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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 1,045 records · Page 58
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

BISON Capability, Validation and Demonstration for Reactivity-Initiated Accidents

Reactivity Initiated Accidents (RIA) are design basis accidents that could have adverse impacts on the core coolability. In the unlikely event that sufficient reactivity is inserted into the reactor core by the ejected/dropped control rod, prompt energy deposition into the fuel can occur, which when sufficiently high can lead to fuel rod failure or, at large energy deposition levels, expulsion of UO2 fragments or molten UO2 material from the fuel rod. This results in a release of fission product and fuel into the coolant and has the potential to compromise core coolability and threatening the pressure boundary of the primary coolant system. The design basis RIA is one of the industry challenging problems that the CASL aimed to address; the CASL RIA Challenge Problem Charter [1] states, ?The Pressurized Water Reactor (PWR) Rod Ejection Accident (REA) and Boiling Water Reactor (BWR) Control Rod Drop Accident (CRDA) are postulated accidents with consequences that are important to nuclear safety (fuel rod integrity and core coolability). Currently each reload core design must be analyzed to meet regulatory acceptance criteria. The goal of CASLs ModSim capability for RIA is to model the event at a higher fidelity, with validation to existing tests, to better model the transient neutronics and the progression of the fuel and cladding thermal-mechanical behavior. These improved analytical capabilities can be used to better inform reload core design, limits on fuel assembly discharge burnup, restrictions on placement of fuel in the reactor, control rod insertion limits, operating margin, and performance sensitivities.? In support of that charter, BISON, the fuel performance code has been used to demonstrate the simulation of thermal-mechanical behavior of LWR fuels during a reactivity-initiated accident. The combination of mechanical, thermal, and thermal-hydraulic phenomena all present during an RIA makes a multi-physics code such as BISON a valuable tool for modeling these scenarios. This paper will highlight many of the activities associated with BISON relevant to reactivity-initiated accident capability development and validation efforts. These efforts have been performed under both CASL and the Nuclear Energy Advanced Modeling and Simulation (NEAMS) programs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Recent developments in DYNSUB: New models, code optimization and parallelization

DYNSUB is a high-fidelity coupled code system consisting of the reactor simulator DYN3D and the sub-channel code SUBCHANFLOW. It describes nuclear reactor core behavior with pin-by-pin resolution for both steady-state and transient scenarios. In the course of the coupled code system's active development, super-homogenization (SPH) and generalized equivalence theory (GET) discontinuity factors may be computed with and employed in DYNSUB to compensate pin level homogenization errors. Because of the largely increased numerical problem size for pin-by-pin simulations, DYNSUB has bene fitted from HPC techniques to improve its numerical performance. DYNSUB's coupling scheme has been structurally revised. Computational bottlenecks have been identified and parallelized for shared memory systems using OpenMP. Comparing the elapsed time for simulating a PWR core with one-eighth symmetry under hot zero power conditions applying the original and the optimized DYNSUB using 8 cores, overall speed up factors greater than 10 have been observed. The corresponding reduction in execution time enables a routine application of DYNSUB to study pin level safety parameters for engineering sized cases in a scientific environment. (authors)

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2001

Modeling of Multi-Tube Pulse Detonation Engine Operation

The present paper explores some preliminary issues concerning the operational characteristics of multiple-tube pulsed detonation engines (PDEs). The study is based on a two-dimensional analysis of the first-pulse operation of two detonation tubes exhausting through a common nozzle. Computations are first performed to assess isolated tube behavior followed by results for multi-tube flow phenomena. The computations are based on an eight-species, finite-rate transient flow-field model. The results serve as an important precursor to understanding appropriate propellant fill procedures and shock wave propagation in multi-tube, multi-dimensional simulations. Differences in behavior between single and multi-tube PDE models are discussed, The influence of multi-tube geometry and the preferred times for injecting the fresh propellant mixture during multi-tube PDE operation are studied.

