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All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Towards Integrated Computational Materials Engineering for Quantifying Performance Impacts of Microstructure and Defect Interactions in Powder Bed Fusion Parts

Powder bed fusion (PBF) additive manufacturing (AM) enables the creation of parts with complexity and functionality levels that were previously impossible with traditional manufacturing methods. By modifying the laser power, hatch spacing, or the numerous other processing parameters, the PBF process supports the production of a wide set of materials and geometries. However, that same process parameter design flexibility causes the process-design space of PBF to be massive and expensive to explore experimentally. Another challenge is quality variation across a build. As a part is being built, geometric variance between locations, such as at a thin-wall section vs. the bulk material, may cause the specified processing parameters to no longer be acceptable for producing defect-free printing. Furthermore, if the processing parameters deviate during the print process, it is difficult to assess if the part will still perform satisfactorily. Integrated Computational Materials Engineering (ICME) provides a way to understand and address these various challenges. This talk will present advancements in process-structure simulations of PBF at NASA Langley Research Center. The ability to simulate grain-scale PBF microstructures using the Physically Based Monte Carlo method will be demonstrated and compared to experimental measurements. Techniques for simulating three-dimensional lack-of-fusion and keyhole porosity defects based on the specific processing conditions and approaches for integrating the two porosity prediction techniques alongside the computational microstructure evolution models will be shown. Finally, the integration of simulated PBF microstructures, embedded process defects, and crystal plasticity finite element models to elucidate the interaction of porosity and microstructure on micromechanical fields will be demonstrated. These integrated techniques demonstrate an example of using ICME to relate processing to performance for PBF AM materials. With continued maturity, it is hoped that such ICME approaches will lead to next-generation computational-materials supported qualification and certification of AM parts.

Additive manufacturing↗

NASA NTRSDate not supplied

In-situ Imaging of Pyrolyzing Aerospace Materials

Tracking morphological changes of materials during heating is crucial to understand its response in fire protection, biofuel production, thermal protection systems (TPS) for hypersonic flight. As materials are heated, they undergo physical and chemical changes due to water loss, stretching or shrinking, pyrolysis and chemical reactions in the ambient environment. The effects of these changes can have a profound impact on the material’s performance, indicated by changes in on the porosity and volume. While materials such as wood shrink as they pyrolyze and lose mass, others swell due to their inherent characteristics when exposed to heat [1]. This study focuses on experiments conducted at the Advanced Light Source (ALS) beamline 8.3.2, where in situ micro-computed tomography (µ-CT) is performed on materials as they are being pyrolyzed. Through in situ µ-CT, the change in total volume and porosity can be obtained in real-time, allowing for better understanding of the underlying thermophysical and chemical processes as a function of temperature. This study also focuses on the implementation of the Porous Microstructure Analysis software (PuMA) [2] to obtain thermal conductivity, permeability, and other properties of the material from the 3D tomographies. The information gained from these tomographies will supplement microscale model development of material morphological change and will aid macroscale modeling for high-temperature applications. For this study, Room Temperature Vulcanizing silicone (RTV) [3-5] is heated from room temperature to 1000°C using an infrared lamp heating system, and tomographies are continuously collected as the sample is heated. The tomographies are then segmented to obtain solid and void phases, from which estimates of pore size, porosity and total volume are extracted as a function of temperature. PuMA is deployed on the segmented tomographies to obtain thermal conductivity, permeability, and other properties as a function of temperature. Preliminary results show that RTV first intumesces (swells) as pyrolysis begins, due to build-up of pyrolysis gases in closed pores, and then shrinks significantly as more open pores are formed and the pyrolysis gases outgas. Pore network visualization of the tomographies using OpenPNM [6] showed the increase in pore connectivity with increase in temperature. Future work will focus on using PuMA to obtain macroscopic properties of RTV as a function of temperature.

