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At least 1,027 records · Page 57

All sources NASA NTRS DOE OSTI

DOE OSTI2017

Method of fabricating electrodes including high-capacity, binder-free anodes for lithium-ion batteries

An electrode (110) is provided that may be used in an electrochemical device (100) such as an energy storage/discharge device, e.g., a lithium-ion battery, or an electrochromic device, e.g., a smart window. Hydrothermal techniques and vacuum filtration methods were applied to fabricate the electrode (110). The electrode (110) includes an active portion (140) that is made up of electrochemically active nanoparticles, with one embodiment utilizing 3d-transition metal oxides to provide the electrochemical capacity of the electrode (110). The active material (140) may include other electrochemical materials, such as silicon, tin, lithium manganese oxide, and lithium iron phosphate. The electrode (110) also includes a matrix or net (170) of electrically conductive nanomaterial that acts to connect and/or bind the active nanoparticles (140) such that no binder material is required in the electrode (110), which allows more active materials (140) to be included to improve energy density and other desirable characteristics of the electrode. The matrix material (170) may take the form of carbon nanotubes, such as single-wall, double-wall, and/or multi-wall nanotubes, and be provided as about 2 to 30 percent weight of the electrode (110) with the rest being the active material (140).

25 ENERGY STORAGE↗

DOE OSTI2020

Analysis of diagonal G and subspace W approximations within fully self-consistent GW calculations for bulk semiconducting systems

Fully self-consistent GW (sc-GW) methods are now available to evaluate quasiparticle and spectral properties of various molecular and bulk systems. However, such techniques based on the full matrix of G and W are computationally demanding. Additionally, the routinely used single-shot GW approximation (G 0 W 0 ) has an undesirable dependency on the choice of initial exchange-correlation functional. In the literature, many so-called self-consistent GW methods are based on diagonal approximation of G and low-ranking approximation of W. It is thus worth checking how good such approximations are in comparison with the full matrix method. In this work, we consider AlAs, AlP, GaP, and ZnS as the prototype systems to perform sc-GW calculations by expressing the full G matrix using a plane-wave basis set. We compared our sc-GW results with the diagonal G and subspace W approximated sc-GW results (sc-GW-diagG and sc-GW-subW methods). In the sc-GW-diagG method, interacting G is expanded in the eigenvectors of noninteracting G such that only diagonal elements are retained, whereas the number of eigenmodes is truncated in sc-GW-subW calculations. A systematic analysis of the results obtained from the above techniques is presented. The differences in the quasiparticle band gap between the approximated and the full matrix sc-GW approaches are mostly less than 1.7%, which validates such widely adopted approximations, and also shows how such low-ranking approximation can be used to include higher-order terms such as the vertex correction.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS2013

Cohesive Modeling of Transverse Cracking in Laminates with a Single Layer of Elements per Ply

This study aims to bridge the gap between classical understanding of transverse cracking in cross-ply laminates and recent computational methods for the modeling of progressive laminate failure. Specifically, the study investigates under what conditions a finite element model with cohesive X-FEM cracks can reproduce the in situ effect for the ply strength. It is shown that it is possible to do so with a single element across the thickness of the ply, provided that the interface stiffness is properly selected. The optimal value for this interface stiffness is derived with an analytical shear lag model. It is also shown that, when the appropriate statistical variation of properties has been applied, models with a single element through the thickness of a ply can predict the density of transverse matrix cracks

