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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 1,099 records · Page 61
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Interfacial characteristics of P91 steel - Inconel 740H bimetallic structure fabricated using wire-arc additive manufacturing

Although bimetallic structures can offer unique solutions to engineering problems with varying functionality, joining two dissimilar alloys using additive manufacturing involves challenges such as cracking and segregation. In this work, bimetallic structures of Inconel 740H superalloy and P91 steel are processed using wire-arc additive manufacturing (WAAM) for the first time. P91 steel is directly deposited over 740H with a cooling time of 20 minutes in between the two depositions. During microstructure characterization, a large gradient zone with coarse grains spanning for ~2200 μm is observed. Moreover, the microhardness of the gradient zone is the least in comparison with the P91 and 740H deposits. No deleterious phase formation is found; however, intergranular cracks are observed along the gradient zone. In order to deduce the reason for cracking, non-equilibrium solidification simulations are performed for the mixed compositions of P91 and 740H in the gradient zone. Here, the reasons for crack formation in the gradient zone are the sudden change in the volumetric coefficient of thermal expansion due to the formation of MC carbides as well as the development of local strains from the thermal residual stresses. Therefore, altering the deposition sequence and introducing gradient layers with mixed composition between the P91 and 740H deposits will be beneficial in achieving defect-free builds. Through the integration of experiments and simulation, this work gains valuable insights into the processability of dissimilar alloy manufacturing using the WAAM technique.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Evolution of carbide precipitates in Haynes® 282 superalloy processed by wire arc additive manufacturing

Precipitation hardening regulated with heat treatments is a critical technique for tuning the mechanical properties of Ni-based superalloys fabricated with additive manufacturing, where mechanical deformation is no longer viable for microstructural refinement. As one of the key precipitates, carbides prevail in the additively manufactured alloys, whose precipitation kinetics remain largely vague. This work studies the influence of heat treatments on the evolution of MC- and M 23 C 6 -type carbides within a Haynes® 282 superalloy prepared by wire arc additive manufacturing (WAAM). SEM-EDS analysis was performed to identify the evolution pathways of the carbides, and TEM and XRD characterizations were carried out to track the crystallographic features. The MC-type carbides are originally present in the as-printed alloy, which distribute uniformly across the whole material and remain largely unchanged in size during the heat treatments. By contrast, the incipiently non-existent M 23 C 6 -type carbides precipitate during an aging treatment at 1010 °C, which majorly extend along the grain boundaries as kinetically feasible sites. Further experimental and computational analysis confirms the enhancing effect of the M 23 C 6 -type carbides on the Vickers hardness. For the first time, this work revealed the evolution pathways of carbides within a Haynes® 282 superalloy prepared by WAAM, providing critical information for tunning the microstructure and mechanical properties. Finally, the carbide evolution kinetics established in this work can be potentially extended to other alloys prepared with WAAM, providing critical information to prevent mechanical failures associated with carbide coarsening.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Microstructure and texture evolution of Cu–Nb composite wires

The evolution of microstructure and texture in Cu–Nb composite wires fabricated by an accumulative drawing and bundling process was investigated by backscattered electron (BSE), electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM). Results indicate the onset of severe curling and shape changing occurred at the size of Nb ∼ 400 nm with a surface increase of about 6.91 μm{sup 2}/μm{sup 3} (the area per unit volume). Two kinds of grain boundaries in Nb are suggested: one is 20°–50° boundary with a rotate/tilt axis around <110> parallel to drawing direction (DD), and another is > 50° boundary with the axis perpendicular to DD. The curling phenomenon occurred at the Cu–Nb interface and is related not only to the deformation mechanism of Nb but also to the presence of interface. This result is distinct from reported works showing that curling takes place when BCC metals are heavily drawn (Area reduction > 73%). The variation in microstructure and texture evolution between Cu and Nb filaments was discussed based on the differences in deformation mechanisms of these two metals. - Highlights: • Microstructure and texture evolution were studied systematically by EBSD. • In Nb, grain boundaries of 20°–50° have a rotate/tile axis around <110>//DD. • The rotation axes of above 50° boundaries are concentrated around <111> ⊥ DD in Nb. • Curling is related to not only deformation mode of BCC but also Cu–Nb interface.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Integrated top-down process and voxel-based microstructure modeling for Ti-6Al-4V in laser wire direct energy deposition process

