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At least 1,171 records · Page 65

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DOE OSTI2020

Experimental Analysis of Salt Hydrate Latent Heat Thermal Energy Storage System With Porous Aluminum Fabric and Salt Hydrate as Phase Change Material With Enhanced Stability and Supercooling

Phase change materials (PCMs), especially salt hydrates possess high volumetric energy storage capacity in their transition temperature range. These materials are used in applications where it is necessary to store thermal energy due to temporary load shift between demand and availability. Thus, possible applications are HVAC, recovery of waste heat, and defense thermal management. Despite salt hydrates potential, the practical feasibility of latent heat storage with salt hydrates is limited due to low power rating, supercooling, phase segregation, and long-term stability. Its low power rating and long-term stability limits its application in most applications. This work experimentally validates the stability and thermal performance of a compact heat exchanger charged with salt hydrate during melting and freezing. The compact heat exchanger was designed with fins on both the heat transfer fluid (HTF) and salt hydrate PCM side. The thermal performance of the latent heat thermal energy storage system (LHTESS) was evaluated for various operating conditions. The results show that LHTESS could achieve an average heat transfer coefficient of 124 and 87 W/(m2 K) during melting and solidification, respectively. The stability of the system in suppressing supercooling was validated over 800 cycles with nucleating agent and active homogenous nucleation techniques. The supercooling was reduced to 3 °C with zinc hydroxyl nitrate as nucleating agent and less than 1 °C with the active homogenous nucleation technique. The LHTESS showed less than 6% degradation in energy storage capacity over 800 cycles.

42 ENGINEERING↗

DOE OSTI2024

Development of Modified Perturbation Solutions to the One-Phase Stefan Problems With a Convective Boundary

The classical Stefan problem is used to track the moving solid-liquid interface during the freezing process. Perturbation theory has often been applied to find an approximate analytical solution due to the nonlinearity of the moving interface. However, the Stefan number (i.e., the sensible over latent heat) must be small and usually less than 0.01 to assume the perturbation expansion, which in turn limits the thermal engineering applications. In this study, a modified perturbation solution is developed by adding a correction term after the leading-order solution to be valid for a much wider range of Stefan numbers (i.e., 0.01 less than or equal to Ste less than or equal to 1). Specifically, a one-phase Stefan problem is first formulated subjected to a convective boundary in the Cartesian, cylindrical, and spherical coordinate systems for inward solidification. The leading-order solution is calculated based on the regular perturbation theory, while the correction term is obtained using the Monte-Carlo method and a multi-variant regression. Results show that the correction term has a linear relationship with the Stefan number and is not significantly influenced by the Biot number. The proposed modified perturbation solution can accurately and rapidly predict the nonlinear moving interface motion for the freezing process.

DIRECT ENERGY CONVERSION,MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Analytical Modeling of Metal Foam Composite Phase Change Materials (PCM) in Thermal Energy Storage Using Asymptotic Analysis

The use of phase change materials (PCMs) for thermal energy storage can release or absorb a significant amount of latent heat during the freezing or melting process, offering a higher energy storage density. One of the main drawbacks of PCMs is their low thermal conductivity, resulting in poor thermal performance. Recent research has attempted to enhance heat transfer and increase the thermal conductivity of PCMs, including the use of metal foams. However, modeling the metal foam composite PCM using conventional methods is computationally expensive. This paper proposes an asymptotic solution for a Stefan-like problem subject to a convective boundary for outward solidification in a hollow cylinder, capable of predicting the freeze-melt cycle of the metal foam composite PCM. Specifically, three temporal regimes and four spatial layers are considered in the asymptotic analysis for each phase change process. The thermal conductivity is calculated by a theoretical three-dimensional tetrakaidecahedron model, while other thermophysical properties are obtained using the method of volume averaging. The results are verified with numerical data and validated against experimental data in the literature. The presented analytical modeling framework could have the potential to be applied to other types of composite PCMs with considerably lower computational costs compared with conventional methods.

analytical model↗

DOE OSTI2026

Enabling On-Demand Aerospace Component Manufacturing: Topology Optimization of GE Engine Bracket and Fabrication Using Metal FFF

Additive Manufacturing (AM) offers advantages over conventional manufacturing processes, particularly by reducing the number of parts produced through multistage combined technologies, but these often result in low manufacturing yields or require post-processing. AM facilitates the production of complex geometries with fine features, overhangs, and lattice structures. For instance, Laser Powder Bed Fusion (LPBF) technology enables the fabrication of intricate parts that can be easily post-processed by removing residual powder. Laser powder bed AM technologies are widely discussed in the literature due to their design freedom in creating complex geometries, with and without the need for support generation. However, rapid solidification due to a thermal gradient in the build direction, which leads to the formation of columnar grains and warpage, is one of the challenges. To address this challenge, we propose layer-by-layer metal FFF technology, followed by the debinding and sintering process, as an alternative to powder- and laser-based approaches. Furthermore, design for additive manufacturing (DfAM) principles are discussed to minimize the need for support generation and enable easy post-processing, thereby improving surface finish to meet high tolerances in fabricating components for aerospace and healthcare applications.

