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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

PowderJet: Spherical metal powder production via multi-orifice droplet-on-demand metal jetting

Leading metal additive manufacturing techniques, such as laser powder bed fusion and directed energy deposition, rely on high-quality spherical metal powders. However, traditional powder production methods like gas atomization face limitations, including low in-spec yield, asphericity, and internal porosity. We introduce PowderJet, a powder production platform that uses electromagnetic pulses to eject liquid metal droplets from a multi-orifice nozzle. Unlike stochastic methods, PowderJet tightly controls powder size, distribution, and purity through a droplet-on-demand approach. We detail the system’s design, operation, and performance using a combined experimental and computational fluid dynamics (CFD) framework. Initial results with Al4008 and Cu110 alloys demonstrate successful production, yielding unsieved aluminum powder batches with a mean diameter of 200 µm and a narrow size distribution (15 µm standard deviation). The produced powders are highly spherical, achieving a roundness > 0.95. PowderJet operates with a small melt volume (3 mL) and supports continuous refilling, enabling production rates between 30 and 140 cm³/hr depending on jetting frequency, number of orifices and particle size. CFD simulations show that future systems could achieve rates exceeding 1000 cm³/hr for particle sizes as small as 40 µm. PowderJet’s high yield of in-spec powder makes it ideal for producing precious or hazardous materials that are inefficient to manufacture using conventional methods. This platform offers a scalable, precise, and efficient solution for producing high-quality powders tailored for advanced manufacturing applications.

Atomization↗
DOE OSTI2025

In Situ, Real-Time Diagnostic to Improve the Liquid Metal Jetting Additive Manufacturing Process [Poster]

Liquid Metal Jetting (LMJ) is a metal additive manufacturing technique that involves jetting molten metal droplets at high frequencies to build solid metal parts. As an alternative to industry standard Lazer Powder Bed Fusion (LPBF) and Direct Metal Writing (DMW) techniques, LMJ poses significant advantages including no powder feed stock, no post sintering process, very high deposition rates, and the capability to print various metals. This summer, I was tasked with improving my old system to process at much higher resolution, Increasing the capture rate, and implementing this diagnostic on various LMJ setups. This system provides a vital longitudinal study to understand individual droplets in the LMJ process.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Impact of droplet oxidation on mechanical properties of an Al-7Si-0.4Mg alloy fabricated with liquid metal jetting

Droplet-on-demand liquid metal jetting (DOD-LMJ) is a new method for additive manufacturing of bulk structural alloys. Here, we report on the microstructure, tensile, and fatigue properties of an Al-7Si-0.4Mg (A356) alloy fabricated with LMJ. Liquid metal droplets were shielded by high-purity Ar gas shroud during deposition. Atom probe tomography revealed that a few nanometers thick (Al-Mg-Si)-O oxide film formed on the droplets despite Ar gas shielding. Tensile tests on peak-aged LMJ A356 alloy showed that yield strength was isotropic (250 MPa), but ductility was lower in the build direction (6.1 ± 1.4 %) compared to the transverse direction (9.4 ± 1.0 %). Lower ductility in the build direction was attributed to delamination of metal-oxide interfaces at layer boundaries. The ductility and yield strength of LMJ A356 were similar to cast A356 and laser powder bed fused (LPBF) A357 alloys, indicating the limited impact of oxide film on tensile properties. The oxide film severely impacted the fatigue properties. Fatigue resistance of LMJ A356 was limited by fatigue crack initiation at lack-of-fusion defects and fatigue crack propagation along layer boundaries by delamination of the metal-oxide interface. The fatigue strength of LMJ A356 at 60 MPa was lower than cast A356 and LPBF A357 alloys in the peak-aged condition. This research underscores the need for managing droplet oxidation during LMJ additive manufacturing of structural alloys.

