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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 1,639 records · Page 91
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Effect of electrode manufacturing defects on electrochemical performance of lithium-ion batteries: Cognizance of the battery failure sources

During LIB electrode manufacturing, it is difficult to avoid the certain defects that diminish LIB performance and shorten the life span of the batteries. This study provides a systematic investigation correlating the different plausible defects (agglomeration/blisters, pinholes/divots, metal particle contamination, and non-uniform coating) in a LiNi 0.5 Mn 0.3 Co 0.2 O 2 positive electrode with its electrochemical performance. Additionally, an infrared thermography technique was demonstrated as a nondestructive tool to detect these defects. The findings show that cathode agglomerates aggravated cycle efficiency, and resulted in faster capacity fading at high current density. Electrode pinholes showed substantially lower discharge capacities at higher current densities than baseline NMC 532 electrodes. Metal particle contaminants have an extremely negative effect on performance, at higher C-rates. The electrodes with more coated and uncoated interfaces (non-uniform coatings) showed poor cycle life compared with electrodes with fewer coated and uncoated interfaces. Further, microstructural investigation provided evidence of presence of carbon-rich region in the agglomerated region and uneven electrode coating thickness in the coated and uncoated interfacial regions that may lead to the inferior electrochemical performance. In conclusion, this study provides the importance of monitoring and early detection of the electrode defects during LIB manufacturing processes to minimize the cell rejection rate after fabrication and testing.

25 ENERGY STORAGE↗
DOE OSTI2018

Template-free preparation and morphology evolution of (Cu, Ni) honeycomb structure via etching additive manufactured Fe-Cu-Ni alloy

Highlights: • (Cu, Ni) honeycomb structure with pore size of ~11 μm and wall thickness of ~200 nm was prepared. • The morphology evolution and the potential formation mechanism of the (Cu, Ni) honeycomb structure were investigated. • A new template-free method of additive manufacturing combined with etching was proposed to prepare ordered porous structure. • This work provides important insights into the preparation of ordered porous structure without template. - Abstract: Metallic ordered porous structures have attracted increasing attention due to their wide range of applications, but their preparation is usually accompanied with the employing of consumable templates. The development of template-free method to prepare metallic ordered porous structure can significantly reduce the cost as well as streamline the procedures. In the present work, a new template-free method of additive manufacturing combined with etching was proposed to prepare ordered porous structures. (Cu, Ni) honeycomb structure with pore size of ~11 μm and wall thickness of ~200 nm was successfully prepared from the Fe-Cu-Ni precursor alloy. The morphology evolution and the potential formation mechanism of the (Cu, Ni) honeycomb structure were studied. This work provides important insights into the preparation of ordered metallic porous structure without template.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Highlights of the special issue on metal additive manufacturing

This editorial introduces a special issue on metal additive manufacturing (AM) discussing the main highlights and contributions to the field of each paper of the special issue classified by alloy type. These papers treat a range of additive manufacturing technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Neutron residual stress measurement and numerical modeling in a curved thin-walled structure by laser powder bed fusion additive manufacturing

Severe residual stresses in metal parts made by laser powder bed fusion additive manufacturing processes (LPBFAM) can cause both distortion and cracking during the fabrication processes. Limited data is currently available for both iterating through process conditions and design, and in particular, for validating numerical models to accelerate process certification. In this work, residual stresses of a curved thin-walled structure, made of Ni-based superalloy Inconel 625™ and fabricated by LPBFAM, were resolved by neutron diffraction without measuring the stress-free lattices along both the build and the transverse directions. The stresses of the entire part during fabrication and after cooling down were predicted by a simplified layer-by-layer finite element based numerical model. The simulated and measured stresses were found in good quantitative agreement. The validated simplified simulation methodology will allow to assess residual stresses in more complex structures and to significantly reduce manufacturing cycle time.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Complex shaped boron carbides from negative additive manufacturing