Tomography↗

NASA NTRS2024

Evaluation of an Al-Cu-Zn-Mg Alloy for Wire-Fed Additive Manufacturing

A collaborative research study was conducted to evaluate an experimental Al-Cu-Zn-Mg alloy, designated Al C380H, developed by Arconic Corporation for wire-fed additive manufacturing (AM) techniques such as NASA’s electron beam freeform fabrication (EBF 3 ) process and the wire arc additive manufacturing (WAAM) process. The goal of the study was to determine, based upon metallurgical properties, whether additively manufactured Al C380H represented a viable alternative for applications currently using wrought 7xxx series aluminum. Al 2319 and Al 7075 were also deposited as AM-compatible and non-AM-compatible baselines, respectively. Evaluation was based on tensile, fracture, and corrosion properties. The strength and ductility of Al C380H-T6 materials produced by EBF3 and WAAM were sufficiently lower than typical values for Al 7050-T7 to indicate that additively manufactured Al C380H is not a viable replacement for current parts fabricated with Al 7050, due largely to the significant losses in Zn and Mg and development of porosity during deposition. EBF 3 parameters that reduced porosity, such as increasing electron beam current, higher raster frequency, sharper beam focus, and slower travel speed, augmented de-alloying of fugitive solute. Further enhancement of Zn and Mg content in Al C380H feedstock wire combined with adjustments to deposition conditions to minimize porosity may enable production of Al C380H parts by EBF 3 or WAAM that are viable replacements for current Al 7050 wrought products.

electron beam freeform fabrication (EBF3)↗

NASA NTRSDate not supplied

Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)

The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.

Adam Johnson↗

DOE OSTI2014

MODELING POTENTIAL IMPACTS OF SO2 CO-INJECTED WITH CO2 ON THE KNOX GROUP, WESTERN KENTUCKY

Understanding potential long-term impacts of CO2 impurities, such as sulfur and nitrogen compounds, on deep carbon storage reservoirs is of considerable interest because co-injection of the impurities with CO2 can bring significant economic and environmental benefits. The Cambrian–Ordovician Knox Group, a thick sequence of dolostone (Beekmantown Dolomite) with minor dolomitic sandstone (Gunter Sandstone), in western Kentucky, USA, has been evaluated as a prospective CO2 sequestration target. In this study, TOUGHREACT was used to build 1-D radial models to simulate the potential impacts of co-injected CO2 and SO2 on minerals, pore fluids, and porosity and permeability in the Beekmantown Dolomite and the Gunter Sandstone. Co-injection of a mass ratio of 2.5 percent SO2 and 97.5 percent CO2, representative of flue gas from coal-fired plants, was simulated and the co-injection simulations were compared to models with CO2 only injections. The model results suggest that the major impacts of added SO2 for both the Beekmantown and the Gunter rocks were significant enhancement of dissolution of dolomite and precipitation of anhydrite, leading to noticeable increases in porosity and permeability. The Gunter Sandstone appeared to be more active with SO2 than the Beekmantown Dolomite. More dolomite was dissolved in the Gunter than in the Beekmantown with the same SO2 impurity. Consequently, porosity was raised more in the Gunter than in the Beekmantown. On the other hand, the impacts on aluminosilicate minerals appeared to be insignificant in both reservoirs, slightly changing the rates of precipitation/dissolution but the overall reaction paths remained the same.

Zhu, Junfeng↗

DOE OSTI2016

Colorometric detection of water using MOF-polymer films and composites

A method including exposing a mixture of a porous metal organic framework (MOF) and a polymer to a predetermined molecular species, wherein the MOF has an open metal site for the predetermined molecular species and the polymer has a porosity for the predetermined molecular species; and detecting a color change of the MOF in the presence of the predetermined molecular species. A method including combining a porous metal organic framework (MOF) and a polymer, wherein the MOF has an open metal site for a predetermined molecular species and the polymer has a porosity for the predetermined molecular species. An article of manufacture including a mixture of a porous metal organic framework (MOF) and a polymer, wherein the MOF has an open metal site for a predetermined molecular species and the polymer has a porosity for the predetermined molecular species.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Laser ultrasonic assessment of the effects of oxidation and microcracking on the elastic moduli of nuclear graphite

