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At least 847 records · Page 47
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Multivariate Analysis of the Influence of Process Parameters on Suspension Plasma-Sprayed Coatings

Suspension plasma spray (SPS) is far more complicated than conventional plasma spray and requires a deep knowledge about the influence of process parameters and their correlations. In this study, YSZ coatings were manufactured by SPS with six different process parameters such as plasma power, suspension mass load, original powder size, substrate surface topology, spray distance, and spray step. Afterwards, the porosity of as-prepared coatings was investigated by image method and X-ray transmission technique. A multivariate analysis on the collected experimental data was carried out by employing mathematical statistics methods. The results showed that: 1) Coating porosity has a negative correlation with plasma power and suspension mass load and a positive correlation with the original powder size, spray distance, spray step, and substrate roughness; 2) Spraying distance is the main factor affecting to coating porosity, followed by suspension mass load and substrate surface roughness, respectively. A linear model for porosity prediction was developed and was verified by experiments. The mechanism by which process parameters influence coating porosity is also discussed.

Zhao, Yongli↗
DOE OSTI2022

Hierarchical printed product and composition and method for making the same

Disclosed herein are embodiments of a printable composition that can be used to make printed products of a chosen material chemistry that have different levels of porosity within the printed product's structure Also disclosed herein are embodiments of a printed product that has multiple levels of porosity throughout its structure, which can include a macroscale level of porosity, a microscale level of porosity, a nanoscale level of porosity and any combination thereof. These printed products can be made using a 3-D printer and can be made from a single printable composition without the need to add different structural components during the production process. Also disclosed herein are embodiments of a method for making and using a printed product.

Lee, Matthew N.↗
DOE OSTI2025

Reaction-Induced Fracturing of Porous Carbonate Rocks during Volume-Increasing Replacement by Witherite

Volume-increasing replacement reactions can lead either to fracturing of the parent phase or to the formation of cohesive layers that passivate further reaction, but the factors that drive one outcome or the other are not understood. In this experimental study, we investigated the volume-increasing replacement of carbonate rocks (consisting of CaCO 3 and CaMg(CO 3 ) 2 ) of different porosity by witherite (BaCO 3 ). Samples were characterized using scanning electron microscopy, Raman spectroscopy, small-angle neutron/X-ray scattering, X-ray tomography, and scanning transmission electron microscopy. We observed the formation of a witherite reaction layer and witherite formation within pores and along grain boundaries. Despite this being a volume-increasing replacement reaction, newly formed witherite was porous, potentially allowing further replacement. Filled fractures were observed in the low-porosity carbonates, whereas witherite formed within pores in high-porosity carbonates. We conclude that fracturing of the parent phase versus passivation is contingent on the initial microstructure of the parent with an optimal degree of porosity required for fracturing.

Calcite↗
DOE OSTI2015

Mechanism of formation of wiggly compaction bands in porous sandstone: 1. Observations and conceptual model

Field observations are combined with microscopic analyses to investigate the mechanism of formation of wiggly compaction bands (CBs) in the porous Jurassic aeolian Aztec Sandstone exposed at Valley of Fire State Park, Nevada. Among the three types of CBs (T1, T2, and T3), we focused on the wiggly CBs (T3), which show a chevron (T3 1 ) or wavy (T3 2 ) pattern with typical corner angles of approximately 90° or 130°, respectively. Where corner angles of wiggly CBs increase to 180°, they become straight CBs (T3 3 ). Image analyses of thin sections using an optical microscope show host rock porosity increases downslope in this dune, and the predominant type of wiggly CBs also varies from chevron to straight CBs. Specifically, band type varies continuously from chevron to wavy to straight where the porosity and grain sorting of the host rock increase systematically. Based on the crack and anticrack models, we infer that the change from chevron to straight CBs is due to increasing failure angle of the sandstone and this may correlate with increasing grain sorting. Wavy CBs with intermediate failure angle and host rock porosity are an intermediate stage between chevron and straight CBs. Previous sedimentological studies also have suggested that grain size and sorting degree increase downslope on the downwind side of sand dunes due to a sieving process of the wind-blown grains. Furthermore, the transition of wiggly CB types in this regard correlates with increasing sorting and perhaps with increasing porosity downslope.

