Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “temperature”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,657 records · Page 92

Deep Learning Advances Arctic River Water Temperature Predictions

The accelerated warming in the Arctic poses serious risks to freshwater ecosystems by altering streamflow and river thermal regimes. However, limited research on Arctic River water temperatures exists due to data scarcity and the absence of robust methodologies, which often focus on large, major river basins. To address this, we leveraged the newly released, extensive AKTEMP data set and advanced machine learning techniques to develop a Long Short-Term Memory (LSTM) model. By incorporating ERA5-Land reanalysis data and integrating physical understanding into data-driven processes, our model advanced river water temperature predictions in ungauged, snow- and permafrost-affected basins in Alaska. Our model outperformed existing approaches in high-latitude regions, achieving a median Nash-Sutcliffe Efficiency of 0.95 and root mean squared error of 1.0°C. The LSTM model learned air temperature, soil temperature, solar radiation, and thermal radiation—factors associated with energy balance—were the most important drivers of river temperature dynamics. Soil moisture and snow water equivalent were highlighted as critical factors representing key processes such as thawing, melting, and groundwater contributions. Glaciers and permafrost were also identified as important covariates, particularly in seasonal river water temperature predictions. Our LSTM model successfully captured the complex relationships between hydrometeorological factors and river water temperatures across varying timescales and hydrological conditions. This scalable and transferable approach can be potentially applied across the Arctic, offering valuable insights for future conservation and management efforts.

54 ENVIRONMENTAL SCIENCES↗

Low temperature dielectric and conductivity relaxation studies on magnetoelectric Pb(Fe{sub 2/3}W{sub 1/3})O{sub 3}

The single phase perovskite Pb(Fe{sub 2/3}W{sub 1/3})O{sub 3} [PFW] was synthesized by modified low – temperature (sintering at 850°C) solid-state reaction. Rietveld refinement ofroom temperature (RT) X-ray diffraction (XRD) and neutron diffraction (ND) patterns of the samples confirm the single phase formation with cubic structure (Pm-3m). Surface morphology of the compounds was studied by Scanning electron microscope (SEM) and average grain size was estimated to be ∼2 µm. The RT dielectric properties of PFW ceramic are studied as a function of frequency from 100 - 1MHz. The temperature dependent (120 – 293K) dielectric properties were studied at few selected frequencies. We found the frequency dependent dielectric constant shows increasing trend with increase in temperature from 120 – 293K, with minimum dielectric loss. The frequency dependence of dielectric loss shows a maximum in between 10 Hz and 1 kHz, confirms the extrinsic phenomena like interfacial polarization due to space charge accumulation at grain boundaries. Impedance spectroscopy is used to study the electrical behaviour of PFW in the frequency range from 100 to 1MHz and in the temperature range from 120 - 293 K. The frequency-dependent electrical data are analysed by impedance formalisms and shows the relaxation (conduction) mechanism in the sample. We suggest this low temperature sintered PFW is a suitable candidate for the multilayer ceramic capacitorsandrelated negative temperature coefficient of resistance type (NTCR) behavior like that of semiconductors.

36 MATERIALS SCIENCE↗

Temperature Dependence of the Upper Critical Field in Disordered Hubbard Model with Attraction

We study disorder effects upon the temperature behavior of the upper critical magnetic field in an attractive Hubbard model within the generalized DMFT+Σ approach. We consider the wide range of attraction potentials U—from the weak coupling limit, where superconductivity is described by BCS model, up to the strong coupling limit, where superconducting transition is related to Bose–Einstein condensation (BEC) of compact Cooper pairs, formed at temperatures significantly higher than superconducting transition temperature, as well as the wide range of disorder—from weak to strong, when the system is in the vicinity of Anderson transition. The growth of coupling strength leads to the rapid growth of H{sub c2}(T), especially at low temperatures. In BEC limit and in the region of BCS–BEC crossover H{sub c2}(T), dependence becomes practically linear. Disordering also leads to the general growth of H{sub c2}(T). In BCS limit of weak coupling increasing disorder lead both to the growth of the slope of the upper critical field in the vicinity of the transition point and to the increase of H{sub c2}(T) in the low temperature region. In the limit of strong disorder in the vicinity of the Anderson transition localization corrections lead to the additional growth of H{sub c2}(T) at low temperatures, so that the H{sub c2}(T) dependence becomes concave. In BCS–BEC crossover region and in BEC limit disorder only slightly influences the slope of the upper critical field close to T{sub c}. However, in the low temperature region H{sub c2} (T may significantly grow with disorder in the vicinity of the Anderson transition, where localization corrections notably increase H{sub c2} (T = 0) also making H{sub c2}(T) dependence concave.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Molybdenum Disilicide Oxidation Kinetics in High Temperature Steam

