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At least 1,765 records · Page 98
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Machine-to-machine variability of roughness and corrosion in additively manufactured 316L stainless steel

Numerous studies on the corrosion response of metal AM have been conducted. Nonetheless, the specimens being tested are commonly ground or polished to remove the outer as-built surface. If metal AM is truly going to be employed as a transformative technology that can produce complex shapes that do not require traditional machining, then the material needs to be evaluated in the as-built state. The reality is that AM alloys have shown significant inconsistencies regarding as-built surface texture, topology, and residual stress. One metric that has shown significant unpredictability in the literature is the susceptibility to localized corrosion of typically passive alloys, such as stainless steel (SS). There are a large number of studies that have attempted to understand the corrosion response of metal AM materials, but these studies are typically performed on materials that have been printed on a single machine and often mechanically polished to a smooth finish. This study compares the corrosion response of as-built AM, laser-beam powder bed fusion (LB-PBF), 316L SS parts that have been fabricated on five different machines. The majority of this work focused on understanding the susceptibility to localized corrosion of AM metals with respect to machine-dependent variables, namely surface roughness, and build angle. Surface roughness data was collected using scanning white light triangulation, laser scanning confocal microscopy, and coherence scanning interferometry. The results show that there is significant variability (p two-tail < 0.05) in the susceptibility to local corrosion initiation of LB-PBF 316L SS samples built on different machines. Surface oxides were probed with electron dispersive spectroscopy and revealed that variations in local corrosion susceptibility likely arise from differences in the stability of the passive film caused by chemical segregation, unique microstructure, and tortuous roughness features at the as-built surfaces. The variability of roughness and corrosion properties from test samples printed on different machines was corroborated by property measurements performed at five different testing sites, proving reproducibility of the data. Most importantly, this study shows that if the as-built surface layer is removed through grinding or electropolishing the machine-to-machine variation observed in the corrosion susceptibility is reduced.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A case study in contrastive learning information combination: Application to technical forensics of additive manufacturing filament source identification

Combination of information from disparate data sources into a single decision is a core challenge in many fields, including the field of technical forensics. Technical forensics (TF) utilizes technical characterization of questioned samples to determine properties of that sample; these properties are then used to infer information of forensic interest, such as provenance, age, or attribution. TF is utilized in traditional forensic applications, such as the attribution of material fragments from an explosive, and in nuclear forensic applications, such as the attribution of actinides which have been interdicted out of regulatory control. The challenge of combining information from disparate sources, described alternately by many terms including “Data Fusion” and “Data Integration”, is exacerbated in the technical forensics domain due to at least two factors: the challenge of interpreting each information source singularly, and the relatively small data set sizes available. Extensive literature exists attempting to combine technical forensics information sources, both in manual and automated processes. These attempts are often bespoke to the specific information sources (such as the bi-, tri-, or quad-isotope chart (Moody, Grant, and Hutcheon 2005)), with some emerging examples of simple early- and late- fusion (, respectively). Simultaneous to the information combination efforts described in the previous paragraph, the field of natural language processing attempted (and largely succeeded) in combining information from multiple non-technical information sources. The ecosystem of “multi-modal” language models, which can take text and images as input, and generate text and images as output, became large and diverse by 2025 (Khan et al. 2025). In a generalized sense, many of these methods are trained by learning neural networks which can convert raw text or images into a vector of numbers describing the text or image, hereafter called “embeddings” and the neural networks performing the conversion are called “embedders”. By using a separate embedder for text and images, finding coincident text and images (such as images with their captions), and optimizing the parameters of the embedders such that the embeddings for the text and the image are similar, the field has found a bridge between text and images (Girdhar et al. 2023). It is the contention of the authors of this report that this insight is not limited to text and images but instead can be extended to any modality which can be found coincidently. The subject of the rest of this report is the application of this method to example multi-modal technical forensic data. Some details about the data used in this report are not appropriate for this report, and are included in a companion report (PNNL-38669).

