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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Origin and Evolution of Organic Matter Preserved in Stardust Cometary Aerogel Tracks

The STARDUST spacecraft captured dust samples from Comet 81P/Wild 2 at a relative velocity of 6.1 km/s in a low density silica aerogel and returned them to the Earth. One of the main of the scientific goals established for the mission was to determine whether comets contained complex organic materials and, contingently, the nature and abundance of this material. [1] Although contamination concerns due to carbonaceous impurities intrinsic to the flight aerogel remain, it is generally accepted that at least a fraction of the captured dust particles contain an indigenous organic component. [2] However, understanding the nature and abundance of this material is complicated by nature of the collection process. The rapid dissipation of particle s kinetic energy during its impact and deceleration cause both the particle and surrounding aerogel to experience an intense thermal pulse of upwards of 2000K for a period up to several hundred nanoseconds [3]. During this period thermal alteration and or destruction of organic species present in the impacting particle are likely to occur. We have used the technique of ultrafast two-step laser mass spectrometry (ultra L2MS) [4] to investigate how the nature and distribution of aromatic and conjugated organic species varies between and within aerogel cometary tracks and their associated terminal particles.

McKay, D.S.↗
DOE OSTI2025

Accelerating Discovery of Solid‐State Thin‐Film Metal Dealloying for 3D Nanoarchitecture Materials Design through Laser Thermal Gradient Treatment

Thin‐film solid‐state metal dealloying (thin‐film SSMD) is a promising method for fabricating nanostructures with controlled morphology and efficiency, offering advantages over conventional bulk materials processing methods for integration into practical applications. Although machine learning (ML) has facilitated the design of dealloying systems, the selection of key thermal treatment parameters for nanostructure formation remains largely unknown and dependent on experimental trial and error. To overcome this challenge, a workflow enabling high‐throughput characterization of thermal treatment parameters is demonstrated using a laser‐based thermal treatment to create temperature gradients on single thin‐film samples of Nb‐Al/Sc and Nb‐Al/Cu. This continuous thermal space enables observation of dealloying transitions and the resulting nanostructures of interest. Through synchrotron X‐ray multimodal and high‐throughput characterization, critical transitions and nanostructures can be rapidly captured and subsequently verified using electron microscopy. The key temperatures driving chemical reactions and morphological evolutions are clearly identified. While the oxidation may influence nanostructure formation during thin‐film treatment, the dealloying process at the dealloying front involves interactions solely between the dealloying elements, highlighting the availability and viability of the selected systems. Further, this approach enables efficient exploration of the dealloying process and validation of ML predictions, thereby accelerating the discovery of thin‐film SSMD systems with targeted nanostructures.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Development of a Techno-Economic Analysis Framework for a Solar Thermochemical Fuel Production Process

