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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Bounds on the Rate-Dependent Plastic Flow of Tantalum up to 75 GPa

In this study we report on the continued development of thermodynamics-based analysis of shock waves propagation with the objective of extracting information related to materials strength at high strain rates and pressures. Building on previous results reported for peak stresses of 10 GPa and 25 GPa, we present a series of three-step gas-gun shock experiments designed to explore the pressure and strain rate dependence of plastic flow in polycrystalline tantalum. These experiments at nominal peak stresses of 50 GPa and 75 GPa show the irreversible deformation before pullback to be almost entirely confined to the shock loading, with negligible plastic relaxation on the post-shock plateau. We also add a reverse-ballistics shot at 25 GPa, which was designed to reveal the pullback response with negligible interference from free-surface effects. General thermodynamic considerations allow us to place bounds on the plastic behavior even for parts of the curve that change far too rapidly for the velocimetric time resolution of (conservatively) ~ 5 ns. To analyze the data, we found it necessary to substantially improve the interpolation/extrapolation scheme in order to improve its robustness, flexibility and range of applicability. We describe the new scheme based on splines, as well as an extension of free-surface corrections to the post-shock rarefaction waves. Reanalysis with the new scheme produces results essentially within the error bars previously reported, showing that the known systematic errors associated with free-surface effects are relatively inconsequential for determining thermodynamic paths.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Critical Minerals from Waste Streams in the Powder River Basin of Wyoming and Montana, USA

Background/Objectives. Critical minerals (CM) are essential for numerous industrial and defense applications, including green technologies that will help to meet carbon emission reduction goals. Many CM are currently mined and processed in countries that lack stringent environmental and labor regulations. Unconventional sources such as existing industrial waste streams could play a part in building an ethical CM supply chain. Additionally, waste streams created in the extraction and processing of CM could be used for other industrial or commercial purposes, thereby reducing waste and advancing a circular economy. Approach/Activities. The Department of Energy funded Powder River Basin (PRB) CORE-CM project is exploring all aspects of the carbon ore, rare earth element (REE), and CM value chain, including the potential for extraction of CM from industrial waste streams in the basin. Waste streams that have potential as CM feedstocks are being inventoried to assess the concentration of CM in each waste stream and to estimate volume and accessibility. Although basin-specific technologies for extraction of CM are still in development, waste streams that may be produced during these processes are being cataloged and mapped to potential secondary uses. Results/Lessons Learned. Initial studies of the CM potential of PRB coal ash show that this waste stream contains concentrations of greater than 300 ppm total REE (Bagdonas et al., 2022, Renewable and Sustainable Energy Reviews). Moreover, calcium-rich PRB coal ash is amenable to REE extraction (Taggart et al., 2016, Environmental Science and Technology). Wyoming coal is shipped to 28 states, meaning that coal ash produced at power stations across the US represents a potential widespread resource for the extraction of REE. In addition to coal mining and coal fired electricity generation, the PRB is home to other energy industries including oil and gas production, in-situ uranium mining, and bentonite mining. Historically, precious and base metal mining has taken place on the perimeter of the PRB. Waste streams from these industries are currently being evaluated for their CM potential. Assessing the CM resource potential of waste streams could contribute to the development of an ethical CM supply chain. Results from these studies can be replicated for other waste streams, increasing the likelihood of successful creation of circular economies.

Phillips, Erin↗
DOE OSTI2022

Experimental Studies and Energy Modeling for Evaluating Performance of Various Deep Wall Retrofits

The Pacific Northwest National Laboratory, Oak Ridge National Laboratory, and the University of Minnesota conducted a three-year, multipart study on residential retrofit wall assemblies. The project, which was funded by the U.S. Department of Energy’s Building Technology Office, aimed to compare a range of residential wall retrofit systems that prioritized affordability, durability, and energy savings potential. The research team identified, constructed, tested, simulated, and analyzed the feasibility and economics of 16 wall retrofit assemblies (14 test configurations and two baseline configurations) that can be applied to the exterior side of existing walls (either with or without the existing cladding). The 16 wall assemblies were installed in an in-situ laboratory environment, to evaluate the ease of construction and study the thermal and hygrothermal performance of the walls. This paper presents the methodology used to evaluate the thermal performance of the walls and discusses the energy modeling results of the study. The results from the experiments were used to calibrate a THERM model of each wall assembly, which was then applied to a whole building using the EnergyPlus 8.6 simulation engine. A residential prototype building was used to extrapolate whole-building energy savings in each U.S. climate zone. To capture the conditions of the largest number of homes in the United States, the most frequent building characteristics (e.g., attic insulation level, window specifications, foundation insulation, etc.) were extracted from ResStock data and applied to the prototype model. Results from the energy modeling showed that the climate zones with the highest potential for retrofit savings are those which are heating-dominated (i.e., Cold and Very Cold climate designations). In these climate zones, heating and cooling energy savings due to the wall retrofits alone ranged from 21.5% to 38.2%.