58 GEOSCIENCES↗
DOE OSTI2017

Fracture capture of organic pores in shales

Shales are heterogeneous media with porosity at many scales and in many microtextural positions, including within organic matter and clay aggregates. Because these materials have contrasting mechanical properties, it remains unclear how induced fractures manage to connect with this porosity whether during hydrocarbon production, wastewater injection, or carbon-capture-and-storage efforts. To explore porosity changes related to fracturing, we experimentally failed shale samples in a triaxial load apparatus and observed changes in microstructure through scanning electron microscopy, low-pressure nitrogen sorption, and nuclear magnetic resonance. We observed a system of microcracks, many of which were likely experimentally induced and localized on grain boundaries. In some cases these fractures propagated into regions of natural porosity in organic matter. In the subsurface this “fracture capture” likely enhances pore connectivity, but only selectively depending upon mechanical conditions. Finally, fracture capture is one possible mechanism by which multiscale compositional heterogeneity in shales may affect rheological heterogeneity.

58 GEOSCIENCES↗
DOE OSTI2026

Optimization of Processing, Microstructure, and Hardness of an Al–Ce–Ni–Mn–Zr Alloy With Laser Additive Manufacturing

Here, this study examines the processing behavior, microstructure, surface roughness, and hardness properties of an aluminum alloy containing 8.2 Ce, 4.5 Ni, 0.5 Mn, and 0.7 Zr (wt%) fabricated using laser powder bed fusion. Sixty samples were produced across a range of laser powers, scan speeds, and hatch spacings to evaluate their effect on porosity, hardness, and microstructural features. Porosity was measured using X-ray computed tomography, while microstructure and surface roughness were characterized by scanning electron (SEM) and laser confocal microscopy. High dense and cracking-free Al–Ni–Ce alloy was successfully manufactured. Porosity showed a U-shaped dependence on energy input, increasing under both insufficient and excessive melting conditions. Hardness increased with cooling rate due to finer cellular structures and solute redistribution. A general statistical model was developed to capture the relationships between processing parameters and material response. Results identify a narrow processing window defined by laser powers between 350 and 370 W, scan speeds from 1400 to 1800 mm/s, and hatch distances between 0.14 and 0.18 mm. Within this window, porosity is minimized (below 0.01%) and hardness is maximized (up to 160 HV), demonstrating that careful control of these parameters enables dense, high strength aluminum components suitable for demanding structural applications.

Aluminum alloys↗
DOE OSTI2025

Isolated vesicles in submarine pumice: insights from the 2019 Volcano F eruption, Kingdom of Tonga

No reliable method can distinguish between subaerial and submarine pumice, but recent work shows that highly vesicular (total porosity, φ > 65%) submarine pumice from the 2012 Havre and 2021 Fukutoku Oka-no-Ba eruptions contains abundant isolated porosity (connectivity, C < 0.6). This differs from textural measurements of subaerial pumice with similarly high vesicularities, where high connectivities (C > 0.8) are often measured. To investigate the implications of this under-studied texture for bubble nucleation, growth, and coalescence dynamics at submarine eruptions, we analyze the textural characteristics of rafted pumice clasts from the 2019 submarine eruption of Volcano F, located along the Tonga-Kermadec Arc. We examined clasts collected while floating near the vent (50–200 km) and distally on the shores of Fiji (900 km). Using helium pycnometry and X-ray tomography (XRT), we quantified porosity and connectivity in 45 pumice lapilli, classifying them by vesicle macrotexture and edge morphology. Microvesicular clasts, the majority of which have breadcrust and cauliflower textures, exhibit the lowest connectivities (C = 0.61 ± 0.2), while macrovesicular clasts have high connectivities with C ~ 1. We propose that isolated porosity abundance varies according to clast location in the eruption column post-fragmentation. Microvesicular clasts erupted on the edges of the column and experienced high levels of seawater ingestion and subsequent quenching of the entire clast. Macrovesicular clasts, in contrast, erupted in the center of the eruption column and were thus thermally insulated, allowing magmatic bubbles in the molten pumice to nucleate, grow, and coalesce for longer. Our results and interpretation imply that low connectivity, microvesicular clasts preserve pre and syn-eruptive bubble processes at the 2019 Volcano F eruption.

