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At least 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

An in situ imaging investigation of the effect of gas flow rates on directed energy deposition

Gas flow rates in Directed Energy Deposition (DED) Additive Manufacturing (AM) can significantly affect the quality of built parts by altering melt pool geometry. Using a DED process replicator and in situ synchrotron radiography, together with analogous experiments in an industrial DED machine, we investigate the impact of carrier gas and shield gas flow rates on build quality. The results reveal that there is a critical shield gas flow rate above which melt pools are flattened, tracks widen, and thus layer thickness decreases. The reduction in layer thickness is most prominent in conditions with low carrier gas flow rate, as the highly turbulent shield gas flow may divert slow moving powder particles away from the melt pool, decreasing capture efficiency. Very high flow rates increase internal porosity, as fast-moving particles impacting the melt pool surface can entrain chamber gas behind them. High gas flow rates also cool the melt pool, creating shallower melt pools with increased thermal gradients near the solidification front, increasing pore entrapment in the solidified track.

Additive manufacturing↗
DOE OSTI2022

Development and testing of a solar flux heating freeze recovery system for molten salt parabolic troughs

A major obstacle preventing commercialization of molten salt parabolic trough plants is freeze protection and recovery of the solar field. One of the most common nitrate salt compositions under consideration allows for solar field outlet temperatures up to 565°C and begins solidifying above 240°C. Using molten salt directly in the solar field can significantly reduce thermal energy storage costs and the higher temperature compared to oil heat transfer fluids can power a more efficient power cycle, but the very high freezing point is cause for concern. This work builds on a previous modeling effort investigating different methods for melting Solar Salt frozen in the solar field, which suggested the viability of a novel solar heating method to lower costs of the freeze protection system. In this work higher fidelity models are developed to better investigate the melting process with a more detailed 3D geometry which includes the insulated bellows. The thermal-fluid model of the melting process is updated to include temperature dependent density and data for solid phase properties. In addition, a finite element model is developed to resolve thermal stresses at the point with highest thermal gradients. Results with the new model confirm the viability of using controllable solar flux heating to thaw salt frozen in the solar field without damaging the receiver; however, the presence of non-illuminated sections significantly slows down the melting process. Solar heating simulations with pauses off-sun of 120 and 60 s require 18.5 and 11.9 h to melt salt from a night-time temperature of 10°C with 1000 W m2 DNI, which results in maximum thermal stresses of 48.2 and 53.5 MPa, respectively. Adding 150 W m−1 to the solar heating simulation with a 60 s pause off-sun decreases both the melt time and thermal stresses due to the more uniform heating, suggesting a combined heating method may be the best option.

14 SOLAR ENERGY↗
DOE OSTI2022

Microstructural examination of interactions between chromia-based refractory and nuclear glass in a melter

This study shows the effects of nuclear waste glass production on Monofrax K-3 refractory corrosion. A continuously fed research-scale melter containing an Fe- and Ni-rich simulated nuclear waste feed with borosilicate glass-forming chemicals was cyclically melted at 1150°C and idled at 1050°C for a total of 11 weeks. Chemical maps using scanning electron microscopy show the interactions between the quenched melt and the refractory. Nanoscale X-ray-computed tomography was used for a three-dimensional visualization of certain parts of the interface. Unreacted K-3 consists of primarily corundum (Al,Cr) 2 O 3 and spinel (Fe 2+ ,Mg)(Al,Cr) 2 O 4 interlocking crystalline phases. Some of the Cr from the refractory interacts with the Ni and Fe from the melt to form a reaction layer comprising (Ni,Fe 2+ )(Cr,Fe 3+ ) 2 O 4 spinel crystals. Simultaneously, melt components (Na,Si) infiltrate into the refractory. This interaction proceeds at the expense of the integrity of the refractory structure. Intact refractory grains (e.g., (Al,Cr) 2 O 3 ) as well as the reaction layer itself can lose mechanical integrity and spall off into the melt, especially near the top of the melter. As the reaction layer can be a protective boundary for the refractory against further melt infiltration, a reduction in the reaction layer thickness allows an increase in refractory corrosion.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Sensitivity of Thermal Predictions to Uncertain Surface Tension Data in Laser Additive Manufacturing

