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

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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

What lies beneath: Vertical temperature heterogeneity in a Mediterranean woodland savanna

As the availability of satellite and airborne thermal infrared remote sensing (TIR-RS) data increases and their spatial, temporal, and spectral resolutions improve, researchers are finding diverse applications for TIR-RS measurements. TIR-RS is now commonly applied in regional- and continental-scale analyses, such as those focused on fire and surface energy balance. However, its application lags in plant physiology and ecology, for which a finer-scale understanding of plant canopy temperatures would be useful to elucidate plant water dynamics, for example. In particular, while methods to disaggregate TIR-RS pixels in horizontal space have advanced, possible vertical stratification of plant canopy temperature and its implications for understanding the correspondence between TIR-RS and finer-scale, field-based thermal measurements (e.g. made with a thermal camera) remain unexplored. Here, we use data from a thermal camera deployed concurrently with the recent ECOSTRESS mission to quantify vertical temperature gradients within tree canopies and temperatures of over- vs. under-story plants in a Mediterranean woodland savanna. We then leverage diverse ancillary data to maximize the geometric comparability of ECOSTRESS and thermal camera measurements, in order to assess the extent to which the two forms of thermal measurements correspond. Specifically, we ask: (1) What are the patterns of intra-canopy and over- vs. under-story vertical temperature in a Mediterranean woodland savanna?, and (2) How can vertically-resolved, but spatially-limited field-based temperature measurements be reconciled with spatially-extensive, but surface-only, temperature measurements of a space-borne remote sensor? Further, we found consistent patterns of vertical thermal heterogeneity both within tree canopies and between ecosystem over- and under-stories. The daytime difference between the top and bottom thirds of blue oak canopies was, on average, 0.48 ° C – and sometimes several times larger. Notably, canopy tops are cooler, likely associated with the under-story grass reaching daytime temperatures often exceeding over-story temperatures by 10° C. Given the consistency of the intra-canopy temperature gradients, we expected the ECOSTRESS sensor would be in better agreement with camera measurements of canopy tops than bulk canopies or canopy bottoms. However, within-canopy gradients were overwhelmed by other sources of disagreement between the measurements, in part associated with upscaling camera measurements across space. Overall, thermal camera and ECOSTRESS measurements were largely in agreement at night (pixel RMSE = 1.1°C), but they were more divergent during times of low (but >0 W/m2) and high incoming solar radiation (daytime pixel RMSE = 3.5°C).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

How does negative triangularity mitigate ITG turbulence and transport?

Improved confinement in negative triangularity (NT) experiments is attributed to reduced fluxes driven by micro-turbulence. The physical mechanism of why thermal confinement improves in NT relative to PT is unknown. This study employs gyrokinetic flux tube simulations using the GENE code with local Miller equilibrium to elucidate the physical mechanisms behind the beneficial effects of NT flux surface shapes. The focus is on collisionless ion temperature gradient (ITG) driven turbulence with adiabatic electrons. The kinetic profiles are held fixed across a scan of triangularity values, thus enabling comparisons on a level playing field. The reduced linear growth rates for NT is shown to be due to a reduced eigenmode averaged magnetic drift frequency and a wider, stronger negative local magnetic shear region about the outboard mid-plane. The nonlinear heat flux is lower for NT than that for PT, due to reduced radial correlation length and increased correlation time (τ c ) of fluctuations. These, in turn, are due to a comparatively higher level of self-generated zero-frequency E × B zonal shearing rate ω E in NT as compared to PT. Though the linear zonal potential residual is lower for NT, the nonlinearly generated E × B zonal shearing rate is higher for NT than for PT. This outcome is linked to the distinctive features of the radial wavenumber spectra of the zonal potential and the zonal shearing rate. The dimensionless parameter ω E τ c is suggested as a figure of merit. This is higher for NT than for PT. Thus, the reduced heat diffusivity for NT is linked to increased ω E τ c . Self-generated temperature corrugations (i.e. zonal temperature gradients) are much weaker than the background mean temperature gradient. Nevertheless, temperature corrugations are more pronounced in NT than in PT.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Phenotypic plasticity of fungal traits in response to moisture and temperature

