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At least 1,207 records · Page 67
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Additive manufacturing power map to mitigate overhang structure

A laser powder bed fusion additive manufacturing system for producing a part by creating a power map that is an intelligent feed forward model to control the laser powder bed fusion additive manufacturing for producing the part and using the power map to control the laser powder bed fusion additive manufacturing for producing the part. This includes an apparatus for producing a part including a powder bed, a laser that produces a laser beam, a proportional integral derivative controller that creates a power map that describes laser power requirements as the laser moves along a path, wherein the laser power requirements prevent defects in the part.

Khairallah, Saad A.↗
DOE OSTI2022

Particulates for additive manufacturing techniques

A method of making a particulate for an additive manufacturing technique includes receiving particulate at a chemical vapor deposition (CVD) reactor, flowing a hydrocarbon gas into the CVD reactor, decomposing the hydrocarbon gas in the CVD reactor, and depositing a carbonaceous coating on the particulate using a product of the decomposed hydrocarbon gas. The coating deposited over the particulate has a reflectivity that is lower than the reflectivity the underlying particulate body to reduce an energy input requirement for purposes of fusing the particulate into a layer of an article using an additive manufacturing technique. In embodiments, the coated particulate can be received at an additive manufacturing apparatus and fused into a layer of an article as a metallic-carbon composite using a high-density energy source.

42 ENGINEERING↗
DOE OSTI2022

Systems and methods for powder bed additive manufacturing anomaly detection

Detection and classification of anomalies for powder bed metal additive manufacturing. Anomalies, such as recoater blade impacts, binder deposition issues, spatter generation, and some porosities, are surface-visible at each layer of the building process. A multi-scaled parallel dynamic segmentation convolutional neural network architecture provides additive manufacturing machine and imaging system agnostic pixel-wise semantic segmentation of layer-wise powder bed image data. Learned knowledge is easily transferrable between different additive manufacturing machines. The anomaly detection can be conducted in real-time and provides accurate and generalizable results.

Scime, Luke R.↗
DOE OSTI2022

Additive manufacturing methods using aluminum-rare earth alloys and products made using such methods

Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.

Plotkowski, Alex J.↗
DOE OSTI2023

ADDITIVE MANUFACTURING AND REGULATORY TESTING OF CANISTERS FOR SPENT NUCLEAR FUEL MANAGEMENT

The back end of the fuel cycle focuses on the interim storage, transportation, and final disposition of the spent nuclear fuel from nuclear reactors. Commercial light water nuclear power stations across the United States operate with fuel assemblies being irradiated for up to 6 years (planned) in the reactor pressure vessel. After their planned irradiation, the fuel assemblies are moved to a spent fuel pool within the facility complex. After the spent nuclear fuel is removed from the fuel pool, it is typically inserted into a welded metal canister that can be transferred between overpacks for storage, transportation and possibly disposal. Most dry storage systems being used by industry today use dual purpose canisters (DPCs), designed for use in storage and transportation overpacks, but not specifically designed for disposal. Triple purpose-canisters, designed for disposal in addition to storage and transportation, have also been researched. Traditional manufacturing methods for spent fuel canisters involve fusion welding along the length or circumference of the canister which results in high tensile residual stresses in the joint weld zone (WZ) and heat affected zone (HAZ). In this paper, spent fuel canister designs were printed by wire arc additive manufacturing (AM) using the 316L SS welding wire to demonstrate: 1. Feasibility of spent nuclear fuel canister fabrication using this advanced manufacturing method, 2. Dynamic response of the additive manufacture canister design when subjected to the federally mandated Normal Conditions of Transport (NCT) and Hypothetical Accident Conditions (HAC) physical tests for Type B packages. This paper will focus on the canister printing design and structural tests. The AM 3D printed design, regulatory testing, and post-test evaluation of the canister tested to the 10 CFR 71.71 and 10 CFR 71.73 requirements will be presented. One AM canister design was subjected to the penetration, free drop, and puncture test. Before and after the dynamic structural tests, the AM canister design was scanned with a handheld scanner to capture a 3D CAD geometry to compare to the 3D printed canister design in the deformed shape. The scanned geometry was sectioned in areas with deformation and the cross-section profile was measured to determine accurate and repeated results of the deformed shape of the AM canister design.

