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At least 1,027 records · Page 57

Development of an in-situ multi-component reinforced Al-based metal matrix composite by direct metal laser sintering technique — Optimization of process parameters

In the present investigation, an in-situ multi-component reinforced aluminum based metal matrix composite was fabricated by the combination of self-propagating high-temperature synthesis and direct metal laser sintering process. The different mixtures of Al, TiO{sub 2} and B{sub 4}C powders were used to initiate and maintain the self-propagating high-temperature synthesis by laser during the sintering process. It was found from the X-ray diffraction analysis and scanning electron microscopy that the reinforcements like Al{sub 2}O{sub 3}, TiC, and TiB{sub 2} were formed in the composite. The scanning electron microscopy revealed the distribution of the reinforcement phases in the composite and phase identities. The variable parameters such as powder layer thickness, laser power, scanning speed, hatching distance and composition of the powder mixture were optimized for higher density, lower porosity and higher microhardness using Taguchi method. Experimental investigation shows that the density of the specimen mainly depends upon the hatching distance, composition and layer thickness. On the other hand, hatching distance, layer thickness and laser power are the significant parameters which influence the porosity. The composition, laser power and layer thickness are the key influencing parameters for microhardness. - Highlights: • The reinforcements such as Al{sub 2}O{sub 3}, TiC, and TiB{sub 2} were produced in Al-MMC through SHS. • The density is mainly influenced by the material composition and hatching distance. • Hatching distance is the major influencing parameter on porosity. • The material composition is the significant parameter to enhance the microhardness. • The SEM micrographs reveal the distribution of TiC, TiB{sub 2} and Al{sub 2}O{sub 3} in the composite.

36 MATERIALS SCIENCE↗

Advanced morphological analysis of patterns of thin anodic porous alumina

Different conditions of fabrication of thin anodic porous alumina on glass substrates have been explored, obtaining two sets of samples with varying pore density and porosity, respectively. The patterns of pores have been imaged by high resolution scanning electron microscopy and analyzed by innovative methods. The regularity ratio has been extracted from radial profiles of the fast Fourier transforms of the images. Additionally, the Minkowski measures have been calculated. It was first observed that the regularity ratio averaged across all directions is properly corrected by the coefficient previously determined in the literature. Furthermore, the angularly averaged regularity ratio for the thin porous alumina made during short single-step anodizations is lower than that of hexagonal patterns of pores as for thick porous alumina from aluminum electropolishing and two-step anodization. Therefore, the regularity ratio represents a reliable measure of pattern order. At the same time, the lower angular spread of the regularity ratio shows that disordered porous alumina is more isotropic. Within each set, when changing either pore density or porosity, both regularity and isotropy remain rather constant, showing consistent fabrication quality of the experimental patterns. Minor deviations are tentatively discussed with the aid of the Minkowski measures, and the slight decrease in both regularity and isotropy for the final data-points of the porosity set is ascribed to excess pore opening and consequent pore merging. - Highlights: • Thin porous alumina is partly self-ordered and pattern analysis is required. • Regularity ratio is often misused: we fix the averaging and consider its spread. • We also apply the mathematical tool of Minkowski measures, new in this field. • Regularity ratio shows pattern isotropy and Minkowski helps in assessment. • General agreement with perfect artificial patterns confirms the good manufacturing.

36 MATERIALS SCIENCE↗

The distribution and mechanism of pore formation in copper foams fabricated by Lost Carbonate Sintering method