In this paper, complex shaped boron carbide with carbon (B 4 C/C) at near-full densities were achieved for the first time using negative additive manufacturing techniques via gelcasting. Negative additive manufacturing involves 3D printing of sacrificial molds used for casting negative copies. B 4 C powder distributions and rheology of suspensions were optimized to successfully cast complex shapes. In addition to demonstrating scalability of these complex geometries, hierarchically meso-porous structures were also shown to be possible from this technique. Resorcinol-Formaldehyde (RF) polymer was selected as the gelling agent and can also pyrolyze into a carbon aerogel network to act as the sintering aid for B 4 C. Finally, due to the highly effective distribution of in situ carbon for the B 4 C matrix, near-full sintered density of 97–98% of theoretical maximum density was achieved.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Geometrical defect detection for additive manufacturing with machine learning models

This study proposed a scheme based on Machine Learning (ML) models to detect geometric defects of additively manufactured objects. The ML models are trained with synthetic 3D point clouds with defects and then applied to detect defects in actual production. Using synthetic 3D point clouds rather than experimental data could save a huge amount of training time and costs associated with many prints for each design. Besides distance differences of individual points between source and target point clouds, this scheme uses a new concept called “patch” to capture macro-level information about nearby points for ML training and implementation. Numerical comparisons of prediction results on experimental data with different shapes showed that the proposed scheme outperformed the existing Z-difference method in the literature. Five ML methods (Bagging of Trees, Gradient Boosting, Random Forest, K-nearest Neighbors and Linear Supported Vector Machine) were compared under various conditions, such as different point cloud densities and defect sizes. Bagging and Random Forest were found the two best models regarding predictability; and the right patch size was found to be at 20. The proposed ML-based scheme is applicable to in-situ defect detection during additive manufacturing with the aid of a proper 3D data acquisition system.

Additive manufacturing↗
DOE OSTI2024

Development of a high-temperature Inconel 625 heat exchanger by model design and binder jetting additive manufacturing

A nickel-based Inconel 625 superalloy heat exchanger for high-temperature applications was developed via binder jetting additive manufacturing. The material properties were characterized first on printed and sintered parts. Two sintering temperatures were used to investigate the effects of the temperature on densification and microstructure. For channel geometry design, the heat transfer capabilities of the heat exchanger were optimized for the cross-section geometry of fluid flow channels in a counterflow configuration, and a stress analysis was conducted to investigate the effects of channel geometry. After headers were incorporated into the heat exchanger as a one-piece component, a prototype was printed. A complete depowdering was achieved via compressed air blowing, and sintering was performed with the developed profile. Ultimately, a one-piece heat exchanger with a nearly full density was obtained. Heat transfer tests were performed on this unit, and the results were compared with those from the simulations. In this study, systematic processes were developed for an additively manufactured Inconel-based heat exchanger for high-pressure, high-temperature heat transfer applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Additive manufacturing of metal matrix composites

Although Metal matrix composites (MMCs) are superior to most sought-after metallic alloys, their challenging fabricability has limited their widespread use in bulk-form applications. Among the many advanced fabrication techniques, Additive Manufacturing (AM), owing to its unique capabilities to produce near-net shapes, has drawn significant traction in the past two decades, especially for materials that are difficult to process using traditional methods. However, unlike pure metal/alloy systems, MMCs are highly sensitive to the processing conditions prevailing in AM techniques due to factors such as the high melting point of reinforcement particles and the potential for in-situ reactions. Therefore, it may be a while before metal matrix composites are commercially produced via AM. This review will discuss the current state-of-the-art design, fabricability, and performance of various additively manufactured MMCs. A particular focus will be on microstructural evolution and microstructure-property relationships. The most employed AM techniques, such as directed energy deposition, powder bed fusion, binder jetting, sheet lamination, and solid-state friction stir processing, are fundamentally different in terms of thermo-kinetics, forming the perspective for this review. A detailed comparison of microstructural evolution and process parameter optimization, including feedstock preparation methods and the role of machine learning and modeling among the different AM processes, is also presented. Finally, a critical evaluation of emerging AM technologies for MMCs is also provided, highlighting their potential advantages and challenges.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Establishing a process-structure-property-performance framework for SLS additive manufacturing through integrated multiscale modeling