The Fuel Cycle Research and Development program’s Advanced Fuels Campaign is currently supporting a range of experimental efforts aimed at the development and qualification of ‘accident tolerant’ nuclear fuel forms. One route to enhance the accident tolerance of nuclear fuel is to replace the zirconium alloy cladding, which is prone to rapid oxidation in steam at elevated temperatures, with a more oxidation-resistant cladding. Several cladding replacement solutions have been envisaged. The cladding can be completely replaced with a more oxidation resistant alloy, a layered approach can be used to optimize the strength, creep resistance, and oxidation tolerance of various materials, or the existing zirconium alloy cladding can be coated with a more oxidation-resistant material. Molybdenum is one candidate cladding material favored due to its high temperature creep resistance. However, it performs poorly under autoclave testing and suffers degradation under high temperature steam oxidation exposure. Development of composite cladding architectures consisting of a molybdenum core shielded by a molybdenum disilicide (MoSi 2 ) coating is hypothesized to improve the performance of a Mo-based cladding system. MoSi 2 was identified based on its high temperature oxidation resistance in O 2 atmospheres (e.g. air and “wet air”). However, its behavior in H 2 O is less known. This report presents thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and x-ray diffraction (XRD) results for MoSi 2 exposed to 670-1498 K water vapor. Synthetic air (80-20%, Ar-O 2 ) exposures were also performed, and those results are presented here for a comparative analysis. It was determined that MoSi 2 displays drastically different oxidation behavior in water vapor than in dry air. In the 670-1498 K temperature range, four distinct behaviors are observed. Parabolic oxidation is exhibited in only 670-773 K water vapor, a temperature range in which the material pests in dry O 2 environments. From 877-1084 K in water vapor, MoSi 2 undergoes rapid mass gain resulting in oxidation throughout the bulk of the sample at 980 K and 1084 K. The resulting material displays swelling and warping after the 980-1084 K exposures. A pre-passivation heat treatment performed at 1395 K was found capable of producing a coarse SiO 2 layer that limited pesting at lower temperatures in water vapor over the time periods investigated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Sound Speed as a Candidate for Internal Temperature Monitoring During Solid Phase Processing of Materials

Internal temperature is an important parameter for understanding the solid phase processing (SPP) of materials and improving feedback control of these processes. Friction stir processes, shear assisted processing and extrusion (ShAPE ™ ), and ultrahigh velocity (UHV) cold spray are examples of such processes. Simple thermal models based on temperatures measured at the boundary of the deforming body cannot capture the dynamic nature of temperature generation within the deforming solid. One possibly way of understanding internal temperature is by measuring sound speed, which varies as a function of temperature for materials and directing ultrasonic wave propagation through selected material volumes of interest. In this project, longitudinal wave speed is estimated for aluminum 6061. Piezoelectric materials bonded to a specimen provided data from which longitudinal wave speed was estimated. A discussion evaluated the linear relationship of wave speed versus temperature and postulated how wave speed measurements could be used to estimate the internal temperature of selected material volumes for feedback during SPP of materials. Instrumentation, data and analysis, and a discussion are reviewed.

36 MATERIALS SCIENCE↗

An Updated Global Grid Point Surface Air Temperature Anomaly Data Set: 1851-1990 (revised 1991) (NDP-020)