Structure-property relationships in bulk materials can be important in establishing sensing methods to assess the state of material microstructure. This is particularly true for nuclear graphites since these materials can display anisotropy and can become oxidized under service conditions. Both anisotropy and oxidation-induced porosity can influence structural integrity and this must be confirmed during the lifetime of the material. In this work, laser ultrasonic methods were used to measure the elastic response of various graphite grades with a focus on NBG-18, NBG-25 and IG-110. Results of laser ultrasonic measurements in oxidized graphites show that the moduli decrease with increasing porosity. This variation can be interpreted successfully using effective medium models if the characteristics of graphite porosity are taken into account. Results of laser ultrasonic shear wave birefringence measurements can be used to assess elastic anisotropy. This anisotropy can be expressed in terms of the orientation distribution coefficients W400 and W200. Interpretation of results requires the use of appropriate property-averaging schemes.

Zeng, Fan W.↗

DOE OSTI2019

Electrochemical energy storage device

An electrochemical energy storage device includes an anode having a first mixture which includes a first plurality of electrically conductive carbon-comprising particles having a first average porosity, and lithium metal materials. The weight ratio of the first plurality of carbon-comprising and lithium metal materials is from 30:1 to 3:1. A cathode includes a second mixture having a second plurality of electrically conductive carbon-comprising particles having a second average porosity greater than the first average porosity, and lithium-intercalating metal oxide particles. The weight ratio of the second plurality of carbon-comprising and lithium-intercalating metal oxide particles is from 1:20 to 5:1. The weight ratio between the lithium metal materials loaded in the anode and the second plurality of carbon-comprising particles in the cathode is from 0.1-10%. An electrolyte physically and ionically contacts the anode and the cathode, and fills the pore volume in the anode, cathode and a porous separator.

Zheng, Jian-ping↗

DOE OSTI2019

Integrated Hardfacing of Stellite-6 Using Hybrid Manufacturing Process

Hybrid manufacturing systems provide a platform for integrated additive, subtractive and inspection methods on a single machine setup. The present work explores use of hybrid manufacturing for hardfacing of performance components for improving wear resistance. In this work, Stellite-6 was applied to a 410 stainless steel substrate using a hybrid manufacturing system incorporating multi-axis directed energy deposition and machining. Experimental testing was conducted to determine the effects of hybrid manufacturing parameters on internal porosity, surface porosity and microstructure in the cladded material, as well as on the roughness of the final machined surface. Correlation between porosity measurements made by x-ray tomography and surface dye-penetrant testing is presented and determination of ideal process parameters for hardfacing of components using hybrid manufacturing systems is briefly discussed.

