Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “fusion science”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Factor VIII moiety of recombinant Factor VIII Fc fusion protein impacts Fc effector function and CD16 + NK cell activation

Recombinant Factor VIII-Fc fusion protein (rFVIIIFc) is an enhanced half-life therapeutic protein product used for the management of hemophilia A. Recent studies have demonstrated that rFVIIIFc interacts with Fc gamma receptors (FcγR) resulting in the activation or inhibition of various FcγR-expressing immune cells. We previously demonstrated that rFVIIIFc, unlike recombinant Factor IX-Fc (rFIXFc), activates natural killer (NK) cells via Fc-mediated interactions with FcγRIIIA (CD16). Additionally, we showed that rFVIIIFc activated CD16 + NK cells to lyse a FVIII-specific B cell clone. Here, we used human NK cell lines and primary NK cells enriched from peripheral blood leukocytes to study the role of the FVIII moiety in rFVIIIFc-mediated NK cell activation. Following overnight incubation of NK cells with rFVIIIFc, cellular activation was assessed by measuring secretion of the inflammatory cytokine IFNγ by ELISA or by cellular degranulation. We show that anti-FVIII, anti-Fc, and anti-CD16 all inhibited indicating that these molecules were involved in rFVIIIFc-mediated NK cell activation. To define which domains of FVIII were involved, we used antibodies that are FVIII domain-specific and demonstrated that blocking FVIII C1 or C2 domain-mediated membrane binding potently inhibited rFVIIIFc-mediated CD16 + NK cell activation, while targeting the FVIII heavy chain domains did not. We also show that rFVIIIFc binds CD16 with about five-fold higher affinity than rFIXFc. Based on our results we propose that FVIII light chain-mediated membrane binding results in tethering of the fusion protein to the cell surface, and this, together with increased binding affinity for CD16, allows for Fc-CD16 interactions to proceed, resulting in NK cellular activation. Our working model may explain our previous results where we observed that rFVIIIFc activated NK cells via CD16, whereas rFIXFc did not despite having identical IgG1 Fc domains.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Revealing transient powder-gas interaction in laser powder bed fusion process through multi-physics modeling and high-speed synchrotron x-ray imaging

Laser powder bed fusion (LPBF) is an emerging metal additive manufacturing process. The gas-driven powder motions in laser powder bed fusion have significant influence on the build quality. However, the transient powder-gas interaction has not been well understood due to the challenges in quantitative experiment measurements. In this work, the powder-gas interaction for a single pulse laser illuminating on the powder bed is studied. We establish a multi-physics model to simulate the complex liquid/gas flow as well as the gas-driven powder motions, which is substantiated by high-speed synchrotron x-ray imaging. We identify and quantify four characteristic modes of powder-gas interaction in LPBF. The motion of a powder is controlled by one or multiple interaction modes collectively. As revealed by simulations and confirmed by experiments, powders can merge into the molten pool from its rim, be ejected at different divergence angles (powder spattering), or dive into the molten pool to cause significant molten pool fluctuation. Overall, our results provide insights toward the driving forces controlling the dynamic powder behavior, which pave the way for reducing structure defects during the build process.

36 MATERIALS SCIENCE↗
DOE OSTI2025

In-Situ Process Monitoring Evaluation and Demonstration using Advanced Characterization with Laser Powder Bed Systems

Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) worked with EOS Group to evaluate the current in-situ sensor capabilities of an EOS M290 Laser Powder Bed Fusion machine. The M290 was fitted with a 1 Mega-Pixel (MP) grayscale visible-light camera and a 5 MP temporally integrated (TI) near-infrared (NIR) camera. One print from stainless steel (SS) 316 and two from Inconel 625 (IN625) were performed where data including in-situ imaging and a machine log file were captured. These data were subsequently analyzed using a Dynamic Multi-Scale Segmentation Convolutional Neural Network (DMSCNN) trained on user defined classes and correlated to as-printed flaws, in the form of porosity, discovered in X-Ray Computed Tomography (XCT). In Phase I, two indications were detected in-situ and spatially correlated to stochastic lack-of-fusion flaws discovered using XCT. In Phase II, using these links from in-situ signatures to XCT flaw populations, a second neural network (NN) was trained to create a Voxelized Property Prediction Model (VPPM) to predict porosity percentages within the part using only features garnered from the in-situ data from two IN625 complex geometries. The VPPM was able to accurately predict porosity values for IN625 parts with an R 2 value of 0.764.

