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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Metallic Powder Core Tubular Wire (PCTW) Development for Additive Manufacturing

NASA Langley Research Center (LaRC) in Hampton, VA, and the Center for Welding, Joining, and Coating Research (CWJCR) in the Department of Metallurgical and Materials Engineering at the Colorado School of Mines (CSM) in Golden, CO, have collaborated for nearly fifteen years to develop metallic powder core tubular wire (PCTW) feedstock for additive manufacturing (AM) using electron beam deposition. The motivation for this development was to offset dealloying observed during deposition of titanium and aluminum alloy solid wire feedstock in the LaRC electron beam freeform fabrication (EBF3) system and to explore novel alloy compositions by tailoring the powder fill. EBF3 is a fusion-based AM process that is performed under vacuum and is consequently prone to vaporization loss of low vapor pressure alloying elements. Research spanning four graduate student research projects succeeded in developing the basic methodology to fabricate PCTW, the mass balance equations used to define the powder fill, microstructure control through particulate inoculation, and the feasibility of producing metal matrix composite materials. Metallic PCTW is comprised of a thin foil sheath wrapped around a powder blend. Fabrication of PCTW at CSM was accomplished using a tubular wire mill system to first bend a flat strip into a u-shaped cross section, deposit a powder fill, create a lap joint to seal the wire, and draw to final diameter. Powder management systems were developed to ensure uniform mixing of powder constituents and identify feed rates for optimum fill ratios. Processing parameters were successfully developed for titanium and aluminum alloy sheaths to account for material work hardening during drawing. Mass balance equations were developed to account for compositional contributions of the sheath and powder fill. PCTW composition can be adjusted through selection of the sheath or powder materials. PCTWs were successfully developed to offset Al loss in deposits of Ti-6-4 and Mg loss in Al 6061, resulting in deposits that were within the composition limits for each material. Ti-6-4 deposits were fabricated using PCTW comprised of commercially pure (CP) titanium sheath and a fill of pre-alloyed Ti-6-4 powder with additions of elemental Al and V powders. Additions of both elements were required to account for the CP Ti from the sheath, and Al was further enhanced to offset documented losses in EBF3 deposits. For Al 6061 deposits, composition was modulated through the choice of sheath material. The PCTW was made using an Al 5052 sheath to supplement Mg content and a fill composition of pre-alloyed 6061 powder with additions of Si and Cu.The slower solidification rate of the EBF3 process compared with laser powder bed fusion processes can lead to coarse-grained microstructures and mechanical property anisotropy. EBF3deposits of Ti-6-4 exhibited large epitaxially grown β grains, which result in degraded mechanical properties in the deposition direction. Microstructure refinement was achieved through a combination of electron beam modulation and the use of a PCTW designed for Ti-6-4 deposits and modified by the addition of powder made from Fe and B. Resulting deposits exhibited reductions in β grain size, α phase colony intercept length and lath width, and an increased volume fraction of β phase. The mechanism of microstructure refinement was related to precipitation of boride particles. Hardness testing confirmed that mechanical property anisotropy was reduced and an overall increase in hardness was achieved.Metal matrix composite (MMC) materials offer strength and stiffness benefits over unreinforced materials. Two methods were investigated using PCTW technology for producing Al 6061 basedMMC materials; the direct addition of SiC reinforcing particles and the in-situ generation of reinforcements through reaction synthesis of precursor powders. Al 6061 based MMCs reinforced with SiC exhibited particle clustering and formation of aluminum carbides during deposition. The application of a Ni coating to the SiC particles prior to incorporation into the powder fill eliminated aluminum carbide formation and aided particle distribution during deposition. Modulation of beam focus and power further reduced aluminum carbide formation and aided particle distribution. In reaction synthesis, precursor additions undergo an exothermic reaction during deposition to form new ceramic products, generally of finer scale than the initial precursor components. The product phases provide reinforcement in the MMC and act as nucleation sites during solidification, resulting in grain refinement, improved mechanical properties, and reduced susceptibility to solidification cracking. Higher tensile strength and stiffness were demonstrated in Al 6061 based MMCs with 2 vol% reinforcement. These combined research efforts demonstrate the potential of PCTW technology for customizing of alloy composition and achieving microstructure control. A manufacturing process for titanium- and aluminum-based PCTWs was developed based on iterative design, theoretical calculations, and empirical data. PCTW technology successfully mitigated Al loss from Ti-6-4 and Mg loss in Al 6061, resulted in grain refinement in Ti-6-4, and demonstrated fabrication of Al based MMCs