Nagda, Harshil↗
NASA NTRSDate not supplied

Operational Modal Analysis of the Artemis I Dynamic Rollout Test and Wet Dress Rehearsal

NASA has developed an expendable heavy lift launch vehicle capability, the Space Launch System (SLS), to support lunar and deep space exploration. The uncrewed Artemis I was the first flight of this new launch vehicle and tested critical systems for the upcoming crewed Artemis II flight to the moon. Accelerations were recorded at a multitude of locations on Artemis, the Mobile Launcher (ML), and the Crawler Transporter (CT)during the rollout of Artemis I from the Vehicle Assembly Building (VAB) to Launch Pad 39B March 2022 and is referred to as the Artemis I Dynamic Rollout Test (DRT). While Artemis I was at Launch Pad 39B, the Wet Dress Rehearsal (WDR) was performed to demonstrate launch readiness and acceleration measurements were also recorded. Finally, Artemis I rolled back from Launch Pad 39B to the VAB in April 2022, where acceleration measurements were also recorded and is referred to as the rollback portion of DRT. Because the forces during rollout and at the launch pad acting on Artemis I, the ML, and the CT are not directly measurable, Operational Modal Analysis (OMA) techniques, instead of traditional Experimental Modal Analysis (EMA) techniques, were used to identify modal characteristics. The OMA analysis of DRT and WDR directly builds upon the lessons learned from the OMA analysis of an earlier rollout of the ML from the VAB. DRT and WDR dynamic characteristics will be used to support SLS Integrated Modal Test finite element model correlation efforts and Exploration Ground System ML and CT finite element model verification and validation, which are part of the Building Block approach the Space Launch System program has implemented. The dynamic characteristics extracted from DRT as well as the rollout acceleration time histories themselves will be used in the development of generic rollout forcing functions that will provide refined estimates of the Artemis IV rollout forces, which will have the heavier and larger SLS Block 1B launch vehicle and Mobile Launcher 2 (ML-2). This paper briefly describes Artemis I, the ML, and the CT physical characteristics, DRT rollout/rollback and WDR data collection, the challenges in implementing OMA techniques due in part to the CT harmonics, and how these challenges were overcome to obtain the Artemis I DRT configuration and WDR configuration modal characteristics.

Apollo↗
NASA NTRSDate not supplied

Operational Modal Analysis of the Artemis I Dynamic Rollout Test and Wet Dress Rehearsal

NASA has developed an expendable heavy lift launch vehicle capability, the Space Launch System (SLS), to support lunar and deep space exploration. The uncrewed Artemis I was the first flight of this new launch vehicle and tested critical systems for the upcoming crewed Artemis II flight to the moon. Accelerations were recorded at a multitude of locations on Artemis, the Mobile Launcher (ML), and the Crawler Transporter (CT)during the rollout of Artemis I from the Vehicle Assembly Building (VAB) to Launch Pad 39B March 2022 and is referred to as the Artemis I Dynamic Rollout Test (DRT). While Artemis I was at Launch Pad 39B, the Wet Dress Rehearsal (WDR) was performed to demonstrate launch readiness and acceleration measurements were also recorded. Finally, Artemis I rolled back from Launch Pad 39B to the VAB in April 2022, where acceleration measurements were also recorded and is referred to as the rollback portion of DRT. Because the forces during rollout and at the launch pad acting on Artemis I, the ML, and the CT are not directly measurable, Operational Modal Analysis (OMA) techniques, instead of traditional Experimental Modal Analysis (EMA) techniques, were used to identify modal characteristics. The OMA analysis of DRT and WDR directly builds upon the lessons learned from the OMA analysis of an earlier rollout of the ML from the VAB. DRT and WDR dynamic characteristics will be used to support SLS Integrated Modal Test finite element model correlation efforts and Exploration Ground System ML and CT finite element model verification and validation, which are part of the Building Block approach the Space Launch System program has implemented. The dynamic characteristics extracted from DRT as well as the rollout acceleration time histories themselves will be used in the development of generic rollout forcing functions that will provide refined estimates of the Artemis IV rollout forces, which will have the heavier and larger SLS Block 1B launch vehicle and Mobile Launcher 2 (ML-2). This paper briefly describes Artemis I, the ML, and the CT physical characteristics, DRT rollout/rollback and WDR data collection, the challenges in implementing OMA techniques due in part to the CT harmonics, and how these challenges were overcome to obtain the Artemis I DRT configuration and WDR configuration modal characteristics.