Martinez, Oscar↗
DOE OSTI2023

Continuous toolpaths for additive manufacturing

Toolpath generation for additive manufacturing systems involves operations on polygonal contours derived from a model for additively manufacturing a structure. One aspect involves modifying or creating a model to allow parts to be printed without starting and stopping the printing equipment by generating continuous toolpaths or toolpaths having a reduced number of isolated paths. Another aspect involves modifying a slicing engine to generate a continuous toolpath or toolpath having a reduced number of isolated paths based on a representation of an object to be additively manufactured. Another aspect involves selectively placing the gaps at alternating positions among the sliced layers to create a zippering effect.

Borish, Michael C.↗
DOE OSTI2023

Indirect additive manufacturing process

A method for indirect additive manufacturing of an object, the method comprising: (i) separately feeding a powder from which said object is to be manufactured and either a difunctional curable monomer according to Formula (I) or an adhesive polymer binder into an additive manufacturing device; (ii) dispensing selectively positioned droplets of said difunctional curable monomer or adhesive polymer binder, from a printhead of said additive manufacturing device, into a bed of said powder to bind particles of said powder with said difunctional curable monomer or adhesive polymer binder to produce a curable preform having a shape of the object to be manufactured; and, in the case of the difunctional curable monomer, (iii) curing said curable preform to form a crosslinked object.

Saito, Tomonori↗
DOE OSTI2023

Additively featured plates for heat exchangers

Hybrid additive featured plates used to form an overall microchannel heat exchanger and corresponding method of manufacture are disclosed. Various additive manufacturing (AM) techniques may be used to form walls defining microchannel features on a plate substrate. The manufacturing method is a hybrid process in that leverages both additive and conventional manufacturing techniques to minimize both cost and fabrication time.

Carlson, Matthew David↗
DOE OSTI2023

Defect-resistant plastic scintillators with aliphatic additives

A plastic scintillator includes a polymer matrix, an aliphatic additive present in the polymer matrix in an effective amount to impart fog resistance to the plastic scintillator, and at least one fluorescent dye in the polymer matrix, the dye being effective to provide scintillation upon exposure to radiation. The effective amount of the aliphatic additive is in a range of greater than 0 weight percent up to 5 weight percent relative to the total weight of the plastic scintillator. Moreover, the aliphatic additive has a structure comprising up to 300 repeat units.

Mabe, Andrew Neil↗
DOE OSTI2023

Additively manufacturing fluorine-containing polymers

A system and method of additively manufacturing a part including electrically conductive or static dissipating fluorine-containing polymers. The method includes depositing fluorine-containing polymer additive manufacturing material onto a build platform, selectively cross-linking portions of the deposited additive manufacturing material, and curing the selectively cross-linked portions such that the part is at least one of electrically conductive and static dissipating.

Selter, Thomas Matthew↗
DOE OSTI2023

Semi-solid electrodes with a polymer additive

Embodiments described herein relate generally to electrochemical cells having semi-solid electrodes that include a gel polymer additive such that the electrodes demonstrate longer cycle life while significantly retaining the electronic performance of the electrodes and the electrochemical cells formed therefrom. In some embodiments, a semi-solid electrode can include about 20% to about 75% by volume of an active material, about 0.5% to about 25% by volume of a conductive material, and about 20% to about 70% by volume of an electrolyte. The electrolyte further includes about 0.01% to about 1.5% by weight of a polymer additive. In some embodiments, the electrolyte can include about 0.1% to about 0.7% of the polymer additive.