36 MATERIALS SCIENCE↗
DOE OSTI2020

VRC34-Antibody Lineage Development Reveals How a Required Rare Mutation Shapes the Maturation of a Broad HIV-Neutralizing Lineage

Rare mutations have been proposed to restrict the development of broadly neutralizing antibodies against HIV-1, but this has not been explicitly demonstrated. We hypothesized that such rare mutations might be identified by comparing broadly neutralizing and non-broadly neutralizing branches of an antibody-developmental tree. Because sequences of antibodies isolated from the fusion peptide (FP)-targeting VRC34-antibody lineage suggested it might be suitable for such rare mutation analysis, we carried out next-generation sequencing (NGS) on B cell transcripts from donor N123, the source of the VRC34 lineage, and functionally and structurally characterized inferred intermediates along broadly neutralizing and poorly neutralizing developmental branches. The broadly neutralizing VRC34.01 branch required the rare heavy-chain mutation Y33P to bind FP, whereas the early bifurcated VRC34.05 branch did not require this rare mutation and evolved less breadth. Our results demonstrate how a required rare mutation can restrict development and shape the maturation of a broad HIV-1-neutralizing antibody lineage.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Advancement of hybrid fluid-kinetic modeling for HEDP and ICF science

We report on the development progress of a hybrid fluid-kinetic code for simulating fluids and plasmas in a wide range of environments, such as laser–matter interactions, inertial confinement fusion, magnetic confinement fusion, and pulsed power. The suite of numerical tools under development utilizes heterogeneous computer architectures and leverages the benefits of particle–based simulation techniques. By working to combine the kinetic particle-in-cell (PIC) model with a particle-based fluid simulation technique, such as smoothed particle hydrodynamics, we are developing a flexible framework capable of accurately modeling complex flows within and between kinetic and fluid regimes. The TriForce code is under development as a C++ framework for parallel, 3D, particle-based, hybrid fluid-kinetic plasma simulations. The fluid half of TriForce will be based upon the meshless smoothed-particle-hydrodynamics (SPH) approach, well-suited for shear, mixing, and turbulence, whereas the kinetic half resembles a traditional particle-in-cell (PIC) code; other particle-based approaches to fluid modeling that do use a mesh are also possible to use and are under investigation. Maxwell’s electromagnetic field equations are solved either via explicit or implicit algorithms or approximated via resistive magnetohydrodynamics (MHD) using an Ohm’s law and resulting induction equation (extended MHD is under development). A primary goal of enabling direct comparisons, from the same code, between results from the variants of MHD and implicit electromagnetic solutions is to improve our fundamental understanding of systems with magnetic fields. The code is under development to recover results from both radiation-MHD and fully kinetic codes in those limits, and is continuing to be developed from other follow-on grants to operate in between where both descriptions may co-exist and interact. For certain applications, it is desired for a simulation to contain fluid ions and electrons as well as kinetic ions and electrons. Typically, it is too computationally intensive to model a full-scale ICF or HEDP experiment fully kinetically since many cycles are expended with very small time steps on modeling the fluid part of a material that is well treated by the fluid approximation. In this case, many traditional PIC particles can be replaced with a single fluid particle representing the thermal part of the distribution function, and there are fewer needed kinetic particles, which describe the non-thermal part and can be sub-cycled relative to the fluid particle advance. Furthermore, a pure fluid code may, depending on the problem, simply lack many physically important details that are beyond the scope of its reduced approximations and assumptions. In this report, we summarize the objectives achieved in the development of the collisional and kinetic half of the code, and the physics problems to which the code has been applied in the areas of advanced and innovative fusion concepts, pulsed power, and magneto-inertial fusion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Dislocation generation in diamond under extreme loading

