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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
DOE OSTI2026

Supervised Learning-Based Spatial Position Estimation with Vertical Displacement for Hovering UAV Wireless Power Transfer

This study presents a supervised learning-based spatial position estimation approach for wireless power transfer (WPT) systems supporting hovering unmanned aerial vehicle (UAV) charging. Unlike stationary charging scenarios, hovering UAVs introduce continuous lateral misalignment and vertical displacement, leading to variations in magnetic coupling and reduced power transfer efficiency. To address this challenge, the proposed method estimates the relative spatial position of the receiver coil using only electrical measurements obtained at the secondary side. A supervised learning model is trained to map output voltage and current features to spatial coordinates, enabling position awareness without requiring external sensors, vision systems, or communication links. The sensing functionality is inherently integrated into the WPT system, allowing simultaneous power transfer and localization through the same magnetic interface. Experimental validation is conducted on a laboratory-scale prototype under varying lateral offsets and air-gap conditions. In addition, spline-based interpolation is employed to increase spatial data density for training. The results demonstrate that the proposed framework can capture spatial variations associated with both lateral and vertical displacement, providing reliable position estimation under hovering conditions. This work establishes a hardware-efficient, sensorless solution for UAV wireless charging and serves as a baseline for advanced data-driven position estimation methods in dynamic WPT systems.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗
DOE OSTI2026

Extension of Clad Damage Propagation Model for Fission Gas Dispersal and Two-Phase Flow Effects in MOOSE SubChannel Module

This report presents an extension of the Clad Damage Propagation (CDAP) model implemented in the MOOSE SubChannel Module (SCM) to capture post-failure fission-gas dispersal and two-phase flow effects in sodium-cooled fast reactor assemblies. The extended model tracks discharged gas axially and radially, computes channel-averaged flow quality and void fraction using a Lockhart–Martinelli framework, evaluates two-phase frictional pressure-drop multipliers, determines inlet mass-flow degradation under fixed core pressures, and applies an intensified-void-based heat-transfer degradation to affected fuel pins. Radial plume expansion is parameterized using mineral-oil jet experiments mapped to sodium conditions via Reynolds–Weber similarity. Implementation details are documented, along with the new methods and user inputs needed to control plume mapping and two-phase behavior. Demonstration simulations for 19- and 37-pin bundles show that breach size and inlet velocity strongly influence propagation potential: small breaches (≤0.5 mm) produce limited degradation while larger breaches (~1 mm) can drive oscillatory temperature spikes and enhanced failure propagation, especially at higher velocities. These results demonstrate that the extended CDAP model provides a more complete framework for quantifying cladding damage propagation and evaluating propagation potential in transient scenarios. The approach remains computationally efficient, consistent with subchannel-level analysis, yet incorporates sufficient physics to bridge localized post-failure effects with bundle- and assembly-scale degradation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

The Emission and Suppression of Line Features in Luminous Transients

Featureless optical and ultraviolet (UV) spectra are a puzzling signature to emerge from recent observations of luminous fast blue optical transients (LFBOTs) and some tidal disruption events (TDEs). We describe the landscape of source and gas properties that are expected to form H, He I , and He II emission lines, and map spectral types to the parameter space of luminosity and system radius. Using one-dimensional radiative transfer calculations, we show that high source luminosities (L > 10 44 erg s −1 ) and compact ejecta radii (r < 10 14 cm) produce featureless spectra, due to the high temperature and ionization state of the emitting medium. Intermediate luminosities and moderately compact systems can generate He II -dominated spectra, while lower luminosities and more extended atmospheres result in conspicuous H and He I emission. Large expansion velocities (v ≥ 0.1c) can further broaden lines such that they blend into the continuum. Featureless UV spectra may require even more extreme ionization environments or velocities in order to suppress the many intrinsically strong metal lines at those wavelengths. Applying this framework to understand the absence of features observed in LFBOTs and featureless TDEs, we find that, under the optically thick, quasi-thermal conditions considered here, nonhomologous, compact outflows are likely necessary for featurelessness to persist in optical and UV spectra.