Singh, Abhishek [University of Michigan, Ann Arbor↗

DOE OSTI2022

Analysis of Conduction Cooling Strategies for Wire Arc Additive Manufacturing

Metal additive manufacturing (AM) processing consists of numerous parameters which take time to optimize for various geometries. One aspect of the metal AM process that continues to be explored is the control of thermal energy accumulation during component manufacturing due to the melting and solidification of the feedstock. Excessive energy accumulation causes thermal failure of the component while minimal energy accumulation causes lack of fusion with the build plate or previous layer. The ability to simulate the thermal response of an AM component can increase research efficiency by reducing the time to optimize thermal energy accumulation. This paper presents an effective implementation of finite element analysis to determine the thermal response of a wire arc additive manufactured component with various build plate sizes and cooling methods including, integral build plate cooling, oversized build plates with passive cooling, and non-integral build plate cooling. The use of integral build plate cooling channels was shown to decrease the interpass temperature at the conclusion of the build process by 55% and build plate temperature by 96% compared to the conventionally deposited sample with 20 second dwell time. The use of a tall build plate with passive cooling was shown to reduce the interpass temperature by 32% as compared to the conventionally deposited sample with 20 second dwell time. Each cooling strategy evaluated decreased the interpass temperature within a range of 20–55% which enables higher deposition rates and decreased dwell times during depositions. The cooling strategies are designed to be implemented in a hybrid or retrofit AM platform to mitigate concerns of the thermal input from the additive process having detrimental effects on the precision of the machining process. This paper shows that accurate simulations of all strategies can be used to accurately predict the thermal response of the various strategies discussed. These cooling strategies will allow for increased deposition rates with comparable interpass temperature and decreased dwell time, increasing deposition efficiency. This model and these simulations are verified by experimental results. It is concluded that passive strategies, such as the over-sized tall build plate, can be used when liquid coolant in the AM environment could negatively affect the deposition process. Active cooling strategies, such as the integral build plate cooling could be used if low thermal conductivity materials are deposited or higher material deposition rates are desired. This paper discusses the use of active and passive cooling used during AM and shows how a simulation model can be used to make design choices for cooling strategies. The model also enables verification of select critical process parameters such as dwell times for a desired interpass temperature.

Heinrich, Lauren↗

DOE OSTI2017

Bright and durable field-emission source derived from frozen refractory-metal Taylor cones

A novel method for creating conical field-emission structures possessing unusual and desirable physical characteristics is described. This process is accomplished by solidification of electrostatically formed high-temperature Taylor cones created on the ends of laser melted refractory-metal wires. Extremely rapid freezing ensures that the resultant solid structures preserve the shape and surface smoothness of the flawless liquid Taylor-cones to a very high degree. The method also enables in situ and rapid restoration of the frozen cones to their initial pristine state after undergoing physical degradation during use. This permits maximum current to be delivered without excessive concern for any associated reduction in field-emitter lifetime resulting from operation near or even above the damage threshold. In addition to the production of field emitters using polycrystalline wires as a substrate, the feasibility of producing monocrystalline frozen Taylor-cones having reproducible crystal orientation by growth on single-crystal wires was demonstrated. Finally, the development of the basic field-emission technology, progress to incorporate it into a pulsed electron gun employing laser-assisted field emission for ultrafast experiments, and some additional advances and opportunities are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Measuring the melting curve of iron at super-Earth core conditions

The discovery of more than 4500 extrasolar planets has created a need for modeling their interior structure and dynamics. Given the prominence of iron in planetary interiors, we require accurate and precise physical properties at extreme pressure and temperature. A first-order property of iron is its melting point, which is still debated for the conditions of Earth’s interior. Here, we used high-energy lasers at the National Ignition Facility and in situ x-ray diffraction to determine the melting point of iron up to 1000 gigapascals, three times the pressure of Earth’s inner core. We used this melting curve to determine the length of dynamo action during core solidification to the hexagonal close-packed (hcp) structure. We find that terrestrial exoplanets with four to six times Earth’s mass have the longest dynamos, which provide important shielding against cosmic radiation.