Synthetic liquid fuels can provide a drop-in substitute for fossil-based fuels in sectors such as aviation and maritime, where electrification is not a viable option due to the need for high specific energy density. However, for these alternative fuels to be adopted at a commercial scale, their price must be competitive compared to their fossil-based counterparts. The reverse water-gas shift (RWGS) reaction offers a promising pathway, using hydrogen (sourced from electrolysis) and carbon dioxide as the feed and reacting to produce syngas - a mixture of H2 and CO at a specific ratio. Syngas is a useful precursor that can be converted into fuels and chemicals via known downstream processes, such as liquid transportation fuels via Fischer-Tropsch (FT) synthesis. The RWGS reaction is currently not applied in commercial scale, unlike the rest of the components in the process chain (electrolyzers and syngas-to-fuel synthesis units). The RWGS reaction poses several challenges due to its restrictive thermodynamics. Being an equimolar reaction, high temperatures and a large excess of H2 are needed to achieve reasonable CO2 conversion at equilibrium. This has detrimental effects on practical process implementation and the quality of syngas that can be produced, with direct effect on the energy and capital requirements, as well as the need for expensive downstream separation. In this work, we are proposing to develop a new concentrating solar thermal (CST) compatible RWGS reactor, performing the reaction in a 2-step chemical looping process using metal oxide at a temperature range of 600-800 degrees Celsius. By decoupling the reactor from the solar receiver, the Generation 3 (Gen3) CST technology could be utilized, together with its proposed thermal energy storage (TES) technology, benefitting from a good match to the required temperatures. CST technology is a viable option for supplying the heat that could be rapidly deployed in scale, thus being a good match to the gas-to-liquid (GTL) process which requires a large minimal scale to be commercially viable. The integration of TES with CST also allows operating the plant at large annual capacity factors and avoids multiple shutdown/startup cycles, thus fitting into the steady-state operation mode that most GTL processes require. The main innovation in the proposed design hinges on a countercurrent reaction design using a packed bed reactor. In 2019 Metcalfe et al. showed the benefits of countercurrent species exchange could be realized in a redox chemical-looping processes, by storing the favorable countercurrent chemical potential profiles in a packed bed of non-stoichiometric oxide. Metcalfe et al. applied this breakthrough concept to the WGS reaction, which is conventionally a co-feed catalytic process, showing a dramatic improvement. Bulfin et al. (2023) performed a similar proof-of-concept demonstration for the RWGS reaction using CeO2, achieving cumulative and peak CO2 conversions of 88% and 95%, respectively, compared to a thermodynamic limit of 58% for the co-feed catalytic process at the same conditions. In our new REGENLOOP project, we are developing a reactor prototype from the heat-exchange packed bed reactor-type, a commonly used reactor in the chemical industry. The endothermic heat of reduction will be supplied to the reactor using CST, while the same heat transfer fluid (HTF) mechanism will be used to extract the exothermic heat of oxidation. An array of multiple reactors is used to supply constant high-purity CO stream, that is then mixed with H2 from electrolysis to produce a high-purity syngas at the required composition. By removing the CO-CO2 separation after the RWGS process, significant energy and cost reduction can be achieved. A physics-based TEA framework is currently being developed, covering all the major plant processes, from the solar collection through storage, chemical looping RWGS, GTL, and auxiliary unit operations, up to the liquid hydrocarbon product. This modeling framework will utilize reduced-order models for the chemical looping RWGS and TES, CST modeling using SolarPILOT, and Aspen Plus for the GTL. By using this combined physics-based approach, the effects of design/operating parameters on the performance and cost can be elucidated. In our presentation, the modeling framework will be presented in detail, including preliminary cost predictions of using this plant configuration under a few selected relevant case studies. This study will be used to identify the major cost drivers, informing further system design and optimization needed to chart the way for a commercially viable pathway.

14 SOLAR ENERGY↗
DOE OSTI2025

Strategies for Fabricating Molybdenum Structures Using Laser Powder Bed Fusion

Advances in manufacturing techniques are viewed as enabling technologies for development of high performance nuclear fuel forms that couple high uranium density with improvements to key properties such as thermal conductivity unattainable through conventional fabrication routes. Additive manufacturing (AM) enables the fabrication of complex fuel geometries that are difficult or impossible to achieve using conventional manufacturing methods. Melting-based AM processes, such as laser powder bed fusion (LPBF), provide high geometric resolution (>200 µm depending on the feature) across a variety of metal alloys, including those suitable for high-temperature fuel cladding applications, such as Nb, W, and Mo. Molybdenum is particularly attractive due to its high thermal conductivity, low thermal expansion, and excellent mechanical stability at elevated temperatures. However, its high melting temperature and brittle nature at low temperatures pose significant challenges during LPBF processing. Rapid solidification inherent to LPBF induces high residual stresses, often leading to post-solidification cracking, which limits the manufacturability of Mo components via this method.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1999

Characterization of Optical Lenses to be Considered for the Imaging of Crystal Dendrite Growth

Dynamic fracture is a phenomenon that is extremely sensitive to small perturbations in system parameters. This phenomenon is, in some ways, similar to that of dendritic crystal growth, although it is governed by different physical principles. Crystal dendrite growth patterns are affected by parameters such as temperature, pressure, and gravity. By studying the behavior of crystal dendrites in a controlled, microgravity environment, a greater understanding of dynamic fracture could be revealed. A sealed cubical container contains four stingers, which facilitate the growth of crystal dendrites. The container has five windows and is emersed in a liquid, for thermal isolation. The tip of a dendrite can advance in any direction, therefore three-dimensional images of the process are desired. Furthermore, because of the rapid growth rate, a fast image frame rate is required for accurate tracking of dendrite tip velocity. In addition, optical parameters such as field of view, depth of focus, and resolution are examined, as well as the working distance between a lens and the target of observation.