This NDP presents land-based monthly surface-air-temperature anomalies (departures from a 1951-1970 reference period mean) on a 5° latitude by 10° longitude global grid. Monthly surface-air-temperature anomalies (departures from a 1957-1975 reference period mean) for the Antarctic (grid points from 65°S to 85°S) are presented in a similar way as a separate data set. The data were derived primarily from the World Weather Records and from the archives of the United Kingdom Meteorological Office. This long-term record of temperature anomalies may be used in studies addressing possible greenhouse-gas-induced climate changes. To date, the data have been employed in producing regional, hemispheric, and global time series for determining whether recent (i.e., post-1900) warming trends have taken place. The present updated version of this data set is identical to the earlier version for all records from 1851-1978 except for the addition of the Antarctic surface-air-temperature anomalies beginning in 1957. Beginning with the 1979 data, this package differs from the earlier version in several ways. Erroneous data for some sites have been corrected after a review of the actual station temperature data, and inconsistencies in the representation of missing values have been removed. For some grid locations, data have been added from stations that had not contributed to the original set. Data from satellites have also been used to correct station records where large discrepancies were evident. The present package also extends the record by adding monthly surface-air-temperature anomalies for the Northern (grid points from 85°N to 0°) and Southern (grid points from 5°S to 60°S) Hemispheres for 1985-1990. In addition, this updated package presents the monthly-mean-temperature records for the individual stations that were used to produce the set of gridded anomalies. The periods of record vary by station. Northern Hemisphere data have been corrected for inhomogeneities, while Southern Hemisphere data are presented in uncorrected form.For access to the data files, click this link to the CDIAC data transition website: http://cdiac.ess-dive.lbl.gov/ndps/ndp020.html

54 ENVIRONMENTAL SCIENCES↗

High‐Resolution Dynamical Downscaling Ensemble Projections of Future Extreme Temperature Distributions for the United States

Abstract The aim of this study is to examine projections of extreme temperatures over the continental United States (CONUS) for the 21st century using an ensemble of high spatial resolution dynamically downscaled model simulations with different boundary conditions. The downscaling uses the Weather Research and Forecast model at a spatial resolution of 12 km along with outputs from three different Coupled Model Intercomparison Project Phase 5 global climate models that provide boundary conditions under two different future greenhouse gas (GHG) concentration trajectories. The results from two decadal‐length time slices (2045–2054 and 2085–2094) are compared with a historical decade (1995–2004). Probability density functions of daily maximum/minimum temperatures are analyzed over seven climatologically cohesive regions of the CONUS. The impacts of different boundary conditions as well as future GHG concentrations on extreme events such as heat waves and days with temperature higher than 95°F are also investigated. The results show that the intensity of extreme warm temperature in future summer is significantly increased, while the frequency of extreme cold temperature in future winter decreases. The distribution of summer daily maximum temperature experiences a significant warm‐side shift and increased variability, while the distribution of winter daily minimum temperature is projected to have a less significant warm‐side shift with decreased variability. Using “business‐as‐usual” scenario, 5‐day heat waves are projected to occur at least 5–10 times per year in most CONUS and ≥95°F days will increase by 1–2 months by the end of the century.

54 ENVIRONMENTAL SCIENCES↗

Superior High-Temperature Strength in a Supersaturated Refractory High-Entropy Alloy

Refractory high-entropy alloys (RHEA) show promising applications at high temperatures. However, achieving high strengths at elevated temperatures above 1,173K is still challenging due to heat softening. Using intrinsic material characteristics as the alloy-design principles, a single-phase body-centered-cubic (BCC) CrMoNbV RHEA with high-temperature strengths (beyond 1,000 MPa at 1,273 K) is designed, superior to other reported RHEAs as well as conventional superalloys. The origin of the high-temperature strength is revealed by in-situ neutron scattering, transmission-electron microscopy, and first-principles calculations. The CrMoNbV’s elevated-temperature strength retention up to 1,273 K arises from its large atomic-size and elastic-modulus mismatches, the insensitive temperature dependence of elastic constants, and the dominance of non-screw character dislocations caused by the strong solute pinning, which makes the solid-solution strengthening pronounced. The alloy-design principles and the insights in this study pave the way to design RHEAs with outstanding high-temperature strength.

36 MATERIALS SCIENCE↗

A Fast‐Charging and High‐Temperature All‐Organic Rechargeable Potassium Battery

Abstract Developing fast‐charging, high‐temperature, and sustainable batteries is critical for the large‐scale deployment of energy storage devices in electric vehicles, grid‐scale electrical energy storage, and high temperature regions. Here, a transition metal‐free all‐organic rechargeable potassium battery (RPB) based on abundant and sustainable organic electrode materials (OEMs) and potassium resources for fast‐charging and high‐temperature applications is demonstrated. N‐doped graphene and a 2.8 m potassium hexafluorophosphate (KPF 6 ) in diethylene glycol dimethyl ether (DEGDME) electrolyte are employed to mitigate the dissolution of OEMs, enhance the electrode conductivity, accommodate large volume change, and form stable solid electrolyte interphase in the all‐organic RPB. At room temperature, the RPB delivers a high specific capacity of 188.1 mAh g −1 at 50 mA g −1 and superior cycle life of 6000 and 50000 cycles at 1 and 5 A g −1 , respectively, demonstrating an ultra‐stable and fast‐charging all‐organic battery. The impressive performance at room temperature is extended to high temperatures, where the high‐mass‐loading (6.5 mg cm −2 ) all‐organic RPB exhibits high‐rate capability up to 2 A g −1 and a long lifetime of 500 cycles at 70–100 °C, demonstrating a superb fast‐charging and high‐temperature battery. The cell configuration demonstrated in this work shows great promise for practical applications of sustainable batteries at extreme conditions.