VanDerMeer, Frans P.↗

DOE OSTI2022

Replica symmetry breaking for the integrable two-site Sachdev–Ye–Kitaev model

We analyze a two-body non-Hermitian two-site Sachdev–Ye–Kitaev (SYK) model with the couplings of one site complex conjugated to the other site. This model, with no explicit coupling between the sites, shows an infinite number of second-order phase transitions, which is a consequence of the factorization of the partition function into a product over Matsubara frequencies. We calculate the quenched free energy in two different ways: first in terms of the single-particle energies and second by solving the Schwinger–Dyson equations of the two-site model. The first calculation can be done entirely in terms of a one-site model. The conjugate replica enters due to non-analyticities when Matsubara frequencies enter the spectral support of the coupling matrix. The second calculation is based on the replica trick of the two-site partition function. Both methods give the same result. The free-fermion partition function can also be rephrased as a matrix model for the coupling matrix. Up to minor details, this model is the random matrix model that describes the chiral phase transition of QCD, and the order parameter of the two-body model corresponds to the chiral condensate of QCD. Comparing to the corresponding four-body model, we are able to determine which features of the free energy are due to the chaotic nature of the four-body model. The high-temperature phase of both models is entropy dominated, and in both cases, the free energy is determined by the spectral density. The chaotic four-body SYK model has a low-temperature phase whose free energy is almost temperature-independent, signaling an effective gap of the theory even though the actual spectrum does not exhibit a gap. On the other hand, the low-temperature free energy of the two-body SYK model is not flat; in fact, it oscillates to arbitrarily low temperature. This indicates a less desirable feature that the entropy of the two-body model is not always positive in the low-temperature phase, which most likely is a consequence of the non-hermiticity.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2017

Novel Transparent Phosphor Conversion Matrix with High Thermal Conductivity for Next Generation Phosphor-Converted LED-based Solid State Lighting

The low thermal conductivity of state-of-the-art polymer encapsulants (k ~ 0.15 Wm-1K-1) limits the efficiency and power density of current phosphor conversion light emitting diodes (pc-LEDs). The technical objective of this project was to demonstrate synthesis and processing schemes for the fabrication of polymer hybrid encapsulants with a thermal conductivity exceeding k = 0.4 Wm-1K-1 for LED applications. The ‘hybrid polymer’ approach encompasses the dispersion of high thermal conductivity particle fillers (zinc oxide, ZnO as well as the alpha-polymorph of alumina, Al2O3) within a polysiloxane matrix (poly(dimethylsiloxane), PDMS as well as poly(phenyl methyl siloxane), PPMS) to increase the thermal conductivity while maintaining optical transparency and photothermal stability at levels consistent with LED applications. To accomplish this goal, a novel synthesis method for the fabrication of nanosized ZnO particles was developed and a novel surface chemistry was established to modify the surface of zinc oxide particle fillers and thus to enable their dispersion in poly(dimethyl siloxane) (PDMS) matrix polymers. Molecular dynamics and Mie simulations were used to optimize ligand structure and to enable the concurrent mixing of particles in PDMS/PPMS embedding media while also minimizing the thermal boundary resistance as well as optical scattering of particle fillers. Using this approach the synthesis of PDMS/ZnO hybrid encapsulants exhibiting a thermal conductivity of 0.64 Wm-1K-1 and optical transparency > 0.7 mm-1 was demonstrated. A forming process based on micromolding was developed to demonstrate the forming of particle filled PDMS into film and lens shapes. Photothermal stability testing revealed stability of the materials for approximately 4000 min when exposed to blue light LED (450 nm, 30 W/cm2). One postgraduate and seven graduate students were supported by the project. The research performed within this project led to fifteen publications in peer-reviewed journals and one patent application. The grant stimulated a multi-investigator research collaborations among seven investigators at Carnegie Mellon University to address the challenge of encapsulants in pc-LED applications. The grant also catalyzed the future collaboration between researchers at Carnegie Mellon University and OSRAM Sylvania to address challenges associated with the use if polymers in LED applications.

36 MATERIALS SCIENCE↗

NASA NTRS1998

Scaling up the Single Transducer Thickness-Independent Ultrasonic Imaging Method for Accurate Characterization of Microstructural Gradients in Monolithic and Composite Tubular Structures

Ultrasonic velocity/time-of-flight imaging that uses back surface reflections to gauge volumetric material quality is highly suited for quantitative characterization of microstructural gradients including those due to pore fraction, density, fiber fraction, and chemical composition variations. However, a weakness of conventional pulse-echo ultrasonic velocity/time-of-flight imaging is that the image shows the effects of thickness as well as microstructural variations unless the part is uniformly thick. This limits this imaging method's usefulness in practical applications. Prior studies have described a pulse-echo time-of-flight-based ultrasonic imaging method that requires using a single transducer in combination with a reflector plate placed behind samples that eliminates the effect of thickness variation in the image. In those studies, this method was successful at isolating ultrasonic variations due to material microstructure in plate-like samples of silicon nitride, metal matrix composite, and polymer matrix composite. In this study, the method is engineered for inspection of more complex-shaped structures-those having (hollow) tubular/curved geometry. The experimental inspection technique and results are described as applied to (1) monolithic mullite ceramic and polymer matrix composite 'proof-of-concept' tubular structures that contain machined patches of various depths and (2) as-manufactured monolithic silicon nitride ceramic and silicon carbide/silicon carbide composite tubular structures that might be used in 'real world' applications.