Tan, Taison↗
DOE OSTI2018

Content Addition and Testing for 2017 NRC Amendment for the Versa-Pac Type A Fissile Packaging - 18120

The Versa-Pac is a certified Type A, fissile packaging (USA NRC Certificate no. USA/9342/AF-96), often used as a waste package for one time use. Continuous content additions have improved the versatility of the package resulting in expanded uses for the nuclear industry. Principal design of the Versa-Pac packaging maintains the use of an inner liner positioned inside a 55-gallon (VP-55) or 110-gallon drum (VP-110), as used for decades in the transport and disposal of Type A fissile materials. The Versa-Pac is used directly or in conjunction with pails, pipe containers, poly bottles, and a variety of smaller containers, inserts and vessels. The Versa-Pac content developments assist the industry with site shutdown, decommissioning, and cleanup operations, allowing for removal, transport, and storage options for the residual waste materials. A 2017 NRC license amendment application adds new capabilities to the Versa-Pac that include a low 1.25 wt% {sup 235}U enriched uranium loading, small quantities of UF{sub 6} in the form of 1S and 2S cylinders, and a payload mass increase from 250 to 350 pounds for the Versa-Pac 55-gallon version (VP-55). The lower uranium enrichment loading of 1.25 wt% {sup 235}U allows for a higher uranium mass limit. The inclusion of 1S and 2S UF{sub 6} cylinders fills an industry need to remove and dispose of long-stored material during site cleanup activities. The content payload mass limit is increased for low contaminated or radioactive heavy metal contents, such as cut plant components and ingots. Regulatory certification of new contents is demonstrated by test, analysis, and a combination of these techniques to show that the design function of the Versa-Pac as a Type A fissile package remains unchanged. Specific UF{sub 6} criticality and thermal analysis upgrades are added to the design documentation to accommodate 1S and 2S UF{sub 6} cylinders. The parameters for criticality analyses are simplified, ensuring no credit for cylinder containment is required for HAC thus reducing the reliance on a single specific shoring device. An upgrade of the Versa-Pac thermal analysis demonstrates compliance with ANSI N14.1 UF{sub 6} cylinder thermal limits. A new drop test sequence for the VP-55 was performed, documenting the addition of the 350-pound payload and demonstrating the VP-55 maintains structural integrity during the NCT and HAC drop, crush and puncture events as defined by 10 CFR 71. The testing and analyses show no loss of the material occurs and the package maintains the material in a subcritical state. This paper traces the engineering and licensing efforts involved in expanding the Versa-Pac's versatility for the 2017 NRC amendment application; summarizing the new testing and results for the payload increase, the content addition criticality and thermal evaluations, and content description for the Versa-Pac Safety Analysis Report. The NRC license amendment is scheduled for Winter 2017. Testing and supporting analyses reported in the Versa-Pac Safety Analysis Report demonstrates the content developments met the performance requirements of 10 CFR 71 for a Type A fissile package. A revision of the NRC Certificate of Compliance is expected in Spring 2018. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Depletion Analysis of Additively Manufactured Control Elements in HFIR

The High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory is a flux-trap type research reactor which provides one of the highest steady-state neutron sources in the world. HFIR neutrons are used for a range of research applications, including scattering experiments, materials irradiation, and isotope production. The HFIR core operates at 85 MW and is light water cooled and moderated. The core consists of several concentric cylindrical regions, as depicted in Fig. 1. At the center of the core is the flux trap, where the thermal flux reaches a maximum on the order of 10{sup 15} neutrons/cm{sup 2}-s. Immediately surrounding the flux trap are two annular fuel elements, an inner fuel element and an outer fuel element, each loaded with hundreds of thin fuel plates curved into an involute shape. Surrounding the outer fuel element are two thin control elements (CEs), an inner CE (ICE) and an outer CE (OCE). The CEs are axially zoned into three regions according to absorption strength: the white regions contain only structural aluminum and do not significantly contribute to absorption; the gray regions contain tantalum (Ta) as the primary absorber with a concentration of 30% by volume; and the black regions contain europium in the form of Eu{sub 2}O{sub 3} with a concentration of 33% by volume. A thick beryllium reflector is the final core component surrounding the CEs. A particular challenge to efficient maintenance and continued operation of HFIR is fabrication of the CEs, the current methods for which are tedious, outdated, and expensive. In an effort to improve the operational economics of HFIR and to demonstrate the application of advanced manufacturing techniques to the production of nuclear reactor components, the ultrasonic additive manufacturing (UAM) process is being investigated for fabrication of the HFIR CEs. This application of UAM involves directly embedding small cylindrical compacts (∼5.6 mm diameter, ∼1.7 mm thick) containing 60% neutron poison by volume into an aluminum matrix, using energy from ultrasonic vibrations to bond the compacts to the aluminum. The CEs contain discrete regions of absorbing material, in contrast to the standard design with homogeneously distributed absorbers. This novel design necessitates an investigation into how the HFIR core neutronic behavior differs from the case with homogeneous CEs so as to ascertain the feasibility of using additively manufactured CEs in HFIR. From an operations perspective, it is desirable for the discrete CEs to match the performance of the homogeneous CEs as closely as possible so as to avoid reconsideration of established safety margins. Earlier analyses of HFIR under beginning of cycle (BOC) conditions have indicated that although absorption properties on a local scale differ significantly between CE designs, the macroscopic behavior (neutron multiplication and flux and power distributions) of the HFIR core is not significantly altered. This study now addresses CE performance throughout depletion of the HFIR core during a reactor cycle. These analyses help to construct a more complete picture of the feasibility of employing additively manufactured CEs in HFIR and will reveal any adjustments which must be made to the design in order to maintain acceptable performance. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