25 ENERGY STORAGE↗

Baseplate Temperature–Dependent Vertical Composition Gradient in Pseudo–Bilayer Films for Printing Non–Fullerene Organic Solar Cells

Numerous previous reports on the sequential deposition (SD) technique have demonstrated that this approach can achieve a p–i–n active layer architecture with an ideal vertical composition gradient, which is one of the critical factors that can influence the physical processes that determine the photovoltaic performance of organic solar cells. Herein, a commonly used photovoltaic system comprised of PM6 as a donor and Y6 as an acceptor is investigated with respect to sequential blade–processing deposition to comprehensively explore the morphology characteristics as a function of baseplate temperature. A systematic study of the temperature–dependent blend morphology elucidates the SD–processed configuration merits and device physics behind temperature–controlled degree of vertical composition gradient, and constructs the temperature–microstructure–property relationship for the corresponding photovoltaic parameters. The result shows, as the temperature increases, the morphology of the active layer has undergone a distinct evolution from the pseudo–bulk heterojunction to a pseudo–planar heterojunction and then to a pseudo–planar bilayer, leading to a non–monotonic correlation between baseplate temperature and device performance. Further, this investigation not only reveals the importance of precisely controlling baseplate temperature for gaining vertical morphology control, but also provides a path toward rational optimization of device performance in the lab–to–fab transition.

14 SOLAR ENERGY↗

A comparison of pulsed and continuous lasers for high-temperature Raman measurements of anhydrite

Oxygen carrier particles (OCPs) serve as fuel oxidant in emerging chemical looping combustion systems. However, chemical looping combustion process optimization is hindered by the lack of online sensors for measurements of OCP oxidation states at temperatures up to 1,000 °C and pressures up to 10 atm. We are investigating Raman spectroscopy as a potential solution, as this technique is known for its ability to provide noninvasive, molecularly specific information in real time in a wide variety of applications. As a case study, Raman spectra from high–temperature (>1,000 °C) anhydrite, a potential OCP, are presented using pulsed and continuous wave excitation at 532 nm. When pulsed excitation is coupled with time–gated detection, background signal from thermal radiation can be significantly reduced from single pulse spectra, outperforming results using an ungated detector. Also, laser heating of the sample is not observed but laser–induced breakdown spectra increasingly appear with increasing temperature and pulse intensity. Compared with pulsed excitation, continuous wave excitation with longer acquisition time, offers higher signal to noise and avoids the risk for laser–induced breakdown spectra but demonstrates minor sample heating. Finally, the data demonstrate practical utility by (a) providing a calibration of anhydrite's ν 1 (1,017 cm –1 ) Raman temperature–dependent band position and by (b) providing estimates of temperature using the ratios of the Stokes/anti–Stokes ν 1 integrated intensities. Furthermore, these results demonstrate the first high–temperature, pulsed Raman spectra from anhydrite while evaluating challenges associated with high–temperature, Raman measurements of OCP materials in general.

20 FOSSIL-FUELED POWER PLANTS↗

Standards development for modules in high temperature micro-environments

Photovoltaic (PV) module qualification standards, IEC 61215 and IEC 61730, were designed to apply to “general open-air climates” and IEC 61730 specifically indicated applicability of ambient air temperature of 40°C. Additionally, these standards provided allowances for so-called “open rack mounted PV modules” without a clear definition of “open-rack.” These implied restrictions and allowances meant that hotter climates or thermally restrictive installation methods may not be covered by these often customer-mandated certification standards. This is particularly salient for the significant growth regions of the Middle East and India that would be expected to operate at significantly higher temperatures. The applicability of these documents raised issues over the definition of “open rack” and the fact that the geographic location is just as important as the mounting configuration in assessing the impact of the micro-environment of a PV module. This work summarizes the scientific background for IEC Technical Specification 63126:2020 ED1, titled “Guidelines for qualifying PV modules components and materials for operation at high temperatures.” This standard was recently published by the IEC and is the first step in a systematic effort to rework these standards to address the question of temperature more directly. Instead of specifying a mounting condition, we specify different suites of tests suitable for a system (PV module, mounting style, and location) defined by the 98th percentile cell temperature. With a defined temperature regime to work from, this allowed us to use existing literature research combined with additional modeling work to determine, which tests would need to be modified. This resulted in suggested changes to material thermal indices, thermal cycling temperatures, hot spot testing, ultraviolet testing, and bypass diode testing among other tests and characteristics described in this study.