Laser-wire metal additive manufacturing (AM) is one of the ideal direct energy deposition (DED) processes for creating large-scale parts with a medium level of complexity. However, the DED process involves complex thermal signatures and wide length scales making the fabrication of realistic AM components and part qualification often reliant on experimental trial-and-error optimization. While experimental measurements over the full volume of a part are valuable and necessary, measuring the entire area of a part is significantly laborious and practically infeasible, particularly for large parts in terms of cost and rapid qualification. Therefore, in this work, we developed an effective thermal and microstructure modeling framework based on the Johnson–Mehl-Avrami-Kolmogorov (JMAK) and Koistinen & Marburger (KM) models through a top-down approach that considers plate distortion-affected thermal profiles. A voxel-by-voxel simulation method is used to predict individual phase fractions of Ti-6Al-4 V. The predicted results were validated through detailed metallurgical measurements. A combined voxel-by-voxel approach with a sparse data reconstruction technique produced a near-perfect reconstruction of the original data. This approach anticipates a significant reduction in data points and computation time and resources. Lastly, we conclude with potential extensions of this work to other modeling efforts.

36 MATERIALS SCIENCE↗
DOE OSTI2017

On the toughness scatter in low alloy C-Mn steel samples fabricated using wire arc additive manufacturing

Low alloy carbon manganese (C-Mn) steel builds were fabricated using a wire based additive manufacturing system developed at Oak Ridge National Laboratory. Specimens were fabricated in the X,Y and Z direction and detailed mechanical testing was performed. The mechanical testing results showed a significant scatter in tensile ductility and significant variation in Charpy toughness. Further detailed microstructure characterization showed significant microstructural heterogeneity in builds fabricated in each direction. The scatter in mechanical properties was then rationalized based on the microstructural observations and the underlying changes in the local heat transfer conditions. Lastly, the results indicate that when fabricating parts using C-Mn low alloy steel welds the process parameters and tool path should be chosen such that the cooling rate from 800 °C to 500 °C is greater than 30 s to avoid formation of martensite austenite (MA) phases, which leads to toughness reductions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Simultaneously improved electrical and mechanical performance of hot-extruded bulk scale aluminum-graphene wires

Aluminum-based alloys are highly sought after as lightweight alternatives in electric grid applications. Improving the electrical conductivity of aluminum alloys has the potential to increase the energy efficiency of power transport. Here we used a hot extrusion process to synthesize AA1100 alloy with low-cost reduced graphene oxide nanoparticles to manufacture ultra-conductive aluminum composites in this study. The effects of graphene content on the electrical and mechanical performance of the composites were evaluated. The macroscale AA1100/graphene wires demonstrated a 2.1% enhancement in electrical conductivity at 20 °C, while the ultimate tensile strength increased by 6.1%. A Zener-Hollomon model was used to confirm the in-process exfoliation of the agglomerated graphene nanoparticle feedstock into high electrical conductivity graphene-like flakes during extrusion. They may have provided high-velocity carrier pathways leading to the enhanced electrical performance of the alloy. Transmission electron microscopy at aluminum-graphene interfaces ensures the preclusion of detrimental carbide formation during composite synthesis while confirming the structure graphene-like flakes. The in-process exfoliation provides an economically viable technique to produce bulk scale graphinated aluminum composites for advanced application and can be applied more generally to other alloy systems.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Comparison of experimental and simulation results on interior subchannels of a 61-pin wire-wrapped hexagonal fuel bundle

