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At least 1,261 records · Page 70
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Alternating chempolishing and electropolishing for interior and exterior surface finishing of additively manufactured (AM) metal components

Additively manufactured (AM) components’ surface finishing is crucial in adopting them for intended applications in challenging environments involving fatigue, corrosion, high temperature, and nuclear radiation. In our prior research, chempolishing (C) was utilized as an electroless etching process that uniformly smoothens complex AM components’ accessible interior and exterior surfaces (Tyagi et al. Additive Manufacturing, 25:32–38, 22). A wide range of electropolishing (E) has been demonstrated for AM surface finishing. However, electropolishing can impact a surface that can be juxtaposed to counter electrode and can yield a very smooth surface to sub-micrometer level roughness. However, a knowledge gap exists about the impact of applying both approaches on the same surface one after another and what new advantages may arise because of combining two methods. This paper uses dual-stage liquid-based surface finishing strategies produced by alternating the chempolishing (C) and electropolishing (E) steps. Two dual-stage surface finishing approaches, i.e., chempolishing followed by electropolishing (CE) and electropolishing followed by chempolishing (EC), were performed on the 316 stainless AM steel component. Impacts of EC and CE approaches were compared with single-stage C and E surface finishing approaches. An optical microscope and mechanical profilometer were utilized to investigate the wide range of surface roughness parameters. CE and EC produced Ra ~ 1.4 µm and ~ 1.6 µm, respectively. Surface roughness on CE- and EC-treated AM samples was lower than those individually treated by C and E approaches. Scanning electron microscopy provided further insights into the microstructural difference between CE- and EC-treated AM samples. This paper reports a liquid contact angle study on CE- and EC-treated AM samples to provide insights into the relative difference in surface energy that is crucial for making coatings on AM parts. A spectroscopic reflectance study was also employed to register the difference in physical properties of AM components treated with CE and EC approaches. Further, this study reveals industrially practicable interior and exterior surface finishing approaches for complex AM metal components that require minimum tooling and real-time process monitoring.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Build plate conduction cooling for thermal management of wire arc additive manufactured components

Wire arc additive manufacturing (WAAM) allows for quick, large component manufacturing with fast deposition rates while leveraging readily available wire feedstock that is significantly cheaper than metal powder. However, the increased deposition rate of this process requires enhanced thermal management as failures can occur due to overheating. A common strategy to mitigate overheating is to dwell, or pause, between individual layers; however, this can significantly increase build times and eliminate the advantage of additive manufacturing being able to manufacture components quickly. To help mitigate this issue, this study explores the use of active cooling to maintain process control and to decrease overall build time. In this work, conductive cooling applied to either the bottom or side of the print substrate was explored. Results from this study showed that bottom build plate active cooling can be used to decrease dwell times by up to 50% and decrease cool-down to room temperature after the building process by up to 75%. Results from this study demonstrate that the use of active cooling strategies for WAAM can be used for better thermal control over the process and should be further investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Experimental approach for development of a powder spreading metric in additive manufacturing

The powder spreading is a vital step of powder-based additive manufacturing (AM) processes. The quality of spread powder can considerably influence the properties of fabricated parts. Poorly packed powder beds with high surface roughness result in printed part layers with large porosity and low dimensional accuracy, leading to poor mechanical properties. Therefore, the powder spreadability and its dependence on process parameters and powder characteristics should be quantified to improve the efficiency of powder-based AM methods. This study proposes a novel dimensionless powder spreadability metric that can be commonly used in different powder-based AM processes. The quality of spread powder in terms of powder bed density and surface roughness was evaluated by adjusting the process parameters including recoating velocity and layer thickness, and powder characteristics including particle size distribution. In addition, the dynamic repose angle was proposed and examined as another powder spreadability metric. Furthermore, the results showed that these two proposed metrics were strongly correlated and lower recoating velocity and larger layer thickness led to higher spreadability and lower dynamic repose angle.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Computationally inexpensive part-scale thermal history of additive friction-stir deposition

This study presents an analytical model for steady-state power generation and tool heat loss in additive friction-stir deposition (AFSD), developed to enable part-scale thermal simulation while remaining computationally inexpensive. The model predicts total generated power, yielding 3.7–4.7 kW across deposition temperature setpoints of 400–460 °C for the deposition of AA6061 with a Be-Cu tool. This corresponds to 90–95% of the reported spindle power. Tool heat loss is experimentally determined by calibrating a steady-state energy balance between the generated power, the substrate-deposition thermal gradient, and a temperature dependent tool heat loss term: q tool (T) = a + b (T - 400°C) with a = 2.7 x 10 6 Wm -2 and b = 9.5 x 10 3 Wm -2 K -1 . The calibration indicates that about 69% of the generated heat is conducted into the tool for this configuration, which is much higher than previously reported. The calibrated heat-source is implemented in finite element software (Adamantine) to simulate the transient thermal history of a 100 cm 3 representative build in 8 min on a standard desktop (at 0.635 mm build-height resolution). For the first three layers, the substrate temperatures between simulation and experiment are within 10% mean absolute percentage error. Sensitivity analysis indicates that uncertainties in average deposition temperature and deformation localization (stir-zone geometry, depth, and spatial dependance of strain-rate and flow stress) dominate model variance, motivating additional experimental verification.