Ebrahimi, Houshang B.↗
DOE OSTI2014

Towards a unified description of the hydrogen bond network of liquid water: A dynamics based approach

The definition of a hydrogen bond (H-bond) is intimately related to the topological and dynamic properties of the hydrogen bond network within liquid water. The development of a universal H-bond definition for water is an active area of research as it would remove many ambiguities in the network properties that derive from the fixed definition employed to assign whether a water dimer is hydrogen bonded. This work investigates the impact that an electronic-structure based definition, an energetic, and a geometric definition of the H-bond has upon both topological and dynamic network behavior of simulated water. In each definition, the use of a cutoff (either geometric or energetic) to assign the presence of a H-bond leads to the formation of transiently bonded or broken dimers, which have been quantified within the simulation data. The relative concentration of transient species, and their duration, results in two of the three definitions sharing similarities in either topological or dynamic features (H-bond distribution, H-bond lifetime, etc.), however no two definitions exhibit similar behavior for both classes of network properties. In fact, two networks with similar local network topology (as indicated by similar average H-bonds) can have dramatically different global network topology (as indicated by the defect state distributions) and altered H-bond lifetimes. A dynamics based correction scheme is then used to remove artificially transient H-bonds and to repair artificially broken bonds within the network such that the corrected network exhibits the same structural and dynamic properties for two H-bond definitions (the properties of the third definition being significantly improved). The algorithm described represents a significant step forward in the development of a unified hydrogen bond network whose properties are independent of the original hydrogen bond definition that is employed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Behavior of an air-cooled thermosiphon during a non-air gas ingress event

Here, this study investigates the transient response of an air-cooled thermosiphon subjected to a sudden non-air gas ingress event. Results presented are from experimental testing conducted on a large-scale thermal hydraulic facility that examines heat removal performance of the Reactor Cavity Cooling System (RCCS) concept, a passive safety system for advanced nuclear reactors. Relying on buoyancy driven natural circulation flow, these systems feature a series of riser standpipes and coupled chimney network that provide a pathway for heat rejection to the atmosphere. In this work, the facility was modified to allow a transition of the draft intake from normal ambient air, to draft intake from an open-top volume containing high purity argon. Testing began by establishing normal operation and allowing the facility to reach steady-state thermal hydraulic flow conditions with natural air draft. The transitioned sequence was then initiated which simultaneously changed the inlet boundary from open air to a pathway from the quiescent argon volume. This event caused 1,200 cu-feet of the heavy gas, twice the internal volume of total facility flow path, to be drawn into the inlet plenum and ingress into the heated riser standpipes. With the upper chimney network still containing residual air, there was insufficient density difference to maintain buoyancy driven natural circulation. After a period of only 90 s past the ingress event, the facility experienced complete flow stagnation before entering an extended period of severely degraded system flow. Due to the cessation of bulk fluid movement and subsequent failure of its heat removal function, fluid and structural temperatures began to rise sharply. Re-circulation patterns developed within the multiple parallel riser standpipes, where hot gas near the outlets was observed to travel downward and re-enter the inlet of adjacent channels. After approximately 18-minutes, fluid temperatures and their associated density difference rose to a level sufficient to allow reestablishment of buoyancy driven system flow, and ultimately, recovery of facility operation to normal behavior.

42 ENGINEERING↗
DOE OSTI2012

Influence of V/III growth flux ratio on trap states in m-plane GaN grown by ammonia-based molecular beam epitaxy

Deep level transient spectroscopy (DLTS) and deep level optical spectroscopy (DLOS) were utilized to investigate the behavior of deep states in m-plane, n-type GaN grown by ammonia-based molecular beam epitaxy (NH{sub 3}-MBE) as a function of systematically varied V/III growth flux ratios. Levels were detected at E{sub C} - 0.14 eV, E{sub C} - 0.21 eV, E{sub C} - 0.26 eV, E{sub C} - 0.62 eV, E{sub C} - 0.67 eV, E{sub C} - 2.65 eV, and E{sub C} - 3.31 eV, with the concentrations of several traps exhibiting systematic dependencies on V/III ratio. The DLTS spectra are dominated by traps at E{sub C} - 0.14 eV and E{sub C} - 0.67 eV, whose concentrations decreased monotonically with increasing V/III ratio and decreasing oxygen impurity concentration, and by a trap at E{sub C} - 0.21 eV that revealed no dependence of its concentration on growth conditions, suggestive of different physical origins. Higher concentrations of deeper trap states detected by DLOS with activation energies of E{sub C} - 2.65 eV and E{sub C} - 3.31 eV in each sample did not display measureable sensitivity to the intentionally varied V/III ratio, necessitating further study on reducing these deep traps through growth optimization for maximizing material quality of NH{sub 3}-MBE grown m-plane GaN.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Intriguing Effects of Halogen Substitution on the Photophysical Properties of 2,9-(Bis)halo-Substituted Phenanthrolinecopper(I) Complexes