To understand the process-microstructure relationships in additive manufacturing (AM), it is necessary to predict the solidification characteristics in the melt pool. This study investigates the influence of Marangoni driven fluid flow on the predicted melt pool geometry and solidification conditions using a continuum finite volume model. A calibrated laser absorptivity was determined by comparing the model predictions (neglecting fluid flow) against melt pool dimensions obtained from single laser melt experiments on a nickel super alloy 625 (IN625) plate. Using this calibrated efficiency, predicted melt pool geometries agree well with experiments across a range of process conditions. When fluid mechanics is considered, a surface tension gradient recommended for IN625 tends to overpredict the influence of convective heat transfer, but the use of an intermediate value reported from experimental measurements of a similar nickel super alloy produces excellent experimental agreement. Despite its significant effect on the melt pool geometry predictions, fluid flow was found to have a small effect on the predicted solidification conditions compared to processing conditions. We find that this result suggests that under certain circumstances, a model only considering conductive heat transfer is sufficient for approximating process-microstructure relationships in laser AM. Extending the model to multiple laser passes further showed that fluid flow also has a small effect on the solidification conditions compared to the transient variations in the process. Furthermore, limitations of the current model and areas of improvement, including uncertainties associated with the phenomenological model inputs are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Compositional zoning of the Otowi Member of the Bandelier Tuff, Valles caldera, New Mexico, USA

The Otowi Member of the Bandelier Tuff erupted at ca. 1.60 Ma from the Valles caldera (New Mexico, USA). It consists of as much as 400 km 3 (dense rock equivalent) of strongly differentiated high-silica rhyolite and shows systematic upward variations in crystallinity, mineral chemistry, and trace element concentrations through its thickness, but the major element composition is almost constant and is near the low-pressure granite minimum. Incompatible trace elements in whole pumice fragments and glasses show well-correlated linear covariations. Upward zoning to lower abundances of incompatible trace elements is accompanied by development of overgrowths on quartz and alkali feldspar, although earlier-formed interiors of quartz and feldspar have near-constant compositions throughout the tuff, modified by cation diffusion in the case of feldspar. Melt inclusions in remnant quartz cores show diverse Pb isotope ratios, pointing to a wide range of distinct protoliths that contributed rhyolitic melt to the Otowi magma. Mineral thermometers suggest a modest temperature gradient through the melt body, perhaps of 40 °C, at the time of eruption. Chemical, textural, and mineralogical variations and volume-composition relations through the tuff are consistent with an origin for zoning by melting of a high-crystallinity cumulate layer beneath cognate supernatant liquid to produce denser, remobilized liquid of accumulative composition (i.e., the “modified mush model”). Melting may have occurred in several episodes. The latest of these episodes, probably thousands of years prior to eruption, introduced new rhyolitic liquid into the system and was associated with a thermal excursion, recorded in core compositions of pyroxene, during which much of the earlier crystal mass was dissolved. This left inherited cores and interiors of accumulated quartz and feldspar mantled with new growth having less-evolved compositions (higher Ti, Sr, and Ba). Changing solubility of zircon during cumulate melting produced a reversal of Zr concentrations. There is no clear petrologic evidence of a recharge eruption trigger; nonetheless, compositional zoning resulted mainly from repeated recharge-induced remobilization of quartz-feldspar cumulate. The Otowi system was built, evolved, and modified by several events over the course of a few hundred thousand years.