Phenotypic plasticity of traits is commonly measured in plants to improve understanding of organismal and ecosystem responses to climate change but is far less studied for microbes. Specifically, decomposer fungi are thought to display high levels of phenotypic plasticity and their functions have important implications for ecosystem dynamics. Assessing the phenotypic plasticity of fungal traits may therefore be important for predicting fungal community response to climate change. Here, we assess the phenotypic plasticity of 15 fungal isolates (12 species) from a Southern California grassland. Fungi were incubated on litter at five moisture levels (ranging from 4–50% water holding capacity) and at five temperatures (ranging from 4–36 °C). After incubation, fungal biomass and activities of four extracellular enzymes (cellobiohydrolase (CBH), β -glucosidase (BG), β -xylosidase (BX), and N-acetyl- β - D -glucosaminidase (NAG)) were measured. We used response surface methodology to determine how fungal phenotypic plasticity differs across the moisture-temperature gradient. We hypothesized that fungal biomass and extracellular enzyme activities would vary with moisture and temperature and that the shape of the response surface would vary between fungal isolates. We further hypothesized that more closely related fungi would show more similar response surfaces across the moisture-temperature gradient. In support of our hypotheses, we found that plasticity differed between fungi along the temperature gradient for fungal biomass and for all the extracellular enzyme activities. Plasticity also differed between fungi along the moisture gradient for BG activity. These differences appear to be caused by variation mainly at the moisture and temperature extremes. We also found that more closely related fungi had more similar extracellular enzymes activities at the highest temperature. Altogether, this evidence suggests that with global warming, fungal biodiversity may become increasingly important as functional traits tend to diverge along phylogenetic lines at higher temperatures.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Numerical Investigation of the characteristics of pressurized biomass-oxy-combustion

As a second generation of oxy-fuel combustion technologies, pressurized oxy-combustion has a potential to improve the process efficiency and economy. With the modern decarbonization needs, biomass combustion is considered to be nearly CO2 neutral, and thus co-firing biomass with coal in an oxy-combustion process can achieve a negative CO2 balance. The size of the biomass fuel particles is a key parameter in an entrained flow combustor because large biomass particles, exceeding some threshold size, may only partially be burnt due to the restrictions on the heat transport, thereby diminishing the combustion efficiency. While such a threshold particle size has been scrutinized at an atmospheric pressure, the present study extends the analysis to elevated pressures. Specifically, two scenarios were set up, for experimental-scale and full-scale pressurized oxy-combustors, with the threshold sizes of biomass particles appearing 0.5 mm and 5 mm, respectively, without temperature gradient in biomass particles. With temperature gradient, the parametric study included the particles in the range from 0.15 mm to 5 mm. It is shown that the thermal-thin model is applicable to spherical biomass particles not exceeding 0.15 mm. The impact of the heating rate on biomass particle devolatilization was also investigated and the biomass devolatilization could happen in less than 1 second; the same amount of heat energy could induce different volatile release rates.

Li, Lei↗
DOE OSTI2022

The role of ETG modes in JET–ILW pedestals with varying levels of power and fuelling

Abstract We present the results of GENE gyrokinetic calculations based on a series of JET–ITER-like-wall (ILW) type I ELMy H-mode discharges operating with similar experimental inputs but at different levels of power and gas fuelling. We show that turbulence due to electron-temperature-gradient (ETGs) modes produces a significant amount of heat flux in four JET–ILW discharges, and, when combined with neoclassical simulations, is able to reproduce the experimental heat flux for the two low gas pulses. The simulations plausibly reproduce the high-gas heat fluxes as well, although power balance analysis is complicated by short ELM cycles. By independently varying the normalised temperature gradients ( ω T e ) and normalised density gradients ( ω n e ) around their experimental values, we demonstrate that it is the ratio of these two quantities η e = ω T e / ω n e that determines the location of the peak in the ETG growth rate and heat flux spectra. The heat flux increases rapidly as η e increases above the experimental point, suggesting that ETGs limit the temperature gradient in these pulses. When quantities are normalised using the minor radius, only increases in ω T e produce appreciable increases in the ETG growth rates, as well as the largest increases in turbulent heat flux which follow scalings similar to that of critical balance theory. However, when the heat flux is normalised to the electron gyro-Bohm heat flux using the temperature gradient scale length L T e , it follows a linear trend in correspondence with previous work by different authors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

The Thermal Response of a Packed Bed Thermal Energy Storage System upon Saturated Steam Injection Using Distributed Temperature Sensing