Praniewicz, Maxwell↗

DOE OSTI2020

DOE Award No.: DE-FE0023919 Phase 3 Scientific/Technical Report

This is the Phase 3 Report for the ‘Deepwater Methane Hydrate Characterization and Scientific Assessment or Genesis of Methane Hydrates in the Gulf of Mexico (GOM2)’ research project (DOE Award No. DE-FE0023919). The report summarizes activities from January 16, 2018 to September 30, 2019. The project is led by the University of Texas at Austin (UT). The objective is to gain insight into the nature, formation, occurrence and physical properties of methane hydrate-bearing sediments for the purpose of methane hydrate resource appraisal through the planning and execution of drilling, coring, logging, testing and analytical activities that assess the geologic occurrence, regional context, and characteristics of marine methane hydrate deposits in the Gulf of Mexico outer continental shelf (OCS). We determined that it would not be possible to pursue the project with the International Ocean Discovery Program (IODP) and then developed a revised science and operations plan to maximize the science using a commercial vessel within the budget that is available. We improved the scientific capability of the UT pressure core center by adding the ability to X-ray pressure cores, and the ability to cut and store multiple core samples for experimental analysis. We transferred pressure cores to peer institutions, including the National Energy Technology Lab (NETL) the United States Geological Survey (USGS Woods Hole). We made advances in understanding the composition and source of gasses locked in the methane hydrate from Green Canyon 955 (GC-955). We developed approaches to determine the in-situ salinity of hydrate-bearing samples, revealing that the in situ salinity of the GC 955 reservoir is just above that of seawater. We determined that the GC-955 hydrate reservoir is composed of sandy silt with a high concentration of hydrate interbedded with clayey silt with no hydrate present. We determined that some or all of the intervals bounding the hydrate reservoir are composed of material similar to the reservoir (sandy silt with hydrate and clayey silt with no hydrate), but with a lower net to gross. We determined that the reservoir effective permeability at a hydrate saturation of ~80-90 % is ~0.1 mD (or 1.0×10-16 m2) to ~0.5 mD (or 5.0×10-16 m2) and the intrinsic permeability is ~12 mD (or 1.2×10-14 m2). The GC-955 reservoir in-situ porosity of sandy silt is 0.38 to 0.40 and is largely independent of effective stress, and that the porosity of clayey silt is 0.33 at an in situ effective stress of 3.8 MPa to ~0.37 at zero effective stress. We developed a systematic, repeatable approach to studying hydrate reservoir properties by reconstituting individual lithofacies from dissociated pressure cores. We determined index properties of GC-955 reservoir, including liquid limit and plasticity, porosity, capillary behavior, and particle size distribution. We developed a more robust pressure coring technology. We finalized and published the UT-GOM2-1 Expedition Volume and we finalized a dedicated volume on the UT-GOM2-1 expedition that will be published in the American Association of Petroleum Geologists Bulletin (AAPG) in spring 2020.

03 NATURAL GAS↗

DOE OSTI2025

Impacts of Biomass Feedstock Pre-Processing on Heat and Mass Transfer During Pyrolysis Using X-Ray Computed Tomography and Multiscale Modeling

Knowledge of the transport properties of biomass particles such as porosity, tortuosity, and permeability is paramount for high-fidelity modeling of biomass pyrolysis due to the heat and mass transfer limitations imposed by particle microstructure. X-ray computed tomography (XCT) is a non-destructive imaging method that enables full 3D reconstructions of the biomass particle microstructure with high resolution, permitting direct calculation of porosity, tortuosity, and permeability from real particle geometries. In this study, XCT imaging revealed the 3D microstructures of particles and chars from pyrolytic conversion of cylindrically cut or milled/pelletized loblolly pine samples. The porosity, tortuosity, and permeability were calculated directly from the XCT geometries via open-source microstructural analysis tool MATBOX+TauFactor (https://github.com/NREL/MATBOX_Microstructure_analysis_toolbox) and computational fluid dynamics (CFD) simulations using our solver, Mesoflow (https://github.com/NREL/mesoflow). These properties were used in a reactor scale model developed in COMSOL of the single particle reactor at NREL to investigate the impact of feedstock pre-processing on biomass conversion during pyrolysis with rigorous experimental validation.

biomass↗

DOE OSTI2023

Assessing pore network heterogeneity across multiple scales to inform CO2 injection models