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hybrid Additive Manufacturing of Island Grain Bicrystals

We demonstrate cylindrical island grain bicrystals grown via a hybrid additive manufacturing/directional solidification technique. The island grain bicrystal is formed using a specialized mold in which one grain (the island) is enveloped by another larger grain (the surrounding matrix). The grain boundary plane orientation varies continuously around the circumference of the island grain, making these specimens ideal for probing grain boundary structure–property relations. We report thermal groove angle measurements along the grain boundary in a tin island grain bicrystal which show the grain boundary energy as a function of a single degree of freedom in the five-dimensional grain boundary parameter space.

Ware, Logan↗
DOE OSTI2025

Mechanical and Tribological Performance of Additively Manufactured Nanocrystalline Aluminum via Cryomilling and Cold Spray

In this study, nanocrystalline (NC) aluminum (Al) and magnesium (Mg)-doped Al bulk components were fabricated using a hybrid manufacturing process that combines cryomilling and high-pressure cold spray (HPCS) additive deposition techniques. Yttria-stabilized zirconia (YSZ) was also added during the HPCS process to improve deposition efficiency and build-up thickness via peening. The evolution of morphology, crystallite size, and elemental composition of both cryomilled powders and cold-sprayed (CS’ed) components was systematically characterized using X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and Transmission Electron Microscopy (TEM). Mechanical characterization was performed using Vickers microhardness and uniaxial tensile testing, while the tribological behavior was assessed using sliding wear tests under dry/lubricated conditions. XRD analysis revealed that increased cryomilling duration led to significant crystallite refinement, which directly correlated with enhanced hardness and strength. This mechanical strengthening was accompanied by an increase in coefficient of friction (COF) and lower wear rates. The results also showed that the Mg-doped Al exhibited superior hardness, tensile strength, and tribological performance compared to pure Al. The study further explores the underlying mechanisms responsible for these enhancements, highlighting the potential of solute-assisted grain boundary stabilization in tailoring high-performance NC Al alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fabricating and Testing Additively Manufactured Components for Tritium Service Consideration

This SRTE PDRD sponsored project produced test articles, tooling, and training articles for evaluation. In addition, the hydrogen compatibility of the alloys that can be readily produced by the Arcam A2X was tested. During the evaluation it was determined that the mechanical properties were more sensitive to build plate location than hydrogen exposure. Hydrogen pressure – volume-temperature experiments showed that the as-fabricated samples did not absorb hydrogen readily, but activated samples did.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Improved digital construction binder solution utilizing calcium aluminate additive for Infrastructure Scale Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Kerneos Inc., a Division of Imerys USA, Inc. to develop an improved digital construction binder using calcium aluminate additives produced by Kerneos along with locally available concrete materials. When the two-stage (2K) binder formulation was added to commercially available Portland Limestone Cement and sand to form a digital construction mortar, its strength exceeded a number of commercially available digital construction binders both at early and later ages. At the same time, the developed formulation showed precise control of setting time after addition and showed very low shrinkage making it a strong, reliable, and easily customizable alternative to fixed proprietary digital construction binders.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Improved digital construction binder solution utilizing calcium aluminate additive for Infrastructure Scale Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Kerneos Inc., a Division of Imerys USA, Inc. to develop an improved digital construction binder using calcium aluminate additives produced by Kerneos along with locally available concrete materials. When the two-stage (2K) binder formulation was added to commercially available Portland Limestone Cement and sand to form a digital construction mortar, its strength exceeded a number of commercially available digital construction binders both at early and later ages. At the same time, the developed formulation showed precise control of setting time after addition and showed very low shrinkage making it a strong, reliable, and easily customizable alternative to fixed proprietary digital construction binders.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Hardness Measurements and Interface Behavior of SiC-B 4 C-Si Multiple Phase Particulate Composites Made with Melt Infiltration and Additive Manufacturing

