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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 1,207 records · Page 67
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Technical Gaps in Hanford High-Level Waste Solids Settling Behavior and Settling Time Evaluation for Direct Feed High-Level Waste (DFHLW) Operations

Settling of high-level waste (HLW) solids in process vessels is a key conceptual process step in providing HLW feed directly to the Hanford Waste Treatment and Immobilization Plant (WTP) HLW Vitrification Facility. Direct Feed High-Level Waste (DFHLW) is a potential approach to initiating HLW vitrification prior to completing of the WTP Pretreatment Facility. Settling would be used with subsequent supernatant decant to concentrate HLW feed. To support planning for DFHLW, Washington River Protection Solutions (WRPS) requested support from the Pacific Northwest National Laboratory to evaluate the current data set available to predict the time needed for HLW solids to settle, to identify gaps in the understanding and predictive capability of HLW solids waste settling times, and to provide scoping estimates of the potential settling time. Eight technical gaps were identified for predicting settling times and characteristics of the formed sediment layers including: Gap 1: In-Tank Settling Rates Faster than Settling of Laboratory Samples, Gap 2: Effect of Sludge Leaching/Washing on Predicted Settling Times, Gap 3: Predicting Waste Settling from Waste Chemistry (Waste Type), Gap 4: Predicting Waste Settling from Particle Size and Density Distributions (PSDDs), Gap 5: Insufficient Laboratory and In-Tank Settling Data to Represent Hanford Waste, Gap 6: Methods for Real-Time, In-Tank Tracking of Settling, Gap 7: Prediction of Sediment Erosion Resistance as a Function of Settling Time, and Gap 8: Prediction of Sediment Solids Content as a Function of Settling Time. In addition to the data gaps, an overarching observation of the settling rate and settled layer data is the significant variation in behavior. At similar solids concentrations, settling rates can vary by as much as 3 orders of magnitude depending on the source waste tank, and significantly different settling rates are noted between laboratory and in situ tests for the same waste tank. The range of average solids concentration in existing HLW sediment, which may have been quiescent for decades, can vary from less than 7 wt% to greater than 74 wt% solids. The shear strengths (or yield stresses) measured on laboratory samples range from less than 27 Pa to greater than 6400 Pa. These variations can challenge process planning for the application of a settle/decant process for DFHLW. This report describes the significance of the gaps to the settle/decant process and presents uncertainties by way of examples. Potential technical approaches for resolving these gaps are described and the estimated difficulty in resolving these gaps is evaluated. Based on the significance of the gap and the difficulty of resolution, recommendations are made to address specific gaps. Scoping estimates of the potential settling times for DFHLW solids have been made based on the existing data set with its associated gaps. Depending on the process vessel depth and final sediment concentration, substantial fractions of the scoping estimate results for settling times for characterized HLW exceed the 2-week period that has been previously assumed for process planning. There is also significant disparity, potentially greater than a factor of 5000 difference, in the estimated settling times depending on process vessel depth and final sediment solid concentration. This variation in results underscores the significance of the identified gaps and uncertainties with respect to process planning for utilizing settle/decant operations for DFHLW.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Origin of Unusual Acidity and Li+ Diffusivity in a Series of Water-in-Salt Electrolytes.

Superconcentrated aqueous electrolytes ("water-in-salt" electrolytes, or WiSEs) enable various aqueous battery chemistries beyond the voltage limits imposed by the Pourbaix diagram of water. However, their detailed structural and transport properties remain unexplored and could be better understood through added studies. Here, we report on our observations of strong acidity (pH 2.4) induced by lithium bis(trifluoromethane sulfonyl)imide (LiTFSI) at superconcentration (at 20 mol/kg). Multiple nuclear magnetic resonance (NMR) and pulsed-field gradient (PFG) diffusion NMR experiments, density functional theory (DFT) calculations, and molecular dynamics (MD) simulations reveal that such acidity originates from the formation of nanometric ion-rich structures. The experimental and simulation results indicate the separation of water-rich and ion-rich domains at salt concentrations >= 5 m and the acidity arising therefrom is due to deprotonation of water molecules in the ion-rich domains. As such, the ion-rich domain is composed of hydrophobic -CF3 (of TFSI-) and hydrophilic hydroxyl (OH-) groups. At 20 m concentration, the tortuosity and radius of water diffusion channels are estimated to be similar to 10 and similar to 1 nm, respectively, which are close to values obtained from hydrated Nafion membranes that also have hydrophobic polytetrafluoroethylene (PTFE) backbones and hydrophilic channels consisting of SO3- ion cluster networks providing for the transport of ions and water. Thus, we have discovered the structural similarity between WiSE and hydrated Nafion membranes on the nanometer scale.