As part of a joint U.S. Department of Energy project, Framatome, Argonne National Laboratory, Terrapower, and Texas A&M University have collaborated to produce experimental data and computational results to characterize the flow behavior of a 61-pin wire-wrapped hexagonal fuel bundle. Here, comparisons are made between Texas A&M’s experimental particle image velocimetry velocity field measurements and Argonne National Laboratory’s large-eddy simulation results in an interior subchannel for a Reynolds number of 19,000. It can be concluded that the shape and magnitude of the mean vertical velocity component is in excellent agreement for the selected horizontal line plots. Maximum relative errors are less than 10% until the subchannel walls are approached. Finally, the shape and, to a lesser extent, magnitude of the mean horizontal velocity component is in satisfactory agreement between the particle image velocimetry and large-eddy simulation results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

The wiring diagram for plant G signaling

Like electronic circuits, the modular arrangement of cell-signaling networks decides how inputs produce outputs. Animal heterotrimeric guanine nucleotide binding proteins (G-proteins) operate as switches in the circuits that signal between extracellular agonists and intracellular effectors. There still is no biochemical evidence for a receptor or its agonist in the plant G-protein pathways. Plant G-proteins deviate in many important ways from the animal paradigm. This paper covers important discoveries from the last two years that enlighten these differences and ends describing alternative wiring diagrams for the plant signaling circuits regulated by G-proteins. Finally, we propose that plant G-proteins are integrated in the signaling circuits as variable resistor rather than switches, controlling the flux of information in response to the cell's metabolic state.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2016

Quasi one-dimensional band dispersion and surface metallization in long-range ordered polymeric wires

We study the electronic structure of an ordered array of poly(para-phenylene) chains produced by surface-catalyzed dehalogenative polymerization of 1,4-dibromobenzene on copper (110). The quantization of unoccupied molecular states is measured as a function of oligomer length by scanning tunnelling spectroscopy, with Fermi level crossings observed for chains longer than ten phenyl rings. Angle-resolved photoelectron spectroscopy reveals a quasi-one-dimensional valence band as well as a direct gap of 1.15 eV, as the conduction band is partially filled through adsorption on the surface. Tight-binding modelling and ab initio density functional theory calculations lead to a full description of the organic band-structure, including the k-dispersion, the gap size and electron charge transfer mechanisms, highlighting a strong substrate-molecule interaction that drives the system into a metallic behaviour. In summary, we have fully characterized the band structure of a carbon-based conducting wire. This model system may be considered as a fingerprint of -conjugation of surface organic frameworks.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Nanoscale membranes that chemically isolate and electronically wire up the abiotic/biotic interface

Abstract By electrochemically coupling microbial and abiotic catalysts, bioelectrochemical systems such as microbial electrolysis cells and microbial electrosynthesis systems synthesize energy-rich chemicals from energy-poor precursors with unmatched efficiency. However, to circumvent chemical incompatibilities between the microbial cells and inorganic materials that result in toxicity, corrosion, fouling, and efficiency-degrading cross-reactions between oxidation and reduction environments, bioelectrochemical systems physically separate the microbial and inorganic catalysts by macroscopic distances, thus introducing ohmic losses, rendering these systems impractical at scale. Here we electrochemically couple an inorganic catalyst, a SnO 2 anode, with a microbial catalyst, Shewanella oneidensis , via a 2-nm-thick silica membrane containing -CN and -NO 2 functionalized p -oligo(phenylene vinylene) molecular wires. This membrane enables electron flow at 0.51 μA cm −2 from microbial catalysts to the inorganic anode, while blocking small molecule transport. Thus the modular architecture avoids chemical incompatibilities without ohmic losses and introduces an immense design space for scale up of bioelectrochemical systems.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Majorana zero modes in Y -shape interacting Kitaev wires

Motivated by the recent experimental realization of minimal Kitaev chains using quantum dots, we investigate the Majorana zero modes (MZM) in Y-shape Kitaev wires. We solve the associated Kitaev models analytically at the sweet spot (t h = Δ) and derive the exact form of MZM wave-functions in this geometry. We observed exotic multi-site MZMs located near the junction center, on the nearby edge sites of each leg. This result is important for potential braiding of Majoranas and the performance of Y-junctions made from arrays of quantum dots. Furthermore, we study the stability of local (single-site) and multi-site MZMs modes in the presence of Coulomb repulsion, using density matrix renormalization group theory. Our local density-of-states calculation shows that these multi-site MZMs are as equally topologically protected as the single-site MZMs when in the presence of Coulomb repulsion or when away from the sweet-spot.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A co-registered in-situ and ex-situ dataset from wire arc additive manufacturing process

Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data-centric approach emphasizes leveraging sensor data available throughout the production process to optimize performance. Integration of extensive data analysis provides opportunities for improving precision, reducing waste, and enhancing the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes a comprehensive description of the deposition process, process parameters, welding characteristics and acoustic data collected in-situ, and X-Ray Computed Tomography data of the build.