Wing, Frank M.↗
DOE OSTI2025

A mechanistic study on environment gas in laser powder bed fusion

A variety of protective or reactive environmental gases have recently gained growing attention in laser-based metal additive manufacturing (AM) technologies due to their unique thermophysical properties and the potential improvements they can bring to the build processes. However, much remains unclear regarding the effects of different gas environments on critical phenomena in laser AM, such as rapid cooling, energy coupling, and defect generation. Through simultaneous high-speed synchrotron x-ray imaging and thermal imaging, we identify distinct effects of two environmental gases in laser AM and gained a deeper understanding of the underlying mechanisms. Compared to the commonly used protective gas, argon, it is found that helium has a negligible effect on cooling the part. However, helium can suppress unstable keyholes by decreasing effective energy absorption, thus mitigating keyhole porosity generation and reducing pore size under certain processing conditions. In conclusion, these observations provide guidelines for the strategic use of environmental gases in laser AM to produce parts with improved quality.

36 MATERIALS SCIENCE↗
DOE OSTI2024

One-Pot Coating of Ceramic Powders by Exfoliated Boron Nitride Layers with a Dense CO 2 Medium and Ultrasound-Aided Mixing

The coating or doping of substrates by two-dimensional materials to impart superior functional properties (such as improved thermal conductivity, bacterial resistance, reduced friction) is receiving increased attention. Environmentally benign, rapid and scalable coating techniques are desirable for this purpose. Here, we report a novel process for coating alumina, silicon carbide and boron carbide substrates with hexagonal boron nitride (h-BN) layers. The process consists of two sequential steps. First, h-BN layers are exfoliated from bulk h-BN in supercritical carbon dioxide (scCO 2 ) using ultrasound-aided mixing. This step is followed by self-assembly (i.e., coating) of the exfoliated h-BN on the substrates in liquid CO 2 also aided by ultrasound. The liquid CO 2 state is achieved by simply lowering the pressure and temperature of the first step below the critical point of CO 2 (P c = 72.8 atm; T c = 31.1 °C). Scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) micrographs clearly reveal the exfoliation of h-BN under scCO 2 conditions as well as the h-BN assembly on various substrates under liquid CO 2 conditions. X-ray diffraction patterns confirm the structural integrity of the coated h-BN layers. It was also confirmed that without a transition to the liquid CO 2 phase following exfoliation in scCO 2 , there was negligible coating of h-BN on the substrates. Researchers in the field could consider this benign process to rapidly coat or dope materials with h-BN and other 2D materials to impart improved functional properties in myriad applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Deactivation of Mo/H-ZSM-5 in Microwave-Assisted and Thermal-Driven Methane Dehydroaromatization

A better understanding of catalyst deactivation is needed to improve catalyst design and performance in microwave-enhanced methane dehydroaromatization (MDA). Here, this study investigates the deactivation of a molybdenum supported H-ZSM-5 zeolite (Mo/H-ZSM-5) catalyst in MDA under microwave-heated conditions, comparing its performance to that of the same catalyst under conventional heating. While the microwave-assisted (MW) process achieved higher benzene yields, the catalyst experienced faster deactivation due to the selective and rapid deposition of coke within the pores of the zeolite, as confirmed through Brunauer–Emmett–Teller (BET), X-ray diffraction (XRD), ammonia-temperature programmed desorption (NH 3 -TPD), thermal gravimetric analysis (TGA), temperature programmed oxidation (TPO), and X-ray photoelectron spectroscopy (XPS) analyses. The quantification of total coke content via TGA/TPO and surface carbon (XPS) revealed that nearly twice as much coke was deposited on the catalyst under MW conditions compared to that on the conventionally heated material, and the coke exhibited a more conductive and graphitic nature. The accelerated deactivation rates were attributed to the formation of hot spots in the MW system, leading to enhanced coupling with coke formed in situ during the reaction and resulting in increased Mo reduction. Observations indicated that the CO activation used to carburize the catalyst prior to the reaction is not advantageous in the MW heating environment. The presence of large amounts of Mo oxides at elevated temperatures (through hot spots) exposed to methane leads to instability under the reaction conditions. Optimizing the activation environment and improvement of the Mo dispersion within the pores are potential strategies to improve catalyst stability.

