousands of dollars in savings per year over current industry practices.

14 SOLAR ENERGY↗
DOE OSTI2023

Islands in the fluid: islands are common in cosmology

We discuss the possibility of entanglement islands in cosmological spacetimes with a general perfect fluid with an equation of state w. We find that flat universes with time-symmetric slices where the Hubble parameter vanishes always have islands on that slice. We then move away from such slices, considering still universes with a general perfect fluid. Under the local thermal equilibrium assumption, the comoving entropy density s c is constant. As a result, the conditions for an island become an inequality between the energy density (or Hubble parameter) and the temperature at some time of normalization. The consequences are that islands can exist for practically all fluids that are not radiation, i.e. w ≠ 1/3. We also discuss the ramifications of our results for universes with spatial curvature. Finally, we show that islands occur in the Simple Harmonic Universe model which has no classical singularity at the background level, in contrast to all previous examples where islands occurred only in space-times with singularities.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Analysis of strategies to meet ASHRAE S241 infectious aerosol control targets by space type and region using EnergyPlus™ simulations

Professional organizations, such as ASHRAE, have recently proposed new voluntary standards for controlling infectious aerosols. Specifically, ASHRAE Standard 241 (S241) defines equivalent clean air targets for a range of space types that can be met through combinations of mitigation measures. This paper seeks to inform the selection of measures by space type and climate zone through building simulations that quantify the impacts of increased outdoor air ventilation; increasing filtration and/or adding germicidal ultraviolet (GUV) in the central heating, ventilation, and air-conditioning (HVAC) systems; or using portable air cleaners (PACs), upper room GUV, or whole room GUV approaches to increase equivalent clean air delivery. The measures are assessed individually and in practical combinations for their ability to meet S241 in four space types (offices, classrooms, dining areas, and healthcare waiting rooms) using prototype buildings modeled using EnergyPlus. The mitigation measures are compared holistically against baseline building operations using metrics for equivalent clean air, energy, and comfort. The results in this study show that single measures can meet S241 for offices with minimal impacts on energy and comfort, while either upper room GUV systems or combinations of measures such as MERV 13 HVAC filtration with PACs are needed to meet S241 for classrooms. The dining area and healthcare waiting room targets cannot be met in this study when assuming design occupancy and MS2 as the challenge agent, even when combining multiple measures together. This paper provides valuable considerations when designing measures to meet S241 for a range of spaces and scenarios.

GUV↗
DOE OSTI2023

Optimization and understanding of ZnO nanoarray supported Cu-ZnO-Al 2 O 3 catalyst for enhanced CO 2 -methanol conversion at low temperature and pressure

Cu-ZnO-Al 2 O 3 is the most widely applied catalyst for CO 2 hydrogenation to methanol. However, it is still a challenge to produce methanol using this catalyst under low-temperature (<250 °C) and low-pressure (<10 bar) conditions with desirable yield and selectivity. In this work, by tuning the experimental processing parameters such as solvent, loading amount, and annealing temperature, highly improved ZnO nanoarray supported Cu-ZnO-Al 2 O 3 catalysts have been successfully demonstrated. Here, by using organic solvent (N,N-dimethylformamide (DMF), acetone, or isopropanol) for dip-coating loading process instead of deionized (DI) water, Cu-ZnO-Al 2 O 3 nanocatalysts was comparatively better dispersed on the nanorod array support with populated and abundant active sites, thus enhancing the methanol yield. With the control of the loading amount and annealing temperature, finely distributed Cu nanoparticles were obtained on the ZnO nanorod surfaces to enhance the interactions between Cu and ZnO nanorod surfaces. Further improvement of the catalyst performance is demonstrated by tuning the reaction space velocity. At 200 °C and 10 bar conditions, the optimized catalyst achieved a methanol yield of 6.46 mol h –1 kg –1 with 100 % selectivity. The good stability after prolonged testing of the catalysts demonstrates the potential practical implementation. The in situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) measurements under the 1 bar reveal that the CO 2 hydrogenation to methanol on the ZnO nanoarray supported Cu-ZnO-Al 2 O 3 catalyst follows the CO reaction pathway, due to the surface oxygen vacancies on ZnO nanorods which facilitate CO 2 dissociation.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2022

Dipolar Heteronuclear Correlation Solid-State NMR Experiments between Half-Integer Quadrupolar Nuclei: The Case of 11 B– 17 O