High-Temperature Oxidation Behavior of Wrought and Additive Manufactured Alloys in Direct-Fired Supercritical CO2 Power Cycle Environments

Materials selection is a key concern for corrosion resistance in elevated temperature and pressure direct-fired supercritical CO2 (sCO2) power cycles. The effect of elevated pressure on corrosion resistance can be critical, as impurities within the supercritical fluid such as H2O and O2 can have additional corrosion effects than found at ambient pressure conditions. Several wrought nickel-based commercial alloys (230, 263, 282, 617, 625, 740H) were exposed to direct-fired conditions (95CO2 – 4H2O – 1 O2) at 750 °C at both atmospheric pressure (0.1 MPa) and supercritical conditions (20 MPa) for over 2,000 h. Additionally, additive manufactured (AM) 282 produced by laser powder bed fusion (LPBF) were also included in the exposures. Supercritical conditions affected the oxidation behavior of several alloys. Most notably, water-vapor assisted Cr-oxide volatilization was observed at 750 °C supercritical conditions. Many alloys did not form sufficient protective Cr-oxide scales at supercritical conditions, leading to increased oxidation at elevated pressure. Differences in oxidation behavior were also observed for 282 AM samples compared to their wrought counterparts, with the differences also dependent on the LPBF build parameters and post-production treatments (heat treatment and surface finishing procedures). The AM samples formed Mo-rich carbides in the alloy beneath the oxide following sCO2 exposure, implying potentially higher levels of carbon uptake relative to the wrought

Carney, Casey↗
DOE OSTI2024

Effect of Minor Ce Additions on Corrosion Behavior of Experimental Pipeline Steel

Minor additions of rare earth elements (REEs) have been shown to improve various steel properties. In particular, Cerium (Ce), as a relatively abundant and inexpensive element, has received attention as a potentially beneficial minor alloying addition for a variety of steel applications, including pipelines materials. The objective of this work is to investigate the effect of Ce on corrosion performance of experimental high-strength pipeline steel. Electrochemical corrosion experiments were carried out on steel without and with 0.006, 0.018, and 0.03 wt.% of Ce in 3.5 wt.% NaCl saturated with CO2 at 20 oC. For comparison purposes, X100 carbon steel specimens machined from an experimental pipe with a yield strength of 731 MPa were tested under the same conditions. The electrochemical techniques employed included: potentiodynamic polarization (PDP), linear polarization resistance (LPR), and electrochemical impedance spectroscopy (EIS). In addition, post-corrosion surface characterization was performed using scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS), while crystalline phases were determined by X-ray diffraction (XRD). The corrosion of base metal without Ce was lower (0.15 mm/y) compared to carbon steel X100 (0.9 mm/yr). The electrochemical results showed that adding Ce accelerates corrosion rates compared to base metal without Ce. No pitting corrosion of tested steel was detected.