Aspegren, Olivia [University of California, Berkel↗
DOE OSTI2020

Moiré quantum chemistry: Charge transfer in transition metal dichalcogenide superlattices

Transition metal dichalcogenide (TMD) bilayers have recently emerged as a robust and tunable moiré system for studying and designing correlated electron physics. In this Rapid Communication, by combining a large-scale first-principles calculation and continuum model approach, we provide an electronic structure theory that maps long-period TMD heterobilayer superlattices onto diatomic crystals with cations and anions. We find that the interplay between the moiré potential and Coulomb interaction leads to filling-dependent charge transfer between different moiré superlattice regions. Further, we show that the insulating state at half filling found in recent experiments on WSe 2 /WS 2 is a charge-transfer insulator rather than a Mott-Hubbard insulator. Our work reveals the richness of simplicity in moiré quantum chemistry.

36 MATERIALS SCIENCE↗
DOE OSTI2024

New Tank Mapping Method Improves Waste Removal Process

Savannah River Mission Completion is the Liquid Waste (LW) contractor at the Savannah River Site (SRS). The LW mission is tasked with treating and disposing of legacy nuclear waste. There are multiple facilities involved in this work, including the Concentration, Storage, and Transfer Facilities (CSTF), the Defense Waste Processing Facility (DWPF), the Salt Waste Processing Facility (SWPF), and the Saltstone Production Facility (SPF). The CSTF includes 43 underground waste tanks used to store and support processing of radioactive liquid waste. Waste removal activities, such as salt dissolution campaigns and sludge agitation, are conducted within the CSTF waste tanks to convert the waste into a form that allows for downstream processing at other LW facilities. While performing these waste removal campaigns, camera inspections are performed to assess the quantity and distribution of the remaining waste within the waste tank (i.e. saltcake or sludge). Understanding the quantity and distribution of the salt/sludge within the waste tanks allows for improved waste removal strategies (e.g. mixing pump operation) and refined safety controls. Typically, several camera inspections are performed during a waste removal transfer to verify the elevation of the visible salt/sludge mounds against the known elevation of the liquid surface. The camera inspection footage must then be interpreted by a trained engineer who will develop a 2-D map that depicts the waste distribution at various elevations within the waste tank. This tank mapping is then used in conjunction with conservative assumptions to evaluate the volume of saltcake or sludge that is present within the waste tank.

Mini, Melany↗
DOE OSTI2024

Mapping structural and dynamic divergence across the MBOAT family

Membrane-bound O-acyltransferases (MBOATs) are membrane-embedded enzymes that catalyze acyl chain transfer to a diverse group of substrates, including lipids, small molecules, and proteins. MBOATs share a conserved structural core, despite wide-ranging functional specificity across both prokaryotes and eukaryotes. The structural basis of catalytic specificity, regulation and interactions with the surrounding environment remain uncertain. Here, we combine comparative molecular dynamics (MD) simulations with bioinformatics to assess molecular and interactional divergence across the family. In simulations, MBOATs differentially distort the bilayer depending on their substrate type. Additionally, we identify lipid binding sites surrounding reactant gates in the surrounding membrane. Complementary bioinformatic analyses reveal a conserved role for re-entrant loop-2 in MBOAT fold stabilization and a key hydrogen bond bridging DGAT1 dimerization. Finally, we predict differences in MBOAT solvation and water gating properties. These data are pertinent to the design of MBOAT-specific inhibitors that encompass dynamic information within cellular mimetic environments.

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

Towards automated and real-time multi-object detection of anguilliform fishes from sonar data using YOLOv8 deep learning algorithm

Eels (Anguilla spp.), including American eels (Anguilla rostrata), European eels (Anguilla anguilla), and Japanese eels (Anguilla japonica), are species of critical management and regulatory concern due to their vulnerability to various stressors during downstream migrations. Accurate and efficient detection of migrating eels can improve our understanding of fish behaviors and fish-hydraulic structure interactions, thereby facilitating the design, operation, and optimization of more effective downstream passage facilities from both biological and economic perspectives. However, a real-time, automated framework for detecting migrating eels in real-world applications is currently lacking. Leveraging imaging sonar as a reliable technology for fish passage monitoring, field data are acquired using imaging sonar and then converted to single sonar frames/images for subsequent analysis. In this study, a framework based on the You Only Look Once Version 8 (YOLOv8)-based convolutional neural network is proposed for multi-object detection of eels and non-eel fish using the sonar images after image subtraction and additional wavelet denoising. The results from both training and testing phases demonstrate that the framework's ability can successfully detect both eels and non-eel fish in preprocessed sonar images, achieving F1-scores and mAP@0.50 exceeding 0.84. Additionally, the incorporation of wavelet denoising during preprocessing slightly improve detection performance. Furthermore, the transferability of this framework from eel to lamprey detection is demonstrated to be feasible given the similar morphological characteristics of these two species. Overall, the proposed framework achieves accurate and efficient detection of migrating eels, providing reliable and real-time information that can help conserve vulnerable eel and eel-like populations.