42 ENGINEERING↗
DOE OSTI2018

Evidence from EXAFS for Different Ta/Ti Site Occupancy in High Critical Current Density Nb 3 Sn Superconductor Wires

To meet critical current density, Jc, targets for the Future Circular Collider (FCC), the planned replacement for the Large Hadron Collider (LHC), the high field performance of Nb 3 Sn must be improved, but champion J c values have remained static for the last 10 years. Making the A15 phase stoichiometric and enhancing the upper critical field H c2 by Ti or Ta dopants are the standard strategies for enhancing high field performance but detailed recent studies show that even the best modern wires have broad composition ranges. To assess whether further improvement might be possible, we employed EXAFS to determine the lattice site location of dopants in modern high-performance Nb 3 Sn strands with J c values amongst the best so far achieved. Although Ti and Ta primarily occupy the Nb sites in the A15 structure, we also find significant Ta occupancy on the Sn site. These findings indicate that the best performing Ti-doped stand is strongly sub-stoichiometric in Sn and that antisite disorder likely explains its high average H c2 behavior. These new results suggest an important role for dopant and antisite disorder in minimizing superconducting property distributions and maximizing high field J c properties.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Rapid data acquisition and machine learning-assisted composition design of functionally graded alloys via wire arc additive manufacturing

Abstract The lack of high-quality datasets in materials science hinders artificial intelligence (AI)-driven alloy design. To address this challenge, wire arc additive manufacturing (WAAM) was employed to fabricate graded alloys, generating extensive data for machine learning (ML)-assisted property prediction. ML models were developed using high-throughput experiments, computational models, and genetic algorithm to optimize feature selection, successfully predicting hardness and porosity. The ML model demonstrated its efficacy by designing a gradient alloy with enhanced properties. However, scaling up revealed uncertainties in tensile property and porosity due to differences in size and thermal conditions between the designed alloy build and the gradient print used to construct the ML model. This underscores the need for uncertainty quantification and process optimization in WAAM-driven alloy design. Our work advances AI-integrated additive manufacturing, offering a rapid approach to exploring process–structure–property relationships and accelerating materials development.

Wang, Xin↗
DOE OSTI2015

Emergence of reconfigurable wires and spinners via dynamic self-assembly

Dissipative colloidal materials use energy to generate and maintain structural complexity. The energy injection rate, and properties of the environment are important control parameters that influence the outcome of dynamic self-assembly. Here we demonstrate that dispersions of magnetic microparticles confined at the air-liquid interface, and energized by a uniaxial in-plane alternating magnetic field, self-assemble into a variety of structures that range from pulsating clusters and single-particle-thick wires to dynamic arrays of spinners (self-assembled short chains) rotating in either direction. The spinners emerge via spontaneous breaking of the uniaxial symmetry of the energizing magnetic field. Demonstration of the formation and disaggregation of particle assemblies suggests strategies to form new meso-scale structures with the potential to perform functions such as mixing and sensing.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Proton-coupled electron transfer across benzimidazole bridges in bioinspired proton wires