Diamond is, by virtue of its high bonding forces and Peierls-Nabarro barrier stresses, among the hardest materials on earth due to the difficulty of generating and moving dislocations. We demonstrate, using molecular dynamics and analytical calculations, that the generation of defects is dependent on loading orientation. Shock-loading single-crystal diamond along [001] and [011] to a stress of 137 GPa did not reveal dislocations, whereas loading along [111] generated profuse dislocations. The introduction of a void at the latter orientation generated dislocations at 72.6 GPa. Two slip systems were identified: <011>{100} and <112>{111}. The threshold for plastic deformation in diamond is orientation dependent and significantly lower than reported in previous studies: 0.14 G (shear modulus). The void collapse generated localized amorphization for [001]. In conclusion, these results on the anisotropy of plasticity and void effects have relevance for the improvement of symmetry in the collapse of diamond capsules in inertial fusion experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Melt-Pool Dynamics and Microstructure of Mg Alloy WE43 under Laser Powder Bed Fusion Additive Manufacturing Conditions

Magnesium-based alloy WE43 is a state-of-the-art bioresorbable metallic implant material. There is a need for implants with both complex geometries to match the mechanical properties of bone and refined microstructure for controlled resorption. Additive manufacturing (AM) using laser powder bed fusion (LPBF) presents a viable fabrication method for implant applications, as it offers near-net-shape geometrical control, allows for geometry customization based on an individual patient, and fast cooling rates to achieve a refined microstructure. In this study, the laser–alloy interaction is investigated over a range of LPBF-relevant processing conditions to reveal melt-pool dynamics, pore formation, and the microstructure of laser-melted WE43. In situ X-ray imaging reveals distinct laser-induced vapor depression morphology regimes, with minimal pore formation at laser-scan speeds greater than 500 mm/s. Optical and electron microscopy of cross-sectioned laser tracks reveal three distinct microstructural regimes that can be controlled by adjusting laser-scan parameters: columnar, dendritic, and banded microstructures. These regimes are consistent with those predicted by the analytic solidification theory for conduction-mode welding, but not for keyhole-mode tracks. The results provide insight into the fundamental laser–material interactions of the WE43 alloy under AM-processing conditions and are critical for the successful implementation of LPBF-produced WE43 parts in biomedical applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Registration and fusion of large-scale melt pool temperature and morphology monitoring data demonstrated for surface topography prediction in LPBF

In-situ monitoring technologies for laser powder bed fusion (LPBF) additive manufacturing often face one key challenge, extracting the ultrafast melt pool (MP) signatures for understanding the localized part properties. Further, the spatial information of each monitored MP signature is essential for correlating the MP – part property. This spatial information is often unavailable especially from commercial LPBF printers. Many MP monitoring methods have been reported and utilized. However, very few of these have the MP’s spatial information. To overcome this challenge, in this work we report a method for spatially registering the key MP signatures (MP intensity, temperature, and area) to the monitored print parts. The MP signatures are obtained from our coaxial high-speed single-camera based two-wavelength imaging pyrometry (STWIP) system and the MP spatial information is obtained from an off-axis camera system. A machine learning aided image analysis method is employed to retrieve the spatial distribution of MPs within the corresponding part’s coordinates system. Then, the MP signature maps (MPSMs) are reconstructed by mapping the STWIP measured MP signatures to the registered MP coordinates. Further, a long short-term memory (LSTM) neural network is developed for estimating the layer surface topography from the registered MPSMs. The obtained results indicate that the layer surface topography can be more accurately estimated by using MP temperature signature rather than MP intensity and/or area signatures as in common practice. Finally, our developed methods for MP monitoring, registration, and MP-surface topography prediction offer advanced capabilities for the online detection of process anomalies and part defects.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Modeling powder spreadability in powder-based processes using the discrete element method

