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NASA NTRS2020

A 3D Model to Predict Explicit Morphologies and Volume Fraction of Lack-of-Fusion Pores Generated in Selective Laser Melting Processes

The performance of an additively manufactured (AM) component is dependent on the distribution of process-induced defects in addition to the complex microstructure of the material, surface roughness of the component and the process-induced residual stresses. For instance, it has been well demonstrated that lack-of-fusion (LoF) pores produced in the selective laser melting (SLM) AM process can significantly limit the fatigue performance of the material. Although two-dimensional (2D) models exist to predict the 2D profiles of LoF pores, the 2D pore profiles cannot be directly inserted into a three-dimensional (3D) microstructure domain that is output from several prevailing process simulation packages. A few commercial packages that simulate the SLM process can predict LoF pores in a 3D domain, but the morphologies of LoF pores are voxelated and hence do not capture sharp corners of the pores, thereby obviating their use in fatigue crack initiation studies. In order to address the aforementioned gaps, a high-fidelity model that predicts not only the volume fraction, but also the explicit 3D morphologies and spatial distributions of LoF pores has been developed using a computer aided design-based environment. The model has been partially validated for Ti-6Al-4V alloy by comparing the predictions of the volume fraction of LoF pores predicted by the model with experimental data obtained from the literature. Absolute error in predicted volume fraction of LoF pores varied between 5.16% and 1.87% for energy density values between 13 J/mm3 and 45 J/mm3 where a significant amount (over 3% volume fraction) of LoF porosity was measured. The absolute error was within 1.87% for energy density values greater than 45 J/mm3.

Saikumar R. Yeratapally↗

NASA NTRS1992

Extreme value statistics analysis of fracture strengths of a sintered silicon nitride failing from pores

Statistical analysis and correlation between pore-size distribution and fracture strength distribution using the theory of extreme-value statistics is presented for a sintered silicon nitride. The pore-size distribution on a polished surface of this material was characterized, using an automatic optical image analyzer. The distribution measured on the two-dimensional plane surface was transformed to a population (volume) distribution, using the Schwartz-Saltykov diameter method. The population pore-size distribution and the distribution of the pore size at the fracture origin were correllated by extreme-value statistics. Fracture strength distribution was then predicted from the extreme-value pore-size distribution, usin a linear elastic fracture mechanics model of annular crack around pore and the fracture toughness of the ceramic. The predicted strength distribution was in good agreement with strength measurements in bending. In particular, the extreme-value statistics analysis explained the nonlinear trend in the linearized Weibull plot of measured strengths without postulating a lower-bound strength.

Chao, Luen-Yuan↗

NASA NTRSDate not supplied

Modeling Pore Closure in the Hot Isostatic Pressing of Additively Manufactured Inconel 718 Samples

Additive manufacturing provides opportunity for a new world of possibilities for metallic component design and fabrication; however, as-built part quality is notoriously variable, anisotropic, and degraded by porous defects. To improve quality, parts are commonly post processed using a variety of techniques including hot isostatic pressing (HIP). During HIP, high temperature and pressure is employed to improve microstructure and reduce pore volume by inducing visco-plastic deformation in the metallic substrate. Validated computational capabilities can provide predictions to guide the selection of processing condition, expected pore reduction, and the effects of varying entrapped gas in the pores. This discussion describes a micro-scale finite element structural model developed to predict pore closure due to HIP in as-built additively manufactured Inconel 718 samples produced by the laser powder bed fusion process. The model accounts for plastic deformation, creep, and internal pressure for a single pore. Pores are characterized in physical samples before and after HIP, and model predictions are compared to this measured data.

defect model prediction↗

NASA NTRS1973

Pore Structure Analysis of RSI Tile

Mercury porosimetry gives a means of characterizing RSI tile pore structure in terms of porosity, pore size distribution, bulk density, specific surface area, mean pore diameter, and mean fiber diameter. It also allows the determination of the effects of heat treatment on these parameters. It is limited in application to open-pored structures, however, since any closed pore volume is ignored.