Reaction-bonded SiC-B 4 C-Si ceramic composites were binder jet 3D-printed and subsequently pressureless-melt-infiltrated with molten Si. The addition of B 4 C aided the Si infiltration to produce a highly dense composite. The microstructures and phases of these composites were examined. The measured hardness values of each constituent with Vickers and nanoindentation matched the bulk values, and the macro-hardness values with Knoop and spherical indentation represented the bulk, composite hardness values of all three phases together, which was close to a rule of mixtures value. For particulate-based composites, this is a significant finding. The interfacial bonds of SiC and Si were imaged using scanning transmission electron microscopy to view intimacy, whereas the crack propagation was examined with carefully placed indents. This work demonstrated that pressureless melt infiltration with a reactive particle provides a method to shape non-wetting reaction-bonded ceramic composites with limited shrinkage and high density and provides insights into the mechanical behavior with numerous indentation techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Design and Experimental Demonstration of an Additive Manufactured Smart Oxy-Methane Burner for High Pressure and Supercritical Combustion

Pressurized oxy combustion-based systems can improve efficiency by recovering latent heat of the steam in the Flue Gas and achieving 90% CO2 capture. In addition, the novel Directly Heated Supercritical Carbon Dioxide (DH-SCO2) power cycles can achieve high thermal efficiencies and provide nearly full carbon capture. Additionally, due to the reduction of flue gas at higher pressure, smaller system size and capital cost reductions are also possible. Recent thermodynamic analysis of the DH-SCO2 cycle performed by the UTEP research team shows that combustion conditions in the vicinity of 300 bar pressure and 1000-1400 K temperature allow for relatively high system efficiencies while operating within the limit of available combustor materials. However, the realization of a directly heated supercritical power cycle requires combustion systems to operate in supercritical conditions and at temperature far below the blowout limit of conventional flames (above 1500 K). The thermodynamic properties along with the combustion properties and kinetics are unexplored at such conditions. Additionally, the interaction of the supercritical environment with energy components is also unknown. High-pressure combustion tests are performed using a smart burner at some intermediate pressure ranges (<20 bar) to help minimize these knowledge gaps. The knowledge obtained from the high-pressure test will assist in understanding the combustion chamber pressurization mechanism, ignition and flame behavior at the elevated pressure. The obtained data will act as a systematic first step in testing at higher pressures of 100 and 300 bar pressures.The primary purpose of this Dissertation is to demonstrate the operability of a low NOx smart burner for oxy-methane combustion at high pressure (< 20 bar) and scalable up to supercritical conditions. A shear co-axial smart burner is designed with a real-time temperature monitoring capability to understand the burner face interaction at high-pressure conditions. In addition, the burner has four independent injection ports to allow the independent injection of fuel and dilution gases in the combustor. The maximum operating capability of the burner is 575 kWth. The burner was fabricated using a Laser Powder Bed Fusion process with Nickel Alloy 718. A powder removal technology was invented comprising ultrasonic vibration, liquid nitrogen exposure and media blasting to remove powders from internal channels of the burner. The burner operability tests are performed in the high-pressure combustor and the swirl combustor. The high-pressure combustor was used to investigate the burner operability and thermal soak back at different pressurized conditions. The experimental tests in high-pressure combustor up to 275 kWth input resulted in 16.5 bar chamber pressure and 198°C thermal soaks back to the burner. The burner was capable of providing the required thermal input within a 3% deviation range. In addition, soot formation occurred at high-pressure tests. The swirl combustor was used to observe the flame stability of the burner. Flame lift-off was observed for jet velocities above 450 m/s. Additionally, lift-off decreased for low co-flow velocities. CO2 dilution experiments showed increased flame instabilities for all conditions above 50% dilution ratios. At lower thermal inputs, partial flame blow-offs occurred for dilution ratios above 50%. All conditions significantly reduced the flame temperature and increased the flame lift-off height. Finally, a 2nd generation AM smart burner was designed using the knowledge from the 1st generation burner experiments. The 2nd generation burner incorporated two sets of swirlers with 0.9 swirl no. A cooling system was also designed for long-duration tests at higher pressures. The thermal input and division of the burner's power are kept the same as the 1st generation burner. The burner is to be fabricated using nickel-alloy 718 for high-pressure handling capability. The design can sustain at high-pressure conditions up to 100 bar.

Islam, Md Nawshad Arslan↗
DOE OSTI2021

Impact on Cycle Efficiency of Small Combined Heat and Power Plants from Increasing Firing Temperature Enabled by Additive Manufacturing of Turbine Blades and Vanes

The results of this study show that a 180°F (100°C) increase in firing temperature can increase the gas turbine efficiency by 1 percentage point without improving cooling effectiveness and add 2 additional percentage points in efficiency by using advanced turbine blades with higher internal cooling efficiency. The engine upgrades evaluated in this study show potential for increasing the CHP cycle efficiency by 3 percentage points while increasing the steam generation rate by 8%.