Powder-bed fusion (PBF) processes refer to a subset of Additive Manufacturing (AM) techniques where powder is spread on the build-plate before melting (by a laser or electron beam). While PBF processes are attractive due to their ability for realizing complex structures that are either difficult or impossible to create through conventional means, the parts fabricated with these techniques can exhibit defects such as pores, inclusions, and excessive surface roughness. To minimize these defects, much research has been dedicated towards process maturation by optimizing laser or electron beam parameters. However, these developmental efforts typically do not address the recoating process where achieving dense and uniform layers of powder is a necessity for ensuring process repeatability and part quality. While the recoating process can be studied through experimentation, the dynamics of particle movement are difficult to analyze experimentally. Therefore, here, in this study, powder spreading in PBF was simulated through the Discrete Element Method (DEM) to elucidate the mechanisms that control powder-bed quality. Utilizing the Buckingham Pi theorem, a dimensionless metric referred to as the spreading index is developed that combines powder-bed density, roughness, and particle size to assess the quality of powder layers. The formulated spreading index is then related to several dimensionless quantities that provide insight into the mechanisms dominating powder spreading in PBF. The DEM simulations conducted in this work focused on the scenario where powder is spread onto an existing powder bed and revealed that a reduction in the recoating velocity causes an increase in the spreading index while little to no impact on the spreading index was observed when varying layer thickness from 30 μm to 75 μm.Particle size effects on the powder-bed quality were also investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Scalable in situ non-destructive evaluation of additively manufactured components using process monitoring, sensor fusion, and machine learning

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. However, the current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques, which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. In this work, an in situ NDE (INDE) system was engineered to detect subsurface flaws detected in X-Ray Computed Tomography (XCT) directly from process monitoring data. A multilayer, multimodal data input allowed the INDE system to detect numerous subsurface flaws in the size range of 200–1000µm using a novel human-in-the-loop annotation procedure. Furthermore, a framework was established for generating probability-of-detection (POD) and probability-of-false-alarm (PFA) curves compliant with NDE standards by systematically comparing instances of detected subsurface flaws to post-build XCT data. Here, we also introduce for the first time in the AM in situ sensing literature the a 90/95 – the flaw size corresponding to a 90% detection rate on the lower 95% confidence interval of the POD curve. The INDE system successfully demonstrated POD capabilities commensurate with traditional NDE methods. Traditional ML performance metrics were also shown to be inadequate for assessing the ability of the INDE system’s flaw detection performance. It is the hope of the authors that future studies will adopt the POD and PFA approach outlined here to provide better insight into the utility of process monitoring for AM.

36 MATERIALS SCIENCE↗
DOE OSTI2020

An additive manufacturing design approach to achieving high strength and ductility in traditionally brittle alloys via laser powder bed fusion

Additive Manufacturing (AM) presents unprecedented opportunities to enable design freedom in parts that are unachievable via conventional manufacturing. However, AM-processed components generally lack the necessary performance metrics for widespread commercial adoption. We present a novel AM processing and design approach using removable heat sink artifacts to tailor the mechanical properties of traditionally low strength and low ductility alloys. The design approach is demonstrated with the Fe-50 at.% Co alloy, as a model material of interest for electromagnetic applications. AM-processed components exhibited unprecedented performance, with a 300 % increase in strength and an order-of-magnitude improvement in ductility relative to conventional wrought material. These results are discussed in the context of product performance, production yield, and manufacturing implications toward enabling the design and processing of high-performance, next-generation components, and alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modelling the complex evaporated gas flow and its impact on particle spattering during laser powder bed fusion