Additive Friction-Stir Deposition↗
DOE OSTI2018

Adaptive wavelet compression of large additive manufacturing experimental and simulation datasets

New manufacturing technologies such as additive manufacturing require research and development to minimize the uncertainties in the produced parts. The research involves experimental measurements and large simulations, which result in huge quantities of data to store and analyze. We address this challenge by alleviating the data storage requirements using lossy data compression. We select wavelet bases as the mathematical tool for compression. Unlike images, additive manufacturing data is often represented on irregular geometries and unstructured meshes. Thus, we use Alpert tree-wavelets as bases for our data compression method. We first analyze different basis functions for the wavelets and find the one that results in maximal compression and miminal error in the reconstructed data. We then devise a new adaptive thresholding method that is data-agnostic and allows a priori estimation of the reconstruction error. Finally, we propose metrics to quantify the global and local errors in the reconstructed data. One of the error metrics addresses the preservation of physical constraints in reconstructed data fields, such as divergence-free stress field in structural simulations. While our compression and decompression method is general, we apply it to both experimental and computational data obtained from measurements and thermal/structural modeling of the sintering of a hollow cylinder from metal powders using a Laser Engineered Net Shape process. The results show that monomials achieve optimal compression performance when used as wavelet bases. The new thresholding method results in compression ratios that are two to seven times larger than the ones obtained with commonly used thresholds. Overall, adaptive Alpert tree-wavelets can achieve compression ratios between one and three orders of magnitude depending on the features in the data that are required to preserve. Furthermore, these results show that Alpert tree-wavelet compression is a viable and promising technique to reduce the size of large data structures found in both experiments and simulations.

42 ENGINEERING↗
DOE OSTI2021

Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Selective laser melting is receiving increasing interest as an additive manufacturing technique. Residual stresses induced by the large temperature gradients and inhomogeneous cooling process can favour the generation of cracks. In this work, a crystal plasticity finite element model is developed to simulate the formation of residual stresses and to understand the correlation between plastic deformation, grain orientation and residual stresses in the additive manufacturing process. The temperature profile and grain structure from thermal-fluid flow and grain growth simulations are implemented into the crystal plasticity model. An element elimination and reactivation method is proposed to model the melting and solidification and to reinitialize state variables, such as the plastic deformation, in the reactivated elements. The accuracy of this method is judged against previous method based on the stiffness degradation of liquid regions by comparing the plastic deformation as a function of time induced by thermal stresses. The method is used to investigate residual stresses parallel and perpendicular to the laser scan direction, and the correlation with the maximum Schmid factor of the grains along those directions. The magnitude of the residual stress can be predicted as a function of the depth, grain orientation and position with respect to the molten pool. The simulation results are directly comparable to X-ray diffraction experiments and stress–strain curves.

316 stainless steel↗
DOE OSTI2025

Mechanical and Thermal Characterization of Additively Manufactured Carbon/Nylon 12 and Carbon/PEEK Composites

This study explores additive manufacturing of carbon fiber-reinforced thermoplastic composites using the Composite-Based Additive Manufacturing (CBAM) process. Carbon/Nylon 12 and Carbon/PEEK composites were fabricated and evaluated through mechanical (compression, tensile, flexural, and impact) and thermal (DSC and TGA) tests. Carbon/PEEK exhibited superior mechanical performance, with 97.5% higher tensile strength, 79.8% higher elastic modulus, and 59.6% higher flexural strength compared to Carbon/Nylon 12. Thermal testing showed that Carbon/PEEK had higher thermal stability, beginning degradation at 350 °C versus 298 °C for Carbon/Nylon. These results indicate that CBAM-fabricated Carbon/PEEK composites are suitable for applications requiring high strength and temperature resistance.