Roth, Don J.↗

DOE OSTI2023

The microstructure and He + ion irradiation behavior of novel low-activation W-Ta-Cr-V refractory high entropy alloy for nuclear applications

Microstructure and nanohardness of a nearly equimolar W-Ta-Cr-V high entropy alloy (HEA), as well as its irradiation response under He + irradiation, were investigated. The single-phase body-centered cubic nanostructured alloy with a 1 µm thick layer was fabricated on a silicon substrate using a magnetron sputtering method. The HEA film has a complex microstructure consisting of micrometric domains that exhibit internal nanostructure controlled by their crystal orientation. The measured nanohardness of the W-Ta-Cr-V alloy is 13 ± 2 GPa, which significantly exceeds the hardness of nanocrystalline tungsten as a result of the high solid-solution strengthening effect. In order to evaluate the irradiation resistance of the HEA film, the material was irradiated with 200 keV He + ions at room temperature, with two different ion fluences: 1 × 10 16 and 5 × 10 16 ions/cm 2 . Using transmission electron microscopy, a high density of extremely fine He bubbles is observed that were uniformly distributed in the matrix. The increase of He + ion fluence increased the density of bubbles, whereas their size remained at a similar level, which indicates that the damage proceeds by the nucleation of additional He bubbles, not by their growth.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Theoretical oxidation state analysis of Ru-(bpy){sub 3}: Influence of water solvation and Hubbard correction in first-principles calculations

Oxidation state is a powerful concept that is widely used in chemistry and materials physics, although the concept itself is arguably ill-defined quantum mechanically. In this work, we present impartial comparison of four, well-recognized theoretical approaches based on Lowdin atomic orbital projection, Bader decomposition, maximally localized Wannier function, and occupation matrix diagonalization, for assessing how well transition metal oxidation states can be characterized. Here, we study a representative molecular complex, tris(bipyridine)ruthenium. We also consider the influence of water solvation through first-principles molecular dynamics as well as the improved electronic structure description for strongly correlated d-electrons by including Hubbard correction in density functional theory calculations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Growth of Cd 0.9 Zn 0.1 Te 1-y Se y Single Crystals for Room Temperature Gamma-Ray Detection

Quaternary Cd 0.9 Zn 0.1 Te 1-y Sey (CZTS) single crystals, a novel room-temperature nuclear radiation detector semiconductor material, have been grown using a modified vertical Bridgman method (VBM) and a travelling heater method (THM). The percentage concentration of selenium in the VBM-grown crystal was 3% and that in the THM-grown crystal was 2%. While the THM Frisch collar detector (4.4 × 4.4 × 10.7 mm 3 ) produced a highly resolved pulse height spectra (PHS) with a resolution of ~1.06% for 662-keV gamma rays without any correction, the VBM-grown detector (10 × 10 × 2 mm 3 ) offered a high energy resolution of ~2% after application of a digital biparametric correction. The high-resolution performance of these detectors has been attributed to the addition of Se in the Cd 0.9 Zn 0.1 Te (CZT) matrix. Ab-initio calculations based on density functional theory (DFT) also confirmed that the addition of Se in the CZT matrix helps to reduce the formation of TeCd and the TeZn anti-sites. The VBM-grown crystals were characterized using powder x-ray diffraction (XRD) and energy dispersive x-ray spectroscopy (EDS). While XRD results revealed sharp diffraction peaks confirming the crystalline nature of the grown crystal, the EDS results confirmed the targeted stoichiometry of the elemental composition. The bulk resistivity of the grown crystal was calculated to be ~3 × 10 10 Ω-cm from current-voltage characteristics recorded at room temperature in a planar configuration, ensuring that the grown CZTS crystals have low dark current as required for detector-grade crystals.