Permeability↗
DOE OSTI2019

Predicting the reliability of an additively-manufactured metal part for the third Sandia fracture challenge by accounting for random material defects

We describe an approach to predict failure in a complex, additively-manufactured stainless steel part as defined by the third Sandia Fracture Challenge. A viscoplastic internal state variable constitutive model was calibrated to fit experimental tension curves in order to capture plasticity, necking, and damage evolution leading to failure. Defects such as gas porosity and lack of fusion voids were represented by overlaying a synthetic porosity distribution onto the finite element mesh and computing the elementwise ratio between pore volume and element volume to initialize the damage internal state variables. These void volume fraction values were then used in a damage formulation accounting for growth of these existing voids, while new voids were allowed to nucleate based on a nucleation rule. Blind predictions of failure are compared to experimental results. The comparisons indicate that crack initiation and propagation were correctly predicted, and that an initial porosity field superimposed as higher initial damage may provide a path forward for capturing material strength uncertainty. Here, the latter conclusion was supported by predicted crack face tortuosity beyond the usual mesh sensitivity and variability in predicted strain to failure; however, it bears further inquiry and a more conclusive result is pending compressive testing of challenge-built coupons to de-convolute materials behavior from the geometric influence of significant porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Geohydrodynamic Parameters and Their Implications on the Coastal Conservation: A Case Study of Abak Local Government Area (LGA), Akwa Ibom State, Southern Nigeria

A total of 14 vertical electrical soundings using Schlumberger electrode configuration and the complementary laboratory analysis of aquifer samples were carried out in the Abak Local Government Area of Akwa Ibom State, the coastal region of Nigeria. The study focused on the estimation of geohydrodynamic parameters of the frequently exploited aquifers and the implication of hydrodynamic parameters on the lithostratigraphy and the anticipated exposure of the assessed geologic formation at the shorelines. These parameters were porosity (&straightphi;), tortuosity (τ), formation factor (F), aquifer water formation resistivity (R{sub w}) and coefficient of permeability/hydraulic conductivity (K). Computation of the effective porosities from the aquifer cuttings was carried out using wet weight–dry weight technique and petrophysical techniques. The F values were computed using the aquifer formation bulk resistivity measured from field 1-D resistivity data analysis, whose interpretation was constrained by nearby borehole information. The formation pore water resistivities were estimated from the laboratory using electrical resistivity metre. The Win RESIST software program was used in interpreting the field data electronically. The results of interpretation gave the primary parameters of saturated and unsaturated units of the coastal regions used in this work. The area generally shows seemingly high porosity with high coefficient of permeability. The primary and secondary parameters have been contoured to model their distributions. Besides, some functional relations have been realized through regression analyses. The contour distribution of the geohydrodynamic parameters indicates the vulnerability of the water repositories to contaminations as well as the vulnerability of the shoreline to waterborne erosion. The seemingly high effective porosity in the compliant laboratory and calculated values indicate that the coastal region is neither lithified nor compacted/consolidated. This signals the possibility of the formation to be easily eroded, weathered or flooded where these units are exposed to water current. With these revelations, the shorelines could be properly managed and conserved by geotechnically reinforcing with hard and water-resistant concrete that can protect the vulnerable and erosion-prone porous sediments.

58 GEOSCIENCES↗
DOE OSTI2018

Effect of Pore Size, Morphology and Orientation on the Bulk Stiffness of a Porous Ti35Nb4Sn Alloy

The metal foams of a titanium alloy were designed to study porosity as well as pore size and shape independently. These were manufactured using a powder metallurgy/space-holder technique that allowed a fine control of the pore size and morphology; and then characterized and tested against well-established models to predict a relationship between porosity, pore size and shape, and bulk stiffness. Among the typically used correlations, existing power-law models were found to be the best fit for the prediction of macropore morphology against compressive elastic moduli, outperforming other models such as exponential, polynomial or binomial. Other traditional models such as linear ones required of updated coefficients to become relevant to metal porous sintered macrostructures. The new coefficients reported in this study contribute toward a design tool that allows the tailoring of mechanical properties through porosity macrostructure. The results show that, for the same porosity range, pore shape and orientation have a significant effect on mechanical performance and that they can be predicted. Conversely, pore size has only a mild impact on bulk stiffness.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Fabrication and Characterization of Core–Shell Density-Graded 316L Stainless Steel Porous Structure