The effectiveness of a thermal energy storage (TES) system is typically characterized with the help of thermal stratification or temperature gradients along the direction of heat injection, which is typically the flow direction of heat transfer fluid. The steepness of temperature gradients are a direct indicator of the effectiveness or efficiency of the heat storage or dispatch process. The temperature gradient evolution along the packed bed of ceramic particles upon saturated steam injection is presented in this work. Distributed temperature sensing based on optical frequency domain reflectometry was deployed in a packed bed of ceramic particles to capture the thermal front evolution in the axial direction. The physical processes accompanying steam injection in packed beds are complex due to phase change, transitioning two-phase flow, and changes in condensate accumulation. Therefore, the variation of thermal response of the TES system for various steam injection flow rates was experimentally studied using a high-resolution distributed temperature sensing system in a chemically inert alumina particle-packed bed. Distinct zones of different heat transfer modes were observed during the steam injection experiments. A distinct conduction zone, evident from diffuse thermal fronts, was observed at low flow rates, and these thermal gradients became sharper as the flow rate increased. The diffuse thermal fronts in the heat storage media suggest a low exergy efficiency of the TES system, as energy losses started initiating before a significant fraction of the bed was saturated with steam.

25 ENERGY STORAGE↗
DOE OSTI2020

A molecular dynamics simulation study of thermal conductivity anisotropy in β-octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazocine (β-HMX)

Molecular dynamics (MD) simulations were used to predict the thermal conductivity of β-octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazocine (β-HMX) along directions normal to the (011), (110), and (010) crystal planes. These directions were selected based on the measured morphological importance of the corresponding crystal surfaces. A reverse non-equilibrium MD approach was used wherein a constant heat flux is imposed along a prescribed direction and the resulting steady-state temperature gradient determined. The coefficient of thermal conductivity λ is the quotient of heat flux and temperature gradient (i.e. Fourier's law). Finite-size effects and sensitivity to imposed heat flux were investigated. The results reveal a modest dependence of the conductivity on crystal orientation, significant finite-size effects, and low sensitivity to imposed flux so long as the Fourier's law analysis is limited to the spatial interval in the simulation cell for which the temperature gradient is constant. Infinite-length thermal conductivities were estimated by linear regression of λ -1 (L) versus reciprocal cell length L -1 for each direction. The predicted values are systematically larger, but within a factor of two, than most published experimental determinations, the latter of which were obtained for pressed-powder or composite samples rather than oriented single crystals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Sensitivity study of hydrogen Soret transport in yttrium Hydride-Based nuclear fuel

Yttrium hydride is an excellent solid neutron moderator material for high temperature nuclear reactor applications due to its high hydrogen density and exceptional hydride stability at high temperatures. Despite these attractive characteristics, the details of how hydrogen behaves within yttrium hydride while temperature gradients exist are still not well understood. The evolution of the hydrogen composition profile resulting from a temperature gradient requires knowledge of hydrogen’s heat of transport, a critical parameter that has not yet been measured for this material. In this work, we perform hydride redistribution, hydrogen dissociation, and hydrogen leakage calculations while varying the Soret heat of transport of hydrogen in yttrium hydride to elucidate the sensitivity of hydride stability under temperature gradients to this parameter. This study analyzes hydride stability of a hypothetical uranium-yttrium hydride nuclear fuel design during operation of a high temperature liquid metal-cooled nuclear reactor. Assuming U-YH x could be fabricated in a physically stabilized manner, this fuel system can likely maintain hydride stability while operating at very high power densities and temperatures. We find that even though the hydrogen dissociation pressure in the gas gap does vary by several percent as the heat of transport temperature parameter is varied, the hydrogen content in the U-YH x fuel meat is relatively insensitive to this parameter over the course of a high burnup fuel cycle; this is due to yttrium hydride’s excellent hydrogen retention under the high temperature conditions considered here. Here, this suggests that hydride stability analyses are insensitive to the value of the Soret heat of transport in U-YH x under steady state liquid metal-cooled reactor conditions. However, the susceptibility to internal gas overpressurization-induced stress-rupture of the cladding during a high temperature transient is more sensitive to this parameter due to the non-linear dependence of hydrogen gas dissociation pressure vs. composition and temperature.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

In-Situ Spatial Mapping of Hydrogen in Yttrium Hydrides at LANSCE (FY23 Version, Rev. 1)