58 GEOSCIENCES↗

DOE OSTI2013

Recrystallization and modification of the stainless-steel surface relief under photonic heat load in powerful plasma discharges

Targets made of ITER-grade 316L(N)-IG stainless steel and Russian-grade 12Cr18Ni10Ti stainless steel with a close composition were exposed at the QSPA-T plasma gun to plasma photonic radiation pulses simulating conditions of disruption mitigation in ITER. After a large number of pulses, modification of the stainless-steel surface was observed, such as the formation of a wavy structure, irregular roughness, and cracks on the target surface. X-ray and optic microscopic analyses of targets revealed changes in the orientation and dimensions of crystallites (grains) over a depth of up to 20 μm for 316L(N)-IG stainless steel after 200 pulses and up to 40 μm for 12Cr18Ni10Ti stainless steel after 50 pulses, which is significantly larger than the depth of the layer melted in one pulse (∼10 μm). In a series of 200 tests of ITER-grade 316L(N)-IG ITER stainless steel, a linear increase in the height of irregularity (roughness) with increasing number of pulses at a rate of up to ∼1 μm per pulse was observed. No alteration in the chemical composition of the stainless-steel surface in the series of tests was revealed. A model is developed that describes the formation of wavy irregularities on the melted metal surface with allowance for the nonlinear stage of instability of the melted layer with a vapor/plasma flow above it. A decisive factor in this case is the viscous flow of the melted metal from the troughs to tops of the wavy structure. The model predicts saturation of the growth of the wavy structure when its amplitude becomes comparable with its wavelength. Approaches to describing the observed stochastic relief and roughness of the stainless-steel surface formed in the series of tests are considered. The recurrence of the melting-solidification process in which mechanisms of the hill growth compete with the spreading of the material from the hills can result in the formation of a stochastic relief.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

Laser-Induced Modification of the Surface of Ge{sub 2}Sb{sub 2}Te{sub 5} Thin Films: Phase Changes and Periodic-Structure Formation

Submicron periodic lattices are formed at the surface of phase-change-memory film materials based on the complex chalcogenide Ge{sub 2}Sb{sub 2}Te{sub 5} when exposed to nanosecond laser pulses. The geometric characteristics and structural properties of laser-induced lattices are studied by optical and atomic-force microscopies and Raman spectroscopy. It is shown that, at appropriately chosen parameters of exposure to laser radiation, it is possible to implement periodic modulation of the refractive index in the structures formed. Modulation is due to the postexposure solidification of grating ridges and valleys in different phase states, whose dielectric constants widely differ from each other. In the vicinity of the maxima of the wavy structure, the amorphous state is mainly formed, whereas in the region of minima, the Ge{sub 2}Sb{sub 2}Te{sub 5} structure corresponds mainly to the crystalline phase.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Tusas, Version 1.0

Tusas is a general / flexible software framework for solving coupled systems of onlinear partial differential equations. Tusas was originally developed for phase-field simulation of solidification. In order for Tusas to be effective, the PDEs must be compatible with structured or unstructured Lagrange (nodal) finite element discretizations and explicit (Euler) or implicit (Euler, Trapezoid, BDF2) temporal discretizations.

Newman, ChristopherK.↗

DOE OSTI2023

muMatScale

Code for modeling solidification microstructure based on the Cellular Automata method for binary/pseudo-binary alloys. This code is derived from the open-source software uMatIC developed at the Imperial College London https://www.imperial.ac.uk/engineering-alloys/research/software

Yuan, Lang [Univ. of South Carolina, Columbia, SC ↗

DOE OSTI2025

Establishing model credibility for process-microstructure-property relationships in additive manufacturing using exascale computing

Additive Manufacturing (AM) of alloys holds significant promise as a disruptive technology in various industries, yet its adoption is often hindered by challenges in achieving consistent part quality. These issues are primarily due to the complex process-microstructure-property (PSP) relationships inherent to AM. Computational models can greatly aid in understanding these relationships, but their widespread impact and adoption has been limited by a lack of validated, open-source, and computationally efficient PSP modeling frameworks and hardware limitations. Here, this study leverages the ExaAM software suite and data from the AMBench-2018 series of laser powder bed fusion (LPBF) benchmark experiments to perform a comprehensive model assessment, including verification, validation, sensitivity analysis, and uncertainty quantification. The RADICAL-EnTK workflow manager was used to perform an ensemble of heat transport, solidification, and mechanical response simulations on the exascale computer Frontier, considering uncertainties in critical model inputs such as laser spot size and nucleation parameters, and consisting of 125 explicit grain structure simulations and 7875 crystal plasticity simulations. For a selected location within the Inconel 625 AMBench-2018 test artifact, sensitivity analysis and uncertainty quantification were performed using the predicted distributions of grain structure and mechanical properties. Qualitative agreement was found between the predicted grain size and texture and the observed AMBench-2018 microstructure, the mean predicted yield stress was within 5% of the experimental measurement mean, and the mean predicted engineering stress at 5% strain was within 10% of the experimental measurement mean. The insights gained from development and validation of the ExaAM PSP modeling framework will help guide future directions for enhancing the credibility and reliability of PSP models in AM, thereby accelerating the adoption of AM technologies in various industries.