Whittemore, O. J., Jr.↗

NASA NTRS1982

Pore size engineering applied to starved electrochemical cells and batteries

To maximize performance in starved, multiplate cells, the cell design should rely on techniques which widen the volume tolerance characteristics. These involve engineering capillary pressure differences between the components of an electrochemical cell and using these forces to promote redistribution of electrolyte to the desired optimum values. This can be implemented in practice by prescribing pore size distributions for porous back-up plates, reservoirs, and electrodes. In addition, electrolyte volume management can be controlled by incorporating different pore size distributions into the separator. In a nickel/hydrogen cell, the separator must contain pores similar in size to the small pores of both the nickel and hydrogen electrodes in order to maintain an optimum conductive path for the electrolyte. The pore size distributions of all components should overlap in such a way as to prevent drying of the separator and/or flooding of the hydrogen electrode.

Abbey, K. M.↗

NASA NTRS1993

Quantitative Mapping of Pore Fraction Variations in Silicon Nitride Using an Ultrasonic Contact Scan Technique

An ultrasonic scan procedure using the pulse-echo contact configuration was employed to obtain maps of pore fraction variations in sintered silicon nitride samples in terms of ultrasonic material properties. Ultrasonic velocity, attenuation coefficient, and reflection coefficient images were obtained simultaneously over a broad band of frequencies (e.g., 30 to 110 MHz) by using spectroscopic analysis. Liquid and membrane (dry) coupling techniques and longitudinal and shear-wave energies were used. The major results include the following: Ultrasonic velocity (longitudinal and shear wave) images revealed and correlated with the extent of average through-thickness pore fraction variations in the silicon nitride disks. Attenuation coefficient images revealed pore fraction nonuniformity due to the scattering that occurred at boundaries between regions of high and low pore fraction. Velocity and attenuation coefficient images were each nearly identical for machined and polished disks, making the method readily applicable to machined materials. Velocity images were similar for wet and membrane coupling. Maps of apparent Poisson's ratio constructed from longitudinal and shear-wave velocities quantified Poisson's ratio variations across a silicon nitride disk. Thermal wave images of a disk indicated transient thermal behavior variations that correlated with observed variations in pore fraction and velocity and attenuation coefficients.

Roth, Don J.↗

NASA NTRSDate not supplied

Computational investigation on the combined effect of pore attributes on strain concentrators in metal additively manufactured materials

Metal additive manufacturing provides a pathway for creating highly optimized components. However, porosity continues to be a prevalent issue for fatigue performance despite best efforts in optimizing process parameters and postprocessing techniques. This work uses finite element analysis to conduct a parametric study to link various pore attributes (i.e., aspect ratio, orientation, and location) to strain concentration factors (SCF) under elastic/plastic deformation during uniaxial loading. Keyhole and lack-of-fusion pores are idealized by prolate and oblate ellipsoids, respectively. Each simulation of the parametric study assumes a single isolated pore in a Ti-6Al-4V material, modeled with J2-plasticity. A reduced-order model is developed to relate pore attributes to SCF, and then used to quantify the variability in SCF for a given experimentally characterized probability distribution of pore attributes. This reduced-order model can be used in a production environment to provide a first-order evaluation to rapidly screen sub-optimally performing components.

Additive Manufacturing↗

NASA NTRS1986

Knudsen diffusion - The effect of small pore size and low gas pressure on gaseous transport in soil

The analytical principles and applications of the theory of Knudsen diffusion are reviewed, with emphasis on gas transport in the soils of planetary bodies. Knudsen diffusion occurs when the mean free path of diffusing gas molecules surpasses the size of the pores through which diffusion proceeds. The process is then dominated by collisions with the pore walls. Computational techniques for deriving the Knudsen coefficient for soils with a nonreentrant cross-section shape are reviewed, along with methods of deriving a coefficient for soils which permit both Knudsen and bulk diffusion. Sample calculations for three pore-size distributions are provided to illustrate the decrease in transport efficiency with increasingly smaller soil pore sizes.