This report summarizes the development of neutron imaging capabilities and experimental activities performed at the Los Alamos Neutron Science Center (LANSCE) with the main goal of measuring temperature-driven hydrogen diffusion within bulk-yttrium hydride (YH x ) materials. Yttrium hydride is the leading candidate to serve as a solid neutron moderator in microreactor cores, owing to its high density of hydrogen atoms as well as its superior thermal stability compared to all other metal hydrides. The experimental results and technique developments reported herein support the U.S. Department of Energy Office of Nuclear Energy’s (DOE-NE) Microreactor Program under Technology Maturation. In particular, it addresses the critical need to experimentally validate and verify hydrogen-diffusion models of metal hydrides used in high-temperature microreactor designs by means of high-spatial-resolution neutron imaging. These capabilities were designed to apply large temperature gradients across centimeter-sized YH x pellets to simulate conditions faced in the microreactor environment. In principle, neutron imaging, combined with in-situ sample heating, enables near real-time tracking of hydrogen diffusion in YH x on the sub-millimeter scale. In this report, an overview of neutron imaging methodology and technologies are given in the context of recent spatial measures of hydrogen concentrations in similar metal hydrides. Additionally, the commissioning and operation of a custom-built compact dual-zone furnace is given along with details on three in-situ heating measurements of YH x performed over the 2020 to 2022 LANSCE operation cycles. The aims of these experiments ranged from furnace commissioning, determining sample quality, i.e., hydrogen uniformity via neutron computed tomography, and studying the effects of applied temperature-gradients on YH x pellets. Analyses and results from these neutron imaging measurements are given along with outlooks and guidelines for optimal future hydrogen diffusion measurements. Our conclusions are as follows. Image analyses indicate that centimeter-sized yttrium hydride cylindrical pellets exhibit uniform, whole-body hydrogen desorption and absorption without clear temperature dependence as reflected in the image attenuation at the opposing ends of each sample. This suggests that despite the large magnitude in temperature gradients applied by the furnace heating elements, the sample equilibrates to an unknown intermediate temperature. The origin of this result is likely the combination of short sample length (∼1cm) and use of a TZM can for containment where the latter created a thermal short across the sample. Nevertheless, the results from the most recent measurements indicate that neither significant concentration gradients of hydrogen were formed in centimeter-sized samples through the entire temperature range (25 °C to 950 °C) nor any formed due to temperature gradients on the order of 50 °C/cm up to 700 °C/cm. Furthermore, images from the FY2021 and FY2022 measurements indicate that samples of YH x , fabricated from either the direct hydride or powder metallurgy methods, are highly uniform in their hydrogen concentration to within the measurements’ spatial resolutions. The following questions arise from these latest results: 1) What is the intermediate temperature of the pellets in the TZM cans? 2) How quickly does the temperature equilibrate within the sample? and, 3) Do the observed changes in image attenuation follow known pressure-composition-temperature relations of yttrium hydride?

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Toward High Conversion Efficiency of Thermoelectric Modules through Synergistical Optimization of Layered Materials

Abstract Waste‐heat electricity generation using high‐efficiency solid‐state conversion technology can significantly decrease dependence on fossil fuels. Here, a synergistical optimization of layered half‐Heusler (hH) materials and module to improve thermoelectric conversion efficiency is reported. This is realized by manufacturing multiple thermoelectric materials with major compositional variations and temperature‐gradient‐coupled carrier distribution by one‐step spark plasma sintering. This strategy provides a solution to overcome the intrinsic concomitants of the conventional segmented architecture that only considers the matching of the figure of merit ( zT ) with the temperature gradient. The current design is dedicated to temperature‐gradient‐coupled resistivity and compatibility matching, optimum zT matching, and reducing contact resistance sources. By enhancing the quality factor of the materials by Sb‐vapor‐pressure‐induced annealing, a superior zT of 1.47 at 973 K is achieved for (Nb, Hf)FeSb hH alloys. Along with the low‐temperature high‐ zT hH alloys of (Nb, Ta, Ti, V)FeSb, the single stage layered hH modules are developed with efficiencies of ≈15.2% and ≈13.5% for the single‐leg and unicouple thermoelectric modules, respectively, under Δ T of 670 K. Therefore, this work has a transformative impact on the design and development of next‐generation thermoelectric generators for any thermoelectric material families.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Effect of radial pressure corrugations and profile shearing on turbulence in Fusion plasmas

Microturbulence can produce stationary fine-scale radial corrugations on the plasma density and temperature gradients in magnetic confinement fusion devices. We show that these structures play a significant role in regulating turbulent transport. We focus on the pedestal, studying electron-temperature-gradient (ETG) mode destabilisation and saturation in the presence of radial corrugations on the electron temperature gradient that could result from microtearing turbulence. A linear dispersion relation is derived for a shearless slab case, which indicates that in the presence of a sinusoidal background corrugation, each ETG mode splits into three distinct eigenvalues, with one being the original, one being more unstable and one being less unstable. However, despite the presence of more unstable linear modes, nonlinear gyrokinetic simulations of ETG with corrugated background electron temperature show a reduction of fluxes. Our investigation reveals a radial variation of the phase velocity of the modes that is proportional to the diamagnetic drift velocity and the local pressure gradient. The associated profile shearing breaks the turbulent eddies apart, reducing the transport level. This profile shearing resulting from fine-scale pressure corrugations could be a ubiquitous turbulence saturation mechanism not just in Fusion plasmas, but in Astrophysics and other areas.