Three new copper(I) complexes [Cu-(L-x)(2)](+)(PF6-) (where L-x stands for 2,9-dihalo-1,10-phenanthroline and X = Cl, Br, and I) have been synthesized in order to study the impact of halogen substituents tethered in the alpha position of the chelating nitrogen atoms on their physical properties. The photophysical properties of these new complexes (hereafter named Cu-X) were characterized in both their ground and excited states. Femtosecond ultrafast spectroscopy revealed that early photoinduced processes are faster for Cu-I than for Cu-Cl or Cu-Br, both showing similar behaviors. Their electronic absorption and electrochemical properties are comparable to benchmark [Cu(dmp)(2)](+) (where dmp stands for 2,9-dimethyl-1,10-phenanthroline); furthermore, their optical features were fully reproduced by time-dependent density functional theory and ab initio molecular dynamics calculations. All three complexes are luminescent at room temperature, showing that halogen atoms bound to positions 2 and 9 of phenanthroline are sufficiently bulky to prevent strong interactions between the excited Cu complexes and solvent molecules in the coordination sphere. Their behavior in the excited state, more specifically the extent of the photoluminescence efficiency and its dependence on the temperature, is, however, strongly dependent on the nature of the halogen. A combination of ultrafast transient absorption spectroscopy, temperature-dependent steady-state fluorescence spectroscopy, and computational chemistry allows one to gain a deeper understanding of the behavior of all three complexes in their excited state.

Brown-Xu, Samantha↗
DOE OSTI2026

Influence of Nd(II) and Nd(III) Ions on the Speciation and Kinetic Dynamics of Radiolytic Transients in Molten LiCl-KCl Eutectic Salt Mixtures

In the pyrochemical reprocessing of used nuclear fuel, understanding the effects of ionizing radiation on the chemical behavior of fission products in molten chloride eutectic salt is crucial. Here, this study investigates the impact of radiation on the chemical and kinetic speciation of Nd ions in molten LiCl-KCl eutectic, which are challenging to separate due to their multivalent oxidation states and comproportionation reactions. Electron pulse radiolysis techniques were used to determine transient absorption spectra, chemical kinetics, and activation parameters for the reaction of Nd ions with the primary products of molten LiCl-KCl eutectic radiolysis: the solvated electron (e S - ) and dichlorine radical anion (Cl 2 •- ). Initially, Nd(III) reacted rapidly with e S - , forming Nd(II) with a second-order rate coefficient of k = (4.54 ± 0.07) × 10 10 M -1 s -1 at 673 K. The resulting Nd(II) ions then reacted slowly with Cl 2 •- , regenerating Nd(III) with an estimated rate of k = (1.72 ± 0.04) × 10 10 M -1 s -1 at 673 K. Additionally, the comproportionation reaction of Nd(III) and Nd(s) to form Nd(II) was monitored chemically and electrochemically. This work suggests that the comproportionation reaction of Nd(III) with Nd(s) to form Nd(II) is unstable in molten LiCl-KCl eutectic.

36 - MATERIALS SCIENCE↗
NASA NTRS1972

Finite element analysis of large transient elastic-plastic deformations of simple structures, with application to the engine rotor fragment containment/deflection problem

Assumed-displacement versions of the finite-element method are developed to predict large-deformation elastic-plastic transient deformations of structures. Both the conventional and a new improved finite-element variational formulation are derived. These formulations are then developed in detail for straight-beam and curved-beam elements undergoing (1) Bernoulli-Euler-Kirchhoff or (2) Timoshenko deformation behavior, in one plane. For each of these categories, several types of assumed-displacement finite elements are developed, and transient response predictions are compared with available exact solutions for small-deflection, linear-elastic transient responses. The present finite-element predictions for large-deflection elastic-plastic transient responses are evaluated via several beam and ring examples for which experimental measurements of transient strains and large transient deformations and independent finite-difference predictions are available.