Wolff, J. A.↗
DOE OSTI2025

Confocal Raman Microscopy for Measuring In Situ Temperature-Dependent Structural Changes in Poly(Ethylene Oxide) Thin Films

Crystallization from the melt is a critical process governing the properties of semi-crystalline polymeric materials. While structural analyses of melting and crystallization transitions in bulk polymers have been widely reported, in contrast, those in thin polymer films on solid supports have been underexplored. Herein, in situ Raman microscopy and self-modeling curve resolution (SMCR) analysis are applied to investigate the temperature-dependent structural changes in poly(ethylene oxide) (PEO) films during melting and crystallization phase transitions. By resolving complex overlapping sets of spectra, SMCR analysis reveals that the thermal transitions of 50 µm thick PEO films comprise two structural phases: an ordered crystalline phase and a disordered amorphous phase. The ordered structure of the crystalline PEO film entirely disappears as the polymer is heated; conversely, the disordered structure of the amorphous PEO film reverts to the ordered structure as the polymer is cooled. Broadening of the Raman bands was observed in PEO films above the melting temperature (67 °C), while sharpening of bands was observed below the crystallization temperature (45 °C). The temperatures at which these spectral changes occurred were in good agreement with differential scanning calorimetry (DSC) measurements, especially during the melting transition. The results illustrate that in situ Raman microscopy coupled with SMCR analysis is a powerful approach for unraveling complex structural changes in thin polymer films during melting and crystallization processes. Furthermore, we show that confocal Raman microscopy opens opportunities to apply the methodology to interrogate the structural features of PEO or other surface-supported polymer films as thin as 2 µm, a thickness regime beyond the reach of conventional thermal analysis techniques.

Koh, Miharu [Department of Chemistry, University o↗
DOE OSTI2021

Ultrafast visualization of phase transitions in nonequilibrium warm dense matter

Intense ultrafast laser excitation brings materials into highly nonequilibrium states with complex solid–liquid phase transitions. These ultrafast processes yield warm dense matter (WDM) conditions characterized by comparable thermal and Fermi energies, and strong ion–ion coupling. Here, we review recent studies employing mega-electron-volt ultrafast electron diffraction to resolve the structural dynamics of nonequilibrium WDM created by femtosecond laser heating of solids. Furthermore, for the study of warm dense gold, the results showed homogeneous melting that occurs within tens of picoseconds at absorbed energy densities of 0.4–1.4 MJ/kg. These results constrained the electron–ion coupling rate and revealed the melting sensitivity to nucleation seeds. For the study of radiation-damaged tungsten, the results showed a melting transition below the melting temperature. Molecular dynamics simulations suggested that this melting behavior is driven by vacancy defect clusters from radiation damage. These studies provided atomic-level insights into the melting behavior of materials under extreme conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Oxygen isotope ratios in zircon and garnet: A record of assimilation and fractional crystallization in the Dinkey Dome peraluminous granite, Sierra Nevada, California

Abstract The 119 Ma Dinkey Dome pluton in the central Sierra Nevada Batholith is a peraluminous granite and contains magmatic garnet and zircon that are complexly zoned with respect to oxygen isotope ratios. Intracrystalline SIMS analysis tests the relative importance of magmatic differentiation processes vs. partial melting of metasedimentary rocks. Whereas δ18O values of bulk zircon concentrates are uniform across the entire pluton (7.7‰ VSMOW), zircon crystals are zoned in δ18O by up to 1.8‰, and when compared to late garnet, show evidence of changing magma chemistry during multiple interactions of the magma with wall rock during crustal transit. The evolution from an early high-δ18O magma [δ18O(WR) = 9.8‰] toward lower values is shown by high-δ18O zircon cores (7.8‰) and lower δ 18O rims (6.8‰). Garnets from the northwest side of the pluton show a final increase in δ18O with rims reaching 8.1‰. In situ REE measurements show zircon is magmatic and grew before garnets. Additionally, δ18O in garnets from the western side of the pluton are consistently higher (avg = 7.3‰) relative to the west (avg = 5.9‰). These δ18O variations in zircon and garnet record different stages of assimilation and fractional crystallization whereby an initially high-δ18O magma partially melted low-δ18O wallrock and was subsequently contaminated near the current level of emplacement by higher δ18O melts. Collectively, the comparison of δ18O zoning in garnet and zircon shows how a peraluminous pluton can be constructed from multiple batches of variably contaminated melts, especially in early stages of arc magmatism where magmas encounter significant heterogeneity of wall-rock assemblages. Collectively, peraluminous magmas in the Sierran arc are limited to small <100 km2 plutons that are intimately associated with metasedimentary wall rocks and often surrounded by later and larger metaluminous tonalite and granodiorite plutons. The general associations suggest that early-stage arc magmas sample crustal heterogeneities in small melt batches, but that with progressive invigoration of the arc, such compositions are more effectively blended with mantle melts in source regions. Thus, peraluminous magmas provide important details of the nascent Sierran arc and pre-batholithic crustal structure.