Marcia S Domack↗
NASA NTRS2024

Structural Differences Between Insoluble Organic Matter in Matrix and Chondrules: Potential Insights into Pre-Parent Body Thermal Alteration

Carbon is a major molecular constituent of primitive chondrites of low petrologic grade. A majority of the carbon (>70%) is in the insoluble organic matter (IOM) fraction that cannot be extracted from the meteorite sample using polar or nonpolar solvents. The IOM is comprised of a kerogen-like macromolecular carbon (MMC) structure that consists of aromatic rings connected by highly branching aliphatic chains. Raman spectroscopy is highly sensitive to IOM due to a strong resonance enhancement that occurs for all visible excitation wavelengths, making Raman a powerful in-situ probe of IOM. The Raman spectrum of IOM consists of two primary bands, the G band originates from all carbon-carbon bonds in the MMC structure and the D band that originates from carbon 6-member ring breathing motions. The peak position and width of the G and D bands probe the structure of the IOM. Using Raman spectroscopy, the IOM structure has been shown to correlate with the thermal alteration history of the meteorite, allowing for petrologic grade classification to the tenths place in the 3.0-3.9 range. Here, we have collected Raman images of GRA 06100,41 (CR2) for the examination of the IOM spatial distribution and observe significant differences between the IOM in the matrix and chondrules.

R S Jakubek↗
DOE OSTI2021

Real-time visualization of particle evolution during reactive flux-assisted processing of aluminum melts

Here, a multi-modal, multi-scale correlative tomography investigation of Al-TiC metal matrix composites processed via flux-assisted reaction synthesis is reported. Synchrotron X-ray microradiography is utilized to visualize the reaction and particle evolution in real-time. Changes in particle diameter and areal number density suggest that the process is nucleation- rather than growth-dominated. At 950 °C, the bulk of the reaction takes place in a relatively short time span of less than 600 s. The microstructure is imaged at higher resolution in 2D (scanning electron microscopy) and 3D (synchrotron X-ray nanotomography), revealing the formation of carbide particles with a hexagonal platelet morphology. We propose that the morphology arises due to the incorporation of Si impurities during the experiment. It is expected that the correlative tomography workflow and analysis may guide future metal matrix composite (MMC) processing strategies.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Tribological behavior of hybrid Aluminum-TiB 2 metal matrix composites for brake rotor applications

Here, this research investigates the feasibility of hybrid aluminum metal matrix composites (MMC) incorporating TiB 2 particles for brake rotor applications. The composites were produced by incorporating both in-situ, submicron-sized TiB 2 particles and regular micron-sized TiB 2 powders via stir and squeeze casting techniques into A206 aluminum alloy matrix. Systematic adjustments in the fractions of in-situ and ex-situ TiB 2 particles were conducted to evaluate their impact on wear behavior and mechanisms. Combination of both particle types allowed composites with up to 10 vol% of reinforcements. Composites with higher proportions of ex-situ particles demonstrated increased wear resistance compared to those solely composed of in-situ particles, control specimens without TiB 2 , and conventional cast iron counterparts. The lowest wear rate for the hybrid composites sliding against phenolic brake pads was 1.1 × 10 -5 mm 3 /Nm, signifying a 3-fold reduction relative to cast iron sliding against the same pads. Wear analysis elucidated distinctive mechanisms within the hybrid composites, characterized by mild fragmented abrasive wear, adhesive wear, and plastic deformation, accompanied by the formation of an intermixed tribo-oxide layer.