Geologic heterogeneity is a key feature that must be considered when translations of scaled data are performed. This paper presents the assessment of geologic heterogeneity using a multiscale workflow that includes image analysis-based methods coupled with well log analysis to provide data in which fractals and machine learning methods estimate the carbon dioxide (CO 2 ) storage resource potential of a reservoir. The heterogeneity of rock properties of the complex Bell Creek reservoir in Montana, USA, was explored at the pore scale (~nm to mm), core scale (~mm to m), and well scale (~cm to m). The data used in this study included advanced image analysis of micro-CT (computed tomography) images (pore scale), thin sections (pore scale), plugs and core images (core scale) and well logs (well scale). The micro-CT images were segmented using a U-net segmentation approach into objects of pores and grains. Further, the segmented images were reconstructed into subvolumes of different sizes. Physical properties (porosity and permeability) and fractal dimensions were calculated for the various subvolumes, and Lorenz coefficient (Lc) values, a single parameter to describe the degree of heterogeneity within a pay zone section, were calculated from thin-section images and well logs. Porosity and fractal dimension values were used to estimate the 188-µm threshold of representative elementary volume (REV) in this study. Both the Lc and fractal dimension values were found to be negatively correlated. When these two parameters are combined, it is possible to discern differences in the complex porous networks of the samples analyzed in this study.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Reformulating a Gurson-based dynamic damage model and demonstrating improved predictive power and numerical robustness

The original Tepla (TEnsile PLAsticity) ductile damage model, based on the Gurson yield surface, has long been used to model damage evolution and material failure under dynamic loading. Unfortunately, Tepla suffered from mesh sensitivity, numerical instability, and limited predictive capability. Here, we theoretically reformulate Tepla to address these issues. We especially focus on the prediction of porosity, which is the key state variable used for modeling ductile damage, as compared to more easily measured surface velocities, which are at best an indirect measure of damage. Key model changes include separating the viscosity during volumetric void growth from underlying shear strength behavior and switching to an iterative bisection solver. The new Tepla is then calibrated on incipient spall experiments on half-hard copper and tantalum, which demonstrate its ability to simultaneously fit the model to recovered porosity distributions and measured surface velocities, a stringent test. Improved numerical behavior, such as greatly reduced mesh sensitivity, is also shown in those simulations. Finally, the new Tepla model is applied to several high-explosive loaded, sweeping wave experiments, showing the ability of the model to predict behavior on tests with significantly different loading conditions and histories than the calibration data.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Role of Zeolite Structural Properties toward Iodine Capture: A Head-to-head Evaluation of Framework Type and Chemical Composition

This study evaluated zeolite-based sorbents for iodine gas [I2(g)] capture. Based on the framework structures and porosities, five zeolites, including two faujasite (FAU), one ZSM-5 (MFI), one mesoMFI, one ZSM-22 (TON), as well as two mesoporous materials, were evaluated for I2(g) capture at room temperature and 150 °C in an iodine-saturated environment. From these preliminary studies, the three best-performing zeolites were ion-exchanged with Ag+ and evaluated for I2(g) capture under similar conditions. Energy-dispersive X-ray spectroscopy data suggest that Ag-FAU frameworks were the materials with the highest capacity for I2(g) in this study, showing ~3× higher adsorption compared to Ag-mordenite (Ag-MOR) at room temperature, but X-ray diffraction measurements show that the faujasite structure collapsed during the adsorption studies because of dealumination. The Ag-MFI zeolites are decent sorbents in real-life applications, showing both good sorption capacities and higher stability. In-depth analyses and characterizations, including synchrotron X-ray absorption spectroscopy, revealed the influence of structural and chemical properties of zeolites on the performance for iodine adsorption from the gas phase.

aluminosilicate zeolites, iodine, porosity, acidit↗

DOE OSTI2019

Utah FORGE: Earth Model Native State Simulation Results

Utah FORGE phase 2C Native State Simulation zip contains the data used for the boundary conditions and subsequent native state simulation results obtained using the simulation code FALCON. Data are from the nodes of the simulation domain, with used a uniform 50m spacing over a 2500 X 2500 X 2750m domain approximately centered on the FORGE footprint. There is also a read me text file, that is included, containing metadata. The Reservoir Porosity and Upscale DFN Permeability zip contains the data used for the spatial distribution of the anisotropic permeability and porosity used in the native state simulation of the Utah FORGE site. Please contact Robert Podgorney at the Idaho National Laboratory with questions, robert.podgorney@inl.gov. There is also a read me text file included containing metadata.