14 SOLAR ENERGY↗

Simultaneous Independent Control of Tool Axial Force and Temperature in Friction Stir Processing

Maintaining consistent tool depth relative to the part surface is a critical requirement for many Friction stir processing (FSP) applications. Force control is often used with the goal of obtaining a constant weld depth. When force control is used, if weld temperature decreases, flow stress increases and the tool is pushed up. If weld temperature increases, flow stress decreases and the tool dives. These variations in tool depth and weld temperature cause various types of weld defects. Robust temperature control for FSP maintains a commanded temperature through control of the spindle axis only. Robust temperature control and force control are completely decoupled in control logic and machine motion. This results in stable temperature, force and tool depth despite the presence of geometric and thermal disturbances. Performance of this control method is presented for various weld paths and alloy systems.

force control↗

Electronic and Magnetic Investigations on Fe{sub 2}NiTe Alloy with High Curie Temperature

Full-potential local-orbital minimum-basis and spin-polarized relativistic Korringa-Kohn-Rostoker along with Monte Carlo simulations are applied to study the electronic and magnetic properties of Fe{sub 2}NiTe with Hg{sub 2}CuTi structure. The analysis of orbital population shows the electrons of 4s, 3d, 4d, and 4p from transition metal and 5s, 5d, and 5p from Te atom participating in bonding. It is demonstrated by the density of states of d-d and p-d hybridizations. Calculations show the magnetic moment is carried mainly by Fe atoms. Accordingly, the exchanges of Fe constituents play a leading role in interactions. By using the calculated Heisenberg exchange coupling parameters, the Curie temperature is estimated to be 761.38 K within mean-field approximation. In order to obtain more accurate value of the Curie temperature, Monte Carlo method is adopted to model the normalized magnetization as functions of the temperature, the obtained 507.93 K value is noticeably higher than the room temperature, which is favorable in realistic spintronics application. Finally, the magnetic moments, exchange interactions, and Curie temperatures in the range of 5.4 to 6.5 Å are calculated; the results implies the Curie temperatures are still above room temperature between given lattice intervals.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Stages of Mechanical Alloying in Systems with Different Solubility Cu–Zn and Au–Co in the Case of Cold and Low-Temperature Deformation by Torsion Under Pressure

Methods of X-ray structural analysis and durometry, as well as electron microscopy were used to identify the stages of mechanical alloying in the case of torsion under high quasi-hydrostatic pressure on Bridgman anvils in the Cu–Zn and Au–Co systems that have different mutual solubility and enthalpy of mixing. It was established that decrease in temperature of mechanical alloying from room temperature (cold deformation) to the boiling temperature of liquid nitrogen (80 К, low-temperature deformation) has a considerable impact on mechanical alloying at different processing stages and on characteristics of an alloy synthesized by deformation. In the Cu–Zn system, when the ratio of powder components corresponds to the solid solution of α-brass in equilibrium state, as deformation increased, one observed consecutive change of evolution stages of the powder mix to the state of copper-based solid solution. At the same time, when processing temperature decreases, larger deformation is required to achieve analogous structural changes. In the Au–Co system characterized by absence of solubility at room and lower temperatures, one also observes the stages of powder mix evolution with the increase in deformation. However, complete dissolution occurs in the case of processing at 80 К, while larger deformation is required in the case of increase in mechanical alloying temperature. The paper examines possible mechanisms of solid solution formation in the system of components that are mutually insoluble under equilibrium conditions.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Phase Transformation and Lattice Parameter Changes of Non-trivalent Rare Earth-Doped YSZ as a Function of Temperature