FOS: Physical sciences↗
DOE OSTI2021

Turbulent impurity transport simulations in Wendelstein 7-X plasmas

A study of turbulent impurity transport by means of quasilinear and nonlinear gyrokinetic simulations is presented for Wendelstein 7-X (W7-X). The calculations have been carried out with the recently developed gyrokinetic code stella. Different impurity species are considered in the presence of various types of background instabilities: ion temperature gradient (ITG), trapped electron mode (TEM) and electron temperature gradient (ETG) modes for the quasilinear part of the work; ITG and TEM for the nonlinear results. While the quasilinear approach allows one to draw qualitative conclusions about the sign or relative importance of the various contributions to the flux, the nonlinear simulations quantitatively determine the size of the turbulent flux and check the extent to which the quasilinear conclusions hold. Although the bulk of the nonlinear simulations are performed at trace impurity concentration, nonlinear simulations are also carried out at realistic effective charge values, in order to know to what degree the conclusions based on the simulations performed for trace impurities can be extrapolated to realistic impurity concentrations. The presented results conclude that the turbulent radial impurity transport in W7-X is mainly dominated by ordinary diffusion, which is close to that measured during the recent W7-X experimental campaigns. Finally, it is also confirmed that thermodiffusion adds a weak inward flux contribution and that, in the absence of impurity temperature and density gradients, ITG- and TEM-driven turbulence push the impurities inwards and outwards, respectively.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Hydrogen transport in yttrium hydride under asymmetric heat

Metal hydrides are a promising moderator material for high temperature fission reactors. Yttrium hydride can be loaded to a high hydrogen density with relatively high hydrogen stability at temperatures up to 800°C. This makes yttrium hydride a potential moderator material for microreactors as foreseen in the fission surface power program. However, during the operation of such advanced reactors temperature gradients are expected which can change the local hydrogen density in the moderator. Hydrogen diffusion in metals is driven by a concentration gradient (Fick’s law) and thermal diffusion (Soret diffusion). Thermal diffusion is the transport of hydrogen, or other species, due to a temperature gradient. For example, hydrogen might migrate from the hot side of a sample to the cold side of a sample. Measuring Fickian diffusion is achieved through various permeation or absorption experiments, however measuring thermal diffusion is challenging and has rarely been performed. The Hydrogen Experimental Apparatus for Thermal Diffusion (HEATD) experiment is designed to induce thermal diffusion in samples and quench those samples so that the hydrogen distribution can be analyzed using hot vacuum extraction (HVE). One side of the sample was heated to a high temperature e.g., 800°C, while the other side of the sample is at a lower temperature. The sample was held under the applied temperature gradient for a given time until the anticipated hydrogen diffusion has occurred. The actual time depends depend on the sample composition and hydrogen concentration. The results from HVE showed that thermal diffusion took place in the specimen and the Soret coefficient was calculated.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mo-100 Disk Structural Integrity Tests I

The NorthStar pressed and sintered 29 mm diameter, 0.5 mm thick Mo-100 disks will be subjected to large temperature gradients when in beam during production. The beam preferentially heats the disk center, while the aggressive cooling by the helium keeps areas outside the beam spot relatively cool. The result is a temperature gradient of up to 900°C over the radial distance of 14.5 mm. To test the disk integrity with this high temperature gradient, a special holder for a single disk was made such that proper cooling can be applied as in the design target and the disk heating can be replicated with induction heating. NorthStar press and sintered disks were used for these tests.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Thermoacoustic Soret separation

In a fluid mixture in a channel with an axial time-averaged temperature gradient, high-amplitude oscillating flow can greatly increase the axial flux of thermal diffusion (Soret) separation of the components of the mixture. The enhancement occurs when the oscillating lateral temperature gradient greatly exceeds the axial gradient, causing a large oscillating concentration that can be favorably time-phased with the oscillating flow. This process can occur even with a negligible pressure oscillation or with a negligible temperature response to pressure, as is the case in most liquid solutions. The thermal boundary condition imposed by realistic solids on thermoacoustic liquids is imperfect, adding mathematical complications that are absent for typical gases, for which the solid surface is temporally isothermal. Compared with gas mixtures, the high Lewis number in typical liquid solutions reduces the separation flux associated with the time-averaged temperature gradient, but it also reduces the remixing associated with the time-averaged mole-fraction gradient. For large enough channels, the second-law separation efficiency is only slightly reduced from that of steady liquid Soret separation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Magnonic analog of the Edelstein effect in antiferromagnetic insulators