Deep learning↗
DOE OSTI2024

ATLAS-MAP: An Automated Test Station for Gated Electronic Transport Measurements

The diversification of electronic materials in devices provides a strong incentive for methods to rapidly correlate device performance with fabrication decisions. In this work, we present a low-cost automated test station for gated electronic transport measurements of field-effect transistors. Utilizing open-source PyMeasure libraries for transparent instrument control, the “ATLAS-MAP” system serves as a customizable interface between sourcemeters and samples under test and is programmed to conduct transfer curve and van der Pauw methods with static and sweeping gate voltages. Zinc oxide transistors of variable thickness (5, 10, and 20 nm) and channel size (50 μm to 3 mm, of equal length and width) were fabricated to validate the design. Standardization of testing procedures and raw data formatting enabled automated data analysis. A detailed list of parts and code files for the system are provided.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Computation of high-frequency magnetoelastic waves in layered materials

Here, the direct calculation of magnetoelastic wave dispersion in layered media is presented using an efficient, accurate computational technique. The governing, coupled equations for elasticity and magnetism, the Navier and Landau-Lifshitz equations, respectively, are linearized to form a quadratic eigenvalue problem that determines a complex web of wave-number–frequency dispersion branches and their corresponding mode profiles. Numerical discretization of the eigenvalue problem via a spectral collocation method (SCM) is employed to determine the complete dispersion maps for both a single, finite-thickness magnetic layer and a finite magnetic-nonmagnetic double-layer. The SCM, previously used to study elastic waves in nonmagnetic media, is fast, accurate, and adaptable to a variety of sample configurations and geometries. Emphasis is placed on the extremely high-frequency regimes being accessed in ultrafast magnetism experiments. The dispersion maps and modes provide insight into how energy propagates through the coupled system, including how energy can be transferred between elastic- and magnetic-dominated waves as well as between different layers. The numerical computations for a single layer are further understood by a simplified analytical calculation in the high-frequency, exchange-dominated regime where the resonance condition required for energy exchange (an anticrossing) between quasi-elastic and quasi-magnetic dispersion branches is determined. Nonresonant interactions are shown to be well approximated by the dispersion of uncoupled elastic and magnetic waves. The methods and results provide fundamental theoretical tools to model and understand current and future magnetic devices powering spintronic innovation.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Hydrogen density mapping in biomolecular crystals through dynamic nuclear polarization

Many fundamental biological processes, including those in photosynthetic reaction centers and enzyme active sites, involve charge and energy transfer, bond cleavage, protonation and hydrogen bonding. Because H atoms play such central roles in these reactions, accurately determining their positions is essential. Yet, conventional X-ray crystallography primarily resolves the heavy atoms in biological structures and provides limited insight into hydrogen, even at atomic resolution. Neutron macromolecular crystallography (NMC) overcomes this limitation by offering exceptional sensitivity to hydrogen and deuterium. Here, we present a theoretical framework for the development of dynamic nuclear polarization NMC (DNP-NMC) techniques, which exploit the alignment of neutron and proton nuclear spins to enhance and tune the hydrogen signal contribution. The DNP-NMC approach advances the resolution of H atoms within biomolecular crystals, whether bound to protein residues or present in solvent. The method establishes key relationships for the coherent structure factor of polarized neutron scattering from hydrogenous matter. It theoretically achieves full accuracy in phase reconstruction and offers a path to improve neutron structure determination, achieving accuracies exceeding ≳80% by incorporating titration states. Using a variant of the hybrid input/output phase-retrieval algorithm, it allows recovery of the hydrogen density with ≳90% phase accuracy. In conclusion, we further discuss sources of experimental uncertainty for the upcoming DNP-enabled, quasi-Laue IMAGINE-X experiment at Oak Ridge National Laboratory's High Flux Isotope Reactor.