Geochemistry & Geophysics↗
DOE OSTI2021

Alternative Liquid DSA Containers for Sludge Slurry Storage in the SRNL Shielded Cells

A pending revision of the Documented Safety Analysis (DSA) for the Savannah River National Laboratory (SRNL) defines “DSA containers'’ for liquid sludge slurries as containers not susceptible to a flashing spray release in a fire and requires that a list of DSA containers be maintained. High Level Waste (HLW) samples are typically received from the Savannah River Site (SRS) tank farm after retrieval from the storage tanks. Glass bottles are preferred for long-term storage of radioactive liquid sludge slurry samples but are not on the DSA container list. An evaluation has been conducted to identify vessel lids for the glass bottles that would vent prior to pressurization and liquid superheating in a fire event. Low melting Field's Metal eutectic alloy with a melting point of 62°C has been identified as a preferred material of construction for vessel lids for this application because the material is resistant to puncture and is expected to have good chemical compatibility and radiation stability in the shielded cells environment. A test vessel was designed to evaluate the alloy and confirm that it would melt before the water in the vessel reaches the boiling point. The tests confirmed: 1) that the reported melting point of the alloy was accurate, 2) that a top fashioned from this material will melt creating an open atmosphere in the vessel headspace prior to sample boiling under moderate and fast heating rates, and 3) that nonuniform heating of the bottle from the bottom also results in melting of the alloy prior to boiling. Based on the results, neither an engulfing fire with standing or toppled bottles or a fire producing localized heat at the vessel bottom would result in flashing spray conditions. It is recommended that glass vessels of various volumes ranging from 125 mL to 1 gallon with modified tops containing the specified Field's Metal eutectic alloy which are appropriately designed to avoid flashing spray material releases be added to the DSA container list. These vessels will be utilized in the Shielded Cells for the storage of radioactive liquid samples of sludge slurries. Use of these vessels will also be advantageous for other liquid samples containing accountable amounts of nuclear material throughout other SRNL laboratories. Similarly constructed paraffin vessel lids could also potentially be added to the approved list, though additional testing would be required.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Alternative Liquid DSA Containers for Sludge Slurry Storage in the SRNL Shielded Cells

A pending revision of the Documented Safety Analysis (DSA) for the Savannah River National Laboratory (SRNL) defines “DSA containers” for liquid sludge slurries as containers not susceptible to a flashing spray release in a fire and requires that a list of DSA containers be maintained. High Level Waste (HLW) samples are typically received from the Savannah River Site (SRS) tank farm after retrieval from the storage tanks. Glass bottles are preferred for long-term storage of radioactive liquid sludge slurry samples but are not on the DSA container list. An evaluation has been conducted to identify vessel lids for the glass bottles that would vent prior to pressurization and liquid superheating in a fire event. Low melting Field’s Metal eutectic alloy with a melting point of 62 °C has been identified as a preferred material of construction for vessel lids for this application because the material is resistant to puncture and is expected to have good chemical compatibility and radiation stability in the shielded cells environment. A test vessel was designed to evaluate the alloy and confirm that it would melt before the water in the vessel reaches the boiling point. The tests confirmed: 1) that the reported melting point of the alloy was accurate, 2) that a top fashioned from this material will melt creating an open atmosphere in the vessel headspace prior to sample boiling under moderate and fast heating rates, and 3) that nonuniform heating of the bottle from the bottom also results in melting of the alloy prior to boiling. Based on the results, neither an engulfing fire with standing or toppled bottles or a fire producing localized heat at the vessel bottom would result in flashing spray conditions.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