To examine the effect of doping/co-doping on high-temperature phase compositions of YSZ, stand-alone YSZ and CeO{sub 2} and Nb{sub 2}O{sub 5} co-doped YSZ samples were prepared using mechanical alloy and high-temperature sintering. XRD analysis was performed on these samples from room temperature to 1100 °C. The results show that the structure for the co-doped samples tends to be thermally stable when the test temperature is higher than a critical value. Monoclinic phase was dominant in Nb{sub 2}O{sub 5} co-doped YSZ at temperatures lower than 600 °C, while for the YSZ and CeO{sub 2} co-doped YSZ, cubic/tetragonal phase was dominant in the whole test temperature range. The lattice parameters for all the samples increase with increasing test temperature generally. The lattice parameters for the two non-trivalent rare earth oxides co-doped YSZ show that the lattice parameter a for the cubic phase of the Ce{sup 4+} co-doped YSZ is consistently greater than that of 7YSZ which is related to the presence of larger radius of Ce{sup 4+} in the matrix. The lattice parameters a, b, c for the monoclinic phase of Ce{sup 4+} co-doped YSZ are much closer to each other than that of the Nb{sup 5+} co-doped YSZ, indicating the former has better tendency to form cubic/tetragonal phase, which is desired for vast engineering applications.

36 MATERIALS SCIENCE↗

Temperature and dose effects on dislocation loops in self-ion irradiated high-purity iron

Body-centered cubic (BCC) Fe-based alloys are promising candidate materials for advanced nuclear reactors. However, a detailed understanding of irradiation induced dislocation loop microstructure development remains unresolved. It is a widespread belief that 〈001〉 loops become increasingly favorable over ½〈111〉 loops as irradiation temperature rises above ∼300 C. Unfortunately, the temperature effects on 〈001〉 loop have been primarily examined in in-situ irradiation on TEM thin foils but poorly explored on bulk Fe due to exceedingly limited experimental studies on bulk specimens, raising concerns about the potential influence of TEM thin foil artifacts on observed results. Here, in this study, we conducted experiments on ultra-high purity BCC Fe specimens irradiated with 6.7–8 MeV Fe ions over a wide temperature range on bulk samples. We investigated the effects of temperature (T irr = 250–500 °C), dose rate (10⁻⁵ to 10⁻³ dpa/s), and dose (0.35 to 3.5 dpa) on the formation and evolution of 〈001〉 and ½〈111〉 loops as well as cavity (void) formation. Post-irradiation Burgers vector analysis via g•b method on dislocation segments and loops revealed that 〈001〉 loop fraction does not show a monotonic positive correlation with irradiation temperature. Combined with previous and current theoretical as well as experimental findings, we explore the temperature effects on all existing models of 〈001〉 loop formation. We conclude that the prevailing reports regarding the dominance of 〈001〉 loops in Fe at elevated temperatures are mainly attributable to the loss of glissile ½〈111〉 clusters in TEM thin foil experiments.

36 MATERIALS SCIENCE↗

Elucidating the effect of preheating temperature on melt pool morphology variation in Inconel 718 laser powder bed fusion via simulation and experiment

In laser powder bed fusion (L-PBF) additive manufacturing, the mechanical performance, microstructure and defects of fabricated parts are closely associated with the melt pool morphology, e.g., its dimension and shape through the building process. Past studies have largely focused on how the process parameters such as laser power and scan speed affect melt pool characteristics. In this study, the melt pool morphology variation as a function of preheating temperature in the conduction, transition, and keyhole regimes and the underlying mechanisms in each regime are investigated through ex-situ sample characterization and computation thermal fluid dynamics (CtFD) simulation. Single tracks with different combinations of laser power and scan speed are deposited on an Inconel 718 bare plate preheated to a temperature range of 100–500 °C in the experiment. Significant changes are observed in melt pool morphology as a function of preheating temperature from optical measurements of melt track cross sections. The depth of melt pool in the three regimes increases monotonically with preheating temperature, e.g., at 500 °C, the experimental melt pool depth is increased by 49% in conduction regime, 34% in transition regime and 33% in keyhole regime, respectively, while the variation of melt pool width in each regime does not all follow an increasing trend but depends on the melt pool regimes. Melt pool width variation in the conduction and transition regimes is found to depend on the enhanced heat conduction directly related to temperature dependent thermal properties. Through validated CtFD simulations, it is found that in the keyhole regime the evaporation mass, recoil pressure, and laser drilling effect is enhanced with higher preheating temperature, which gives rise to a deeper melt pool. The simulations also reveal that preheating temperature significantly elongates the melt track length due to the increased flow rate and strong recoil pressure that accelerates the backward flow.

36 MATERIALS SCIENCE↗