This study presents a comprehensive suite of high-fidelity computational models that integrate multiscale and multiphysics simulations to capture the full Selective Laser Sintering (SLS) additive manufacturing process—from initial melting and solidification to mechanical response under external loads. Process simulations are linked with mechanical analysis through Representative Volume Elements (RVEs), establishing a process-structure–property-performance framework. The interaction between laser light and polyamide 12 (PA12) powder is modeled, accounting for laser characteristics and the optical, thermal, and geometrical properties of the powder. The heat source is incorporated into a heat transfer model, coupled with crystallization kinetics and densification models to predict material density and crystallinity. The porosity distribution from the densification model and crystallinity interpolated from experimental data are used to construct the RVEs. A multi-mechanism constitutive model is then calibrated using mechanical tests to predict the stress–strain response. Simulation results show good agreement with experimental data in terms of porosity, crystallinity, and mechanical performance when sufficient laser power (62 W or higher) is used. This research supports the inverse design of 3D-printed structures by introducing a high-fidelity framework that combines multiscale and multiphysics modeling with experimental calibration for predictive and performance-driven additive manufacturing.

SLS↗
DOE OSTI2021

A scalable digital platform for the use of digital twins in additive manufacturing

We report that while Additive Manufacturing promises to reshape the manufacturing landscape, challenges related to part, and process qualification hinder its widespread adoption. The Instance-Qualified approach seeks to qualify individual parts, even for processes with high variability, by leveraging the concept of a digital twin. This work proposes a scalable cyberphysical infrastructure to enable the construction and use of such digital twins. This work also introduces the concept of an Augmented Intelligence Relay, which allows Artificial Intelligence algorithms to predict component performance for a given application even when it is impractical to perform a large number of physical tests.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Rethinking production of machine tool bases: Polymer additive manufacturing and concrete

Cast iron and steel weldments are the most common machine tool base elements. However, both construction methods have associated disadvantages for domestic machine tool manufacturers. Here, this paper documents the investigation of an alternative method for machine tool base production using concrete to fill an additively manufactured polymer mold, where the motion components are attached to the concrete base after the initial concrete curing. Modal testing results for a three-axis, vertical spindle prototype indicate high damping and stiffness can be achieved using the concrete base construction. Advantages are reduced cost and lead time compared to traditional methods.

Additive manufacturing↗
DOE OSTI2021

Hybrid manufactured dynamometer for cutting force measurement

This paper describes a two-step (additive + subtractive) hybrid manufacturing approach for a laser powder bed fusion 316L stainless steel constrained-motion cutting force dynamometer (PBF CMD). The purpose of the research is to produce a near-net shape metallic dynamometer via additive manufacturing (AM) with post-processing by machining and wire-EDM to achieve the desired surface finish and performance. A cutting force comparison is presented with a commercially-available dynamometer.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis

Aerospace flight panels must provide high strength with low mass. For aluminum panels, it is common practice to begin with a wrought plate and remove the majority of the material to attain the desired structure, comprising a thinner plate with the desired pattern of reinforcement ribs. As an alternative, this study implements hybrid manufacturing, where aluminum is first deposited on a baseplate only at the rib locations using additive friction stir deposition (AFSD). Structured light scanning is then used to measure the printed geometry. This geometry is finally used as the stock model for computer numerical control (CNC) machining. This paper details the hybrid manufacturing process that consists of: AFSD to print the preform, structured light scanning to generate the stock model and tool path, three-axis CNC machining, and post-process measurements for part geometry and microstructure.

42 ENGINEERING↗
DOE OSTI2024

Machine tool cross beam design, fabrication, and testing using metal big area additive manufacturing

This paper describes the application of metal Big Area Additive Manufacturing (mBAAM) to the fabrication of a machine tool cross beam. The replacement of a traditional box design weldment with a new design printed by wire arc additive manufacturing using the MedUSA system at Oak Ridge National Laboratory (ORNL) is detailed. This requires a new design strategy based on the unique mBAAM capabilities. The intent of the new design is to reduce mass, while maintaining the dynamic stiffness. To compare the two designs, the natural frequencies and mode shapes are measured using impact testing and predicted using finite element analysis. It is confirmed that the printed structure dynamics agreed with the numerical model predictions, which demonstrates that it is feasible to model a large-scale mBAAM part and understand its behavior prior to printing. Another notable outcome of this study is that the significant residual stress and distortion in the print indicate that knowledge gaps remain for widespread implementation of mBAAM.