42 ENGINEERING↗
DOE OSTI2021

A moving morphable component‐based topology optimization approach considering transient structural dynamic responses

Abstract A novel approach is developed under the moving morphable component (MMC) framework to solve topology optimization problems considering transient structural dynamic responses, where the structure for optimization is constructed with a collection of structural components, and the structural layout can be described explicitly via only a small number of design variables characterizing the positions and geometries of the components. The transient dynamic response of the structure and corresponding sensitivities are computed via step‐by‐step numerical integration and mode reduction technique is also employed to enhance the computational efficiency. Compared with existing works, the numerical instabilities induced by localized vibration modes can be substantially alleviated and the computational effort for direct sensitivity analysis is significantly reduced in the proposed approach. Two and three‐dimensional numerical examples considering the cases of nonproportional damping mechanism and time‐varying mass are also provided to manifest the validity of the proposed approach.

Li, Jialin↗
DOE OSTI2024

Melting and solidification dynamics during laser melting of reaction-based metal matrix composites uncovered by in-situ synchrotron X-ray diffraction

Laser additive manufacturing (AM) of reaction-based metal matrix composites (MMCs) involves highly complex and non-equilibrium material transformation behavior, including melting, dissolution, precipitation, and solidification. Yet, the dynamics and interplay of these phase transformation processes remain poorly understood, posing substantial challenges in identifying the microstructure formation mechanism, and predicting and controlling the microstructure in the printed parts. Here, in this study, we performed the in-situ X-ray diffraction experiment to characterize the phase evolution dynamics of the 316L + 10 vol.%TiC system during laser melting, which provides direct and quantitative insights of the complex phase reaction and evolution dynamics under rapid heating and cooling conditions relevant to additive manufacturing of reaction-based MMCs. Further in-depth thermodynamic and kinetic calculations revealed that most of the phase evolution behavior observed in the in-situ X-ray diffraction experiment cannot be solely explained by widely used equilibrium thermodynamic models, and diffusion-controlled nonequilibrium dissolution and precipitation kinetics must be considered to elucidate the complex phase evolution behavior, including incomplete TiC dissolution, and three-step TiC precipitation. The three distinct types of precipitates generate unique hierarchical TiC micro- and nanostructures, which enhances the yield strength from 513 MPa to 877 MPa by 71 %, tensile strength from 628 MPa to 1054 MPa by 68 %, and Young's modulus from 193 GPa to 221 GPa by 14 %. The findings of our research provide the knowledge foundation for the design of unique microstructures and advanced MMC materials through laser AM.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Predicting ductility of Mg/SiCp nanocomposite under multiaxial loading conditions based on unit cell modeling

This article presents an investigation on the ductility of Mg/SiCp under nine different multiaxial loading conditions based on a unit cell (or called representative volumetric element, RVE) finite element model. The constitutive relationship of magnesium matrix is characterized by a model combined Lode angle dependent plasticity model with the CPB06 plasticity model, which is able to describe the tension-compression asymmetry in magnesium matrix. The debonding of the matrix-particle interface and matrix fracture are considered by the modified Mohr-Coulomb (MMC) fracture model. Simulation results show that the interface debonding and subsequent matrix fracture are responsible for the ductility and fracture of nanocomposite. The computational results with parametric studies are compared and well correlated with experimental data, and it finally gives a stress-based full fracture locus of Mg/SiCp nanocomposite.