Apollo↗
DOE OSTI2023

Eco-Friendly High-Performance Carbon Building Material Development from Coal

The development of eco-friendly high-performance building materials based on coal-derived materials is greatly beneficial for promoting environmental sustainability and the coal industry. This project focused on advancing technology to create innovative and scalable construction materials from two domestic sources: (1) coal-derived pyrolyzed char (PC), and (2) solvent-extracted coal deposit, extracts, and residue (CDER). It aimed to simultaneously develop and produce two types of coal-derived building products: (1) char-based concrete bricks (CCB) for wall construction in buildings, and (2) carbon-based structural units (CSU) intended as alternatives to traditional wood, concrete, or steel framing structures. The project team has successfully developed methods for manufacturing CCB samples. Extensive experiments were conducted to assess various manufacturing techniques for these samples. This included measuring their physical properties such as thermal conductivity (ranging from 0.26 to 0.38 W/mK) and bulk density (ranging from 0.85 to 1.15 g/cm 3 ), along with their mechanical properties (e.g., compressive strength ranging from 14 to 16 MPa at 28 days) for samples with a PC composition of 70%. Quality assurance and quality control tests, focusing on density and compressive strength, were also performed on samples selected randomly from pilot-scale production, and cured for a long term (over three months). The average long-term compressive strength of two randomly selected CCB samples was measured as 15.1 MPa, which was higher than the required target strength of 14 MPa. This indicates that the manufactured CCB samples from the preliminary pilot scale production run have good quality control and long-term strength performance.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2011

Project Report: Design and Analysis for the Deep Space Network BWG Type 2 Antenna Feed Platform

The following report explains in detail the solid modeling design process and structural analysis of the LNA (Low Noise Amplifier) feed platform to be constructed and installed on the new BWG (Beam Wave Guide) Type-2 tracking antenna in Canberra, Australia, as well as all future similar BWG Type-2 antennas builds. The Deep Space Networks new BWG Type-2 antennas use beam waveguides to funnel and 'extract' the desired signals received from spacecraft, and the feed platform supports and houses the LNA(Low Noise Amplifier) feed-cone and cryogenic cooling equipment used in the signal transmission and receiving process. The mandated design and construction of this platform to be installed on the new tracking antenna will be used and incorporated on all future similar antenna builds.

structural analysis software↗
DOE OSTI2021

Multiscale Reduced Order Modeling and Parameter Estimation for Climate Sciences

Several problems in earth system modeling are dependent on highly multiscale phenomena, such as turbulence, where computational modeling is challenging and expensive. This issue is exacerbated in atmospheric and oceanic domains, due to inherent high-dimensionality of the problem. One approach to this problem has been reduced order modeling (ROM); which aims to represent the key physics of the phenomena as a low-dimensional system. AI methods have huge potential in building accurate, stable ROMs and parameter estimation for these ROMs, as it requires extracting nonlinearities and patterns from simulation and/or observational data. Developing physics-based AI approaches specialized for the complexities of multiscale data, along with strategies to account for uncertainties, will revolutionize rapid modeling, analysis and decision making for earth system problems of practical interest.