42 ENGINEERING↗
DOE OSTI2019

Effect of preheat temperature and post-process treatment on the microstructure and mechanical properties of stainless steel 410 made via ultrasonic additive manufacturing

Ultrasonic additive manufacturing (UAM) is a solid-state manufacturing technology for producing near-net shape metallic parts combining additive ultrasonic metal welding and subtractive machining. Even though UAM has been demonstrated to produce robust metal builds in Al–Al, Al–Ti, Al-steel, Cu–Cu, Al–Cu, and other material systems, UAM welding of high strength steels has proven challenging. This study investigates process and post-processing methods to improve UAM steel weld quality and demonstrates the UAM fabrication of stainless steel 410 (SS 410) builds which possess, after post-processing, mechanical properties comparable with bulk material. Unlike UAM fabrication of softer metals, this study shows that increasing the baseplate temperature from 38°C (100°F) to 204°C (400°F) improves interfacial strength and structural homogeneity of the UAM steel samples. Further improvement in strength is achieved through post-processing. The hot isostatic pressing (HIP) post treatment improves the shear strength of UAM samples to 344 MPa from 154 MPa for as-welded samples. Microstructural analyses with SEM and EBSD show no evidence of body centered cubic (BCC) ferrite to face centered cubic (FCC) austenite transformation taking place during UAM welding of SS 410. The weld quality improvement of UAM steel at higher baseplate temperatures is believed to be caused by the reduction of the yield strength of SS 410 at elevated temperature. Finaly, HIP treatment is shown to increase the overall hardness of UAM SS 410 from 204 ± 7 HV to 240 ± 16 HV due to the formation of local pockets of martensite. Nanohardness tests show that the top of layer n is harder than the bottom of layer n+1 due to grain boundary strengthening.

36 MATERIALS SCIENCE↗
DOE OSTI2022

On the thermal coarsening and transformation of nanoscale oxide inclusions in 316L stainless steel manufactured by laser powder bed fusion and its influence on impact toughness

The thermal evolution of nanoscale oxide inclusions in 316L stainless steel (SS) manufactured by laser powder bed fusion additive manufacturing (AM) was explored. The size, chemical composition, morphology, and distribution of the oxides were characterized as the function of heat treatment conditions. The study revealed the mechanistic driving force of the rapid oxide coarsening during recrystallization. Ostwald ripening governs oxide coarsening. The active grain boundary-oxide interaction at the early stage of recrystallization accelerated oxide coarsening via enhanced solute diffusion along grain boundaries. Pipe diffusion along dislocation cellular boundaries has a negligible contribution to oxide coarsening. At high temperatures (T> 1065 °C), although lattice diffusion primarily controlled the oxide growth, the contribution from the grain-boundary diffusion was necessary. The transformation from MnSiO 3 to CrMn 2 O 4 took place in the un-recrystallized grains but was not observed when recrystallization started. The interaction of grain boundary and oxides during recrystallization resulted in a high fraction of oxides accumulated at grain boundaries. While oxide coarsening does not significantly alter the toughness value, grain-boundary oxides promote microvoid formation and intergranular fracture under Charpy impact in the recrystallized AM 316L SS.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy

In this report the microstructural and strength evolution of an additively manufactured Al-8.6Cu-0.5Mn-0.9Zr alloy upon aging at 300, 350, and 400 °C is investigated. The strengthening phases of the alloy evolve significantly upon aging, with breakdown and spheroidization of the interconnected θ-Al 2 Cu network, dissolution of metastable θ'-Al 2 Cu precipitates, and precipitation of nanometric L1 2 -Al 3 Zr from a matrix supersaturated in Zr. In the peak-aged states, the alloy displays a favorable combination of strength and ductility, with a room-temperature yield strength of 314–341 MPa and ductility of 11–13%. The measured yield strengths for microstructures with different aging treatments are compared to predictions of yield strengths from grain boundary, solid solution, and particle strengthening contributions. The observed strain hardening behavior is related to fundamental precipitate and dislocation interactions. Comparison between predicted and measured strength values indicates a continued need for strengthening models specifically developed for the heterogeneous microstructures of additively manufactured alloys.

36 MATERIALS SCIENCE↗