Additive manufacturing↗

DOE OSTI2016

Numerical investigation of electromagnetic pulse welded interfaces between dissimilar metals

The quality of an electromagnetic pulse weld is strongly affected by a variety of interacting physical phenomena including large plastic deformation, materials mixing, localised heating and rapid cooling, and possible localised melting and interfacial cracks and void. In the present study, a thermomechanically coupled dynamic model has been developed to quantitatively resolve the high speed impact joining interface characteristics as well as the process induced interface temperature evolution, defect formation and possible microstructural composition variations. Reasonably good agreement has been obtained between the predicted results and the experimental measurements in terms of interfacial morphology characteristics. The modelling framework is expected to provide further understanding of the hierarchical interfacial features of the non-equilibrium material joining process and the weld formation mechanisms.

Xu, W.↗

DOE OSTI2025

Time-temperature history and input files for ExaCA v2.0 scaling, performance, and demonstration simulations

The files in this data repository are used in various sections of the manuscript "ExaCA v2.0: A versatile, scalable, and performance portable cellular automata application for additive manufacturing solidification" by Rolchigo et al. (DOI: 10.1016/j.commatsci.2025.113734). The README file references dataset numbers as given in the manuscript's Table 2, as well as the manuscript's relevant subsections.

36 MATERIALS SCIENCE↗

DOE OSTI2012

Self-organization approach for THz polaritonic metamaterials

In this paper we discuss the fabrication and the electromagnetic (EM) characterization of anisotropic eutectic metamaterials, consisting of cylindrical polaritonic LiF rods embedded in either KCl or NaCl polaritonic host. The fabrication was performed using the eutectics directional solidification self-organization approach. For the EM characterization the specular reflectance at far infrared, between 3 THz and 11 THz, was measured and also calculated by numerically solving Maxwell equations, obtaining good agreement between experimental and calculated spectra. Applying an effective medium approach to describe the response of our samples, we predicted a range of frequencies in which most of our systems behave as homogeneous anisotropic media with a hyperbolic dispersion relation, opening thus possibilities for using them in negative refractive index and imaging applications at THz range.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Thermal Effects on Microstructural Heterogeneity of Inconel 718 Materials Fabricated by Electron Beam Melting

Additive manufacturing (AM) technologies, also known as 3D printing, have demonstrated the potential to fabricate complex geometrical components, but the resulting microstructures and mechanical properties of these materials are not well understood due to unique and complex thermal cycles observed during processing. The electron beam melting (EBM) process is unique because the powder bed temperature can be elevated and maintained at temperatures over 1000 °C for the duration of the process. This results in three specific stages of microstructural phase evolution: (a) rapid cool down from the melting temperature to the process temperature, (b) extended hold at the process temperature, and (c) slow cool down to the room temperature. In this work, the mechanisms for reported microstructural differences in EBM are rationalized for Inconel 718 based on measured thermal cycles, preliminary thermal modeling, and computational thermodynamics models. The relationship between processing parameters, solidification microstructure, interdendritic segregation, and phase precipitation (δ, γ´, and γ´´) are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Effect of thermal annealing on microstructure evolution and mechanical behavior of an additive manufactured AlSi10Mg part

The powder-bed laser additive manufacturing (AM) process is widely used in the fabrication of three-dimensional metallic parts with intricate structures, where kinetically controlled diffusion and microstructure ripening can be hindered by fast melting and rapid solidification. Therefore, the microstructure and physical properties of parts made by this process will be significantly different from their counterparts produced by conventional methods. This work investigates the microstructure evolution for an AM fabricated AlSi10Mg part from its nonequilibrium state toward equilibrium state. Special attention is placed on silicon dissolution, precipitate formation, collapsing of a divorced eutectic cellular structure, and microstructure ripening in the thermal annealing process. These events alter the size, morphology, length scale, and distribution of the beta silicon phase in the primary aluminum, and changes associated with elastic properties and microhardness are reported. In conclusion, the relationship between residual stress and silicon dissolution due to changes in lattice spacing is also investigated and discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2017

On single-phase status and segregation of an as-solidified septenary refractory high entropy alloy

Phase predictions and characterizations on as-solidified septenary refractory high-entropy alloy, CrMoNbReTaVW, are presented here. The simulated solidification process predicts a single body-centered-cubic (BCC) crystal structure with the tendency of compositional segregation. X-ray diffraction results confirm the “single-phase-like” BCC structure, while further experimental characterizations reveal the existence of multiple grains with significantly different compositions yet the same crystal structure and similar lattice parameters.

36 MATERIALS SCIENCE↗