Designing molecular platforms for controlling proton and electron movement in artificial photosynthetic systems is crucial to efficient catalysis and solar energy conversion. The transfer of both protons and electrons during a reaction is known as proton-coupled electron transfer (PCET) and is used by nature in myriad ways to provide low overpotential pathways for redox reactions and redox leveling, as well as to generate bioenergetic proton currents. Herein, we describe theoretical and electrochemical studies of a series of bioinspired benzimidazole-phenol (BIP) derivatives and a series of dibenzimidazole-phenol (BI 2 P) analogs with each series bearing the same set of terminal proton-accepting (TPA) groups. The set of TPAs spans more than 6 pK a units. These compounds have been designed to explore the role of the bridging benzimidazole(s) in a one-electron oxidation process coupled to intramolecular proton translocation across either two (the BIP series) or three (the BI 2 P series) acid/base sites. These molecular constructs feature an electrochemically active phenol connected to the TPA group through a benzimidazole-based bridge, which together with the phenol and TPA group form a covalent framework supporting a Grotthuss-type hydrogen-bonded network. Infrared spectroelectrochemistry demonstrates that upon oxidation of the phenol, protons translocate across this well-defined hydrogen-bonded network to a TPA group. The experimental data show the benzimidazole bridges are non-innocent participants in the PCET process in that the addition of each benzimidazole unit lowers the redox potential of the phenoxyl radical/phenol couple by 60 mV, regardless of the nature of the TPA group. Using a series of hypothetical thermodynamic steps, density functional theory calculations correctly predicted the dependence of the redox potential of the phenoxyl radical/phenol couple on the nature of the final protonated species and provided insight into the thermodynamic role of dibenzimidazole units in the PCET process. This information is crucial for developing molecular “dry proton wires” with these moieties, which can transfer protons via a Grotthuss-type mechanism over long distances without the intervention of water molecules.

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

Evaluation of Portable Acceleration Solutions for LArTPC Simulation Using Wire-Cell Toolkit

The Liquid Argon Time Projection Chamber (LArTPC) technology plays an essential role in many current and future neutrino experiments. Accurate and fast simulation is critical to developing efficient analysis algorithms and precise physics model projections. The speed of simulation becomes more important as Deep Learning algorithms are getting more widely used in LArTPC analysis and their training requires a large simulated dataset. Heterogeneous computing is an efficient way to delegate computationally intensive tasks to specialized hardware. However, as the landscape of compute accelerators quickly evolves, it becomes increasingly difficult to manually adapt the code to the latest hardware or software environments. A solution which is portable to multiple hardware architectures without substantially compromising performance would thus be very beneficial, especially for long-term projects such as the LArTPC simulations. In search of a portable, scalable and maintainable software solution for LArTPC simulations, we have started to explore high-level portable programming frameworks that support several hardware backends. In this paper, we present our experience porting the LArTPC simulation code in the Wire-Cell Toolkit to NVIDIA GPUs, first with the CUDA programming model and then with a portable library called Kokkos. Preliminary performance results on NVIDIA V100 GPUs and multi-core CPUs are presented, followed by a discussion of the factors affiecting the performance and plans for future improvements.

Yu, Haiwang↗
DOE OSTI2013

Oblique shock structures formed during the ablation phase of aluminium wire array z-pinches

A series of experiments has been conducted in order to investigate the azimuthal structures formed by the interactions of cylindrically converging plasma flows during the ablation phase of aluminium wire array Z pinch implosions. These experiments were carried out using the 1.4 MA, 240 ns MAGPIE generator at Imperial College London. The main diagnostic used in this study was a two-colour, end-on, Mach-Zehnder imaging interferometer, sensitive to the axially integrated electron density of the plasma. The data collected in these experiments reveal the strongly collisional dynamics of the aluminium ablation streams. The structure of the flows is dominated by a dense network of oblique shock fronts, formed by supersonic collisions between adjacent ablation streams. An estimate for the range of the flow Mach number (M = 6.2-9.2) has been made based on an analysis of the observed shock geometry. Combining this measurement with previously published Thomson Scattering measurements of the plasma flow velocity by Harvey-Thompson et al.[Physics of Plasmas 19, 056303 (2012)] allowed us to place limits on the range of the ZT{sub e} of the plasma. The detailed and quantitative nature of the dataset lends itself well as a source for model validation and code verification exercises, as the exact shock geometry is sensitive to many of the plasma parameters. Comparison of electron density data produced through numerical modelling with the Gorgon 3D MHD code demonstrates that the code is able to reproduce the collisional dynamics observed in aluminium arrays reasonably well.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