dynamic nuclear polarization↗
DOE OSTI2022

The Use of Thermal Cameras for Pedestrian Detection

Visible-range camera sensors have been widely used for pedestrian detection. However, most of the methods, which employ visible-range color cameras, do not perform well under low-light and no-light conditions, e.g. during night time. Since the working principle of thermal camera sensors is mainly based on temperature and not light, they have been employed for person detection to overcome the drawbacks of visible-range sensors under these conditions. Every object gives off thermal energy, which is captured by a thermal camera sensor. When an object becomes hotter, it emits more thermal energy, and is therefore captured as much brighter or vice versa. Yet, compared to visible-range cameras, there are many additional challenges that need to be addressed when detecting pedestrians from thermal camera images. These challenges include bright hot objects close to humans, similar pixel values in an image due to weather conditions, or objects that block thermal cameras such as concrete or glass. Glass acts like a mirror for infrared radiation and reflects whatever is in front of the camera. Thus, novel methods are still required to accomplish pedestrian detection task from thermal camera images. To contribute to these efforts, we propose a new method and a modified object detection network incorporating saliency maps of thermal camera images. The features obtained from thermal images and their corresponding saliency maps are combined to obtain richer representations of pedestrian regions, and better detection performance. We perform extensive evaluations on five different datasets to compare the performance of the proposed approach with two baselines. Moreover, we evaluate and compare the transferability of these approaches by doing leave-one-out cross validation across different datasets. Furthermore, the results show that the proposed approach outperforms the baselines, and has better transferability properties across different thermal image datasets.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Perturbative diffraction methods resolve a conformational switch that facilitates a two-step enzymatic mechanism

Enzymes catalyze biochemical reactions through precise positioning of substrates, cofactors, and amino acids to modulate the transition-state free energy. However, the role of conformational dynamics remains poorly understood due to poor experimental access. This shortcoming is evident with Escherichia coli dihydrofolate reductase (DHFR), a model system for the role of protein dynamics in catalysis, for which it is unknown how the enzyme regulates the different active site environments required to facilitate proton and hydride transfer. Here, we describe ligand-, temperature-, and electric-field-based perturbations during X-ray diffraction experiments to map the conformational dynamics of the Michaelis complex of DHFR. We resolve coupled global and local motions and find that these motions are engaged by the protonated substrate to promote efficient catalysis. This result suggests a fundamental design principle for multistep enzymes in which pre-existing dynamics enable intermediates to drive rapid electrostatic reorganization to facilitate subsequent chemical steps.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2026

Machine Learning Enabled Position Detection for 6.78 MHz UAV Wireless Power Transfer System

This paper presents a novel supervised machine learning (SML) approach for accurate position detection of the receiver coil in wireless power transfer (WPT) systems using only secondary-side electrical measurements, with applications in autonomous unmanned aerial vehicle (UAV) charging. The proposed method trains a supervised learning model to map measured secondary-side voltage and current features to the receiver’s spatial position with high precision. This enables an autonomous UAV to determine its location relative to the primary coil center, the optimal position for maximizing wireless charging efficiency. The sensing method is fully integrated into a standard WPT system, utilizing the same primary and secondary coils for both power transfer and position detection, thereby eliminating additional sensing hardware. The use of a 6.78 MHz operating frequency enhances positional sensitivity, as high-frequency near-field electromagnetic fields respond strongly to small spatial variations. Experimental validation is performed on a 30 W scaled prototype featuring a 210 mm × 140 mm primary coil, a 50 mm × 80 mm receiver coil, and a 15 mm air gap. Results demonstrate reliable position estimation and a strong correlation between predicted position and optimal coil alignment. This integrated framework unifying position detection and wireless charging offers a promising foundation for future autonomous electric vertical takeoff and landing (eVTOL) systems, enabling compact, hardware-efficient, and high-accuracy charging solutions.

Colak, Kerim [New York University]↗
DOE OSTI2023

High–Resolution Maps of Near–Surface Permafrost for Three Watersheds on the Seward Peninsula, Alaska Derived From Machine Learning