Han, Kee Sung↗
DOE OSTI2024

Street-level temperature estimation using graph neural networks: Performance, feature embedding and interpretability

Estimating street-level air temperature is a challenging task due to the highly heterogeneous urban surfaces, canyon-like street morphology, and the diverse physical processes in the built environment. Though pioneering studies have embarked on investigations via data-driven approaches, many questions remain to be answered. Here, in this study, we leveraged an innovative framework and redefined the street-level temperature estimation problem using Graph Neural Networks (GNN) with spatial embedding techniques. The results showed that GNN models are more capable and consistent of estimating street-level temperature among tested locations, benefiting from its unique strength in handling extensive data over unstructured graph topology. In addition, we conducted in-depth analysis of feature importance to enhance the model interpretability. Among the urban features analyzed in this study, the time-variant canopy density and meter-level land use data emerge as crucial factors. Our findings highlight GNN 's high potential in capturing the complex dynamics between urban elements and their impacts on microclimate, thus offering valuable insights for comprehensive urban data collection and urban climate modeling in general. Collectively, this study also contributes to urban planning and policy by providing avenues to enhance city resilience against climate change, thereby advancing the agenda for environmental stewardship and urban sustainability.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Classical and quantum simulations of 1+1-dimensional ${\mathbb{Z}}_{2}$ gauge theory at finite temperature and density

Simulating strongly coupled gauge theories at finite temperature and density is a longstanding challenge in nuclear and high-energy physics with fundamental implications for condensed matter physics. Here, we simulate such systems using minimally entangled typical thermal state (METTS) approaches, which combine classical random sampling with imaginary-time evolution, implementable on either classical or quantum computers, to estimate thermal averages of observables. We study 1+1-dimensional ${\mathbb{Z}}_{2}$ gauge theory coupled to spinless fermionic matter, which maps onto a local quantum spin chain. We benchmark both a classical matrix-product-state implementation of METTS and a recently proposed adaptive variational approach for near-term quantum devices, focusing on the equation of state and measures of fermion confinement. Of particular importance is the choice of basis for METTS sampling, which impacts both the sampling overhead and quantum circuit complexity. Our work sets the stage for future studies of strongly coupled gauge theories using classical and quantum hardware.

Chen, I-Chi [Iowa State Univ., Ames, IA (United St↗
DOE OSTI2022

Substructure in the stellar halo near the Sun: I. Data-driven clustering in integrals-of-motion space

Context. Merger debris is expected to populate the stellar haloes of galaxies. In the case of the Milky Way, this debris should be apparent as clumps in a space defined by the orbital integrals of motion of the stars. Aims. Our aim is to develop a data-driven and statistics-based method for finding these clumps in integrals-of-motion space for nearby halo stars and to evaluate their significance robustly. Methods. We used data from Gaia EDR3, extended with radial velocities from ground-based spectroscopic surveys, to construct a sample of halo stars within 2.5 kpc from the Sun. We applied a hierarchical clustering method that makes exhaustive use of the single linkage algorithm in three-dimensional space defined by the commonly used integrals of motion energy E, together with two components of the angular momentum, L z and L ⊥ . To evaluate the statistical significance of the clusters, we compared the density within an ellipsoidal region centred on the cluster to that of random sets with similar global dynamical properties. By selecting the signal at the location of their maximum statistical significance in the hierarchical tree, we extracted a set of significant unique clusters. By describing these clusters with ellipsoids, we estimated the proximity of a star to the cluster centre using the Mahalanobis distance. Additionally, we applied the HDBSCAN clustering algorithm in velocity space to each cluster to extract subgroups representing debris with different orbital phases. Results. Our procedure identifies 67 highly significant clusters (> 3σ), containing 12% of the sources in our halo set, and 232 subgroups or individual streams in velocity space. In total, 13.8% of the stars in our data set can be confidently associated with a significant cluster based on their Mahalanobis distance. Inspection of the hierarchical tree describing our data set reveals a complex web of relations between the significant clusters, suggesting that they can be tentatively grouped into at least six main large structures, many of which can be associated with previously identified halo substructures, and a number of independent substructures. This preliminary conclusion is further explored in a companion paper, in which we also characterise the substructures in terms of their stellar populations. Conclusions. Our method allows us to systematically detect kinematic substructures in the Galactic stellar halo with a data-driven and interpretable algorithm. The list of the clusters and the associated star catalogue are provided in two tables available at the CDS.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