42 ENGINEERING↗
DOE OSTI2026

Full-Strength Additive Manufacturing of Pure Aluminum Alloy 7075 Using Liquid Metal Jet Printing

Additive manufacturing (AM) of high-strength aluminum alloys can produce high-performance aerospace and biomedical parts with unique geometries and functions. However, many high-performance alloy systems such as AA 7075 pose challenges during AM due to thermal cycles that cause hot cracking, limiting AM to casting-friendly alloys. Stock AA 7075 alloy poses additional challenges due to the excessive growth of insoluble precipitates during casting and needs to be thermomechanically processed to obtain acceptable mechanical properties. Here, this work uses liquid metal jet printing to produce high-resolution pure AA 7075 parts at high strength (593 MPa) and ductility (10 pct), surpassing the specific strength of any type of steel. The parts are printed by depositing fine droplets on a high-temperature substrate that reduces cooling rates, preventing hot cracking. The results show that fully dense, crack-free parts can only be printed at substrate temperatures of 500 °C with a cooling rate threshold of < 2000 K/s to prevent cracking and < 500 K/s to eliminate porosity. The tensile strength, microhardness, and ductility of the parts matched or were beyond the wrought alloy specifications after heat treatment, possibly due to high solidification rates that produce finer insoluble precipitates. Our results indicate that many challenging high-performance alloy systems can now be 3D printed based on the critical thresholds for cooling rates using any AM method that can satisfy these conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Rapid Screening of Liquid Metal Wetting for a Materials Compatibility Library

Wetting behavior of molten metals on solid substrates is a critical phenomenon influencing numerous industrial applications, including welding, anti-corrosion coatings, and metal additive manufacturing (AM). In particular, molten metal jetting (MMJ), an emerging AM technology, requires that the molten metal remain pinned at the nozzle exit. Thus, each new metal requires a specific nozzle material to ensure consistent droplet ejection and deposition, making it important to rapidly identify the appropriate wetting combinations. However, traditional measurements of wetting angles require expensive equipment and only allow one combination of materials to be investigated at a time which can be time consuming. This work introduces a rapid screening method based on sessile droplet experiments to evaluate wetting profiles across multiple metal–substrate combinations simultaneously. This study investigates the wetting interactions of molten Al alloy (Al4008), Cu, and Sn on various ceramic and metal substrates to identify optimal material combinations for MMJ nozzle designs. Results demonstrate that Al4008 achieves wetting on ceramic substrates such as AlN, TiO 2 , and SiC, with varying mechanisms including chemical reactions and weak surface interactions. Additionally, theoretical predictions regarding miscibility gaps and melting point differences were verified for Cu and Sn on refractory metals like Mo and W. Findings from this study contribute to the establishment of a materials compatibility library, enabling the selection of wetting/non-wetting combinations for stable MMJ operation. This resource not only advances MMJ technologies but also provides valuable insights for broader applications such as welding, coating, and printed electronics.

Materials science↗
DOE OSTI2025

Liquid metal-based polarized positron generation benchmark using the GEANT4 toolkit

In this work, we report simulation results for the positron yield and polarization of polarized electron beams incident on GaInSn and PbBi liquid metal targets. One of the proposed upgrades to 12 GeV CEBAF is the use of a continuous wave polarized positron beam for physics experiments. High-Z liquid metal jets are excellent candidates for positron production targets because they can withstand high power beams. Polarized positron beams can be generated from a primary electron beam incident to thick high-Z targets through circular polarized bremsstrahlung conversion to linearly polarized pair production. This polarization transfer from the primary electron beam has been previously demonstrated at Jefferson Lab in the PEPPo experiment with a tungsten target at relatively low energies. Here we report Geant4 simulations for 10 and 120 MeV electron beams incident on GaInSn and PbBi liquid metal targets. These simulations are compared to simulations with a solid tungsten target, as well as with unpolarized simulations using MCNP6.