Here we investigate the nonequilibrium spin polarization due to a temperature gradient in antiferromagnetic insulators, which is the magnonic analog of the inverse spin-galvanic effect of electrons. We derive a linear-response theory of a temperature-gradient-induced spin polarization for collinear and noncollinear antiferromagnets, which comprises both extrinsic and intrinsic contributions. We apply our theory to several noncentrosymmetric antiferromagnetic insulators, i.e., to a one-dimensional antiferromagnetic spin chain, a single layer of kagome noncollinear antiferromagnet, e.g., KFe 3 ( OH ) 6 ( SO 4 ) 2 , and a noncollinear breathing pyrochlore antiferromagnet, e.g., LiGaCr 4 O 8 . The shapes of our numerically evaluated response tensors agree with those implied by the magnetic symmetry. Furthermore, assuming a realistic temperature gradient of 10 K/mm , we find two-dimensional spin densities of up to ~ 10 6 ℏ / cm 2 and three-dimensional bulk spin densities of up to ~ 10 14 ℏ / cm 3 , encouraging an experimental detection

36 MATERIALS SCIENCE↗
DOE OSTI2022

Thermal energy evolution and mechanical deformation of monocrystalline yttria-stabilized zirconia nanoparticles in aerosol deposition processes

Aerosol deposition (AD) is a coating process wherein aerosol particles are impacted on a target substrate. There are fundamental differences between the AD process (cold impact), where particle translational kinetic energy is high and thermal energy is low, and thermal spray deposition (thermal impact), where translational energy is lower but thermal energy is high. To better compare cold and thermal impact effects on particles, we carried out molecular dynamics simulations using yttria-stabilized zirconia (YSZ) nanoparticles on YSZ substrates as a model system. We performed cold impact simulations at 300 K with variable impact velocity in the 500 ms –1 –1500 ms –1 range to understand how increasing translational kinetic energy affects thermal energy and mechanical evolution. We then performed thermal impact simulations at variable temperature and impact velocity, but where the total kinetic energy of the nanoparticle was equivalent to that of a 300 K, 1000 impact. In cold impact, the temperature increases in YSZ nanoparticles at a rate of 10 13 – 10 14 K s –1 , and large temperature gradients result. Conversely, in thermal impact, nanoparticle temperatures remain uniform. Furthermore, the temperature gradients during cold impact coincide with plastic deformation in nanoparticles, while with larger thermal energies, plastic deformation is reduced.

42 ENGINEERING↗
DOE OSTI2026

Which way does the dendrite grow? Competition among epitaxy, preferred growth direction, and thermal gradients in powder bed fusion additive manufacturing

The as-processed microstructure of metal alloy parts manufactured through laser powder bed fusion (LPBF) is heavily derived from the cellular dendritic solidification. The growth direction of dendrites within the melt pool is determined through competition among epitaxial growth, preferred growth directions, and maximum thermal gradients. However, the dominant factor and the specific role of each in developing melt pool microstructures remain unknown. Here, in this study, we performed single laser track scans on an SS316L single crystal substrate and combined experimental characterization of microstructure and crystal orientations with Computational Fluid Dynamics simulations of thermal gradients to evaluate the role of each factor in determining dendritic growth direction and evolution. Our results reveal that epitaxial growth dominates microstructure development by preferentially growing along a single 〈100〉 variant of the single crystal substrate adjacent to the melt pool boundary. Under LPBF’s highly curved and rapidly evolving thermal field, this preferential dendrite variant selection and its continued growth from the melt pool boundary to the centerline are governed by the local temperature gradient magnitude at the solid-liquid interface, rather than by the instantaneous maximum temperature gradient direction alone. Using these findings, we successfully predict changes in the dendrite growth direction with changing laser scan direction on a single crystal substrate, and show that the geometric melt pool centerline can deviate from the microstructural centerline because asymmetric local temperature gradient magnitudes transiently limit growth, resulting in different dendrite travel distances on each side of the melt pool.

36 MATERIALS SCIENCE↗