Additive manufacturing↗
DOE OSTI2018

Measurement of the Kinematic Viscosity of Melted Mixtures of Sodium, Lithium, and Beryllium Fluorides and the Effect of the Eutectic Additive Cerium Trifluoride on the Viscosity

Experimental data on the kinematic viscosity and liquidus temperature of certain fused mixtures of sodium, lithium, and beryllium fluorides were obtained, by the method of damping of torsional oscillations of a cylinder with the experimental melt, in validation of the concept of molten-salt incinerator reactors for incinerating transuranium elements from spent nuclear fuel from light-water reactors. The measurements were conducted from the liquidus temperature to 800°C. The effect of the addition of cerium trifluoride on the viscosity of the eutectic melt 58NaF–15LiF–27BeF{sub 2} was studied. It was shown that the additive appreciably reduces the viscosity at low temperature and also lowers the liquidus temperature. The parameters characterizing the temperature dependence of viscosity were determined for the experimental melts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Microscale drivers and mechanisms of fracture in post-processed additively manufactured Ti–6Al– 4 V

Herein, we focus on understanding the microstructure-fracture correlations in a Ti–6Al– 4 V alloy additively manufactured via electron beam melting (EBM) and subjected to various post-process heat-treatments. Specifically, the as fabricated material is subjected to a sub-transus heat-treatment followed by air-cooling and a super-transus heat-treatment followed by either air- or furnace-cooling. Next, a series of in-situ single edge notch tension (SENT) tests are carried out under a high-resolution digital optical microscope. The panoramic high-resolution images captured during the in-situ tests are then used to characterize the planar deformation on the specimen surface using microstructure-based digital image correlation (DIC). Additionally, the results of the in-situ SENT tests together with DIC and post-mortem fractographic analyses provided us with a better understanding of the microstructure-fracture correlations in these materials. Our results show that the fracture mechanism of the as fabricated and sub-transus heat-treated materials is essentially the same, while the changes in the microstructure following the super-transus heat-treatments significantly affects the fracture mechanism. In this case, several microcracks of hundreds of microns in length first nucleate away from the deformed notch following extreme plastic deformation at discrete locations. Furthermore, the location of these microcracks in the super-transus heat-treated materials is extremely sensitive to the details of the underlying microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Nucleation and growth of chimney pores during electron-beam additive manufacturing

The nucleation and growth of chimney pores during powder-bed, electron-beam additive manufacturing is investigated using in-situ infrared thermography as well as microcomputed tomography of as-printed parts. The pores are found to nucleate at dimples on the part s surface, clearly demonstrating how process parameters can affect surface roughness, which can in turn affect the internal defect structure in an additive manufactured part. Based on the results of this study, several strategies for suppressing the formation of chimney pores are discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Evolution of Micro-structure and Magnetic Properties in L1{sub 0} CoPt Nanoparticles by Au Addition

L1{sub 0} CoPt-Au nanoparticles with face-centered tetragonal (FCT) structure were synthesized by sol-gel technique at 700°C. The micro-structure and magnetism of L1{sub 0} CoPt-Au were measured by different measuring technologies. The influences of Au on the micro-structure and magnetism of L1{sub 0} CoPt nanoparticles were investigated. The Au addition promoted the formation of ordered L1{sub 0} phase CoPt nanoparticles and improved the grain size of L1{sub 0} CoPt nanoparticles When the Au content increased to 10 at.%, coercivity increased and saturation magnetization decreased, which may be originated from the increased order degree and ferrimagnetic nature of L1{sub 0} CoPt nanoparticles. Interestingly, when the Au addition was more than 10 at.%, the coercivity decreased due to the decrease of the order degree.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Trace impurity analysis in uranium oxide via hybrid quantification techniques—gravimetric standard addition and isotope dilution mass spectrometry

Measurement methods for the analysis of trace impurities in uranium materials, essential in nuclear fuel production and nuclear forensics, are continuously improving. Analytical methods were developed with the goal of lowering uncertainties of next generation certified uranium oxide reference materials for trace impurity concentrations. Through addition of a traceable standard directly into the sample, gravimetric standard addition and isotope dilution followed by analysis on an inductively coupled plasma mass spectrometer can achieve lower uncertainties. In conclusion, results for 28 impurities in CRM 124-1 and 124-6 from NBL Program Office were used for validation of accuracy and comparisons of uncertainties.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Tertiary and Quaternary Ammonium-Phosphate Ionic Liquids as Lubricant Additives

In this work we investigated the feasibility of five quaternary (aprotic) and four tertiary (protic) ammonium ionic liquids (ILs) with an identical organophosphate anion as lubricant antiwear additives. Viscosity, oil solubility, thermal stability, and corrosivity of the candidate ILs were characterized and correlated to the molecular structure. The protic group exhibits higher oil solubility than the aprotic group, and longer alkyl chains seem to provide better oil solubility and higher thermal stability. Selected ILs were applied as oil additives in steel-cast iron tribological tests and demonstrated promising anti-scuffing and anti-wear functionality. The thickness, nanostructure, coverage and composition of the tribofilm formed by the besting performing IL were revealed by surface characterization for mechanistic understanding of the tribochemical interactions between the IL and metal surface. Results provide fundamental insights of the correlations among the molecular structure, physiochemical properties and lubricating performance for ammonium-phosphate ILs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Impact of Defects in Powder Feedstock Materials on Microstructure of 304L and 316L Stainless Steel Produced by Additive Manufacturing