In the present work, cylindrical shape 316 L cellular structure with different densities in its core and outer layer (shell) is fabricated by using carbamide as a space holder, via powder metallurgy route and layer-by-layer technique. The arrangement of the created pore is the same as face-centered cubic atomic structure, and different densities are created in two regions by using carbamide particles having two different sizes in the range of 1.7-2 and 2-2.4 mm. The effect of creating a structure with higher porosity (64.5%) in the core and lower porosity (53.8%) in the shell and vice versa and also change in the ratio of the core to the cylinder cross-sectional areas, on the mechanical properties and compaction load bearing of the fabricated foam samples were investigated. In leaching process of the carbamide particles, as an important step of porous structure’s fabrication, it is shown that discontinuous leaching process is more favorable than continuous, by which it would be possible to remove more carbamide particles (around 20%) at the same time. Furthermore, the deformation of the density-graded foam shows the parallel mechanism in the core and shell sections, and the contribution of each part depends on its density and thickness. The energy absorption behavior of the fabricated specimens is evaluated optimally in terms of the energy absorption value associated with the ideal adsorption behavior. The maximum ideal energy absorption efficiency for the samples with more porosity in the shell was approximately equal to 0.91, while for the sample includes the lower amount of porosity in the shell, this value was in the range of 0.85 and 0.89.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Annealing on the Impact Resistance and Fracture Mechanism of PNC-60 Sinters After Cold Plastic Deformation

Compaction of sintered metal powders by free upsetting at room temperature dangerously reduces their plastic properties, particularly the fracture toughness. The reason for the occurrence of two unfavorable phenomena accompanying this deformation route is sought. The first phenomenon depends on the initial porosity of the preform and the amount of cold work resulting in the destruction of bonds and violation of continuity between sintered powder particles. The second phenomenon is the deformation of the metal matrix, which reduces the plasticity of the sintered product. To correctly assess the effect of changes occurring in the matrix as a result of deformation, it is necessary to use the properly defined sintered matrix hardening parameter discussed in this study. The adverse effects of cold forming can be eliminated by annealing the deformed sinters at a temperature below the sintering point and above the recrystallization temperature. The annealing temperature causes favorable changes in the structure and increases the impact resistance of the deformed sinters depending on the degree of deformation of the sintered matrix and the initial porosity of the preform. Annealing at a properly selected temperature restores the ductility of the metal matrix and improves the integrity of the sintered material impaired by the effect of deformation. Annealing also causes favorable changes in the porosity morphology, removing defects in the form of gaps and resulting in the spheroidization of voids. With an appropriately selected initial porosity and degree of deformation, subsequent annealing of sinters compacted by free cold upsetting provides products with strength properties comparable to sinters with the same density and subjected to single compaction and sintering but with considerably higher fracture toughness.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of microstructure and temperature on nuclear graphite oxidation using the 3D Random Pore Model

This work compared the 3D Random Pore Model (3D-RPM) with experimental and characterization data to systematically study the effect of nuclear graphite microstructure and air oxidation temperature. It is well known that oxidation-induced weight loss at elevated temperatures degrades graphite structure and properties; however, a fundamental understanding of the role of graphite microstructure is still unclear. In this work, three diverse grades of nuclear graphite—IG-110, NBG-18, and PCEA—were examined and tested at air oxidation temperatures of 600, 650, 700, and 750 °C following ASTM D7542. Here, the 3D-RPM reproduced the microstructure and temperature dependence of mass loss curves for these grades. For the first time, measurements and modeling were combined to show how bulk density and the amount and spatial distribution of open and closed porosity affects oxidation. IG-110 was less dense and had an open pore network that is finer and more uniformly spread, and showed fastest oxidation. PCEA porosity was less uniform and showed less oxidation, while NBG-18 was more dense, had the least fine and uniform porosity, and showed the slowest oxidation. In general, oxidation proceeds faster if open porosity is more uniformly distributed and can incrementally access closed pore surface area with more ease.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effect of the hydration temperature on the microstructure of Class G cement: C-S-H composition and density

Curing temperature has a significant influence on cement paste microstructure and the properties of its principal hydrate C-S-H. In this paper, the effect of the hydration temperature in the range of 7 °C to 90 °C on the microstructure of a class G oil-well cement is studied. This is done by combining various experimental methods, including X-ray diffraction associated with the Rietveld analysis, thermo-gravimetric analysis, mercury intrusion porosimetry and porosity evaluation by drying. The experimental results show an increase of the capillary porosity and a decrease of the gel porosity by increasing the hydration temperature. This is attributed to a decrease of the C-S-H intrinsic porosity and a corresponding increase of the C-S-H density for higher curing temperatures. The experimental results are used in a simple analysis method to evaluate the density of C-S-H, as well as its C/S ratio and H/S ratio in dry and saturated conditions. The evaluated C-S-H density varies from 1.88 g/cm{sup 3} at 7 °C to 2.10 g/cm{sup 3} at 90 °C. The results also show a decrease of molar C/S ratio with increasing hydration temperature from 1.93 at 7 °C to 1.71 at 90 °C and of the H/S ratio from 5.1 at 7 °C to 2.66 at 90 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of the hydration temperature on the pore structure of cement paste: Experimental investigation and micromechanical modelling