Mo/H-ZSM-5 zeolite↗
DOE OSTI2025

Suppressing Ordering in Equiatomic Fe-Co via Laser Powder Bed Fusion

Neutron and electron diffraction was employed to evaluate the effectiveness of thermal management strategies in suppressing the formation of the equilibrium-ordered B2 (CsCl) phase in equiatomic binary Fe-Co specimens fabricated by laser powder bed fusion additive manufacturing. Specimens with a tensile dogbone geometry were fabricated using various combinations of process parameters (laser power and raster speed) and thermal management strategies (no support struts, struts only in the top gauge section, and struts throughout the gauge section). Diffraction results demonstrate that the rapid solidification during PBF-L effectively minimized B2 formation, with laser power and effective scan velocity having no significant impact on the degree of ordering. Furthermore, the inclusion of support struts in the top grip region had no perceivable impact on ordering, whereas specimens with support struts in the gauge region exhibited no detectable ordering. Results are discussed in the context of thermal finite element analysis predictions.

Laser Material Processing↗
NASA NTRS2004

Microbial Paleontology, Mineralogy and Geochemistry of Modern and Ancient Thermal Spring Deposits and Their Recognition on the Early Earth and Mars"

The vision of this project was to improve our understanding of the processes by which microbiological information is captured and preserved in rapidly mineralizing sedimentary environments. Specifically, the research focused on the ways in which microbial mats and biofilms influence the sedimentology, geochemistry and paleontology of modem hydrothermal spring deposits in Yellowstone national Park and their ancient analogs. Toward that goal, we sought to understand how the preservation of fossil biosignatures is affected by 1) taphonomy- the natural degradation processes that affect an organism from the time of its death, until its discovery as a fossil and 2) diagenesis- longer-term, post-depositional processes, including cementation and matrix recrystallization, which collectively affect the mineral matrix that contains fossil biosignature information. Early objectives of this project included the development of observational frameworks (facies models) and methods (highly-integrated, interdisciplinary approaches) that could be used to explore for hydrothermal deposits in ancient terranes on Earth, and eventually on Mars.

Farmer, Jack D.↗
NASA NTRS1994

Collisional-Radiative Nonequilibrium and Precursor Effects in a Nitrogen Shock Wave

Improvements to a plasma code with a Collisional-Radiative (CR) non-equilibrium model are made, allowing for a more accurate description of the physical processes. The code allows for non-Boltzmann distributions of the electronic excited states by convecting separately each excited state, as a pseudo-specie. Each molecular state has also its own vibrational temperature, while a global rotational temperature is assumed. The free electron temperature is different from those of the excited states, and the electron heat conduction is also included. The CR model also uses a unique coupling between chemistry and vibrational energy (C-V coupling), which is fully coherent, and has the property of establishing thermal equilibrium as well as chemical equilibrium, on its own. We have also included a coupling between electronic excitations and vibrational energy (X-V coupling), which can have a strong influence on the vibrational temperature of some states. The recent improvements include the multi- temperature dependence of the chemical rates for associative ionization, as well as the estimation of the internal energies transferred during this process. Additionally, the distribution of energy into different translational modes (electron and heavy particles) is now correctly modeled. This provides a very rapid heating mechanism for the free electrons, since it is found that the electrons are generated with an average thermal energy of the same order as the heavy particle translational energy. This effect was observed by Gorelov et al in a recent paper, and lead to pronounced peaks in electron temperature immediately behind the shock. We will attempt ro reproduce this phenomenon. The last modification concerns the inclusion of the radiative terms into the calculations, thus enabling us to observe the effect of radiative losses and radiation transport. Preliminary tests have shown that the radiative losses are not negligible, i.e. the shock velocity drops when the radiative emission is included. In addition, we have observed some precursor excitation and ionization phenomena. These may be important at high shock velocities, and this will be investigated in detail. Precursor phenomena were also observed (in air) by Gorelov et al, and our results (for pure nitrogen) will be qualitatively compared with theirs.

Cambier, Jean-Luc↗
NASA NTRS1986

Mass and energy balance of the cold Io torus

A new model of the cold Io torus is described. Ions and energy are injected into the system by independent processes so that the mass balance is isolated from the energy balance. The primary source of energy is local ionization and acceleration of hot pickup ions resulting from charge exchange between thermal ions and an extended cloud of Iogenic sulfur and oxygen atoms. The primary energy loss mechanism of the plasma is collisionally excited line emission at optical wavelengths. The primary ion source is radial diffusion inward from the hot torus on a time scale of 140-710 days. The primary ion loss mechanism is a novel two-step enhanced recombination mechanism involving charge exchange between thermal ions and an extended cloud of neutral SO2 molecules, followed by rapid dissociative recombination of the resultant molecular ion. The model provides a self-consistent solution which reconciles a number of diverse observations with known physical processes.