Clifford, S. M.↗

NASA NTRS1992

Characteristics of square pore and low noise microchannel plate stacks

An evaluation is conducted of several square-pore microchannel plates (MCPs) with either 25- or 85-micron diameter pores and 80:1 or 50:1 channel length/diameter ratio. Flat field measurements show that the 25-micron-pored MCPs, unlike those with 85-micron pores, exhibit periodic modulation; this may be due to the MCP stacking configurations. Attention is given to the relative quantum detection efficiency advantages of the two MCPs.

Siegmund, Oswald H. W.↗

NASA NTRS1991

Modeling the interaction of ultrasound with pores

Factors that affect ultrasonic velocity sensing of density during consolidation of metal powders are examined. A comparison is made between experimental results obtained during the final stage of densification and the predictions of models that assume either a spherical or a spheroidal pore shape. It is found that for measurements made at low frequencies during the final stage of densification, relative density (pore fraction) and pore shape are the two most important factors determining the ultrasonic velocity, the effect of pore size is negligible.

Lu, Yichi↗

NASA NTRS1995

Performance of Small Pore Microchannel Plates

Small pore size microchannel plates (MCP's) are needed to satisfy the requirements for future high resolution small and large format detectors for astronomy. MCP's with pore sizes in the range 5 micron to 8 micron are now being manufactured, but they are of limited availability and are of small size. We have obtained sets of Galileo 8 micron and 6.5 micron MCP's, and Philips 6 micron and 7 micron pore MCP's, and compared them to our larger pore MCP Z stacks. We have tested back to back MCP stacks of four of these MCP's and achieved gains greater than 2 x 1O(exp 7) with pulse height distributions of less than 40% FWHM, and background rates of less than 0.3 events sec(exp -1) cm(exp -2). Local counting rates up to approx. 100 events/pore/sec have been attained with little drop of the MCP gain. The bare MCP quantum efficiencies are somewhat lower than those expected, however. Flat field images are characterized by an absence of MCP fixed pattern noise.

Siegmund, O. H. W.↗

NASA NTRS2008

Investigation of Pore Size Effect On Spray Cooling Heat Transfer With Porous Tunnels

Previous studies have shown that spray cooling heat flux enhancement may be attained by using enhanced surface structures. However, most enhanced surface spray cooling studies have been limited to extended surfaces relative to the base surface. In this study, experiments were conducted to study the effects of pore size on spray cooling heat flux when using porous tunnels. The porous tunnels where placed sub-surface relative to the top of the heater block. Pores of varying size were machined in the top of the heater block leading into the sub-surface tunnels. Pore diameters varied between 0.25 mm and 1.0 mm. Each copper block had a projected cross-sectional area of 2.0 cm(sup 2). Measurements were also obtained on a heater block with a flat surface for baseline comparison purposes. A 2x2 nozzle array was used with PF-5060 as the working fluid. Thermal performance data was obtained under nominally degassed (chamber pressure of 41.4 kPa) conditions with a bulk fluid temperature of 20.5 "C. Results for both the study show that the highest critical heat flux (CHF) attained was 141 w/cm2 using pores 1.0 mm in diameter. This gave an enhancement of 75% relative to the flat surface case under nominally degassed conditions.

Silk, Eric A.↗

NASA NTRS2008

Effect of Processing Pressure on Isolated Pore Formation during Controlled Directional Solidification in Small Channels

Directional solidification experiments were performed, using succinonitrile saturated with nitrogen gas, to examine the effects of in-situ processing pressure changes on the formation growth, and evolution of an isolated, cylindrical gaseous pore. A novel solidification facility, capable of processing thin cylindrical samples (I.D. < 1.0 mm), under controlled pressure conditions, was used for the experiments. A new experimental method for growing the isolated pore from a seed bubble is introduced. The experimental results indicate that an in-situ processing pressure change will result in either a transient change in pore diameter or a complete termination of pore growth, indicating that pressure changes can be used as a control parameter to terminate bubble growth. A simple analytical model has been introduced to explain the experimental observations.