Belarbi, Zineb↗
DOE OSTI2023

A High-Pressure Shock Tube Study of Hydrogen and Ammonia Addition to Natural Gas for Reduced Carbon Emissions in Power Generation Gas Turbines

Ignition delay times from undiluted mixtures of natural gas (NG)/H2/Air and NG/NH3/Air were measured using a high-pressure shock tube at the University of Central Florida. The combustion temperatures were experimentally tested between 1000-1500 K near a constant pressure of 25 bar. Mixtures were kept undiluted to replicate the same chemistry pathways seen in gas turbine combustion chambers. Recorded combustion pressures exceeded 200 bar due to the large energy release, hence why these were performed at the high-pressure shock tube facility. The data is compared to the predictions of the NUIGMech 1.1 mechanism for chemical kinetic model validation and refinement. An exceptional agreement was shown for stoichiometric conditions in all cases but strayed at lean and rich equivalence ratios, especially in the lower temperature regime of H2 addition and all temperature ranges of the baseline NG mixture. Hydrogen addition also decreased ignition delay times by nearly 90%, while NH3 fuel addition made no noticeable difference in ignition delay time. NG/NH3 exhibited similar chemistry to pure NG under the same conditions, which is shown in a sensitivity analysis, demonstrating hydrogen chemistry to be dominant in NG/H2 mixtures and hydrocarbon chemistry to be dominant in NG/NH3 mixtures. The reaction CH3 + O2 = CH3O + O is identified and suggested as a possible modification target to improve model performance. Increasing the robustness of chemical kinetic models via experimental validation will directly aid in designing next-generation combustion chambers for use in gas turbines, which in turn will greatly lower global emissions and reduce greenhouse effects.

Pierro, Michael↗
DOE OSTI2024

Effect of Si Content in Electrode and SiO2 Additions to the Slag during Electroslag Remelting

Evolution of Si concentration in 316 stainless steel electrodes was observed during a melting campaign consisting of recycling electroslag remelted (ESR) ingots to make new electrodes using vacuum induction melting (VIM). This campaign consisted of iterations of VIM + ESR operations to optimize melting parameters. The effect of Si content on the melt parameters and ingot quality was further evaluated and additions of SiO2 to the slag chemistry were studied using research-scale experiments, x-ray diffraction (XRF), combustion analysis, visual inspections, and computational tools. The Si concentration was found to decrease by approximately 600 ppm following ESR of 150 lb. research-scale electrodes. Eventually, this led to failure of the slag skin and direct ingot/crucible contact. Additions of SiO2 to the slag at levels matching the original calculated Si concentration in the electrode did not eliminate the slag skin failure and the current during steady state increased to maintain a constant melt rate. In this investigation, we propose a mechanism of slag skin failure consisting of local concentration of current density due to absence, or breakage, of the SiO2 layer around the molten metal drop during ESR. This theory was reinforced by additional experiments in which Nb was added to the electrode to change the structure of the oxide layer around the drops.

Jablonski, Paul↗
DOE OSTI2024

Titanium Wire Arc Additive Manufacturing Inert Enclosure and Material Handling Safety Considerations

Wire arc additive manufacturing (WAAM) via metal inert gas (MIG)/gas metal arc welding (GMAW) is a viable option for fabrication of large-scale titanium parts; however, it introduces new safety hazards associated with both the material and the additional system hardware required for the process. Localized gas shielding of the weld arc via standard GMAW torch is inadequate for titanium due to its affinity for oxygen; thereby requiring the use of an inert enclosure to protect the weld from entraining oxygen. The use of the inert enclosure presents potential safety hazards such as operator asphyxiation and brings up discussion of confined space considerations. In addition, the titanium welding process creates pyrophoric titanium soot residue around the deposit, which can undergo deflagration during part cleaning and part removal. This paper provides an overview of the titanium WAAM process along with safety considerations for the design and operation of the inert enclosure as well as functional solutions for the safe handling of the titanium soot by-product.

Walters, Alex↗