Permafrost soils are a critical component of the global carbon cycle and are locally important because they regulate the hydrologic flux from uplands to rivers. Furthermore, degradation of permafrost soils causes land surface subsidence, damaging infrastructure that is crucial for local communities. Regional and hemispherical maps of permafrost are too coarse to resolve distributions at a scale relevant to assessments of infrastructure stability or to illuminate geomorphic impacts of permafrost thaw. Here we train machine learning models to generate meter–scale maps of near–surface permafrost for three watersheds in the discontinuous permafrost region. The models were trained using ground truth determinations of near–surface permafrost presence from measurements of soil temperature and electrical resistivity. We trained three classifiers: extremely randomized trees (ERTr), support vector machines (SVM), and an artificial neural network (ANN). Model uncertainty was determined using k–fold cross validation, and the modeled extents of near–surface permafrost were compared to the observed extents at each site. At–a–site near–surface permafrost distributions predicted by the ERTr produced the highest accuracy (70%–90%). However, the transferability of the ERTr to the sites outside of the training data set was poor, with accuracies ranging from 50% to 77%. The SVM and ANN models had lower accuracies for at–a–site prediction (70%–83%), yet they had greater accuracy when transferred to the non–training site (62%–78%). These models demonstrate the potential for integrating high–resolution spatial data and machine learning models to develop maps of near–surface permafrost extent at resolutions fine enough to assess infrastructure vulnerability and landscape morphology influenced by permafrost thaw.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Development of in-use engine speed/torque heat maps across multiple heavy-duty commercial vehicle vocations

The U.S. Department of Energy (DOE) established the SuperTruck program with the goal of achieving brake thermal efficiency (BTE) greater than or equal to 55% as demonstrated in an operational heavy-duty (HD) diesel engine at a 65-miles-per-hour (mph) cruise point. Beyond the line-haul application, HD engines operate in a wide range of speed and torque conditions that are unlikely to yield the same efficiency under real-world operation. Thereby, the in-use engine heat maps described in this paper are a valuable tool to illustrate whether the engine-efficiency “sweet spot” matches the most frequent operating conditions. In this study, NREL developed engine heat maps to quantify the important operating points for various vocations using our Fleet DNA database of commercial fleet vehicle operations data. These heat maps clearly show that high-frequency operating points vary significantly according to vehicle vocation, while only a few of them match the sweet spot. Beyond the illustration, engine in-use heat maps can also be leveraged to build up reduced-order engine-efficiency models, needed by many rapid powertrain simulations. As case studies, nine reduced-order models – including line-haul truck, transfer truck, transit bus, transit bus with compressed natural gas (CNG) engine, drayage, refuse pickup, local delivery, utility truck, and school bus with CNG engine – using a trust-region reflective algorithm to fit the on-road data extracted based on the engine in-use heat maps.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Anaerobic fungi contain abundant, diverse, and transcriptionally active Long Terminal Repeat retrotransposons

Long Terminal Repeat (LTR) retrotransposons are a class of repetitive elements that are widespread in the genomes of plants and many fungi. LTR retrotransposons have been associated with rapidly evolving gene clusters in plants and virulence factor transfer in fungal-plant parasite-host interactions. We report here the abundance and transcriptional activity of LTR retrotransposons across several species of the early-branching Neocallimastigomycota, otherwise known as the anaerobic gut fungi (AGF). The ubiquity of LTR retrotransposons in these genomes suggests key evolutionary roles in these rumen-dwelling biomass degraders, whose genomes also contain many enzymes that are horizontally transferred from other rumen-dwelling prokaryotes. Up to 10% of anaerobic fungal genomes consist of LTR retrotransposons, and the mapping of sequences from LTR retrotransposons to transcriptomes shows that the majority of clusters are transcribed, with some exhibiting expression greater than 104 reads per kilobase million mapped reads (rpkm). Many LTR retrotransposons are strongly differentially expressed upon heat stress during fungal cultivation, with several exhibiting a nearly three-log10 fold increase in expression, whereas growth substrate variation modulated transcription to a lesser extent. We show that some LTR retrotransposons contain carbohydrate-active enzymes (CAZymes), and the expansion of CAZymes within genomes and among anaerobic fungal species may be linked to retrotransposon activity. We further discuss how these widespread sequences may be a source of promoters and other parts towards the bioengineering of anaerobic fungi.