42 ENGINEERING↗
DOE OSTI2021

Scalable nanomanufacturing of chalcogenide inks: a case study on thermoelectric V–VI nanoplates

Solution-processed semiconducting main-group chalcogenides (MMCs) have attracted increasing research interest for next-generation device technologies owing to their unique nanostructures and superior properties. To achieve the full potential of MMCs, the development of highly universal, scalable, and sustainable synthesis and processing methods of chalcogenide particles is thus becoming progressively more important. Here we studied scalable factors for the synthesis of two-dimensional (2D) V–VI chalcogenide nanoplates (M 2 Q 3 : M = Sb, Bi; Q = Se, Te) and systematically investigated their colloidal behaviour and chemical stability. Based on a solvent engineering technique, we demonstrated scale-up syntheses of MMCs up to a 900% increase of batch size compared with conventional hydrazine-based gram-level syntheses, and such a scalable approach is highly applicable to various binary and ternary MMCs. Furthermore, we studied the stability of printable chalcogenide nanoparticle inks with several formulation factors including solvents, additives, and pH values, resulting in inks with high chemical stability (>4 months). As a proof of concept, we applied our solution-processed chalcogenide particles to multiple additive manufacturing methods, confirming the high printability and processability of MMC inks. Furthermore, the ability to combine the top-down designing freedom of additive manufacturing with bottom-up scalable synthesis of chalcogenide particles promises great opportunities for large-scale design and manufacturing of chalcogenide-based functional devices for broad application.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Surface stability and H adsorption and diffusion near surfaces of W borides: a first-principles study

Abstract Understanding the behavior of tungsten boride (W x B y ) surfaces in a fusion reactor environment is an important topic since boronization is a common wall conditioning method used in fusion Tokamaks. We report the results of density functional theory calculations that investigate the surface stability of W x B y (tetragonal I4 1 /amd -WB, hexagonal P 6 3 / mmc -WB 2 and tetragonal I4/m- W 2 B) with low-index orientations, as well as hydrogen (H) energetics near W x B y surfaces. For single element terminated W x B y surfaces, B terminated surfaces are more energetically stable than W terminated as a result of significant reconstruction of B. The H surface adsorption energy and activation energy of H diffusion penetration below W x B y surfaces are mainly related to the outer termination. Specifically, the WB(001) surface terminated with two B layers, referred to as WB(001)-T BB , has higher H adsorption affinity and lower H diffusivity on this surface than other terminations, which is controlled by the significant charge transfer from B to H. However, B atoms on the WB 2 (0001)-T BB surface decrease both H adsorption and diffusivity on the surface, but enhance H diffusion below the surface in comparison to W terminated WB 2 (0001) surface. H would be trapped and diffuse within atomic surface gaps on the WB 2 ( 2 1 ˉ 1 ˉ 0 ) surface, while H below the surface layer would jump along the [0001] direction rather than diffuse into bulk. The surface diffusion activation energy of H on the W 2 B(001) surface slightly varies with terminations. Once H crosses the surface layer of W 2 B(001) with either termination, it prefers to diffuse into the bulk, or back towards the surface, rather than move parallel to the surface. Interestingly, WB 2 (0001) and WB 2 ( 2 1 ˉ 1 ˉ 0 ) surfaces will have relatively higher H retention than the other W x B y surfaces evaluated in this work.

Yang, L. (ORCID:0000000322166071)↗
DOE OSTI2020

Mesoscale to Microscale Coupling for Wind Energy Applications: Addressing the Challenges

The purpose of the US DOE's Mesoscale to Microscale Coupling (MMC) Project is to develop, verify, and validate physical models and modeling techniques that bridge the most important atmospheric scales that determine wind plant performance and reliability. The project seeks to create a new predictive numerical simulation capability that represents a range of dynamic atmospheric flow conditions impacting wind plant performance.

17 WIND ENERGY↗
DOE OSTI2020

Advanced Models and Fast Simulation Algorithms for MARS Plants

With the successful commercialization of modular multilevel converters (MMC) and rapid increase in photovoltaic (PV) penetration and energy storage systems (ESS), one of the research areas being explored dynamically is integration of PV systems and ESS systems to MMCs. On this front, an integrated development of PV plants, ESS, and alternating- and direct-current (ac/dc) systems through Multi-Port Autonomous Reconfigurable Solar (MARS) plant is proposed and being researched upon. However, simulation of MARS systems on traditional existing software takes very long time (order of days) due to the presence of a large number of states and non-linear devices. Therefore, development of fast high fidelity models is of paramount importance to test the hardware design, control design and planning of power system expansions. In this context, two research objectives are addressed in this paper: firstly, an ultra fast single- or multi- CPU simulation algorithm to simulate the MARS system based on state-space models, hybrid discretization algorithm with a relaxation technique that reduces the imposed computational burden and a multi-rate method is presented. Secondly, a reduced order model of MARS is also presented. Both the developed techniques are validated with respect to reference PSCAD/EMTDC model.