How to detect lensing rotation

Gravitational lensing rotation of images is predicted to be negligible at linear order in density perturbations, but can be produced by the post-Born lens-lens coupling at second order. This rotation is somewhat enhanced for Cosmic Microwave Background (CMB) lensing due to the large source path length, but remains small and very challenging to detect directly by CMB lensing reconstruction alone. We show the rotation may be detectable at high significance as a cross-correlation signal between the curl reconstructed with Simons Observatory (SO) or CMB-S4 data, and a template constructed from quadratic combinations of large-scale structure (LSS) tracers. Equivalently, the lensing rotation-tracer-tracer bispectrum can also be detected, where LSS tracers considered include the CMB lensing convergence, galaxy density, and the Cosmic Infrared Background (CIB), or optimal combinations thereof. We forecast that an optimal combination of these tracers can probe post-Born rotation at the level of 5.7σ–6.1σ with SO and 13.6σ–14.7σ for CMB-S4, depending on whether standard quadratic estimators or maximum a posteriori iterative methods are deployed. We also show possible improvement up to 21.3σ using a CMB-S4 deep patch observation with polarization-only iterative lensing reconstruction. However, these cross-correlation signals have non-zero bias because the rotation template is quadratic in the tracers, and exists even if the lensing is rotation free. We estimate this bias analytically, and test it using simple null-hypothesis simulations to confirm that the bias remains subdominant to the rotation signal of interest. Detection and then measurement of the lensing rotation cross-spectrum is therefore a realistic target for future observations.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Quasar UV/X-ray relation luminosity distances are shorter than reverberation-measured radius–luminosity relation luminosity distances

ABSTRACT We use measurements of 59/58 quasars (QSOs), over a redshift range 0.0041 ≤ z ≤ 1.686, to do a comparative study of the radius–luminosity (R − L) and X-ray−UV luminosity (LX − LUV) relations and the implication of these relations for cosmological parameter estimation. By simultaneously determining R − L or LX − LUV relation parameters and cosmological parameters in six different cosmological models, we find that both R − L and LX − LUV relations are standardizable but provide only weak cosmological parameter constraints, with LX − LUV relation data favouring larger current non-relativistic matter density parameter Ωm0 values than R − L relation data and most other available data. We derive LX − LUV and R − L luminosity distances for each of the sources in the six cosmological models and find that LX − LUV relation luminosity distances are shorter than R − L relation luminosity distances as well as standard flat ΛCDM model luminosity distances. This explains why LX − LUV relation QSO data favour larger Ωm0 values than do R − L relation QSO data or most other cosmological measurements. While our sample size is small and only spans a small z range, these results indicate that more work is needed to determine whether the LX − LUV relation can be used as a cosmological probe.

Astronomy & Astrophysics↗
DOE OSTI2024

Analytical noise bias correction for precise weak lensing shear inference

Noise bias is a significant source of systematic error in weak gravitational lensing measurements that must be corrected to satisfy the stringent standards of modern imaging surveys in the era of precision cosmology. This paper reviews the analytical noise bias correction method and provides analytical derivations demonstrating that we can recover shear to its second order using the ‘renoising’ noise bias correction approach introduced by METACALIBRATION. We implement this analytical noise bias correction within the AnaCal shear estimation framework and propose several enhancements to the noise bias correction algorithm. We evaluate the improved AnaCal using simulations designed to replicate Rubin Legacy Survey of Space and Time (LSST) imaging data. These simulations feature semi-realistic galaxies and stars, complete with representative distributions of magnitudes and Galactic spatial density. We conduct tests under various observational challenges, including cosmic rays, defective CCD columns, bright star saturation, bleed trails, and spatially variable point spread functions. Our results indicate a multiplicative bias in weak lensing shear recovery of less than a few tenths of a per cent, meeting LSST Dark Energy Science Collaboration requirements without requiring calibration from external image simulations. Additionally, our algorithm achieves rapid processing, handling one galaxy in less than a millisecond.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Disaggregating Customer-Level Behind-the-Meter PV Generation Using Smart Meter Data and Solar Exemplars