Genetics & Heredity↗
DOE OSTI2022

Mass Transport Limitations and Kinetic Consequences of Corn Stover Deacetylation

Alkaline pretreatment of herbaceous feedstocks such as corn stover prior to mechanical refining and enzymatic saccharification improves downstream sugar yields by removing acetyl moieties from hemicellulose. However, the relationship between transport phenomena and deacetylation kinetics is virtually unknown for such feedstocks and this pretreatment process. Here, we report the development of an experimentally validated reaction–diffusion model for the deacetylation of corn stover. A tissue-specific transport model is used to estimate transport-independent kinetic rate constants for the reactive extraction of acetate, hemicellulose and lignin from corn stover under representative alkaline conditions (5–7 g L -1 NaOH, 10 wt% solids loadings) and at low to mild temperatures (4–70°C) selected to attenuate individual component extraction rates under differential kinetic regimes. The underlying transport model is based on microstructural characteristics of corn stover derived from statistically meaningful geometric particle and pore measurements. These physical descriptors are incorporated into distinct particle models of the three major anatomical fractions (cobs, husks and stalks) alongside an unsorted, aggregate corn stover particle, capturing average Feret lengths of 917–1239 μm and length-to-width aspect ratios of 1.8–2.9 for this highly heterogeneous feedstock. Individual reaction–diffusion models and their resulting particle model ensembles are used to validate and predict anatomically-specific and bulk feedstock performance under kinetic-controlled vs. diffusion-controlled regimes. In general, deacetylation kinetics and mass transfer processes are predicted to compete on similar time and length scales, emphasizing the significance of intraparticle transport phenomena. Critically, we predict that typical corn stover particles as small as ~2.3 mm in length are entirely diffusion-limited for acetate extraction, with experimental effectiveness factors calculated to be 0.50 for such processes. Debilitatingly low effectiveness factors of 0.021–0.054 are uncovered for cobs—implying that intraparticle mass transfer resistances may impair observable kinetic measurements of this anatomical fraction by up to 98%. These first-reported quantitative maps of reaction vs. diffusion control link fundamental insights into corn stover anatomy, biopolymer composition, practical size reduction thresholds and their kinetic consequences. These results offer a guidepost for industrial deacetylation reactor design, scale-up and feedstock selection, further establishing deacetylation as a viable biorefinery pretreatment for the conversion of lignocellulosics into value-added fuels and chemicals.

09 BIOMASS FUELS↗
DOE OSTI2023

Process-dependent anisotropic thermal conductivity of laser powder bed fusion AlSi10Mg: impact of microstructure and aluminum-silicon interfaces

Purpose AlSi10Mg alloy is commonly used in laser powder bed fusion due to its printability, relatively high thermal conductivity, low density and good mechanical properties. However, the thermal conductivity of as-built materials as a function of processing (energy density, laser power, laser scanning speed, support structure) and build orientation, are not well explored in the literature. This study aims to elucidate the relationship between processing, microstructure, and thermal conductivity. Design/methodology/approach The thermal conductivity of laser powder bed fusion (L-PBF) AlSi10Mg samples are investigated by the flash diffusivity and frequency domain thermoreflectance (FDTR) techniques. Thermal conductivities are linked to the microstructure of L-PBF AlSi10Mg, which changes with processing conditions. The through-plane exceeded the in-plane thermal conductivity for all energy densities. A co-located thermal conductivity map by frequency domain thermoreflectance (FDTR) and crystallographic grain orientation map by electron backscattered diffraction (EBSD) was used to investigate the effect of microstructure on thermal conductivity. Findings The highest through-plane thermal conductivity (136 ± 2 W/m-K) was achieved at 59 J/mm 3 and exceeded the values reported previously. The in-plane thermal conductivity peaked at 117 ± 2 W/m-K at 50 J/mm 3 . The trend of thermal conductivity reducing with energy density at similar porosity was primarily due to the reduced grain size producing more Al-Si interfaces that pose thermal resistance. At these interfaces, thermal energy must convert from electrons in the aluminum to phonons in the silicon. The co-located thermal conductivity and crystallographic grain orientation maps confirmed that larger colonies of columnar grains have higher thermal conductivity compared to smaller columnar grains. Practical implications The thermal properties of AlSi10Mg are crucial to heat transfer applications including additively manufactured heatsinks, cold plates, vapor chambers, heat pipes, enclosures and heat exchangers. Additionally, thermal-based nondestructive testing methods require these properties for applications such as defect detection and simulation of L-PBF processes. Industrial standards for L-PBF processes and components can use the data for thermal applications. Originality/value To the best of the authors’ knowledge, this paper is the first to make coupled thermal conductivity maps that were matched to microstructure for L-PBF AlSi10Mg aluminum alloy. This was achieved by a unique in-house thermal conductivity mapping setup and relating the data to local SEM EBSD maps. This provides the first conclusive proof that larger grain sizes can achieve higher thermal conductivity for this processing method and material system. This study also shows that control of the solidification can result in higher thermal conductivity. It was also the first to find that the build substrate (with or without support) has a large effect on thermal conductivity.

Engineering↗