Marthi, Phani Ratna Vanamali↗
DOE OSTI2020

Capacitor Voltage Ripple Estimation and Optimal Sizing of Modular Multi-Level Converters for Variable-Speed Drives

This article deals with the sizing of submodule capacitors for modular multilevel converters (MMCs) used for variable speed drives for medium voltage and high voltage electric machines. Variable speed drives are required to run over a wide frequency range from zero to a few hundred Hz or even over 1 kHz. Under low frequency operation (<30 Hz), a large current ripple flowing through the MMC submodule capacitors will cause significant capacitor voltage fluctuation. This article proposes an optimal submodule capacitor selection method based on the common-mode voltage injection. The proposed sizing model includes two functions: 1) accurately estimating the capacitor voltage ripple based on the drive system parameters; and 2) identifying the minimum capacitance of the submodule capacitors based on the allowed maximum capacitor voltage fluctuations. Simulation and experimental results show that the error between the actual and estimated values of the voltage fluctuation is within 3% using the proposed model.

42 ENGINEERING↗
DOE OSTI2021

Synthesis and structural characterization of orthorhombic Cu 3– δ Sb ( δ ≈ 0.1) and hexagonal Cu 3 Sb 1–x In x (x ≈ 0.2) phases

Cu 3 Sb is a known copper-rich phase in the Cu–Sb binary phase diagram. It is reported to be dimorphic, with a low-temperature form adopting the orthorhombic Cu 3 Ti structure type (space group Pmmn , No. 59). The high-temperature form crystallizes in the cubic space group F m 3 - m $Fm&#x203e;{3}m$ (No. 225), and is isostructural with BiF 3 . Neither polymorph has been carefully characterized to date, with both structures being assigned to the respective structure type, but never refined. With this study, we provide structural evidence, based on single-crystal and powder X-ray diffraction data that the low-temperature orthorhombic phase exists with a significant amount of defects on one of the Cu-sites. As a result, its composition is not Cu 3 Sb, but rather Cu 3– δ Sb ( δ = 0.13(1)). The cubic form could not be accessed as a part of this study, but another Cu-rich phase, Cu 3 Sb ≈0.8 In ≈0.2 , was also identified. It adopts the hexagonal Ni 3 Sn structure type (space group P 6 3 / mmc , No. 194) and represents an In-substituted variant of a hitherto unknown structural modification of Cu 3 Sb. Whether the latter can exist as a binary phase, or what is the minimum amount of In inclusions needed to stabilize it remains to be determined. Measurements of the thermopower of Cu 3– δ Sb ( δ = 0.13(1)) were conducted in the range of 300–600 K and demonstrated a maximum value of ca. 50 μV/K at 600 K, indicative of a p -type transport mechanism. Electrical resistivity measurements for the same sample confirmed that it exhibits metallic-like behavior, with a room temperature value of 0.43 mΩ cm. Electronic structure calculations show the absence of a band gap. Thermal analysis was utilized to ascertain the congruent melting of both phases.

Crystallography↗
DOE OSTI2020

Microcalorimeters for IAEA NML (Annual Report FY2020)

Based on input from Andrey Bosko (IAEA NML) during a visit to LLNL October 17-18, 2019, the project focused on adapting magnetic microcalorimeters (MMCs) for high-resolution decay energy (Q) spectroscopy of actinides. This included fabricating an MMC detector suitable for MeV signals, testing different approaches on how to embed an alpha source inside an absorber, and demonstrating Q-spectroscopy with MMCs.