15 GEOTHERMAL ENERGY↗

DOE OSTI2025

3D Printing of Highly Porous Polypropylene Separators for Lithium‐Ion Batteries Using Fused Deposition Modeling and Thermally Induced Phase Separation

Appearing as one of the key-components of lithium-ion batteries (LIBs), this work specifically focuses on the additive manufacturing (AM) of custom-shape separators, facilitated by the filament material extrusion process, also called fused deposition modeling (FDM). The development and optimization of composite thermoplastic filament feedstocks combining polypropylene and paraffin wax, followed by the 3D printing of the separator membranes is shown. A post-processing step, based on thermal induced phase separation (TIPS), is introduced to promote porosity formation through removal of the paraffin wax sacrificial phase within the 3D printed items. Separators with different polypropylene/paraffin wax ratios are developed and the impact on printability, mechanical strength, porosity, and electrochemical performances, is thoroughly discussed. X-ray micro-computed tomography is employed to assess the geometric fidelity and to detect printing defects in a complex 3D lattice structure. The performance of the 3D printed porous separators is also compared to a commercial separator. This pioneering research establishes a foundation for the creation of porous separators that can adapt to and conform into 3D printed battery architectures with novel form factors, and also creates opportunities for the use of FDM and TIPS for a wide range of applications that employ porous structures beyond the energy storage field.

3D printing↗

DOE OSTI2016

Design Principles for Optimum Performance of Porous Carbons in Lithium-Sulfur Batteries

Here, a series of experiments is presented that establishes for the first time the role of some of the key design parameters of porous carbons including surface area, pore volume, and pore size on battery performance. A series of hierarchical porous carbons is used as a model system with an open, 3D, interconnected porous framework and highly controlled porosity. Specifically, carbons with surface areas ranging from ≈500–2800 m 2 g -1 , pore volume from ≈0.6–5 cm 3 g -1 , and pore size from micropores (≈1 nm) to large mesopores (≈30 nm) are synthesized and tested. At high sulfur loadings (≈80 wt% S), pore volume is more important than surface area with respect to sulfur utilization. Mesopore size, in the range tested, does not affect the sulfur utilization. No relationship between porosity and long-term cycle life is observed. All systems fail after 200–300 cycles, which is likely due to the consumption of the LiNO 3 additive over cycling. Moreover, cryo-scanning transmission electron microscopy imaging of these carbon–sulfur composites combined with X-ray diffraction (XRD) provides further insights into the effect of initial sulfur distribution on sulfur utilization while also revealing the inadequacy of the indirect characterization techniques alone in reliably predicting distribution of sulfur within porous carbon matrices.

25 ENERGY STORAGE↗

DOE OSTI2023

Reduction of Iron‐Ore Pellets Using Different Gas Mixtures and Temperatures

Direct reduction of iron ore (DRI) is gaining an increased attention due to the growing need to decarbonize industrial processes. The current industrial DRI processes are performed using reformed natural gas, which results in CO 2 emission, although it is less than carbothermic reduction in the blast furnace. Carbon‐free reduction may be realized through the utilization of green H 2 as a reducing agent, in place of natural gas. Herein, the effects of various gas mixtures and temperature on the reduction kinetics of the hematite iron‐ore pellets are focused on in this work. Pellets are reduced at 700, 800, 850, and 900 °C in hydrogen and using various gas mixes at 850 °C. Morphology of the pellets is investigated with the help of scanning electron microscopy and mercury intrusion porosimetry. The effects of temperature and gas composition on the reduction kinetics and porosity of the pellets are discussed. A notable effect of reduction rate on the internal structure of the pellets is detected, slower reduction rate yielded bigger pores offsetting the gas composition. Higher temperature results in coarser pores and higher porosity. Finally, increase of CO content in the gas mix also leads to bigger pore size.

36 MATERIALS SCIENCE↗