Cox, Matthew C.↗

NASA NTRS1972

Effect of pore pressure on the velocity of compressional waves in low-porosity rocks.

The velocity V sub p of compressional waves has been measured in rock samples of low porosity to confining pressures P sub c of 2 kb for a number of different constant pore pressures P sub p. An effective pressure defined by P sub e = P sub c-nP sub p, n less than or equal to 1, is found to be the determining factor in the behavior of V sub p rather than an effective pressure defined simply by the differential pressure Delta P = P sub c-P sub p. As pore pressure increases at constant effective pressure, the value of n increases and approaches 1, but as effective pressure increases at constant pore pressure, the value of n decreases. These observations are consistent with Biot's theory of the propagation of elastic waves in a fluid-saturated porous solid.

Todd, T.↗

NASA NTRS1978

High resolution masks for ion milling pores through substrates of biological interest

The feasibility was investigated of electrochemically oxidizing vapor deposited aluminum coatings to produce porous aluminum oxide coatings with submicron pore diameters and with straight channels normal to the substrate surface. Porous aluminum oxide coatings were produced from vapor deposited aluminum coatings on thin stainless steel (304), copper, Teflon (FEP) and Kapton substrates and also on pure aluminum substrates. Scanning electron microscope examination indicated that porous oxide coatings can be produced with straight channels, appropriate pore diameters and none or minimal intervening residual aluminum. The oxide coatings on the copper and Kapton substrates had the straightest channels and in general were superior to those fabricated on the other substrate materials. For oxide coatings fabricated at 600 V and 300 V, pore diameters were 0.4-0.6, and 0.3 micron with center-to-center spacing of 0.7-0.8, and 0.4 micron, respectively. Estimated direct labor and materials costs to prepare an oxide mask is anticipated to be about $4-$6 per square foot.

Donovan, S. S.↗

NASA NTRS1982

A general diagram for estimating pore size of ultrafiltration and reverse osmosis membranes

A slit sieve model has been used to develop a general correlation between the average pore size of the upstream surface of a membrane and the molecular weight of the solute which it retains by better than 80%. The pore size is determined by means of the correlation using the high retention data from an ultrafiltration (UF) or a reverse osmosis (RO) experiment. The pore population density can also be calculated from the flux data via appropriate equations.

Sarbolouki, M. N.↗

NASA NTRS1991

Effect of ohmic, mass-transfer, and kinetic resistances on linear-sweep voltammetry in a cylindrical-pore electrode

A means is presented to account for the effect of ohmic, mass-transfer, and kinetic resistances on linear-sweep voltammograms by modeling a pore in a porous matrix as a cylindrical-pore electrode, and solving the mass and charge conservation equations in the context of this geometry for the simply redox reaction O + ne(-) yield R where both O and R are soluble species. Both analytical and numerical techniques are used to solve the governing equations. The calculated peak currents and potentials are correlated by empirical formulas to the measurable parameters: sweep rate, concentration of the redox species, diffusion coefficient, conductivity of the electrolyte, and pore dimensions. Using the correlations, a methodology is established for determining if the redox reaction kinetics are irreversible or reversible (Nernstian). If the reaction is irreversible, it is shown how the standard rate constant and the transfer coefficient may be extracted from linear-sweep voltammetry data, or, if the reaction is reversible, how the number of electrons transferred may be deduced.

Weidner, John W.↗

NASA NTRS1992

Flows around sunspots and pores

Observations are reported yielding high-resolution white-light data regarding the flow pattern of penumbral material and granules around sunspots and pores. The data are culled from optical observations near the limit of the telescope modulation transfer function, and correlation tracking is employed to track the motions of penumbral features and granules. Dark fibrils and bright grains in the sunspots' inner penumbra regions move toward the umbra, and the opposite occurs in the outer penumbra. Before pore formation and during the pores existence granular flows are found to converge on the features. The paper also details the evolution of an emerging flux region, and two types of photospheric dark alignments are described in the region of new flux emergence.

Wang, Haimin↗