EB Vs PAM Vs VAR for Uranium Alloys

Questions were raised during the February ’97 PDP Meeting at LLNL as to the advisability of funding three separate melting development programs (Advanced Vacuum Arc Remelt (VAR), Plasma Arc Melting (PAM) and Electron Beam Melting (EB)) through PDP in this era of shrinking research funds. The main issues seemed to be: 1) Have we evaluated the potentials of the three processes sufficiently to eliminate any of them out of hand and 2) Have any of these processes to date produced results which show clear advantages over the other two. The feeling at the meeting toward the latter seemed to be that all three processes required further development before they would be accepted by the complex as the standard. As far as evaluating potential for process improvements, however, we at Livermore did go through somewhat of a trade study in 1993 when we proposed the EB route. It seemed to us that even with the elimination of the skull caster via a VIM/VAR/VAR route, the problem of recycle limitations in the VIM step due to excessive carbon pick-up limited the potential for a great improvement in material utilization using this method. A single-step, cold hearth route looked to be the preferable choice. Both EB and PAM are used commercially as cold hearth processes, and both have been used for the production of refractory and specialty metals; EB since the mid 1950’s and PAM since the mid 1980’s. Both seem to have found their individual niches with some applications being suited to EB and others to PAM. Both can be adapted to continuous casting techniques and both are capable of imparting the high heat fluxes necessary to melt refractory metals. The major differences appear to be that for most applications, the EB process is capable of producing a purer product, while PAM results in less loss of volatile components. There exists an abundance of information in the open literature on the results of processing via both routes on various materials. The attached 1984 paper gives a good explanation of electron beam melting and plasma melting, and, I believe, a fair assessment of the advantages and limitations of both processes.

36 MATERIALS SCIENCE↗
DOE OSTI2024

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

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

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Annual carbon dioxide flux over seasonal sea ice in the Canadian Arctic

Continuous measurements of carbon dioxide (CO 2 ) flux were collected from a 10 m eddy covariance tower in a coastal-marine environment in the Canadian Arctic Archipelago over the course of a 17-month period. The extended length of data collection resulted in a unique dataset that includes measurements from two spring melt and summer seasons and one autumn freeze-up. These field observations were used to verify findings from previous theoretical and laboratory experiments investigating air-sea gas exchange in connection with sea ice. The results corroborated previous findings showing that thick ice cover under winter conditions acts as a barrier to gas exchange. In the spring, CO 2 fluxes were downward (uptake) in both the presence of melt ponds and during ice break-up. However, diurnal cycles were present throughout the early spring melt period, corresponding to the opposing influences of freezing and melting at the ice surface. Fluxes measured during melt periods confirmed previous laboratory tank measurements that showed a gas transfer coefficient of melting ice of 0.4 mol m −2 d −1 atm −1 . Open water CO 2 fluxes showed outgassing in early summer and uptake in mid-to-late summer, tied closely to trends in surface water temperature and its effect on the partial pressure of CO 2 in the water. The autumn period of the field campaign represents the first eddy covariance CO 2 fluxes measured over naturally forming sea ice. Our measurements showed mean upward fluxes (outgassing) of 1.1±1.5 mmol m −2 d −1 associated with the freezing of ice – the same order of magnitude found by previous laboratory tank experiments. However, peak flux periods during ice formation had measured fluxes that were a factor of 3 higher than the tank experiments, suggesting the importance of natural conditions (e.g., wind) on air-ice gas exchange. Conducting an Arctic-wide extrapolation we estimate CO 2 outgassing from the freezing period to be a counterbalance equivalent to 5 to 15 % of the magnitude of the estimated Arctic CO 2 sink. Overall, there was no evidence of dramatically enhanced gas exchange in marginal ice conditions as proposed by previous studies. Although the different seasons showed active CO 2 exchange, there was a balance between upward and downward fluxes at this specific location, resulting in a small net CO 2 uptake over the annual cycle of −0.3 g C m −2 .