The additive manufacturing (AM) of metals is becoming an increasingly important production process with the potential to replace traditional techniques such as casting. Laser Powder Bed Fusion (LPBF) is used in many applications to print metal parts from powder. The metal powder is heated locally with sufficient laser radiation that the liquid melt easily reaches its boiling temperature, which leads to a metallic vapour jet that can entrain both powder bed particles and molten droplets. The small size of laser-matter interaction site makes a detailed experimental analysis of the process challenging. Synchrotron X-ray imaging experiments are one of the few methods which can capture the dynamic melting and solidification processes. Comparing such experiments with computer simulations of the process is an important approach in order to better understand the manufacturing process and to analyse the influence of process parameters on the evaporated gas jet and the subsequent impact on particle ejection, leading to potentially reduced AM component quality. The melting and solidification of the metal powder is simulated using an Eulerian multiphase approach based on a control volume discretization of powder bed and substrate and a volume of liquid separation from melt and gas phase. The gas phase modelled as an ideal gas reaches velocities up to 100 m/s. Lagrangian particle tracking in the simulation demonstrates that the velocity fields calculated by the Eulerian multi-phase approach in combination with a standard drag-force model lead to particle accelerations in good agreement with those measured experimentally. In order to avoid numerical laborious Lagrangian calculations, a direct method to compare an Eulerian multiphase simulation with synchrotron X-ray experiments was introduced and validated. This approach is used to analyse the influence of process parameters including laser power and laser speed on the maximal acceleration of particles from the melt pool area. While the particle acceleration increases linearly with line energy in the conduction mode, a linear decrease of the acceleration with increasing line energy can be found in the transition mode before the accel-eration increases again with line energy in the keyhole mode.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Benchmarking Hydrogen Isotope Separation Efficiency of Pd/k–Packed TCAP Columns

By leveraging the large isotope effect in the palladium hydrogen isotope system, the Thermal Cycling Absorption Process (TCAP) provides an efficient and advantageous means to separate protium, deuterium, and tritium. To meet increased future tritium processing demands, such as those needed for fusion power plants, current designs of the separation columns need to be adapted and optimized using the progress made in understanding hydrogen isotope science. One key to this optimization lies in understanding the baseline performance for currently employed separation packing materials. Pd/k and molecular sieves, as commonly used for the separation of hydrogen isotopes, are herein evaluated to establish a baseline for their separation efficiency. Van Deemter plots are formulated, and the influence of each parameter is evaluated to determine areas for improvement.

Thermal Cycling Absorption Process (TCAP)↗
DOE OSTI2024

ASGarD: Adaptive Sparse Grid Discretization

Many areas of science exhibit physical processes that are described by high dimensional partial differential equations (PDEs), e.g., the 4D, 5D and 6D models describing magnetized fusion plasmas, models describing quantum chemistry, or derivatives pricing. Such problems are affected by the so-called “curse of dimensionality” where the number of degrees of freedom (or unknowns) required to be solved for scales as N D where N is the number of grid points in any given dimension D. A simple, albeit naive, 6D example is demonstrated in the left panel of Figure 1. With N = 1000 grid points in each dimension, the memory required just to store the solution vector, not to mention forming the matrix required to advance such a system in time, would exceed an exabyte - and also the available memory on the largest of supercomputers available today. The right panel of Figure 1 demonstrates potential savings for a range of problem dimensionalities and grid resolution. While there are methods to simulate such high-dimensional systems, they are mostly based on Monte-Carlo methods, which rely on a statistical sampling such that the resulting solutions include noise. Since the noise in such methods can only be reduced at a rate proportional to $\sqrt{N_p}$ where N p is the number of Monte-Carlo samples, there is a need for continuum, or grid/mesh-based methods for high-dimensional problems, which both do not suffer from noise and bypass the curse of dimensionality. We present a simulation framework that provides such a method using adaptive sparse grids.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2010

Dynamic Analysis of Sounding Rocket Pneumatic System Revision

The recent fusion of decades of advancements in mathematical models, numerical algorithms and curve fitting techniques marked the beginning of a new era in the science of simulation. It is becoming indispensable to the study of rockets and aerospace analysis. In pneumatic system, which is the main focus of this paper, particular emphasis will be placed on the efforts of compressible flow in Attitude Control System of sounding rocket.