With 73% of all NMR-active nuclei being quadrupolar, there is great interest in the development of NMR experiments that can probe the proximity of quadrupolar spins. Here, pulse sequences for magic-angle spinning (MAS) 11 B– 17 O resonance-echo saturation-pulse double-resonance (RESPDOR) and dipolar heteronuclear multiple quantum correlation (D-HMQC) solid-state NMR experiments were investigated. In these pulse sequences, rotational-echo double-resonance (REDOR) recoupling was used with central transition (CT)-selective π-pulses applied to either the 11 B or 17 O spins to recouple 11 B– 17 O dipolar interactions. 11 B{ 17 O} RESPDOR experiments on 17 O-enriched boric acid and benzene diboronic acid showed that application of dipolar recoupling on the 11 B channel yielded more signal dephasing than when recoupling is applied on the 17 O channel; however, short effective 11 B transverse relaxation time constants (T 2 ') hinder the acquisition of dephasing curves out to long recoupling durations. Application of REDOR recoupling to 17 O spins was found to produce significant dephasing without compromising the 11 B T 2 '. Comparison of experimental 11 B{ 17 O} RESPDOR curves to those of numerical simulations enabled the 17 O isotopic enrichment to be estimated. 2D 11 B{ 17 O} D-HMQC spectra were recorded with either 11 B or 17 O REDOR recoupling under a variety of radio frequency field conditions. Lastly, 2D 11 B{ 17 O} and 23 Na{ 17 O} D-HMQC spectra of an 17 O-enriched sodium borate glass were acquired to demonstrate the practical application of these heteronuclear correlation experiments to probe structural connectivity between two quadrupolar spins. Importantly, the high-field 2D 11 B– 17 O D-HMQC NMR spectrum revealed two unique 17 O sites correlating to 4-coordinate BO 4 ( [4] B), which were attributed to the [3] B–O– [4] B and [4] B–O– [4] B bridging O atoms. Furthermore, the heteronuclear correlation experiments outlined here should be applicable to a variety of quadrupolar spin pairs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Glassy Carbon Substrate Oxidation Effects on Electrode Stability for Oxygen Evolution Reaction Catalysis Stability Benchmarking

Employing benchmarking metrics to capture the activity and stability of electrocatalysts for the oxygen evolution reaction (OER) in acid is a critical practice that enables meaningful comparison of catalyst material candidates reported throughout the literature. In this work, we find that ubiquitously used glassy carbon electrode substrates oxidize under typical OER operating conditions, forming a pacified, electrically insulating, and oxygen-rich surface layer that causes drastic loss of current density over the course of extended chronoamperometric stability tests at an anodic potential of 1.7 VRHE. We show that the experimentally observed stability of glassy carbon-based electrodes is approximately two orders of magnitude lower than that expected solely from dissolution-based catalyst intrinsic stability of Ir-based catalysts. We additionally find that glassy carbon-based electrode stability measured by chronoamperometric holds is greatly impacted by catalyst loading, with high catalyst loadings improving the stability of the overall electrode via a protective effect on the glassy carbon substrate. Altogether, our investigation highlights that glassy carbon is not electrochemically inert under OER conditions on the timescale of common stability tests, which can cause electrodes to exhibit performance losses that do not reflect the intrinsic stability of the actual catalyst material being investigated. In light of our findings, we underscore the usefulness of metrics, such as the S-number, to reflect intrinsic catalyst material stability.

25 ENERGY STORAGE↗
DOE OSTI2024

A Single Compartment Relaxed Eddy Accumulation Method

The relaxed eddy accumulation (REA) method is a widely-known technique that measures turbulent fluxes of scalar quantities. The REA technique has been used to measure turbulent fluxes of various compounds, such as methane, ethene, propene, butene, isoprene, nitrous oxides, ozone, and others. The REA method requires the accumulation of scalar concentrations in two separate compartments that conditionally sample updrafts and downdraft events. It is demonstrated here that the assumptions behind the conventional or two-compartment REA approach allow for one-compartment sampling, therefore called a one compartment or 1-C-REA approach, thereby expanding its operational utility. The one-compartment sampling method is tested across various land cover types and atmospheric stability conditions, and it is found that the one-compartment REA can provide results comparable to those determined from conventional two-compartment REA. This finding enables rapid expansion and practical utility of REA in studies of surface-atmosphere exchanges, interactions, and feedbacks.