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Results of the second Ice Shelf–Ocean Model Intercomparison Project (ISOMIP+)

Ocean-driven basal melting of Antarctic ice shelves plays an important role in the mass loss of the Antarctic Ice Sheet. Ice shelf cavity-resolving ocean models are a valuable tool for understanding ice shelf-ocean interactions and for simulating projections of ice shelf and ocean states under future climate. Designed to assess the current state of ice shelf–ocean modelling, the second Ice Shelf–Ocean Model Intercomparison Project, ISOMIP+, consists of 12 ocean model configurations submitted with a common, idealised experimental setup. Here, we focus on the experiments Ocean0–2 (Asay-Davis et al., 2016), which are ocean models with idealised, static ice shelf geometries, but where the ocean reaches a balance with prescribed far-field ocean conditions. Different thermal transfer coefficient values (ranging from 0.011 to 0.2) are used for each model in the melting parameterisation to achieve a common, tuned melt rate since the models cover a range of types of vertical coordinates, ice–ocean boundary layer treatments, and numerical schemes. These model differences lead to spread in the resultant ocean properties, circulation, boundary-layer structure and spatial distribution of melting. We also highlight similarities between models, such as a shared linear relationship across most models between melt rate and overturning and barotropic streamfunctions during the spin-up and spin-down, demonstrating a robust relationship between melt and circulation across models and forcing conditions. The ISOMIP+ results provide a systematic comparison of ice shelf cavity-capable ocean models. However, we also demonstrate the need for realistic ice shelf–ocean model intercomparison projects (some already underway) to assess model biases and inter-model variation against sparse observations. Further research is needed to understand the differences between models and further improve our modelled representations of the ice–ocean boundary layer and ice shelf cavity circulation.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Impact of Fill Factor on Electro-slag Remelting Operations

Vacuum induction melting (VIM), electro-slag remelting (ESR) and vacuum arc remelting (VAR) are all techniques used to make high quality ingots of complex chemistries. In some cases, all three are used, e.g., alloys for aerospace applications and increasingly those for fossil power applications under extreme conditions. Electroslag remelting operation is a complicated endeavor, dependent upon several factors including operating current, voltage, and geometry. A research scale 440 lb capacity ESR furnace was used to melt low carbon steel (1018 steel) electrodes of different diameters using various melt rates. This was used to assess melt parameters and sidewall and other quality aspects of the product ingots. These observations were compared to results from ESR modeling using MeltFlow-ESR. It was found that fill factor had a significant impact on operating voltage while current had a significant impact on melt rate. Ultimately, a combination of fill factor and power gave the best prediction of melt rate during steady state.

Jablonski, Paul↗
DOE OSTI2020

Thermal Analysis of High Entropy Rare Earth Oxides

Phase transformations in multicomponent rare earth sesquioxides were studied by splat quenching from the melt, high temperature differential thermal analysis and synchrotron X-ray diffraction on laser-heated samples. Three compositions were prepared by the solution combustion method: (La,Sm,Dy,Er,RE) 2 O 3 , where all oxides are in equimolar ratios and RE is Nd or Gd or Y. After annealing at 800 °C, all powders contained mainly a phase of C-type bixbyite structure. After laser melting, all samples were quenched in a single-phase monoclinic B-type structure. Thermal analysis indicated three reversible phase transitions in the range 1900–2400 °C, assigned as transformations into A, H, and X rare earth sesquioxides structure types. Unit cell volumes and volume changes on C-B, B-A, and H-X transformations were measured by X-ray diffraction and consistent with the trend in pure rare earth sesquioxides. The formation of single-phase solid solutions was predicted by Calphad calculations. The melting point was determined for the (La,Sm,Dy,Er,Nd) 2 O 3 sample as 2456 ± 12 °C, which is higher than for any of constituent oxides. An increase in melting temperature is probably related to nonideal mixing in the solid and/or the melt and prompts future investigation of the liquidus surface in Sm 2 O 3 -Dy 2 O 3 , Sm 2 O 3 -Er 2 O 3 , and Dy 2 O 3 -Er 2 O 3 systems.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A first principles framework to predict the transient performance of latent heat thermal energy storage