58 GEOSCIENCES↗
DOE OSTI2024

ML-based Dimension Reduction Strategies

Deep learning (DL)--based surrogate models have achieved success in various applications in carbon capture and storage (CCS). However, the model training on high-dimensional spaces is computationally expensive and impractical for large-scale and complex geological models, because the models usually contain hundreds of thousands to millions of grid cells, each with a set of parameters. Furthermore, the high cost of generating training data with sufficient variation is another limitation of model training on high-dimensional spaces, which may result in overfitting and reduce the model efficiency and prediction performance. We proposed the workflow incorporating dimension reduction methods and deep learning models, which aim to extract the latent variables of input parameters and output state variables, and then build the mapping function at the latent spaces. The proposed workflow can significantly reduce the computational complexity in solving both forward and inverse problems compared to models trained on high-dimensional spaces. Dimensionality reduction models showed great potential in workflows for fast reservoir simulation, history matching, prior model generation, visualization, and more, ultimately enhancing DL model performance in related SMART Work Packages.

Hosseini, Seyyed↗
NASA NTRS1975

Low cost tracking Navaids error model verification

Features and characteristics of the tracking navaids (Microwave Scanning Beam Landing System, Radar Altimeter, Tacan, rendezvous radar and one way Doppler extracter) were investigated. From the investigation, a set of specifications were developed for building equipment to verify the error model of the tracking navaids. Breadboard verification equipment (BVE) was built for the Microwave Scanning Beam Landing System and the radar altimeter. The breadboard verification equipment generates signals to the tracking navaids which simulate the space shuttles trajectory in the terminal area. The BVE simulates sources of navaids error by generating pseudorandom perturbations on the navaids signals. Differences between the trajectory value and the navaid derived values are taped and form the basis for the navaids error model.

Charych, A.↗
NASA NTRSDate not supplied

Lunar Development & Test Facility, JSC B351

In anticipation of extended operations on the lunar sur-face, JSC Building B351 has been prepared to meet test needs to mature technologies that extract resources from lunar regolith, handle lunar regolith or must perform in a dusty lunar environment. Domains such as In-Situ Re-source Utilization (ISRU), dust mitigation, power generation and distribution, robotics and surface tools will all require testing with lunar regolith/simulants to demonstrate flight readiness. The Lunar Development and Test Facility (LDTF) houses environmental test capabilities, including lunar simulants, geared toward advancing Technical Readiness Level (TRL) of these lunar surface technologies. Seen as an agency need to enable and demonstrate new technologies, a portion of the facility capability was developed under the “Dirty Lunar Surface Simulation “project in FY2020, funded by the NASA Game Changing Development program. Some current uses include testing of an oxygen extraction from lunar regolith test, a spacesuit cleaning tool evaluation, and a study to measure dust effects on space radiators (thermal management).

Michael Reddington↗
DOE OSTI2020

Panel Session 34: US DOE Featured Site: Savannah River Operations Office: 70 Years of Service

The Savannah River Site celebrates its 70. anniversary on November 28, 2020. On this date in 1950, President Harry S. Truman requested the Dupont Company to design, build and operate what was then known as the Savannah River Plant in response to the Soviet Union's detonation of its first atomic weapon, which set the Cold War into motion. During the 1950's, six South Carolina towns were relocated for the construction of SRS and by 1953, the 310 square mile site was complete. Nearly 40,000 workers were employed t build five nuclear reactors and support facilities, two chemical separations plants, heavy water extraction plant, nuclear fuel and target fabrication facility tritium extraction facility and waste management facilities. SRS played a key role in winning the Cold War and for seven decades, SRS has been a leader within the DOE complex. Today, the site supports environmental stewardship and maintains the nation's nuclear deterrent while ensuring the safekeeping and disposal of domestic and international nuclear materials. The site continues to support the nation's nuclear defense as it explores new potential NNSA missions. SRS has a proud 70- year history and looks forward to a future of service as a national asset and strong community partner. The session was kicked off with a video message from Secretary of Energy, Dan Brouillette, who thanked employees past and current for their efforts. The video also provided an overview of the history and future of the Site. This panel provided an overview of the Savannah River Site's 70 years of service (history, challenges, opportunities, and future) presented by the SRS's Senior leadership and the local Aiken, South Carolina Mayor. Panelists with presentations: US DOE Secretary Dan Brouillette's Overview of DOE and SRS - A Legacy of 70 Years of Service (Amy Boyette); 70 Years of Service (Michael Budney); 70 Years of Service (Stuart MacVean); SRS Liquid Waste (Thomas Foster); National Nuclear Security Administration (Nicole Nelson-Jean)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Towards an astronomical foundation model for stars with a transformer-based model