Banerjee, T.↗
DOE OSTI2025

Thermomagnetic generators for ultra-low-grade marine thermal energy harvesting

Low-grade thermal gradients in marine environments represent an underexploited energy source for autonomous sensing and monitoring. Converting such small temperature differences into usable electrical power remains a key challenge for ocean-deployed systems. We present a deployable thermomagnetic generator thoroughly characterized for marine-relevant energy harvesting. The device powers an internet-connected sensor and harvests ultra-low temperature differences akin to those at the ocean surface. It draws heat from water and rejects it to ambient air, operating optimally at a temperature difference (ΔT) of ~7.5 °C. Laboratory prototypes generated up to 6.7 mW at ΔT ~ 10 °C with gentle airflow (~1 m s -1 ). A separate controlled wave-tank demonstration validated stable operation and sensor powering under marine-like boundary conditions. Given its voltage and power margins, the generator could sustain multiple sensor nodes. Scalability and material assessments identify modular deployment and non-rare-earth alternatives as pathways toward practical marine energy harvesting and low-grade waste-heat recovery.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Loading Capacity and Dilute Nitric Acid Rinse of Diglycolamide Resin for the Recovery of Transplutonium and Rare Earth Elements from Mark-18A Targets

N,N,N′,N′-tetraoctyldiglycolamide (TODGA) as a resin (“DGA resin”) produced by Eichrom Technologies will be used by Savannah River National Laboratory for the indiscriminate extraction of trivalent actinides and rare earth elements with the intent of recovering Cm and Am from dissolved irradiated 242 Pu Mark-18A targets in 7 to 9 M nitric acid. The extracted constituents will be recovered as an oxide by direct thermal decomposition of the loaded resin followed by calcination of the resultant residue. The characteristics of DGA resin with non-radiological feed simulant representative of the anticipated feed in the Mark-18A process, with Sm and Nd as surrogates for Cm and Am, respectively, including breakthrough point and saturation capacity were evaluated in this work. Additionally, this work examined the losses from the loaded resin by rinsing the resin bed with dilute acid to reduce the nitrate concentration in the resin bed prior to thermal decomposition operations to improve the safety posture of the process. A resin loading profile was developed, and the resin was determined to have a trivalent metal saturation capacity of 74 μmol/mL resin under the experimental conditions evaluated. Following a wash of the loaded resin bed with fresh 8 M HNO 3 , the trivalent metals retained was reduced to 68 μmol/mL resin, which represents the practical capacity of the resin for the Mark-18A process. Lighter lanthanides breakthrough the resin well before the saturation capacity is reached. Rinsing the saturated resin bed with 0.26 M HNO 3 was found to result in a rapid reduction in retention of rare earth elements by the resin. After 2.8 bed volumes of dilute acid rinse, the mean resin bed free acid concentration was reduced to 0.28 M and 3.1 bed volumes of dilute acid rinse resulted in a reduction of the cumulative rare earth element retention to 52 μmol/mL of resin.

Transplutonium separations↗
DOE OSTI2022

Laser melting modes in metal powder bed fusion additive manufacturing

In laser powder bed fusion additive manufacturing of metals, extreme thermal conditions create many highly dynamic physical phenomena such as vaporization and recoil, Marangoni convection, and protrusion and keyhole instability. Collectively however, the full set of phenomena is too complicated for practical applications and, in reality, the melting modes are used as a guideline for printing. With increasing local material temperature beyond the boiling point, the mode can change from conduction to keyhole. These mode designations ignore laser-matter interaction details but in many cases are adequate to determine the approximate microstructures and hence the properties of the build. To date, no consistent, common, and coherent definitions have been agreed upon because of historic limitations in melt pool and vapor depression morphology measurements. Here, we distinguish process-based definitions of different melting modes from those based on postmortem evidence. The latter are mainly derived from the transverse cross-sections of the fusion zone, whereas the former come directly from time-resolved x-ray imaging of melt pool and vapor depression morphologies. These process-based definitions are more strict and physically sound, and they offer new guidelines for laser additive manufacturing practices and create new research directions. Further, we highlight the significance of the keyhole, which substantially enhances the laser energy absorption by the melt pool. Recent studies strongly suggest that stable-keyhole laser melting enables efficient, sustainable, and robust additive manufacturing. The realization of this scenario demands the development of multiphysics models, signal translations from morphology to other feasible signals, and in-process metrology across platforms and scales.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