Moreno, M. A.↗
DOE OSTI2025

P–P Coupling with and without Terminal Metal–Phosphorus Intermediates

Terminal metal–phosphorus (M–P) complexes are of significant contemporary interest as potential platforms for P-atom transfer (PAT) chemistry. Decarbonylation of metal–phosphaethynolate (M–PCO) complexes has emerged as a general synthetic approach to terminal M–P complexes. M–P complexes that are stabilized by strong M–P multiple bonds are kinetically persistent and isolable. In the absence of strong M–P stabilization, the formation of diphosphorus-bridged complexes (i.e., M–P–P–M species) is often interpreted as evidence for the intermediacy of reactive, unobserved M–P species. Here, we demonstrate that while diphosphorus complexes can arise from reactive M–P species, P–P coupling can also proceed directly from M–PCO species without the intermediacy of M–P complexes. Photochemical decarbonylations of a pincer-supported Ni (II)–PCO complex at 77 K afford a spectroscopically observed terminal Ni–P complex, which is best described as a triplet, Ni(II)-metallophosphinidene with two unpaired electrons localized on the atomic phosphorus ligand. Thermal annealing of this transient Ni–P complex results in rapid dimerization to afford the corresponding P 2 2– -bridged dinickel complex. Unexpectedly, the same P 2 2– -bridged dinickel complex can also be accessed via a thermally promoted process in the absence of light. The analysis of reaction kinetics, isotope-labeling studies, and computational results indicate that the thermal P–P coupling process proceeds via a noncanonical mechanism that avoids terminal M–P intermediates. Together, these results represent the first observation of P–P coupling from characterized terminal M–P species and demonstrate that terminal M–P intermediates are not required to obtain P–P coupling products. These observations provide critical mechanistic understanding of the activation modes relevant to P-atom transfer.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

The effects of high-pressure annealing on magnetostructural transitions and magnetoresponsive properties in stoichiometric MnCoGe

In this study, phase transitions (structural and magnetic) and associated magnetocaloric properties of stoichiometric MnCoGe have been investigated as a function of annealing pressure. Metastable phases were generated by annealing at 800 °C followed by rapid cooling under pressures up to 6.0 GPa. The x-ray diffraction results reveal that the crystal cell volume of the metastable phases continuously decreases with increasing thermal processing pressure, leading to a decrease in the structural transition temperature. The magnetic and structural transitions merge and form a first-order magnetostructural transition between the ferromagnetic orthorhombic and paramagnetic hexagonal phases over a broad temperature range (>80 K) spanning room temperature, yielding considerable magnetic entropy changes. These findings demonstrate the utility of thermal processing under high pressure, i.e., high-pressure annealing, to control the magnetostructural transitions and associated magnetocaloric properties of MnCoGe without altering its chemical composition.

Physics↗
NASA NTRS1977

A survey of users of earth resources remote sensing data

The use of Landsat imagery and digital data, Skylab data and high-altitude aerial imagery by industry, government, academic and foreign analysts was surveyed. The study indicated that while most users are satisfied with current Landsat product quality and spectral coverage, there does exist a significant demand for extension of the spectral coverage to thermal and microwave regions, for resolutions in the 20 to 40 and 10 to 20 meter range, and for more rapid data delivery. Problems involving the acceptance of digital processing techniques by some users are also mentioned.