ABSTRACT Rapid strides are currently being made in the field of artificial intelligence using transformer-based models like Large Language Models (LLMs). The potential of these methods for creating a single, large, versatile model in astronomy has not yet been explored. In this work, we propose a framework for data-driven astronomy that uses the same core techniques and architecture as used by LLMs. Using a variety of observations and labels of stars as an example, we build a transformer-based model and train it in a self-supervised manner with cross-survey data sets to perform a variety of inference tasks. In particular, we demonstrate that a single model can perform both discriminative and generative tasks even if the model was not trained or fine-tuned to do any specific task. For example, on the discriminative task of deriving stellar parameters from Gaia XP spectra, we achieve an accuracy of 47 K in Teff, 0.11 dex in log g, and 0.07 dex in [M/H], outperforming an expert XGBoost model in the same setting. But the same model can also generate XP spectra from stellar parameters, inpaint unobserved spectral regions, extract empirical stellar loci, and even determine the interstellar extinction curve. Our framework demonstrates that building and training a single foundation model without fine-tuning using data and parameters from multiple surveys to predict unmeasured observations and parameters is well within reach. Such ‘Large Astronomy Models’ trained on large quantities of observational data will play a large role in the analysis of current and future large surveys.

Leung, Henry W. (ORCID:0000000200362752)↗
DOE OSTI2020

A scoping review of non-destructive testing (NDT) techniques in building performance diagnostic inspections

Understanding building envelope thermodynamics is an essential foundation of building sciences, mainly due to the envelope’s role as a boundary layer for exterior environments, as well as a container and regulator of internal microclimates. This paper presents a scoping literature review of select Non-destructive Testing (NDT) techniques for building envelope scanning and surveying for thermodynamic diagnostics. The investigation focuses specifically on reviewing six NDT techniques: Ground Penetrating Radar (GPR), Light Detection and Ranging (LiDAR)/Laser Scanning, Thermography, Ultrasound, Close-Range Photogrammetry and Through Wall Imaging Radar (TWIR). The aim is to identify knowledge gaps in terms of their use in accurately characterizing envelope compositions for further integration in Building Energy Modeling (BEM). Each technique was evaluated according to set categories imbibed from the American Society of Heating, Refrigerating, and Air Conditioning Engineering (ASHRAE) Standard 211P that showcase the technique’s ability to extract various relevant information. A framework is then developed to inform users on how to use hybrid NDT-based workflows applied in building envelope energy audits. The study concludes by discussing possibilities of utilizing NDT in large-scale audit automation, BEM integration, and developing built environment policies focusing on increasing existing building performance through retrofitting design.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Field validation of data-driven BSDF and peak extraction models for light-scattering fabric shades

Shading and daylighting systems affect cooling, heating, and lighting energy use by modulating solar radiation through the building façade. Characterizing shading systems holistically and accurately helps designers and engineers evaluate shading systems to achieve energy and non-energy performance goals. These complex fenestration systems can be modeled using Bidirectional Scattering Distribution Functions (BSDF), which map incident radiation to hemispherical distributions of outgoing radiation. Data-driven, tabulated BSDFs are derived from interpolated goniophotometer measured data, then sampled during the raytracing calculation. A peak extraction (PE) algorithm was developed to circumvent limits in BSDF angular resolution, where the specular peak is extracted during simulation by evaluating the BSDF in the through direction and surrounding region. The objective of this study was to validate this measurement and modeling workflow using field monitored data from a full scale testbed with eleven installed fabrics of different weaves, openness factors, and colors and assess the accuracy of the workflow under different adaptation and contrast conditions. Test conditions were limited to clear sky conditions with the sun in the field of view. Results showed that, for tensor tree datasets, vertical illuminance, solar luminance (2.5° apex), and daylight glare probability (DGP) were predicted to within a mean bias error (MBE) error of -456 lx (-12.3%), -3.46e5 (-38.4%), and -0.042 (-7.8%) when full PE occurred. With a binary classification of glare/ no glare, DGP was predicted accurately with a true positive rate of 0.98 and true negative rate of 1.0 using tensor tree data and less accurately with Klems BSDF data, particularly for cases of no glare. The workflow may be of insufficient accuracy to distinguish borderline performance between fabrics using the four-point glare scale, particularly under low adaptation, high contrast daylit conditions. Errors were due to reductions in peak shape and intensity across the BSDF interpolation and data reduction workflow. Future work is needed to better preserve measurement fidelity during interpolation and sampling, which in turn will improve PE performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2004