Lizarraga-Rubio, Victor Manuel↗
DOE OSTI2024

Validation of SOLPS-ITER and EDGE2D-EIRENE simulations for H, D, and T JET ITER-like wall low-confinement mode plasmas

Both experiments and simulations with SOLPS-ITER and EDGE2D-EIRENE show that the onset of detachment for the low-field side (LFS) divertor – defined here as the line-averaged upstream density (〈n e 〉 edge ) at which the plasma flux to the LFS target (I LFS-plate ) starts to decrease with increasing 〈n e 〉 edge – is independent of the isotope mass. However, there are three major simulation-experiment discrepancies: (i) the absolute values of I LFS-plate and the electron density (n e ) in the LFS divertor at the onset of detachment are significantly lower in simulations, i.e., approximately a factor of 2 for I LFS-plate and a factor of 3-4 for n e ; (ii) the degree of detachment – defined here as the difference between I LFS-plate at the onset of detachment and at an 〈n e 〉 edge value close to the density limit – is smaller in simulations compared to experiments; and (iii) the experimentally observed larger degree of detachment for D and T plasmas compared to H plasmas cannot be clearly distinguished from the simulation results. There are strong indications that discrepancy (i) is to a large extent caused by neglecting Lyman-opacity effects in our simulations. The simulations predict a similar net volumetric recombination source for all isotopes due to the fact that molecule-activated recombination (MAR) compensates for the reduced electron–ion recombination (EIR) for H, whereas MAR is negligible for D and T. This similar net volumetric recombination source for all isotopes leads to an isotope-independent degree of detachment in simulations. An analysis of the Balmer-α and Balmer-$γ$ emission confirms the underestimate of MAR in simulations (especially for D and T) for the JET metallic wall, which was previously observed for devices with a carbon wall. The underestimate of MAR is an important cause for discrepancy (ii) and the fact that there is a stronger underestimate of MAR for D and T than for H explains discrepancy (iii). Extending the plasma grid to the vessel wall increases I LFS-plate and n e at the onset of detachment by 25%, and the EIR source increases by 80% in detached conditions. Hence, while the extended grid results are closer to the experimental observations, the previously described qualitative discrepancies still persist.

Balmer emission↗
DOE OSTI2025

Taking three-dimensional x-ray diffraction (3DXRD) from the synchrotron to the laboratory scale

Three-dimensional x-ray diffraction (3DXRD), a rotating x-ray diffraction technique, is a powerful tool for studying the micromechanical behavior of polycrystalline materials, capable of measuring the volume, position, orientation, and strain of thousands of grains simultaneously. However, its application has been historically limited to synchrotron facilities. Here, we present the first demonstration of laboratory-scale 3DXRD (Lab-3DXRD) using a liquid-metal-jet source. Lab-3DXRD achieves accuracy comparable to synchrotron-based 3DXRD, as validated against laboratory diffraction contrast tomography (LabDCT) and synchrotron-3DXRD. Over 96% of the grains detected with Lab-3DXRD are cross-validated, particularly for coarse grains (> ~60 μm), while the results suggest that finer grains should be accessible by taking advantage of high-efficiency detectors. We further demonstrate that its sensitivity to finer grains is enhanced by incorporating pre-characterization into the analysis. This study establishes Lab-3DXRD as a practical alternative to synchrotron techniques, making 3DXRD accessible to a wider range of academic and industrial researchers.

characterization and analytical techniques↗
DOE OSTI2026

Design of a high power 8 MeV electron beam injector for the LERF

We present the beamline design for a high power 8 MeV electron injector to be installed at the Low Energy Recirculator Facility (LERF). The injector is designed to provide beam power of up to 80 kW for testing positron source target candidates. We discuss the results of beam dynamics simulations conducted using the General Particle Tracer (GPT) software, where electromagnetic beamline elements were optimized using multi-objective genetic algorithm tools. Additionally, we present preliminary studies on secondary particle generation from both rotating solid and free surface liquid metal jet targets described elsewhere in this workshop.

Lizarraga-Rubio, Victor [Thomas Jefferson National↗
DOE OSTI2026

Design of a high power 8 MeV electron beam injector for the LERF

Here, we present the beamline design for a high power 8 MeV electron injector to be installed at the Low Energy Recirculator Facility (LERF). The injector is designed to provide beam power of up to 80 kW for testing positron source target candidates. We discuss the results of beam dynamics simulations conducted using the General Particle Tracer (GPT) software, where electromagnetic beamline elements were optimized using multi-objective genetic algorithm tools. Additionally, we present preliminary studies on secondary particle generation from both rotating solid and free surface liquid metal jet targets described elsewhere in this workshop.