Customer-level rooftop photovoltaic (PV) has been widely integrated into distribution systems. In most cases, PVs are installed behind-the-meter (BTM), and only the net demand is recorded. Therefore, the native demand and PV generation are unknown to utilities. Separating native demand and solar generation from net demand is critical for improving grid-edge observability. In this paper, a novel approach is proposed for disaggregating customer-level BTM PV generation using low-resolution but widely available hourly smart meter data. The proposed approach exploits the strong correlation between monthly nocturnal and diurnal native demands and the high similarity among PV generation profiles. First, a joint probability density function (PDF) of monthly nocturnal and diurnal native demands is constructed for customers without PVs, using Gaussian mixture modeling (GMM). Deviation from the constructed PDF is utilized to probabilistically assess the monthly solar generation of customers with PVs. Then, to identify hourly BTM solar generation for these customers, their estimated monthly solar generation is decomposed into an hourly timescale; to do this, we have proposed a maximum likelihood estimation (MLE)-based technique that utilizes hourly typical solar exemplars. Leveraging the strong monthly native demand correlation and high PV generation similarity enhances our approach's robustness against the volatility of customers’ hourly load and enables highly-accurate disaggregation. Furthermore, the proposed approach has been verified using real native demand and PV generation data.

14 SOLAR ENERGY↗
DOE OSTI2020

A Climatology and Extreme Value Analysis of Large Hail in China

In this paper, hail size records are analyzed at 2254 stations in China and a hail size climatology is developed based on gridded hail observations for the period 1960–2015. It is found that the annual percentiles of hail size records changed sharply and national-wide after 1980, therefore two periods, 1960–79 and 1980–2015, are studied. There are some similarities between the two periods in terms of the characteristics of hail size such as the spatial distribution patterns of mean annual maximum hail size and occurrence week of annual maximum hail size. The 1980–2015 period had higher observation density than the 1960–79 period, but showed smaller mean annual maximum hail size, especially in northern China. In the majority of grid boxes, the annual maximum hail size experienced a decreasing trend during the 1980–2015 period. A Gumbel extreme value model is fitted to each grid box to estimate the return periods of maximum hail size. The scale and location parameter of the fitted Gumbel distributions are higher in eastern China than in western China, thereby reflecting a greater likelihood of large hail in eastern China. In southern China, the maximum hail size exceeds 127 mm for a 10-yr return period, whereas in northern China maximum hail size exceeds this threshold for a 50-yr return period. Furthermore, the Gumbel model is found to potentially underestimate the maximum hail size for certain return periods, but provides a more informed picture of the spatial distribution of extreme hail size and the regional differences.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

A copula-based rank histogram ensemble filter

Serial ensemble filters implement triangular probability transport maps to reduce high-dimensional inference problems to sequences of state-by-state univariate inference problems. The univariate inference problems are solved by sampling posterior probability densities obtained by combining constructed prior densities with observational likelihoods according to Bayes' rule. Many serial filters in the literature focus on representing the marginal posterior densities of each state. However, rigorously capturing the conditional dependencies between the different univariate inferences is crucial to correctly sampling multidimensional posteriors. This work proposes a new serial ensemble filter, called the copula rank histogram filter (CoRHF), that seeks to capture the conditional dependency structure between variables via empirical copula estimates; these estimates are used to rigorously implement the triangular (state-by-state univariate) Bayesian inference. The success of the CoRHF is demonstrated on two-dimensional examples and the Lorenz'63 problem. A practical extension to the high-dimensional setting is developed by localizing the empirical copula estimation, and is demonstrated on the Lorenz'96 problem.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Yttrium solid phase equation of state with uncertainty quantification

We discuss the development of an equation of state (EOS) for solid yttrium up to roughly 80 GPa. The EOS makes use of different experimental datasets, including measurements of the isobaric density, isobaric specific heat, room temperature isotherm, and principal shock Hugoniot. The fitting procedure is carried out using Markov Chain Monte Carlo (MCMC), where we fit model parameters for both the cold curve and ion thermal models simultaneously. The results show close agreement with experimental data and provide meaningful uncertainty estimates on the model parameters. This work serves as a first step towards a multiphase EOS for yttrium, which will include higher pressure solid phases (> 80 GPa), as well as modeling of the liquid phase.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Development and Validation of Quantitative Model-Based Image Reconstruction for NDE of Reinforced Steel-Lined Concrete Structures: Kal-El FY 2020