Uysal, Selcuk Can↗
NASA NTRSDate not supplied

Enabling Small-Batch Custom Alloy Feedstock Development for Additive Manufacturing

Propulsion, hypersonic, and space nuclear power applications require high strength/high temperature components produced by AM but rely on expensive, supply-chain limited, non-AM optimized metals that lead to high buy-to-fly ratios. In addition, custom alloy development for AM is extremely expensive given the high-cost associated with feedstock development.​ Here, we highlight current efforts to develop a cost-effective process to enable application driven high-throughput AM-optimized metal alloy development using small powder batch processing. A cost-effective process for custom AM-feedstock development will enable fast industry infusion to aid future NASA missions and will enable commercial space partners and supply chain.

Fernando L Reyes Tirado↗
DOE OSTI2025

Additive Manufacturing of Lattice Structures for Catalyst Applications

Abstract The design and fabrication of Inconel 718 open-pore lattice structures via Laser Powder Bed Fusion (LPBF) has been investigated in this research, focusing on applications such as catalyst supports in jet fuel production. The study explores the impact of laser power and scanning speed on the geometrical resolution of these structures aiming to achieve high porosity (porosity > 60%) and specific pore sizes ranging from 500–1000 μm, intending to serve as catalyst supports, replacing conventionally manufactured foams to reduce costs. Results demonstrate the significant influence of processing parameters on the geometrical aspects of printed lattice structures, with laser power having a more pronounced effect on geometrical accuracy than scanning speed. Additionally, the mechanical properties of the printed lattice structures showed a correlation with the lattice strut sizes, as lattices with less porosity and thicker struts resulted in higher maximum shear stress.

Ghanadi, Nahal [Oregon State University] (ORCID:00↗
DOE OSTI2023

Real-time process monitoring for direct ink write additive manufacturing

Direct ink write (DIW) printing of reactive resins presents a unique challenge due to the time-dependent nature of the rheological and chemical properties of the ink. As a result, careful print optimization or process control is important to obtain consistent, high quality prints. The present invention uses a flow-through characterization cell for in situ chemical monitoring of a resin ink during DIW printing. Additionally, in-line extrusion force monitoring can be combined with off-line post inspection using machine vision. By combining in-line spectroscopy and force monitoring, it is possible to follow reaction kinetics (for example, curing of a reactive resin) and viscosity changes during printing, which can be used for a closed-loop process control. Additionally, the capability of machine vision to automatically identify and quantify print artifacts can be incorporated on the printing line to enable real-time, AI-assisted quality control of the printed products. Together, these techniques can form the building blocks of an optimized process control strategy when complex reactive ink must be used to produce printed hardware.

Cook, Adam W.↗
DOE OSTI2022

Multi material/functionally graded wire arc additive manufacturing of high strength steel valves clad with nickel alloy 625 used for oil extraction

This Phase 1 technical collaboration project (ORNL/TM-2022/2683) began on August 1st, 2020 and concluded on July 31st, 2022. The collaboration partner Schlumberger is a large business enterprise assisting oil companies to extract oil from land and subsea cost competitively and safely. It is based in Houston, Texas USA. In this work as study of additive deposition of AWS EF100S-G and AWS ERNiCrMo-3 wires via wire-arc process was conducted.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Heat exchangers fabricated by additive manufacturing, related components, and related methods

A method of forming at least a component of a heat exchanger comprises introducing a feed material comprising a first portion including a matrix material and a second portion including a sacrificial material on a surface of a substrate, exposing at least the first portion to energy to form bonds between particles of the matrix material and form a first thickness of a structure, introducing additional feed material comprising the first portion over the first thickness of the structure, exposing the additional feed material to energy to form a second thickness of the structure, and removing the sacrificial material from the structure to form at least one channel in the structure. Related heat exchangers and components, and related methods are disclosed.

van Rooyen, Isabella J.↗