Wu, R. W.↗
DOE OSTI2019

Interplay between Short and Long-Ranged Forces Leading to the Formation of Ag Nanoparticle Superlattice

Nanoparticle (NP) superlattices have attracted increasing attention due to their unique properties. However, key questions remain for predicting the nanoparticle behavior from interparticle forces, especially the role of hydration force (Fhyd) and its correlation to other forces, regarding the transient and final superlattice configurations. Here we investigated the self-assembly of Ag NPs in aqueous solution by employing in situ liquid cell transmission electron microscopy, combined with atomic force microscopy based force measurements and theoretical calculations. In spite of instantaneous Brownian motion of NPs, a correlation between velocity and van der Waals force (FvdW) on average was observed during the later self-assembly process. In the post-assembly state, a delicate balance between Fhyd and FvdW gives rise to ~ 0.6~0.9 nm separation be-tween NPs in the superlattice. Our study demonstrates pivotal roles of interparticle forces, enabling the control of the separation which is critical for tailoring the properties of superlattices.

Lee, Jaewon↗
DOE OSTI2025

Detecting anomalous SRF cavity behavior with unsupervised learning

We present an unsupervised learning framework for detecting anomalous superconducting radio-frequency (SRF) cavity behavior at the Continuous Electron Beam Accelerator Facility (CEBAF), emphasizing its initial performance and effectiveness. Key to the system’s success was the development of data acquisition systems (DAQs) that capture fast-sampled, information-rich signals, essential for detecting transient effects. The approach involves creating daily cavity-specific models using principal component analysis to handle variations in rf signal behavior and mitigate performance degradation from data drift. This unsupervised method eliminates the need for expensive labeling by continuously updating models with recent data. Deployed and operational for 3 months before a scheduled shutdown, the system successfully identified several issues with DAQ signals, confirming its effectiveness. Despite access to only a fraction of CEBAF’s SRF cavity signals, the framework efficiently detected several instances requiring intervention, demonstrating a significant improvement over traditional, labor-intensive methods of manual plot inspection. Published by the American Physical Society 2025

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Development of a thermal creep model for aluminum alloy 6061 cladding in U-10Mo monolithic fuel plates

Plate-type fuel elements consisting of a high-density, low-enriched uranium (LEU) U–10Mo-based fuel foil encapsulated in an aluminum alloy (AA) cladding are fabricated using the hot isostatic pressing (HIP) technique. During the HIP process, the fuel plate system is heated to 560 °C, then cooled to room temperature. This heat cycle significantly affects the mechanical properties of the aluminum cladding, and experimental investigations have shown that, post-HIP bonding, the mechanical properties of the aluminum cladding transition from those of AA 6061-T6 to something closer to the O temper. More specifically, the ultimate strength of the cladding decreases while its ductility increases, making it challenging to capture the changes in mechanical behavior and material properties. Understanding the residual stresses generated during the HIP process is critical for assessing the fuel plate’s integrity under various temperature, pressure, and irradiation. To simulate the HIP bonding process, the elastic, plastic, and thermal properties of the cladding are assumed to be similar to those of AA 6061-O temper. However, the primary challenge lies in the lack of available data for the creep model of the AA 6061 cladding during this transient process of HIP. The present study focuses on developing a computational model that predicts the creep behavior of the aluminum cladding in the fuel plates during the HIP process, as cladding creep significantly influences the residual stresses generated in U-10Mo fuel plates during HIP fabrication. Furthermore, as HIP bonding occurs at high temperatures that are nearing the melting point of aluminum, the present work considered a temperature-dependent Arrhenius-type creep model. In particular, a hyperbolic sine creep model is employed to estimate the creep properties of the as-fabricated aluminum cladding. In conclusion, the residual stresses predicted in the U-10Mo fuel when using the newly calibrated creep model closely align with the experimental measurements, validating the model’s accuracy.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Inverse Temperature Dependence of Charge Carrier Hopping in Quantum Dot Solids

In semiconductors, increasing mobility with decreasing temperature is a signature of charge carrier transport through delocalized bands. We show that this behavior can also occur in nanocrystal solids due to temperature-dependent structural transformations. Using a combination of broadband infrared transient absorption spectroscopy and numerical modeling, we investigate the temperature-dependent charge transport properties of well-ordered PbS quantum dot (QD) solids. Contrary to expectations, we observe that the QD-to-QD charge tunneling rate increases with decreasing temperature, while simultaneously exhibiting thermally activated nearest-neighbor hopping behavior. Using synchrotron grazing-incidence small-angle X-ray scattering, we show that this trend is driven by a temperature-dependent reduction in nearest-neighbor separation that is quantitatively consistent with the measured tunneling rate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2012