This project studied the capabilities of Model-Based Image Reconstruction (MBIR) and Machine Learning (ML) algorithms in the imaging and estimation of rebar corrosion from ultrasound signals. The application was challenging due to the introduction of a steel liner between the sensor and the concrete containing the rebar. The study focused in a synthetic specimen with a 6.35 mm thick steel liner, and a 19.05 mm diameter rebar at a depth of 44.5 mm and with four levels of corrosion; 0%, 20%, 50%, and 100% corrosion level. The corrosion was applied uniformly around the rebar, generating a ring in the perimeter of the rebar with different acoustic density. In order to generate a realistic synthetic dataset, we added random texture to the concrete of the synthetic specimens. This texture will mimic the variations encountered in real concrete specimens.We adapted our MBIR algorithm for the application and enhanced the algorithm to integrate in the physical model known specimen features, such as the steel liner thickness. The new MBIR method was able to cancel out reverberation from the steel liner and properly image the rebar. In particular, corrosion for the 50% and 100% cases were easily visible and quantitative metrics showed a slight separation for the 0% and 20% levels. The quantitative results were in agreement with the qualitative assessment. We also developed a ML XGBoost model to estimate corrosion level from the ultrasound signals. By combining the ML method with MBIR, we can pinpoint in the ultrasound signals the section that corresponds to the echoes from the rebar. The extract signals are processed by the XGBoost model for prediction. From each system scan, we obtain 15 predictions. The median prediction value is used as the final prediction. The True Acceptance Rate for the method is over 99%.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Application of spectroscopic evidence to diffuse layer model (DLM) parameter estimation for cation adsorption onto ferrihydrite in single- and bi-solute systems

The diffuse layer model (DLM) is one of the most frequently used surface complexation models (SCM) for predicting cation adsorption onto ferrihydrite. However, the DLM with its existing database sometimes fails to predict cation adsorption, especially in multi-solute systems. Notably, the failure is often attributed to inaccurate selection of the surface complexes and/or underestimation of the site density for DLM formulation. DLM simulations of batch adsorption data conducted with cadmium, copper, lead, and zinc on ferrihydrite in CO2 free systems demonstrates the ability of the DLM to fit single-solute data reasonably well but highlights its limitations with respect to predicting bi-solute data. Modifications to the DLM were made in two steps. First, spectroscopic evidence was used to guide cation complexation reactions at the ferrihydrite surface. Second, surface characteristics (reactive site density, specific surface area, and acidity constants) of ferrihydrite were updated according to recent literature. The results from this study suggest that when spectroscopic verification is employed and surface site density is increased, a simple two-site DLM can predict cation adsorption on ferrihydrite in single-solute systems for pH data above 3.5 and in most of the bi-solute systems tested.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Cosmology intertwined: A review of the particle physics, astrophysics, and cosmology associated with the cosmological tensions and anomalies

The standard Λ Cold Dark Matter (ΛCDM) cosmological model provides a good description of a wide range of astrophysical and cosmological data. However, there are a few big open questions that make the standard model look like an approximation to a more realistic scenario yet to be found. In this paper, we list a few important goals that need to be addressed in the next decade, taking into account the current discordances between the different cosmological probes, such as the disagreement in the value of the Hubble constant H 0 , the σ 8 – S 8 tension, and other less statistically significant anomalies. While these discordances can still be in part the result of systematic errors, their persistence after several years of accurate analysis strongly hints at cracks in the standard cosmological scenario and the necessity for new physics or generalisations beyond the standard model. In this paper, we focus on the 5.0 σ tension between the Planck CMB estimate of the Hubble constant H 0 and the SH0ES collaboration measurements. After showing the H 0 evaluations made from different teams using different methods and geometric calibrations, we list a few interesting new physics models that could alleviate this tension and discuss how the next decade's experiments will be crucial. Moreover, we focus on the tension of the Planck CMB data with weak lensing measurements and redshift surveys, about the value of the matter energy density Ω m , and the amplitude or rate of the growth of structure ( σ 8 , f σ 8 ). We list a few interesting models proposed for alleviating this tension, and we discuss the importance of trying to fit a full array of data with a single model and not just one parameter at a time. Additionally, we present a wide range of other less discussed anomalies at a statistical significance level lower than the H 0 – S 8 tensions which may also constitute hints towards new physics, and we discuss possible generic theoretical approaches that can collectively explain the non-standard nature of these signals. Finally, we give an overview of upgraded experiments and next-generation space missions and facilities on Earth that will be of crucial importance to address all these open questions.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Exploring the Structural, Dynamic, and Functional Properties of Metal–Organic Frameworks through Molecular Modeling