Thermal energy storage (TES) is increasingly recognized as an essential component of efficient Combined Heat and Power (CHP), Concentrated Solar Power (CSP), Heating Ventilation and Air Conditioning (HVAC), and refrigeration as it reduces peak demand while helping to manage intermittent availability of energy (e.g., from solar or wind). Latent Heat Thermal Energy Storage (LHTES) is a viable option because of its high energy storage density. Parametric analysis of LHTES in terms of dimensionless numbers is highly desired as a tool to model LHTES systems. One approach is to develop a model equation so as to minimize the error between the model and data obtained from experiments or simulations. While this approach can produce an accurate correlation applicable within the range of data used for its creation, it does not provide physical understanding of the rate-limiting process controlling the transient behavior of the device. In this paper we present an alternative approach whereby the potential rate-limiting processes are identified from first principles and then the key process is determined as a function of time as a LHTES device is charged. For example, in a simple geometry, the melt-fraction can be expected to vary linearly in time if the heat transfer rate is limited by natural convection of the phase changing material and we show it scales with the PCM Grashof number as $Gr^1_p$ and PCM Prandtl number as $Pr_p^{(1/3)}$. On the other hand, if surface area of solid PCM limits the heat transfer rate, the melt fraction increases asymptotically to reach full melting. The existence of these linear and asymptotic regions and the $Gr^1_pP r^{1/3}_p$ shape of the melt fraction curve is verified using our database of 64 simulations. Of practical importance in designing LHTES devices is the melt fraction at which the heat transfer rate ceases to be limited by convection, after which the heat storage rate deteriorates. For our geometry, this is found to be about 90%. This test case of our methodology shows the value of our approach, that predicting heat storage rate based on the rate-limiting physical phenomenon as a function of time is an effective approach to modeling LHTES devices.

25 ENERGY STORAGE↗
DOE OSTI2022

Effect of powder layer thickness on the microstructural development of additively manufactured SS316

By Increasing the powder layer thickness we could increase material deposition rates and reduce build times during laser powder bed fusion (LPBF). However, increasing the powder layer thickness could also negatively affect the local melting and subsequent microstructure of the printed material. This study systematically investigated, for the first time, the defect evolution and microstructural changes of LPBF stainless steel 316 (SS316) processed by using various powder layer thicknesses of 40, 80, and 120 μm while also varying the laser dwell time for the pulsed laser. Through image analysis, the pore density was found to increase with increasing powder layer thickness, particularly when the dwell time was too high or too low. The maximum achievable density (>99%) was found over a wide processing window when using the smallest powder layer thickness of 40 μm between dwell times of 60 and 100 μs. Increasing the powder layer thicknesses to 80 and 120 μm resulted in maximum densities of 98.7 and 96.8%, respectively, but the window for acceptable laser dwell times that could achieve these densities narrowed considerably. A microstructural analysis of the melt pools was performed to measure the melt pool depths and widths, both of which increased with increasing dwell time. However, increasing the powder layer thickness did not affect the melt pool depth and only minorly affected the width. A sub-grain cellular structure distinguished the melt pool boundaries. The cell size increased with increasing dwell time and decreasing powder layer thickness. Moreover, the cell size was used to calculate a cooling rate that had a magnitude of 10 7 K/s and increased with increasing powder layer thickness.

36 MATERIALS SCIENCE↗