Integral and Separate Effects Tests for Thermal Hydraulics Code Validation for Liquid-Salt Cooled Nuclear Reactors

The objective of the 3-year project was to collect integral effects test (IET) data to validate the RELAP5-3D code and other thermal hydraulics codes for use in predicting the transient thermal hydraulics response of liquid salt cooled reactor systems, including integral transient response for forced and natural circulation operation. The reference system for the project is a modular, 900-MWth Pebble Bed Advanced High Temperature Reactor (PB-AHTR), a specific type of Fluoride salt-cooled High temperature Reactor (FHR). Two experimental facilities were developed for thermal-hydraulic integral effects tests (IETs) and separate effects tests (SETs). The facilities use simulant fluids for the liquid fluoride salts, with very little distortion to the heat transfer and fluid dynamics behavior. The CIET Test Bay facility was designed, built, and operated. IET data for steady state and transient natural circulation was collected. SET data for convective heat transfer in pebble beds and straight channel geometries was collected. The facility continues to be operational and will be used for future experiments, and for component development. The CIET 2 facility is larger in scope, and its construction and operation has a longer timeline than the duration of this grant. The design for the CIET 2 facility has drawn heavily on the experience and data collected on the CIET Test Bay, and it was completed in parallel with operation of the CIET Test Bay. CIET 2 will demonstrate start-up and shut-down transients and control logic, in addition to LOFC and LOHS transients, and buoyant shut down rod operation during transients. Design of the CIET 2 Facility is complete, and engineering drawings have been submitted to an external vendor for outsourced quality controlled construction. CIET 2 construction and operation continue under another NEUP grant. IET data from both CIET facilities is to be used for validation of system codes used for FHR modeling, such as RELAP5-3D. A set of numerical models were developed in parallel to the experimental work. RELAP5-3D models were developed for the salt-cooled PB-AHTR, and for the simulat fluid CIET natural circulation experimental loop. These models are to be validated by the data collected from CIET. COMSOL finite element models were used to predict the temperature and fluid flow distribution in the annular pebble bed core; they were instrumental for design of SETs, and they can be used for code-to-code comparisons with RELAP5-3D. A number of other small SETs, and numerical models were constructed, as needed, in support of this work. The experiments were designed, constructed and performed to meet CAES quality assurance requirements for test planning, implementation, and documentation; equipment calibration and documentation, procurement document control; training and personnel qualification; analysis/modeling software verification and validation; data acquisition/collection and analysis; and peer review.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Laser-induced digital oxidation for copper-based flexible photodetectors

Copper oxide compounds (Cu x O) with bandgaps of 1.3–2.1 eV (CuO) and 2.1–2.6 eV (Cu 2 O) have been investigated as promising p-type semiconducting materials. Cu x O is generally obtained by deposition or thermal oxidation, but those methods are not optimal for flexible substrates. Furthermore, additional patterning steps are required to fabricate devices. In this work, we present an easy, controllable method to fabricate a metal-semiconductor-metal (MSM) photodetector using laser-induced oxidation of a thin Cu film. After laser irradiation, the Cu film is heated under ambient conditions, and this leads to a thermal oxidation reaction, in which Cu oxide is monolithically formed in the Cu film and a Cu-Cu x O-Cu MSM structure is produced. Since the laser offers localized heating, an arbitrary CuxO pattern can be written in the Cu film by spatially controlled heating. In addition, by optimizing the heating time, the laser-induced oxidation can be successfully performed even on a flexible substrate. To study the laser-induced oxidation, we examined the correlation between laser parameters and the oxidation pattern and analyzed the composition using scanning electron microscopy, Raman spectroscopy, and X-ray photoemission spectroscopy. Furthermore, we measured the transient photoresponse and employed scanning photocurrent microscopy to investigate the mechanism of carrier transport behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Cyclic loading–unloading impacts on geomechanical stability of multiple salt caverns for underground hydrogen storage