42 ENGINEERING↗
DOE OSTI2020

Outcomes of the DOE Workshop on Atmospheric Challenges for the Wind Energy Industry

The U.S. Department of Energy-funded Mesoscale-to-Microscale Coupling (MMC) project team planned and conducted a virtual Workshop on Atmospheric Challenges for the Wind Energy Industry on October 19 and 20, 2020. The goal of the workshop was to forge a dialog with the community, including industry representatives, on how modeling tools are currently being used, the present active atmospheric modeling research in support of wind energy, and required advancements in capabilities and technology to continue to advance wind energy deployment. The workshop was planned in collaboration with an industry advisory panel that included representatives from wind power plant developers, turbine manufacturers, and companies that provide resource assessment and forecasting services. The format of the workshop included panels from government research sponsors, visionaries from industry, and mixed panels of researchers discussing research status and needs. A shared keynote presentation from the Technical University of Denmark experts anchored the second day of the workshop. An emphasis was placed on understanding the research needs in the offshore environment. In addition, breakout opportunities were provided each day. On the first day, the breakout discussions addressed predesigned questions configured to elicit participants’ thoughts on needed research directions. The second-day breakouts treated three important technical topics through a combination of presentations and group conversations. Each workshop participant chose their breakout preference from among downscaling details, modeling for turbines, and using artificial intelligence for atmospheric modeling. The discussions were robust and productive. The outcomes of the workshop include archiving a series of recommendations from industry and the research community on research directions required to further advance wind energy deployment. Discussions confirmed the need for high-fidelity modeling but that there are specific areas of applicability and other areas where the time and cost of computation is prohibitive. In those cases, the high-fidelity models can inform low-order models that are more practical for real-time or widely deployed applications. Industry must consider the financial cost of performing more expensive modeling approaches, but industry engineers and researchers are using these approaches where there appears to be a return on investment. An emerging type of low-order model is based on machine learning (ML). Participants confirmed that there are many atmospheric phenomena that need to be modeled better, including low-level jets, cold air outbreaks, land-sea induced circulations, diurnal variability, thin stable boundary layers, dynamic changes such as from frontal passage, interaction of wakes and blockage, and more. For the offshore environment, there is wide agreement that some level of ocean-wave-atmospheric coupling is necessary to capture variations in rotor-level winds needed to plan and operate offshore wind plants. Another recurring recommendation is that more observations are needed, particularly for the offshore environment. Those observations should consider the needs for model improvement, both for physically based models and for ML models. Observations must capture atmospheric profiles of variables that are important to understanding and modeling atmospheric and oceanic phenomena that impact boundary layer winds. Models must be validated with data and the uncertainty quantified, particularly those that are sensitive to initial and boundary conditions. Finally, a repeated request was to consider the holistic needs of hybrid plants of wind, solar, and storage resources because those types of plants are likely to be the wave of the future. In addition, industry wishes to understand impacts of the resource under a changing climate for long-term planning.

17 WIND ENERGY↗
DOE OSTI2021

Magnetic Microcalorimeter Gamma Detectors with Ultra-High Energy Resolution (FY2021 Q2 Report)

For a follow-up project, we are currently funded by NA-241 to build a decay energy spectrometer based on the MMC technology developed in this LCP. The IAEA is specifically interested in accurate isotope analysis of small particles that decay energy (Q) spectroscopy is well-suited for. We have established an SP-1 collaboration with the IAEA that is expected to continue beyond FY20.

42 ENGINEERING↗
DOE OSTI2021

FY2021 Report on Magnetic Microcalorimeter Development for the IAEA NML

The goal of this project is to develop high-resolution decay energy spectroscopy (DES) of actinides using magnetic microcalorimeters (MMCs). This requires testing different techniques to fully enclose a source inside an absorber and coupling it to an MMC with optimized energy resolution and speed. The goal is to develop DES with MMCs to allow its transfer to the IAEA Nuclear Materials Laboratory (NML).

42 ENGINEERING↗