In this research, utilizing X-ray computed tomography (XCT), geometrical characterization, and pore formation mechanisms of highly porous copper foams manufactured by powder metallurgical (PM) process are investigated. Open-cell copper foams with porosity percentages of 60% and 80% and with a pore size within the range of 300–600 μm were manufactured by using potassium carbonate as a space holder agent via the Lost Carbonate Sintering (LCS) technique. XCT and SEM were also employed to investigate the three-dimensional structure of foams and to find the effect of the parameters of the space holders on the structural properties of copper foams. The result showed an excellent correlation between the structural properties of the foams including the size and shape of the pores, porosity percentage, volume percentage, particle size, and the shape of the sacrificial agent used. Also, the advanced image analysis of XCT images indicated fluctuations up to ± 10% in porosity distribution across different cross-sections of the foams. Simultaneous thermal analysis (STA: DTA–TG) was also used to study the thermal history of the powders used during the manufacturing process of the foams. The results indicated that the melting and thermal decomposition of the potassium carbonate occurred simultaneously at 920 °C and created the porous structure of the foams. By combining the STA result with the result of the tension analysis of cell walls, the mechanisms of open-pore formation were suggested. In fact, most open pores in the samples were formed due to the direct contact of potassium carbonate particles with each other in green compact. Also, it was found that the thermal decomposition of potassium carbonate particles into gaseous CO{sub 2} led to the production of gas pressure inside the closed pores, which eventually caused the creation of cracks on the cell walls and the opening of the pores in foam's structure. - Highlights: • Structural characterization of copper foam produced by LCS method is investigated by tomography images. • The ability of LCS technique to control structural features of produced foams was proved. • The mechanisms of open pores formation were presented.

36 MATERIALS SCIENCE↗

Characterization of geopolymer fly-ash based foams obtained with the addition of Al powder or H{sub 2}O{sub 2} as foaming agents

Recent innovations in geopolymer technology have led to the development of various different types of geopolymeric products, including highly porous geopolymer-based foams, which are formed by the addition of foaming agents to a geopolymer fly-ash based matrix. These agents decompose, or react with the liquid matrix or oxygen in the matrix, resulting in the release of gases which form pores prior to the hardening of the gel. The hardened structure has good mechanical and thermal properties, and can therefore be used for applications in acoustic panels and in lightweight pre-fabricated components for thermal insulation purposes. This study presents the results of the pore-forming process in the case when two different foaming agents, i.e. aluminium powder amounting to 0.07, 0.13 and 0.20 mass. % and H{sub 2}O{sub 2} amounting to 0.5, 1.0, 1.5 and 2.0 mass. %, were added to a fly-ash geopolymer matrix. The physical, mechanical, and microstructural properties of the thus obtained foams, and the effects of the type and amount of the added foaming agent, are presented and discussed. Highly porous structures were obtained in the case of both of the investigated foaming agents, with overall porosities up to 59% when aluminium powder was added, and of up 48% when H{sub 2}O{sub 2} was added. In the latter case, when 2% of the H{sub 2}O{sub 2} foaming agent was added, finer pores (with diameters up to 500 μm) occurred in the structure, whereas somewhat larger pores (some had diameters greater than 1 mm) occurred when the same amount of aluminium powder was added. The mechanical properties of the investigated foams depended on their porosity. In the case of highly porous structures a compressive strength of 3.3 MPa was nevertheless achieved for the samples containing 0.2% of aluminium powder, and 3.7 MPa for those containing 2.0% of H{sub 2}O{sub 2}. - Highlights: • Preparation of geopolymer foams based on fly ash with the addition of Al powder or H{sub 2}O{sub 2} as foaming agents • Determination of density, porosity and mechanical properties of such foams • Characterization of foaming process by means of X-ray micro-tomography (μcT)

36 MATERIALS SCIENCE↗

Multiscale characterization and comparison of historical and modern nuclear graphite grades

Beginning with Chicago Pile I, graphite has been used as a moderator material in nuclear power stations and is considered a potential material for use in future Generation IV advanced reactors. The microstructure of graphite is responsible for much of its mechanical and thermo-physical properties, and how it responds to irradiation. To understand graphite microstructure, it is necessary to understand its porosity at the macro- and micro-scales; and to understand its porosity, it is necessary to characterize the morphological connectivity of the void content and the two main phases of graphite: filler and binder. Here, using several microscopy and analytical techniques, a detailed examination of the heterogeneity, microstructure and pore structure of different graphite grades and their binder and filler phases is presented. Significant differences were found between coarser and finer nuclear grades. Coarse grades have a more diverse range of filler particles, pores and thermal cracks. Finer grades have a more well-defined pore size distribution, fewer variations of filler particles sizes and do not contain as many large thermal cracks. Fine grades tend to have a well-connected network of pores whereas coarser grades contain a larger content of closed porosity. The framework developed within this work can be applied and used to assess the various graphite grades that would down-select materials for specific use in graphite moderated reactor designs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Effect of laser power on defect, texture, and microstructure of a laser powder bed fusion processed 316L stainless steel