The hydration temperature has a considerable effect on the microstructure of cement paste. The microstructural changes with increasing curing temperature result in a significant decrease of cement mechanical properties. The present work aims at studying these phenomena via micromechanical modelling, based on an experimental characterization of cement microstructure. The pore structure of a class G oil-well cement paste (American Petroleum Institute classification) hydrated at different temperatures, between 7 °C and 90 °C is characterized. Then, the influence of the microstructure variations on the elastic properties of the hardened paste is explored through micromechanical modelling. A previous analysis of the microstructure enabled determining the volume fractions of different phases of a class G cement paste hydrated under different temperatures [1]. A multiscale self-consistent homogenization model is used based on these results to simulate the variations of the mechanical properties with hydration temperature. The results are compared with macro-scale elastic properties obtained from uniaxial compression tests. It is shown that the increasing capillary porosity with elevating hydration temperature, is not sufficient to fully explain this drop of elastic properties. The latter originates mainly from the decrease of the elastic properties of the foam composed of the porous C-S-H intermixed with capillary pores. The pore structure analysis coupled with the micromechanical modelling permitted a back-analysis of the intrinsic porosities of high density and low density C-S-H showing an almost constant LD intrinsic porosity and a significantly decreasing HD intrinsic porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Microstructure and water absorption of ancient concrete from Pompeii: An integrated synchrotron microtomography and neutron radiography characterization

There is renewed interest in using advanced techniques to characterize ancient Roman concrete due to its exceptional durability and low-carbon footprint. In the present work, samples were drilled from the “Hospitium” in Pompeii and were analyzed by synchrotron microtomography (μCT) and neutron radiography to study how the microstructure, including the presence of induced cracks, affects their water adsorption. The water distribution and absorptivity were quantified by neutron radiography. The 3D crack propagation, pore size distribution and orientation, tortuosity, and connectivity were analyzed from μCT results using advanced imaging methods. Porosity was also measured by mercury intrusion porosimetry (MIP) as a reference. Ductile fracture patterns were observed once cracks were introduced. Compared to Portland cement mortar/concrete, the Pompeii samples had relatively high porosity, low connectivity, and a similar coefficient of capillary penetration. In addition, permeability was predicted from models based on percolation theory and pore structure data to evaluate the fluid transport properties. Understanding the microstructure of ancient Pompeii concrete is important because it could inspire the development of modern concrete with high durability.

36 MATERIALS SCIENCE↗
DOE OSTI2021

In situ X-ray imaging of pore formation mechanisms and dynamics in laser powder-blown directed energy deposition additive manufacturing

Directed energy deposition (DED) additive manufacturing (AM) is receiving growing attention in many applications, such as repair, remanufacturing, and fabrication of functionally graded structures. However, the laser-matter interactions and melt pool dynamics in laser DED with powder flow are still unclear, particularly in how pores form and flow inside the melt pool during the process. Understanding the porosity formation mechanisms is critical in the qualification, certification, and overall properties of a DED AM part. Porosity is a common phenomenon and can significantly hinder the quality of DED fabricated parts, as the pores can act as sites of crack nucleation and propagation. Here in this paper, we reveal four types of pore formation mechanisms through in-situ and operando high-speed high-resolution X-ray imaging in the DED AM process. Our results confirm that porosity within the feedstock powder induces pores in the process. We also observed pore formation mechanisms unique to the laser-based, powder-blown DED process as a result of powder delivery, keyhole dynamics, melt pool dynamics, and shield gas. High-speed X-ray images provide direct evidence for pore formation mechanisms and show that the pores related to the interaction between the delivered powder and melt pool are the largest in size in laser-based powder-blown DED AM. These results will guide porosity mitigation, elimination, and control in DED AM.

36 MATERIALS SCIENCE↗