Underground caverns in a salt dome are promising geologic features to store hydrogen because of salt’s extremely low permeability and self-healing behavior. The salt cavern storage community, however, has not fully understood the geomechanical behaviors of salt rock driven by quick operation cycles of injection–production, which may significantly impact the cost-effective storage-recovery performance of multiple caverns. Our field-scale generic model captures the impact of cyclic loading–unloading on the salt creep behavior and deformation under different cycle frequencies, operating pressure, and spatial order of operating cavern(s). This systematic simulation study indicates that the initial operation cycle and arrangement of multiple caverns play a significant role in the creep-driven loss of cavern volumes and cavern deformation. Finally, our future study will develop a new salt constitutive model based on geomechanical tests of site-specific salt rock to probe the cyclic behaviors of salt precisely both beneath and above the dilatancy boundary, including reverse (inverse transient) creep, the Bauschinger effect, and damage-healing mechanism.

08 HYDROGEN↗
DOE OSTI2016

Modular Homogeneous Chromophore–Catalyst Assemblies

Photosynthetic reaction center (RC) proteins convert incident solar energy to chemical energy through a network of molecular cofactors which have been evolutionarily tuned to couple efficient light-harvesting, directional electron transfer, and long-lived charge separation with secondary reaction sequences. These molecular cofactors are embedded within a complex protein environment which precisely positions each cofactor in optimal geometries along efficient electron transfer pathways with localized protein environments facilitating sequential and accumulative charge transfer. By contrast, it is difficult to approach a similar level of structural complexity in synthetic architectures for solar energy conversion. However, by using appropriate self-assembly strategies, we anticipate that molecular modules, which are independently synthesized and optimized for either light-harvesting or redox catalysis, can be organized into spatial arrangements that functionally mimic natural photosynthesis. In this Account, we describe a modular approach to new structural designs for artificial photosynthesis which is largely inspired by photosynthetic RC proteins. We focus on recent work from our lab which uses molecular modules for light-harvesting or proton reduction catalysis in different coordination geometries and different platforms, spanning from discrete supramolecular assemblies to molecule–nanoparticle hybrids to protein-based biohybrids. Molecular modules are particularly amenable to high-resolution characterization of the ground and excited state of each module using a variety of physical techniques; such spectroscopic interrogation helps our understanding of primary artificial photosynthetic mechanisms. In particular, we discuss the use of transient optical spectroscopy, EPR, and X-ray scattering techniques to elucidate dynamic structural behavior and light-induced kinetics and the impact on photocatalytic mechanism. Two different coordination geometries of supramolecular photocatalyst based on the [Ru(bpy)3]2+ (bpy = 2,2'-bipyridine) light-harvesting module with cobaloxime-based catalyst module are compared, with progress in stabilizing photoinduced charge separation identified. These same modules embedded in the small electron transfer protein ferredoxin exhibit much longer charge-separation, enabled by stepwise electron transfer through the native [2Fe-2S] cofactor. We anticipate that the use of interchangeable, molecular modules which can interact in different coordination geometries or within entirely different structural platforms will provide important fundamental insights into the effect of environment on parameters such as electron transfer and charge separation, and ultimately drive more efficient designs for artificial photosynthesis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Role of melt behavior in modifying oxidation distribution using an interface incorporated model in selective laser melting of aluminum-based material

A transient three dimensional model for describing the molten pool dynamics and the response of oxidation film evolution in the selective laser melting of aluminum-based material is proposed. The physical difference in both sides of the scan track, powder-solid transformation and temperature dependent physical properties are taken into account. It shows that the heat energy tends to accumulate in the powder material rather than in the as-fabricated part, leading to the formation of the asymmetrical patterns of the temperature contour and the attendant larger dimensions of the molten pool in the powder phase. As a higher volumetric energy density is applied (≥1300 J/mm{sup 3}), a severe evaporation is produced with the upward direction of velocity vector in the irradiated powder region while a restricted operating temperature is obtained in the as-fabricated part. The velocity vector continuously changes from upward direction to the downward one as the scan speed increases from 100 mm/s to 300 mm/s, promoting the generation of the debris of the oxidation films and the resultant homogeneous distribution state in the matrix. For the applied hatch spacing of 50 μm, a restricted remelting phenomenon of the as-fabricated part is produced with the upward direction of the convection flow, significantly reducing the turbulence of the thermal-capillary convection on the breaking of the oxidation films, and therefore, the connected oxidation films through the neighboring layers are typically formed. The morphology and distribution of the oxidation are experimentally acquired, which are in a good agreement with the results predicted by simulation.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