The effect of laser power on defect characteristics, microstructure development, constituent phases, and crystallographic texture was studied on a laser powder bed fusion (L-PBF) processed 316L stainless steel. A series of cylindrical specimens were additively manufactured as a function of laser power ranging from 380 to 200W with a fixed scan speed of 300 mm/s using a selective laser melting system. The density (in terms of count, surface area, and porosity), size (mean values of major axis length, surface area, and volume), shape (aspect ratio and sphericity), and orientation (in terms of the angle between the major axis and build direction) of macroscopic defects in as-printed L-PBF cylinders were characterized using high-resolution synchrotron x-ray computed microtomography with a 0.65μm resolution. Moreover, the changes in the preferred crystallographic orientations and constituent phases were investigated using high-energy synchrotron x-ray diffraction. Finally, the melt pool shape and grain size/orientation were analyzed using metallography. The results show that the porosity increases linearly from 0.13 to 0.88% with the decrease in laser power. However, even with the decrease in laser power by about half and corresponding seven-fold increase in porosity, the 200W case can still be considered as nearly fully dense. On the other hand, with the same decrease in the laser power, the melt pool size/shape, grain size, and texture changed significantly. In conclusion, the role of energy input in the simultaneous changes in defect properties and microstructure development will be discussed.

36 MATERIALS SCIENCE↗

Closed-loop control of meltpool temperature in directed energy deposition

The objective of this work is to mitigate flaw formation in powder and laser-based directed energy deposition (DED) additive manufacturing process through close-loop control of the meltpool temperature. In this work, the meltpool temperature was controlled by modulating the laser power based on feedback signals from a coaxial two-wavelength imaging pyrometer. The utility of closed-loop control in DED is demonstrated in the context of practically inspired trapezoid-shaped stainlesssteel parts (SS 316L). We demonstrate that parts built under closed-loop control have reduced variation in porosity and uniform microstructure compared to parts built under open-loop conditions. For example, post-process characterization showed that closed-loop processed parts had a volume percent porosity ranging from 0.036% to 0.043%. In comparison, open-loop processed parts had a larger variation in volume percent porosity ranging from 0.032% to 0.068%. Further, parts built with closed-loop processing depicted consistent dendritic microstructure. By contrast, parts built with open-loop processing showed microstructure heterogeneity with the presence of both dendritic and planar grains, which in turn translated to large variation in microhardness

36 MATERIALS SCIENCE↗

PVP-assisted enhancement in ion storage performance of sol-gel derived nano-structured NiCo2O4 thin films as battery-type electrode

Highlights: • Polyvinylpyrrolidone was used to increase the porosity of the sol-gel derived nickel-cobaltite thin films for the first time. • Polymer content of the films was completely degraded during the heating process. • Increase of porosity significantly improved the electrochemical ion storage performance of the fabricated thin films. • Polymer content of the solutions was optimized to obtain the maximum electrochemical capacity. - Abstract: NiCo{sub 2}O{sub 4} thin films were successfully deposited on glass and ITO substrates by sol-gel method. In order to improve the electrochemical ion storage performance, different amounts of polyvinylpyrrolidone (PVP) were added to the solutions as porogen agent, which was totally degraded during the post-annealing process at 500 °C, as confirmed by Fourier transform infrared (FTIR) spectroscopy. The electrode with about 0.07 g/cm{sup 3} PVP content in the solution, exhibited 65% higher specific capacity comparing with the electrode fabricated without PVP, due to significant nano-sized porosity remained after degradation of polymer chains, as displayed by field emission scanning electron micrographs (FESEM) of the surface and cross section of the samples. Also the electrochemical measurements in 1 M KOH aqueous electrolyte revealed the ion storage mechanism of the fabricated samples is battery-type.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Experimental and theoretical assessment of the multi-domain flow behaviour in a waste body during leachate infiltration