Simulations of Hyperthermal Oxygen Beam Exposures

Pulsed sources of hyper-thermal O-atoms are now being extensively used to simulate low-earth orbit (LEO) surface exposure environments. The peak flux of these sources is many orders of magnitude larger than the corresponding LEO flux. Although it is desirable to accelerate the test by using higher fluxes than found in LEO, even commonly used fluxes are large enough to produce multi-collision effects by causing a build-up of gas at the sample surface. In this paper we characterize the physical consequences to the experiment using the direct simulation Monte Carlo (DSMC) method, DSMC allows us to extract the distributions of energy and impact angle for the O-atoms that reach the surface, and to record how strongly the gas build-up at the target assembly deflects flux from downstream instrumentation. By considering a range of source fluxes, we determine the onset conditions and severity of these multi-collision effects. We find that even at common experimental fluxes with a normally incident beam string a flat surface sample, the energy distribution of incident O-atoms broadens and develops a significant low-energy tail. The angular distributions also broaden significantly. The number of O-atoms that reach downstream instrumentation is decreased by approximately 50%. These simulations will aid in the calibration of ground-based O-atom measurements,a nd provide a model for the energy and angular distributions of O-atoms that actually impinge on surface samples.

Finchum, A.↗
NASA NTRS2003

DSMC Simulations of Hyperthermal Oxygen Beam Exposures

Pulsed sources of hyper-thermal O-atoms are now being extensively used to simulate low-earth orbit (LEO) surface exposure environments. The peak flux of these sources is many orders of magnitude larger than the corresponding LEO flux. Although it is desirable to accelerate the test by using higher fluxes than found in LEO, even commonly used fluxes are large enough to produce multi-collision effects by causing a build-up of gas at the sample surface. In this paper we characterize the physical consequences to the experiment using the direct simulation Monte Carlo (DSMC) method. DSMC allows us to extract the distributions of energy and impact angle for the O-atoms that reach the surface, and to record how strongly the gas build-up at the target assembly deflects flux from downstream instrumentation. By considering a range of source fluxes, we determine the onset conditions and severity of these multi-collision effects. We find that even at common experimental fluxes with a normally incident beam striking a flat surface sample, the energy distribution of incident O-atoms broadens and develops a significant low-energy tail. The angular distributions also broaden significantly. The number of O-atoms that reach downstream instrumentation is decreased by approximately 50%. These simulations will aid in the calibration of ground-based O-atom measurements, and provide a model for the energy and angular distributions of O-atoms that actually impinge on surface samples.

Cline, Jason A.↗
DOE OSTI2023

Impact of controlled prewetting on part formation in binder jet additive manufacturing

Binder jetting is an additive manufacturing process that bonds powder through selectively depositing binder by inkjet printing. The part is then extracted and densified by sintering and/or infiltration. The process offers low costs and fast build rates, but properties can be poor due to residual porosity after sintering. The inkjet printing process may contribute to this residual porosity by creating large pores. The droplet kinetic energy ejects some powder particles from the bed and rearranges others. Particle ejection and rearrangement are theorized to create porous regions in binder-jetted parts. In this work, small amounts of moisture are added to the spread powder before printing and the impact on part formation, part properties, and printing parameters measured with varied droplet spacing, droplet velocity, and print frequency. Moisture is added by applying an atomized fluid mixture to the powder between layer spreading and binder printing. The fluid mixture partially evaporates but leaves a stable residue to increase cohesion and enhance imbibition. Moisture addition to the powder increases the range of droplet spacings for line formation while reducing particle ejection, powder rearrangement, and balling in layer and multilayer parts. Excessive moisture addition decreases the effective saturation of printed lines, but saturation in 3D parts is less impacted. Increased surface roughness in the first few layers of a print was also mitigated with prewetting. Finally, high-speed X-ray imaging verified prewetting reduction in particle ejection and rearrangement.

36 MATERIALS SCIENCE↗