42 ENGINEERING↗

NASA NTRS1998

Method Developed for the High-Temperature Nondestructive Evaluation of Fiber-Reinforced Silicon Carbide Ceramic Matrix Composites

Ceramic matrix composites have emerged as candidate materials to allow higher operating temperatures (1000 to 1400 C) in gas turbine engines. A need, therefore, exists to develop nondestructive methods to evaluate material integrity at the material operating temperature by monitoring thermal and mechanical fatigue. These methods would also have potential as quality inspection tools. The goal of this investigation at the NASA Lewis Research Center is to survey and correlate the temperature-dependent damping and stiffness of advanced ceramic composite materials with imposed thermal and stress histories that simulate in-service turbine engine conditions. A typical sample size of 100 by 4 by 2 cubic millimeters, along with the specified stiffness and density, placed the fundamental vibration frequencies between 100 and 2000 Hz. A modified Forster apparatus seemed most applicable to simultaneously measure both damping and stiffness. Testing in vacuum reduced the effects of air on the measurements. In this method, a single composite sample is vibrated at its fundamental tone; then suddenly, the mechanical excitation is removed so that the sample's motion freely decays with time. Typical results are illlustrated in this paper.

Goldsby, Jon C.↗

DOE OSTI2016

Linear response to long wavelength fluctuations using curvature simulations

We study the local response to long wavelength fluctuations in cosmological N -body simulations, focusing on the matter and halo power spectra, halo abundance and non-linear transformations of the density field. The long wavelength mode is implemented using an effective curved cosmology and a mapping of time and distances. The method provides an alternative, more direct, way to measure the isotropic halo biases. Limiting ourselves to the linear case, we find generally good agreement between the biases obtained from the curvature method and the traditional power spectrum method at the level of a few percent. We also study the response of halo counts to changes in the variance of the field and find that the slope of the relation between the responses to density and variance differs from the naïve derivation assuming a universal mass function by approximately 8–20%. This has implications for measurements of the amplitude of local non-Gaussianity using scale dependent bias. We also analyze the halo power spectrum and halo-dark matter cross-spectrum response to long wavelength fluctuations and derive second order halo bias from it, as well as the super-sample variance contribution to the galaxy power spectrum covariance matrix.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2016

SU-G-TeP2-06: Development of Novel Radiochromic Films for Radiotherapy Dosimetry

Purpose: To develop and evaluate novel radiochromic films for quality assurance in radiotherapy dosimetry. Materials and Methods: Novel radiochromic film compositions were formulated using leuco crystal violet (LCV) as a reporting system and tetrabromoethane as a free radical source. The film matrix used consisted of polyurethane polymer mixed with dibutyl phthalate plasticizer (20 wt%). The concentration of the radical initiator was kept constant at 10 wt% and the concentration of the LCV dye varied (1 and 2 wt%). To ensure uniform thickness of the film, its precursors were sandwiched between two pieces of glass separated by a 1 mm gap between during the curing process. The films were cut into pieces and were irradiated with a 6 MV X-ray beam to selected doses. The change in optical density was measured using a flatbed scanner and a spectrophotometer. Results: The results showed that all film formulations exhibited a linear response with dose and an absorption maximum at ∼ 590 nm. The formulation with 2 wt% LCV was ∼ 30% more sensitive to dose than the formulation with 1 wt% LCV. Both films were very deformable. In addition, the radiochromic response of the film was found to bleach over a short period of time (few weeks) allowing the film to be reused for dose verification measurements. Conclusion: Both film formulations displayed excellent sensitivity and linearity to radiation dose and thus can be used for the 2D dosimetry of clinical megavoltage and kilovoltage X-ray beams. In addition, the thickness of the film could easily be increased allowing for their potential use as a deformable bolus material. However, thicker films would need more optimization of the manufacturing procedure to ensure consistent material uniformity and sensitivity are recommended.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2023

Low-velocity repeated impact behaviors of Polymer Fiber Reinforced Plastics (PFRPs)