The optimisation of landfill operation is a key challenge for the upcoming years. A promising solution to improve municipal solid waste (MSW) management is the bioreactor technology. A meso-scale (around 1 m{sup 3}) experimental set-up was performed to study the effect of moisture control in low density conditions with different leachate injection operations and bioreactor monitoring including the use of a neutron probe. The moisture content distribution evolution demonstrates a multi-domain flow behaviour. A classic van Genuchten-Mualem description of the connected porosity proved insufficient to correctly describe the observed phenomena. A bimodal description of the connected porosity is proposed as solution and a connected/non-connected porosities numerical model was applied to the results. The model explains the experimental results reasonably well.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Evolution of Pore Structure in Organic-Lean and Organic-Rich Mudrocks

The pore structure of mudrocks is a key characteristic to evaluate flow behavior through these rocks. Although significant advances have been made to resolve pore characteristics, porosity evolution, or pore connectivity, there is still insufficient knowledge linking porosity evolution to flow and transport in mudrocks. To better understand these links, we conducted very small-angle (VSANS) and small-angle neutron scattering (SANS) experiments on 13 sets of mudrocks from global locations, characterized by differences in composition, maturity, and depositional environment. Our results indicate that a homogeneous pore structure reflects a stable and low-energy depositional environment. Organic-lean mudrocks mainly contain pores <10 nm, which restricts flow and is beneficial for, e.g., caprock seal integrity. Increasing maturity as a result of increasing burial depth, and therefore, temperature leads to porosity evolution. In organic-rich mudrocks (ORMs), this happens through the generation of organic matter pores and pore preservation around diagenetically formed carbonates. ORMs mainly contain macropores (>50 nm), favoring production from, e.g., unconventional reservoirs. SANS-derived pore size distributions will help to better understand fluid imbibition and flow properties in mudrocks through comprehensive quantitative characterization of the nano- to micron scale pore network conduits and their relationships to burial diagenesis.

58 GEOSCIENCES↗

Effect of Electro-Sprayed Porous Electrodes on the Performance and Stability of Water Electrolysis

The efficiency of proton exchange membrane water electrolysis (PEMWE) is a critical issue in realizing the production of green hydrogen. Here, the coexistence of three phases in the catalyst layer of PEMWE causes the mass transport limitation at the interfaces between them. In particular, the vigorous production of gaseous hydrogen and oxygen derived from liquid water is generated in the form of bubbles that seriously deactivate the membrane-electrode assembly (MEA). In this study, we investigated the effect of porous structure in the electrode on the efficiency of hydrogen production at high current density, which is highly related to the mass transport limitation. A widely used commercial catalyst (IrO 2 ) were directly coated on the membrane by the electro-spray method. The porous electrodes on the membrane were formed by the charged catalyst particles that repulsed each other due to the electrostatic forces of the particles. Our membrane electrode assembly (MEA) exhibited outstanding electrolysis performances such as 5.3 A cm -2 and 3.2 A cm -2 at 2.0 V and 1.8 V, respectively, which are the highest values compared with the results published in the current studies. In addition to the porosity, it was confirmed that optimum binder contents positively affect the hydrophobicity and contact resistance of MEA. Through a simple porosity-controlled technique, the performance of PEMWE, in which three phases coexist, can be improved by more than 60 %. Accordingly, we expect that our systematic study on the role of porosity in the electrodes opens a new era to efficiently produce green hydrogen.

catalysts↗

Porous but Mechanically Robust All-Inorganic Antireflective Coatings Synthesized using Polymers of Intrinsic Microporosity