Armen, Jerald↗
DOE OSTI2023

Ultrathick Boron Carbide Coatings for Nuclear Fusion Targets

Boron carbide is an attractive ablator for next-generation inertial confinement fusion (ICF) targets. Here we describe several aspects of our ongoing systematic studies of the deposition and processing of B 4 C coatings for ICF targets. We show that residual compressive stress in films can be reduced and the deposition rate increased by N-doping. Further, we also demonstrate successful Si substrate etching and surface polishing and discuss remaining challenges and offer potential solutions to the buildup of particulates in the deposition chamber during prolonged coating runs, control of nodular growth defects, and lateral nonuniformity of film properties for deposition conditions with relatively low target-to-substrate distances.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Study of the Printability, Microstructures, and Mechanical Performances of Laser Powder Bed Fusion Built Haynes 230

The nickel-based superalloy, Haynes 230 (H230), is widely used in high-temperature applications, e.g., heat exchangers, because of its excellent high-temperature mechanical properties and corrosion resistance. As of today, H230 is not yet in common use for 3D printing, i.e., metal additive manufacturing (AM), primarily because of its hot cracking tendency under fast solidification. The ability to additively fabricate components in H230 attracts many applications that require the additional advantages leveraged by adopting AM, e.g., higher design complexity and faster prototyping. In this study, we fabricated nearly fully dense H230 in a laser powder bed fusion (L-PBF) process through parameter optimization. The efforts revealed the optimal process space which could guide future fabrication of H230 in various metal powder bed fusion processes. The metallurgical analysis identified the cracking problem, which was resolved by increasing the pre-heat temperature from 80 °C to 200 °C. A finite element simulation suggested that the pre-heat temperature has limited impacts on the maximum stress experienced by each location during solidification. Additionally, the crack morphology and the microstructural features imply that solidification and liquation cracking are the more probable mechanisms. Both the room temperature tensile test and the creep tests under two conditions, (a) 760 °C and 100 MPa and (b) 816 °C and 121 MPa, confirmed that the AM H230 has properties comparable to its wrought counterpart. The fractography showed that the heat treatment (anneal at 1200 °C for 2 h, followed by water quench) balances the strength and the ductility, while the printing defects did not appreciably accelerate part failure.

14 SOLAR ENERGY↗
DOE OSTI2020

Size-dependent stochastic tensile properties in additively manufactured 316L stainless steel

Recent work in metal additive manufacturing (AM) suggests that mechanical properties may vary with feature size; however, these studies do not provide a statistically robust description of this phenomenon, nor do they provide a clear causal mechanism. Because of the huge design freedom afforded by 3D printing, AM parts typically contain a range of feature sizes, with particular interest in smaller features, so the size effect must be well understood in order to make informed design decisions. This work investigates the effect of feature size on the stochastic mechanical performance of laser powder bed fusion tensile specimens. A high-throughput tensile testing method was used to characterize the effect of specimen size on strength, elastic modulus and elongation in a statistically meaningful way. The effective yield strength, ultimate tensile strength and modulus decreased strongly with decreasing specimen size: all three properties were reduced by nearly a factor of two as feature dimensions were scaled down from 6.25 mm to 0.4 mm. Hardness and microstructural observations indicate that this size dependence was not due to an intrinsic change in material properties, but instead the effects of surface roughness on the geometry of the specimens. Finite element analysis using explicit representations of surface topography shows the critical role surface features play in creating stress concentrations that trigger deformation and subsequent fracture. The experimental and finite element results provide the tools needed to make corrections in the design process to more accurately predict the performance of AM components.

316L stainless steel↗