Wukelic, G. E.↗
NASA NTRS1997

An Analysis of Closure Mechanisms in the Plasma Wake of the TSS-1R Satellite

Collisionless Plasma Expansion (CPE), also known as "plasma expansion into a vacuum," in its most fundamental form, is the process by which a plasma expands into a void, or region highly depleted of particles. In CPE, the expansion is driven by the highly mobile electron constituent of the plasma as it moves across the density gradient and into the void region. A bi-polar electric field is set up between this rapidly expanding electron front and the massive ions, which have a low thermal speed and lag behind in the region of the plasma-void interface. These ions are quickly accelerated by the expansion electric field and can, theoretically, approach the thermal speed of the electrons. CPE is a fundamental and a very robust process in that it only requires that a sharp density gradient exist in a plasma. It has already been observed to exist in various plasmas ranging over five orders of magnitude in density. The range of phenomena in which CPE has been observed includes the closure of plasma wakes created in simulated space plasmas in the laboratory; it was found to be the process controlling the refilling of the wake created by the Space Shuttle in the ionospheric plasma; and recent in situ data, obtained by the WIND spacecraft as it passed through the wake of the earth's moon last year, have shown CPE to be involved in the closure of the Lunar wake. CPE is also expected to influence the morphology and physics of the solar wind interactions with Mercury and Mars, and has been suggested as a potential factor in such wide ranging phenomena as the acceleration of plasma away from the coma of comets and the energization of ions that underlies the upward expansion of the polar wind into the earth's magnetosphere. The Tethered Satellite System (TSS)-1R data provides an opportunity to test this process in situ under semi-controlled conditions. The available data shows the intensity, drift energy and angle of inclination to the wake of the converging ion streams at a down stream distance of one satellite radius (80 CM).

Stone, N. H.↗
DOE OSTI2025

Mixed Element Microparticle Characterization by Electron Probe Microanalysis

Abstract Microparticle compositional characterization for nuclear forensics has traditionally been achieved by “gold-standard” destructive analytical techniques such as large geometry-secondary ion mass spectrometry and fission track-thermal ionization mass spectrometry, but long processing times and total sample consumption eliminate the option of subsequent analysis by other methods. Electron probe microanalysis has long been widely employed for rapid, nondestructive, micrometer-scale compositional measurements and imaging in fields such as material science and geology and may therefore need to be reevaluated as an alternative tool for microparticle analysis for the nuclear forensics community. This study presents the use of electron probe microanalysis for imaging and quantitative characterization of homogeneous microparticles utilizing a calibration curve based on high-precision quadrupole-inductively coupled plasma-mass spectrometry analyses. Samples of opportunity synthesized at Savannah River National Laboratory, nickel-doped cerium oxide microparticles, were selected as analogs for plutonium-doped uranium oxide microparticles. Positive detection and accurate quantification of variable amounts of nickel dopant down to trace levels (10s of parts per million) suggest applicability of this technique to other mixed element systems (e.g., actinides). Quantitative single-particle characterization via electron probe microanalyzer may thus provide a high fidelity, nondestructive complement to techniques currently in use.

Riche, Alexis T. (ORCID:0009000121978126)↗
DOE OSTI2024

Evaluation of In-Situ AM Process Monitoring Techniques and Potential for Detecting Process Anomalies and Undesirable Microstructures

The US Department of Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing rapid qualification of new materials for fabrication of nuclear relevant components using advanced manufacturing techniques. Particular interest is placed on code-qualifying stainless steel (SS) 316H processed by laser powder bed fusion (LPBF) additive manufacturing. A paradigm that incorporates data from in-situ sensing during the printing, ex-situ characterization, and advanced artificial intelligence–based models was established under the Transformation Challenge Reactor (TCR) program to develop a pedigree for each fabricated component that could be tracked from the feedstock to the component’s release for application. Under the TCR program, the Peregrine software was developed as a tool for incorporating the vast amounts of in-situ and ex-situ characterization data collected; all data stored on a rapidly growing digital platform. The digital platform allows for users to link site-specific process anomalies to the macro- and microstructure. The platform will eventually be able to predict component performance, which will be crucial to qualifying materials and components in risk-averse industries such as those supporting and building nuclear reactors. Current in-situ process monitoring techniques that are already integrated with software like Peregrine are advantageous for identifying process anomalies including powder spatter, component edge swelling, recoating-build interactions, and so on. However, additional data are required to fully predict the resulting microstructures needed for identifying relationships to component performance. The rapid cooling rates observed in LPBF are some of the highest of any bulk manufacturing process, resulting in heterogenous microstructures and typically causing anisotropy in mechanical properties. Moreover, evolved residual thermal stresses are high, which can cause severe defects such as delamination or cracking. Therefore, other in-situ monitoring methods are warranted for exploration to measure and map the thermal history, and potentially the stress state, of each build. This report summarizes different in-situ monitoring strategies proposed for LPBF with a focus on the more developed sensor systems. Novel capabilities for measuring melt pool temperatures are also addressed to better inform modeling efforts.

36 MATERIALS SCIENCE↗