Modern fiber-reinforced composites have become ubiquitous across multiple industries due to their excellent weight-to-strength ratio. Typically glass or carbon fibers are widely used. While Glass or Carbon Fiber-Reinforced Plastics (GFPRs or CFPRs) have good stiffness, strength, and fatigue life, they are expensive and difficult to recycle. Researchers are exploring Polymer Fiber-Reinforced Plastics (PFRPs) as an alternative solution. PFRPs utilize polymer fibers and a polymer matrix. A wide range of materials options is available, including low-cost thermoplastics such as polyethylene or polypropylene. These thermoplastics are easy to handle and recyclable without special methods. Manufacturing parts using thermoplastics are well-established as well. However, their mechanical performances have not been extensively studied compared to GFRPs or CFRPs. This study examines the low-velocity impact resistance of PFRPs made of different thermoplastics. The low-velocity impacts are applied through a drop-weight tower. The experiment is divided into two cases: a single perforation impact and low-energy repeated impacts. Energy absorption and the number of impacts to failure are measured. The results are compared to traditional CFRPs which have a thermoset matrix. The PFRPs demonstrate energy absorption capabilities comparable to or greater than those of CFRPs with respect to specimen thickness and density. Additionally, the PFRPs show significantly higher impacts-to-failure than the CFRPs in low-energy repeated impact tests. This is particularly noteworthy considering that the PFRPs are much simpler and more economical to manufacture than CFRPs. To further

Ko, Seunghyun↗

DOE OSTI2012

NEUTRONICS STUDIES OF URANIUM-BASED FULLY CERAMIC MICRO-ENCAPSULATED FUEL FOR PWRs

This study evaluates the core neutronics and fuel cycle characteristics that result from employing uranium-based fully ceramic micro-encapsulated (FCM) fuel in a pressurized water reactor (PWR). Specific PWR bundle designs with FCM fuel have been developed, which by virtue of their TRISO particle based elements, are expected to safely reach higher fuel burnups while also increasing the tolerance to fuel failures. The SCALE 6.1 code package, developed and maintained at ORNL, was the primary software employed to model these designs. Analysis was performed using the SCALE double-heterogeneous (DH) fuel modeling capabilities. For cases evaluated with the NESTLE full-core three-dimensional nodal simulator, because the feature to perform DH lattice physics branches with the SCALE/TRITON sequence is not yet available, the Reactivity-Equivalent Physical Transformation (RPT) method was used as workaround to support the full core analyses. As part of the fuel assembly design evaluations, fresh feed lattices were modeled to analyze the within-assembly pin power peaking. Also, a color-set array of assemblies was constructed to evaluate power peaking and power sharing between a once-burned and a fresh feed assembly. In addition, a parametric study was performed by varying the various TRISO particle design features; such as kernel diameter, coating layer thicknesses, and packing fractions. Also, other features such as the selection of matrix material (SiC, Zirconium) and fuel rod dimensions were perturbed. After evaluating different uranium-based fuels, the higher physical density of uranium mononitride (UN) proved to be favorable, as the parametric studies showed that the FCM particle fuel design will need roughly 12% additional fissile material in comparison to that of a standard UO2 rod in order to match the lifetime of an 18-month PWR cycle. Neutronically, the FCM fuel designs evaluated maintain acceptable design features in the areas of fuel lifetime, temperature coefficients of reactivity, as well as pin cell and assembly peaking factors. Key Words: FCM, TRISO, Uranium Mononitride, PWR

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1986

Ceramic-ceramic shell tile thermal protection system and method thereof

A ceramic reusable, externally applied composite thermal protection system (TPS) is proposed. The system functions by utilizing a ceramic/ceramic upper shell structure which effectively separates its primary functions as a thermal insulator and as a load carrier to transmit loads to the cold structure. The composite tile system also prevents impact damage to the atmospheric entry vehicle thermal protection system. The composite tile comprises a structurally strong upper ceramic/ceramic shell manufactured from ceramic fibers and ceramic matrix meeting the thermal and structural requirements of a tile used on a re-entry aerospace vehicle. In addition, a lightweight high temperature ceramic lower temperature base tile is used. The upper shell and lower tile are attached by means effective to withstand the extreme temperatures (3000 to 3200F) and stress conditions. The composite tile may include one or more layers of variable density rigid or flexible thermal insulation. The assembly of the overall tile is facilitated by two or more locking mechanisms on opposing sides of the overall tile assembly. The assembly may occur subsequent to the installation of the lower shell tile on the spacecraft structural skin.