Recent work in both 304L and 316L stainless steel produced by additive manufacturing (AM) has shown that in addition to the unique, characteristic microstructures formed during the process, a fine dispersion of sub-micron particles, with a chemistry different from either the powder feedstock or the expected final material, are evident in the final microstructure. Such fine-scale features can only be resolved using transmission electron microscopy (TEM) or similar techniques. The present paper uses electron microscopy to study both the initial powder feedstock and microstructures in final AM parts. Special attention is paid to the chemistry and origin of these nanoscale particles in several different metal alloys, and their impact on the final build. Finally, comparisons to traditional, wrought material will be made.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Hydrogen Addition on Softening and Melting Reduction Behaviors of Ferrous Burden in Gas-Injection Blast Furnace

The softening and melting reduction behaviors of ferrous burden in a gas-injection blast furnace (BF) have been investigated experimentally with the assistance of H{sub 2}. The results indicate that the initial softening temperature of the burden in the BF is lower than that in the traditional BF, while the opposite trend is observed for its melting and dripping temperatures, thus widening the softening range and narrowing the melting zone. As a result, the permeability of the stock column is apparently improved, owing to the decreased amount of the produced melt. After H{sub 2} gas is added, the thickness of the iron shell of the burden pellet increases, and the quantity of its liquid wüstite core decreases due to the higher reduction degree. The reduction rate of iron oxides is much faster than the carburization rate with the H{sub 2} addition, and the dripping behavior of the ferrous burden is determined by the carburization with a high reduction potential. After taking into account the effects of H{sub 2} addition on the iron oxide reduction rate, melt quantity, burden microstructure, and energy consumed by the gas-injection BF, it has been concluded that the optimal H{sub 2} content lies in the range between 10 and 15 pct.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Additive Manufacturing of a Steel–Ceramic Multi-Material by Selective Laser Melting

Most techniques employed for powder bed additive manufacturing (AM) only can handle a single material. However, additional functionality of the structures built, e.g., local insulation, is desirable for more sophisticated applications. In the present work, a multi-material process allowing for realization of a ceramic coating on a steel substrate and a novel sandwich system are introduced. Both were manufactured by selective laser melting (SLM). As a first step, the microstructure of a bulk zirconia–alumina ceramic, directly manufactured by SLM, was examined and its tensile strength determined. Afterwards, the ceramic was manufactured directly on the as-built surface of a tool steel processed by SLM. For this compound, the adhesive strength was determined. Finally, an open porous structure, made of the same tool steel, was built on top of the ceramic layer. The results clearly prove that the SLM process can be used for direct manufacturing of a multi-material sandwich structure made from metal and ceramic, providing an important step towards complex structures functionalized for electric insulation.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additive Manufacturing of Metallic Materials: A Review

In this review article, the latest developments of the four most common additive manufacturing methods for metallic materials are reviewed, including powder bed fusion, direct energy deposition, binder jetting, and sheet lamination. In addition to the process principles, the microstructures and mechanical properties of AM-fabricated parts are comprehensively compared and evaluated. Finally, several future research directions are suggested.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additive Manufacturing of Catalyst Substrates for Steam–Methane Reforming

Steam–methane reforming is a highly endothermic reaction, which is carried out at temperatures up to 1100 °C and pressures up to 3000 kPa, typically with a Ni-based catalyst distributed over a substrate of discrete alumina pellets or beads. Standard pellet geometries (spheres, hollow cylinders) limit the degree of mass transfer between gaseous reactants and catalyst. Further, heat is supplied to the exterior of the reactor wall, and heat transfer is limited due to the nature of point contacts between the reactor wall and the substrate pellets. This limits the degree to which the process can be intensified, as well as limiting the diameter of the reactor wall. Additive manufacturing now gives us the capability to design structures with tailored heat and mass transfer properties, not only within the packed bed of the reactor, but also at the interface between the reactor wall and the packed bed. In this work, the use of additive manufacturing to produce monolithic-structured catalyst substrate models, made from acrylonitrile–butadiene–styrene, with enhanced conductive heat transfer is described. By integrating the reactor wall into the catalyst substrate structure, the effective thermal conductivity increased by 34% from 0.122 to 0.164 W/(m K).

36 MATERIALS SCIENCE↗