This review spotlights the role of atomic-level modeling in research on metal-organic frameworks (MOFs), especially the key methodologies of density functional theory (DFT), Monte Carlo (MC) simulations, and molecular dynamics (MD) simulations. The discussion focuses on how periodic and cluster-based DFT calculations can provide novel insights into MOF properties, with a focus on predicting structural transformations, understanding thermodynamic properties and catalysis, and providing information or properties that are fed into classical simulations such as force field parameters or partial charges. Classical simulation methods, highlighting force field selection, databases of MOFs for high-throughput screening, and the synergistic nature of MC and MD simulations, are described. By predicting equilibrium thermodynamic and dynamic properties, these methods offer a wide perspective on MOF behavior and mechanisms. Additionally, the incorporation of machine learning (ML) techniques into quantum and classical simulations is discussed. These methods can enhance accuracy, expedite simulation setup, reduce computational costs, as well as predict key parameters, optimize geometries, and estimate MOF stability. By charting the growth and promise of computational research in the MOF field, the aim is to provide insights and recommendations to facilitate the incorporation of computational modeling more broadly into MOF research.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Accelerating Battery Simulations by Using High Performance Computing and Opportunities with Machine Learning

The US Department of Energy (DOE) estimates that the battery pack cost of $60 per kilowatt-hour while increasing the driving range to over 300 miles and vehicle charging under 15 min or less would enable mass penetration of electric vehicles in the USA by 2030. These projections are based on the currently available high-density cell chemistry combined with a system level design and optimized electrodes. Electrodes for current state-of-the-art lithium-ion cell technology are fabricated from electrode slurry comprising of active material, polymeric binder, and conductive diluent such as carbon black that are coated on metal current collectors such as copper and aluminum. Given these challenging requirements for development of electrical energy storage devices for future transportation needs, a predictive simulation capability which can accelerate design by considering performance and safety implications of different geometry, materials, and chemistry choices is required. In this chapter, we discuss our state-of-the-art three-dimensional modeling framework, providing examples on battery performance and safety simulations. We also present approaches to use machine learning in the context of large datasets that are becoming available.

Allu, Srikanth↗
DOE OSTI2023

Review of internal and external surface finishing technologies for additively manufactured metallic alloys components and new frontiers

Surface finishing in additive manufacturing (AM) is a technological bottleneck. The field of surface finishing of AM parts is vast because it not only focuses on roughness reduction in the hard-to-access internal surfaces but also includes the scope of adding coatings and sensors. Even though metal AM component is reaching the density and bulk microstructure at par or even better than conventionally produced components, adverse impact of surface roughness and imperfections is becoming the major obstruction. It is observed that external and internal surface roughness of AM components is a high probability cause of many unavoidable issues such as corrosion, incorrect tolerance estimations during the build stage, and the fatigue failure of parts before the expected life cycle. At present, AM field mainly focuses on improving and enhancing the internal and external surface roughness to pass the stringent qualification requirements for actual applications. To address these challenges, researchers worldwide are conducting many experiments and developing different surface finishing techniques. This paper reviews the state-of-the-art knowledge and processes of different surface finishing technology that can be applied to AM metal components. This article mainly highlights several liquid-based surfaces finishing approaches to develop promising surface microstructures on interior and exterior surfaces as a micromachining tool. The future of making strong and self-monitoring AM component requires broadening of surface finishing field and including advanced topics such as coatings and adding sensor technology. We also discuss new frontiers and the scope of future work in the surface finishing field to bring attention to related concerns and possibilities associated with making smart and strong AM components for twenty-first-century integrated engineering systems.

36 MATERIALS SCIENCE↗