Riccitiello, Salvatore R.↗

DOE OSTI2014

Tungsten carbide/porous carbon composite as superior support for platinum catalyst toward methanol electro-oxidation

Graphical abstract: The WC nanoparticles are well dispersed in the carbon matrix. The size of WC nanoparticles is about 30 nm. It can be concluded that tungsten carbide and carbon composite was successfully prepared by the present synthesis conditions. - Highlights: • The WC/PC composite with high specific surface area was prepared by a simple way. • The Pt/WC/PC catalyst has superior performance toward methanol electro-oxidation. • The current density for methanol electro-oxidation is as high as 595.93 A g{sup −1} Pt. • The Pt/WC/PC catalyst shows better durability and stronger CO electro-oxidation. • The performance of Pt/WC/PC is superior to the commercial Pt/C (JM) catalyst. - Abstract: Tungsten carbide/porous carbon (WC/PC) composites have been successfully synthesized through a surfactant assisted evaporation-induced-assembly method, followed by a thermal treatment process. In particular, WC/PC-35-1000 composite with tungsten content of 35% synthesized at the carbonized temperature of 1000 °C, exhibited a specific surface area (S{sub BET}) of 457.92 m{sup 2} g{sup −1}. After loading Pt nanoparticles (NPs), the obtained Pt/WC/PC-35-1000 catalyst exhibits the highest unit mass electroactivity (595.93 A g{sup −1} Pt) toward methanol electro-oxidation, which is about 2.6 times as that of the commercial Pt/C (JM) catalyst. Furthermore, the Pt/WC/PC-35-1000 catalyst displays much stronger resistance to CO poisoning and better durability toward methanol electrooxidation compared with the commercial Pt/C (JM) catalyst. The high electrocatalytic activity, strong poison-resistivity and good stability of Pt/WC/PC-35-1000 catalyst are attributed to the porous structures and high specific surface area of WC/PC support could facilitate the rapid mass transportation. Moreover, synergistic effect between WC and Pt NPs is favorable to the higher catalytic performance.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Half-filled Landau levels: A continuum and sign-free regularization for three-dimensional quantum critical points

In this paper, we explore a method for regulating 2+1D quantum critical points in which the ultraviolet cutoff is provided by the finite density of states of particles in a magnetic field rather than by a lattice. Such Landau-level quantization allows for numerical computations on arbitrary manifolds, like spheres, without introducing lattice defects. In particular, when half-filling a Landau level with $N = 4$ electron flavors, with appropriate interaction anisotropies in flavor space, we obtain a fully continuum regularization of the $\mathrm{O}(5)$ nonlinear sigma model with a topological term, which has been conjectured to flow to a deconfined quantum critical point. We demonstrate that this model can be solved by both infinite density-matrix renormalization group (DMRG) calculations and sign-free determinantal quantum Monte Carlo. DMRG calculations estimate the scaling dimension of the $\mathrm{O}(5)$ vector operator to be in the range $\mathrm{Δ_V}$ ~ $0.55-0.7$, depending on the stiffness of the nonlinear sigma model. Future Monte Carlo simulations will be required to determine whether this dependence is a finite-size effect or further evidence for a weak first-order transition.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

In Situ Prediction of Microstructure and Mechanical Properties in Laser-Remelted Al-Si Alloys: Towards Enhanced Additive Manufacturing

Laser surface remelting of aluminum alloys has emerged as a promising technique to enhance mechanical properties through refined microstructures. This process involves rapid cooling rates ranging from 10 3 to 10 8 °C/s, which increase solid solubility within aluminum alloys, shifting their eutectic composition to a larger value of silicon content. Consequently, the resulting microstructure combines a strengthened aluminum matrix with silicon fibers. This study focuses on the laser scanning of Al-Si aluminum alloy to reduce the size of aluminum matrix spacings and transform fibrous silicon particles from micrometer to nanometer dimensions. Analysis revealed that the eutectic structure contained 17.55% silicon by weight, surpassing the equilibrium eutectic composition of 12.6% silicon. Microstructure dimensions within the molten zones, termed ‘melt pools’, were extensively examined using Scanning Electron Microscopy (SEM) at intervals of approximately 20 μm from the surface. A notable increase in hardness, exceeding 50% compared to the base plate, was observed in the melt pool regions. Thus, it is exemplified that laser surface remelting introduces a novel strengthening mechanism in the alloy. Moreover, this study develops an in situ method for predicting melt pool properties and dimensions. A predictive model is proposed, correlating energy density and spectral signals emitted during laser remelting with mechanical properties and melt pool dimensions. This method significantly reduces characterization time from days to seconds, offering a streamlined approach for future studies in additive manufacturing.

36 MATERIALS SCIENCE↗