Lizarraga-Rubio, Victor Manuel [Thomas Jefferson N↗
DOE OSTI2025

Autonomous Aerosol and Plasma Co‐Jet Printing of Metallic Devices at Ambient Temperature

Abstract Additive manufacturing of metallic materials holds the potential to revolutionize the fabrication of functional devices unattainable via traditional methods. Despite recent advancements, printing metallic materials typically requires thermal processing at elevated temperatures to form dense structures with desired properties, which presents a major challenge for direct printing and integration with temperature‐sensitive materials. Herein, a unique co‐jet printing (CJP) method is reported integrating an aerosol jet and a non‐thermal, atmospheric pressure plasma jet to enable concurrent aerosol deposition of metal nanoparticle inks and in situ sintering at ambient temperature. A machine learning algorithm is integrated with the CJP to perform real‐time defect detection and autonomous correction, enhancing the yield of printed films with high electrical conductivity from 44% to 94%. Concurrent printing and sintering eliminate the need for post‐printing processing, reducing the overall manufacturing time by multiple folds depending on product size. CJP enables direct printing of functional devices on a variety of temperature‐sensitive materials including biological materials. Direct printing of hydration sensors on living plant leaves is demonstrated for long‐duration monitoring of hydration level in the plant. The versatile CJP method opens tremendous opportunities to harmoniously integrate abiotic and biotic materials for emerging applications in wearable/implantable devices and biohybrid systems.

Du, Yipu [Department of Aerospace and Mechanical E↗
DOE OSTI2025

2025 Peregrine in-situ monitoring and training dataset for laser powder bed fusion and binder jet printers

Peregrine, a software tool developed at Oak Ridge National Laboratory (ORNL), was used to collect and analyze in-situ monitoring (ISM) data from a Concept Laser M2 (Colibrium Additive) laser powder bed fusion (L-PBF) printer and an ExOne Innovent (Desktop Metal) binder jet printer. Data for four builds (print jobs) were saved to HDF5 (high performance data) files for release. Additionally, process anomalies were annotated by the authors across 37 image stacks (i.e., print layers) and are also provided as HDF5 files.

36 MATERIALS SCIENCE↗
DOE OSTI2026

The DECam MAGIC Survey: Investigating the Jet Stellar Stream with Photometric Metallicities

Stellar streams are dynamically fragile structures formed by the tidal disruption of dwarf galaxies and stellar clusters. These objects are valuable tracers of the gravitational potential and accretion history of the Milky Way, and are key probes for the presence and interactions of starless dark matter subhalos. The Jet stream is a $\sim 30^\circ$-long stellar stream that is situated at 30.4 kpc and originates from a disrupted globular cluster. It consists of metal-poor stars that follow a retrograde orbit, reducing the impulse imparted from the Milky Way bar and making it especially sensitive to gravitational perturbations from dark matter subhalos. This paper investigates the known extent of the Jet stream by leveraging photometric metallicities derived from a narrowband filter centered on the Ca II H&K lines at $\sim$3950A on the Dark Energy Camera (DECam), as part of the Mapping the Ancient Galaxy in CaHK (MAGIC) survey. The wide field-of-view of DECam enables the efficient derivation of photometric metallicities for stars across the full extent of the stream, allowing for a metallicity-based selection to identify likely members. We demonstrate the efficacy of photometric metallicities in isolating stream members when used with Gaia DR3 proper motions, identifying a sample of 213 candidate Jet stream member stars. This then allows for the study of stream morphology, through which we identify a clear fanning of the stream toward the end farther from the Milky Way bar. We provide a list of candidate members, enabling spectroscopic follow-up of the Jet stream to facilitate further studies of its dynamics.

Do, Ha Q. [Chicago U., Astron. Astrophys. Ctr.] (O↗