Herein, we introduce polymer of intrinsic microporosity 1 (PIM-1) to design single-layer and multilayered all-inorganic antireflective coatings (ARCs) with excellent mechanical properties. Using PIM-1 as a template in sequential infiltration synthesis (SIS), we can fabricate highly uniform, mechanically stable conformal coatings of AlO x with porosities of ~50% and a refractive index of 1.41 compared to 1.76 for nonporous AlO x that is perfectly suited for substrates commonly used in high-end optical systems or touch screens (e.g., sapphire, conductive glass, bendable glass, etc.). We show that such films can be used as a single-layer ARC capable of reduction of the Fresnel reflections of sapphire to as low as 0.1% at 500 nm being deposited only on one side of the substrate. We also demonstrate that deposition of the second layer with higher porosity using block copolymers enables the design of graded-index double-layered coatings. AlO x structures with just two layers and a total thickness of less than 200 nm are capable of reduction of Fresnel reflections under normal illumination to below 0.5% in a broad spectral range with 0.1% reflection at 700 nm. Additionally, and most importantly, we show that highly porous single-layer and graded-index double-layered ARCs are characterized by high hardness and scratch resistivity. The hardness and the maximum reached load were 7.5 GPa and 13 mN with a scratch depth of about 130 nm, respectively, that is very promising for the structures consisting of two porous AlO x layers with 50% and 85% porosities, correspondingly. Such mechanical properties of coatings can also allow their application as protective layers for other optical coatings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Reactive Ballistic Deposition of Nanostructured Model Materials for Electrochemical Energy Conversion and Storage

Finely structured, supported thin films offer a host of opportunities for fundamental and applied research. Nanostructured materials often exhibit physical properties which differ from their bulk counterparts due to the increased importance of the surface in determining the thermodynamics and behavior of the system. Thus, control of the characteristic size, porosity, morphology, and surface area presents opportunities to tailor new materials which are useful platforms for elucidating the fundamental processes related to energy conversion and storage. The ability to produce high purity materials with direct control of relevant film parameters such as porosity, film thickness, and film morphology is of immediate interest in the fields of electrochemistry, photocatalysis, and thermal catalysis. Studies of various photoactive materials have introduced questions concerning the effects of film architecture and surface structure on the performance of the materials, while recent work has demonstrated that nanostructured, mesoporous, or disordered materials often deform plastically, making them robust in applications where volumetric expansion and phase transformations occur, such as in materials for lithium-ion batteries. Moreover, renewed emphasis has been placed on the formation of semi-conductive electrodes with controlled pore-size and large surface areas for the study and application of pseudo-capacitance and cation insertion processes for electrical energy storage. Understanding how the performance of such materials depends on morphology, porosity, and surface structure and area requires a synthesis technique which provides for incremental variations in structure and facilitates assessment of the performance with the appropriate analytical tools, preferably those that provide both structural information and kinetic insight into photoelectrochemical processes.

30 DIRECT ENERGY CONVERSION↗

Characterization of the intragranular water regime within subsurface sediments: Pore volume, surface area, and mass transfer limitations

Although 'intragranular' pore space within grain aggregates, grain fractures, and mineral 24 surface coatings may contain a relatively small fraction of the total porosity within a porous 25 medium, it often contains a significant fraction of the reactive surface area, and can thus strongly 26 affect the transport of sorbing solutes. In this work, we demonstrate a batch experiment 27 procedure using tritium and bromide as high-resolution diffusive tracers to characterize the 28 intragranular pore space. The method was tested using uranium-contaminated sediments from 29 the vadose and capillary fringe zones beneath the former 300A process ponds at the Hanford site 30 (Washington State, USA). Sediments were contacted with tracers in artificial groundwater, 31 followed by replacement of bulk solution with tracer-free groundwater and monitoring of tracer 32 release. From these data, intragranular pore volumes were calculated and mass transfer rates 33 were quantified using a multirate first-order mass transfer model. Tritium-hydrogen exchange 34 on surface hydroxyls was accounted for by conducting additional tracer experiments on sediment 35 that was vacuum dried after reaction. The complementary ('wet' and 'dry') techniques allowed 36 for the simultaneous determination of intragranular porosity and surface area using tritium. The 37 Hanford 300A samples exhibited intragranular pore volumes of {approx}1% of the solid volume and 38 intragranular surface areas of {approx}20-30% of the total surface area. Comparison with N2 gas 39 adsorption suggests that this pore space includes both 'micropores' (< 2 nm diameter) and 40 'mesopores' (> 2 nm). Intragranular porosity estimates obtained using bromide were 41 significantly smaller, likely due to anion exclusion of Br- from pores with negatively charged 42 surfaces.

300A↗

Effect of microstructural features on the laser efficiency of Nd{sup 3+}:Y{sub 3}Al{sub 5}O{sub 12} ceramics

The optical properties and microstructure of transparent Nd{sup 3+}:Y{sub 3}Al{sub 5}O{sub 12} ceramics synthesised by different reactive sintering routes are studied. It is found that the residual porosity of optical ceramics is directly related to the homogeneity of the microstructure of initial compacts, which can be estimated by the existence of particle agglomerates larger than 1 mm in initial nanopowders. A qualitative correlation is established between the residual porosity, the optical losses and the lasing slope efficiency of Nd{sup 3+}:Y{sub 3}Al{sub 5}O{sub 12} ceramics. The maximum laser efficiency (η = 49%) was observed in the samples with the lowest porosity (2.3 × 10{sup -3} vol %). (lasers)

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Revealing Three-Dimensional Morphology in Nanoporous Gold Using Three-Dimensional X-Ray Fresnel Coherent Diffractive Imaging Tomography

Nanoporous metals fabricated by dealloying have a unique bi-continuous, sponge-like porous structure with ultra-high surface area. The unique properties of these materials, especially nanoporous gold, have numerous potential applications in sensors and actuators and in energy-related applications such as catalytic materials, super-capacitors, and battery supports. The degree of porosity and size of the metal ligaments are critical parameters that determine many properties and thus govern the functionalities of nanoporous metals in many applications including energy storage and conversion. Additionally, we used Fresnel coherent diffractive imaging combined with tomographic reconstruction to quantify the nanoscale three-dimensional spatial distribution and homogeneity of the porosity and ligament size within a bulk sample of nanoporous gold. The average porosity and its standard deviation along the axial direction through the sample were determined, as well as the characteristic feature size and its standard deviation. The result shows that free corrosion is an effective way to create homogeneous nanoporous metals with sample sizes on the order of 1 µm.

36 MATERIALS SCIENCE↗

Transport properties of damaged materials. Cementitious barriers partnership

The objective of the Cementitious Barriers Partnership (CBP) project is to develop tools to improve understanding and prediction of the long-term structural, hydraulic, and chemical performance of cementitious barriers used in low-level waste storage applications. One key concern for the long-term durability of concrete is the degradation of the cementitious matrix, which occurs as a result of aggressive chemical species entering the material or leaching out in the environment, depending on the exposure conditions. The objective of the experimental study described in this report is to provide experimental data relating damage in cementitious materials to changes in transport properties, which can eventually be used to support predictive model development. In order to get results within a reasonable timeframe and to induce as much as possible uniform damage level in materials, concrete samples were exposed to freezing and thawing (F/T) cycles. The methodology consisted in exposing samples to F/T cycles and monitoring damage level with ultrasonic pulse velocity measurements. Upon reaching pre-selected damage levels, samples were tested to evaluate changes in transport properties. Material selection for the study was motivated by the need to get results rapidly, in order to assess the relevance of the methodology. Consequently, samples already available at SIMCO from past studies were used. They consisted in three different concrete mixtures cured for five years in wet conditions. The mixtures had water-to-cement ratios of 0.5, 0.65 and 0.75 and were prepared with ASTM Type I cement only. The results showed that porosity is not a good indicator for damage caused by the formation of microcracks. Some materials exhibited little variations in porosity even for high damage levels. On the other hand, significant variations in tortuosity were measured in all materials. This implies that damage caused by internal pressure does not necessarily create additional pore space in the microstructure, but likely creates new thin pathways between existing pore space for species to travel. These results have a significant impact on modeling efforts. Models relating porosity to tortuosity and permeability are unlikely to provide the correct basis for predicting long-term durability of concrete sustaining internal pressures and microcrack formation. Other avenues like the modeling of internal crystallization pressure need to be explored.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Pore Formation in the Laminar Structure of Wear-Resistant Modified Powder Coatings

The open porosity of wear-resistant modified coatings is investigated, and their macrostructure is analyzed. A statistical method is proposed for describing the formation of porosity in the laminar structure of a powder coating. The matrix of transition probabilities is determined for a uniform Markov chain. The porosity of a coating on a smooth substrate is calculated.

36 MATERIALS SCIENCE↗