Bottom Region Research Articles

Strength-ductility mechanism of combined heterostructured CoCrFeMnNi high-entropy alloy prepared by laser heat-treatment process

Two types of typical combined heterostructured CoCrFeMnNi high-entropy alloys with superior mechanical properties that evade the strength-ductility trade-off are fabricated using laser heat-treatment process. The lamellar grain structure with relatively high microhardness can hardly be observed due to the short time annealing at low temperature (873 K for 5 min) before laser scanning. The hetero-deformation induced strengthening, as well as the excellent deformation ability of the bottom hard region which can enhance the interaction between nanotwin-dislocation and maintains the large microhardness difference among the soft-hard layers, are the main factors that improve the yield strength of CoCrFeMnNi high-entropy alloy. Moreover, the combined heterostructured structure without lamellar deformed bands is demonstrated to have a relatively better uniform elongation, which is attributed to the stronger deformation ability of the non-recrystallized grains in the bottom hard region and the effective delay of the crack growth. Consequently, the combined heterostructured structure without lamellae is a promising way to simultaneously improve the strength and ductility, which can be efficiently prepared by the laser surface heat-treatment technique.

Microstructural evolution, crystallographic texture, grain morphology, and mechanical integrity of wire arc additively manufactured Inconel 625 alloy

The material in wire arc additive manufacturing (WAAM) undergoes complex material flow and multiple thermal heating and cooling cycles, forming highly heterogeneous microstructures in terms of size, crystallographic orientations, and mechanical properties. The inhomogeneity also depends on the dislocation density and phases, which are influenced by the thermal history of the process. In this study, the Cold Metal Transfer (CMT) process was used to deposit a 60-layer build of Inconel 625 alloy. Detailed variations in the microstructural size, orientations, and phases along the building direction were studied using optical microscopy, electron backscatter diffraction (EBSD), and X-ray diffraction (XRD). Microstructural observations reveal dendrites, equiaxed crystals, cellular, and columnar structures with primary and secondary dendrites. Dynamic recrystallization (DRX) followed by abnormal grain growth was found in the build. The average grain size varies with deposited height, with a grain size of around 13 ± 1 μm near the substrate, 45 ± 1 μm in the middle region, and 18 ± 1 μm at the top. The top region exhibited a strong intensity of recrystallized Cube, Cube-ND, and Cube-RD textures, with weaker intensities of copper and brass textures. The middle and bottom regions show strong intensities of Goss, copper, F, S, and E textures, respectively. The highest dislocation density of 5.122 × 10−4 nm−2 was found in the top region, while the lowest (4.14 × 10−4 nm−2) was observed in the bottom region. The ultimate tensile strength of the build ranged from 603 ± 05 MPa to 699 ± 10 MPa, while the yield strength varied from 313 ± 07 MPa to 365 ± 08 MPa along different orientations. Vickers hardness results showed a slight variation, from 240 ± 5 to 260 ± 2 HV, from bottom to the top of the deposited build. The findings from this study provide valuable insights into the microstructural evolution mechanism and mechanical behavior of WAAM-fabricated Inconel 625, which can guide other researchers in optimizing process parameters, enhancing material properties, and understanding the effects of thermal history on additive manufacturing of high-performance alloys.

Numerical modeling and parametric analysis of temperature distribution in soil based on water content variation under radio frequency heating for in-situ thermal remediation

Radio frequency heating (RFH) is recognized as an efficient and economical method for volatilizing organic pollutants from contaminated soils. Although some numerical simulations have been conducted to predict temperature changes during RFH, models that account for effects of water content (WC) variation on dielectric properties and temperature evolution in soil were rarely reported. To address this, a three-dimensional numerical model integrating electromagnetic-thermal conversion, heat transfer, and mass transfer was developed with coupling dynamic changes in WC and corresponding impacts on soil properties. The effects of soil types and RFH engineering parameters on temperature evolution and energy utilization were evaluated. The model's temperature prediction was validated using experimental data, indicating that temperature decreases outward from hot electrode, with high-temperature regions forming at the top and bottom regions near electrode. Water evaporation in soil causes a temperature plateau with >76.25 % of energy utilized for heating and evaporating water during 60-d RFH. Moreover, higher soil WC could increase electromagnetic-thermal conversion capability, counteracting the negative impact of increased specific heat capacity on temperature rise. Thermophysical properties of soil are crucial in RFH: sand, with lower specific heat capacity and higher thermal conductivity, results in faster heating rates. While, clay, with higher density and specific heat capacity, results in lower heating rates but greater energy utilization efficiency. Low-power RHF and wider well spacing improve the uniformity of temperature distribution but require more time to reach target temperatures. Moreover, input power influences the magnitude and timing of optimal energy utilization efficiency, while well spacing primarily affects timing. The models developed in this study provide essential guidance for RFH-based soil remediation projects.

Effect of gradually decreasing laser power on the microstructure and properties of laser melting deposited Inconel 718Plus alloy thin-wall

Laser melting deposition (LMD) technology offers a novel method for fabricating superalloy thin-walled parts because of its significant advantage of rapidly producing near-net-shape moldings. However, the coarse columnar crystals in these deposited thin-walled parts resulted in poor mechanical properties, which significantly limited its wide application. To address this problem, a layer-by-layer decreasing laser power deposition strategy (LT) is proposed in this study, which can increase the cooling rate of the molten pool by reducing the thermal cycling. Results indicate that the thin walls of Inconel 718Plus alloy deposited by the LT strategy exhibit dendrites at heights of 4.5 mm (bottom region), 16.5 mm (middle region) and 28.5 mm (top region). The Laves phase at the bottom of the LT alloy thin-wall was randomly distributed granular, which gradually transformed into granular, short-chain and its mixed structures with increasing height. Formation of long-chain Laves phases was hindered by the connection of dendrites. The densely distributed granular Laves phase in the LT strategy alloy thin wall could effectively transfer and dispersed the stress and hindered the crack initiation and extended. Compared to the bottom region, the yield strength of the LT alloy thin-wall in the middle and top region increased by 6.7 % and 12.6 %, and the tensile strength increased by 10.7 % and 16.2 %. In conclusion, the alloy thin-walls fabricated by the LT strategy exhibit superior strength and more balanced mechanical properties.

Microstructure evolution of AlSi10Mg alloy in RAP process

Abstract With its computer-aided layer-by-layer production approach, additive manufacturing (AM) and powder bed laser fusion (PBLF) paved the way to produce metallic parts more precisely than any other manufacturing technique. However, the combinability and the interaction of this relatively new manufacturing technique with the other near-net shape production techniques is still a mystery. In this study, the recrystallization and partial melting (RAP) behavior, which is a feedstock production approach for semisolid forming methods, investigated on AlSi10Mg parts produced by PBLF and conventional casting were compared in terms of microstructural and hardness evaluations. After the reheating process, the globalization of Si particles and the breakdown of the Si network around the melt pools were displayed with light microscope and scanning electron microscope (SEM) images. The hardness values of the PBLF as-fabricated specimens were found to be significantly higher than the as-cast specimens; however, the values were almost equaled after the RAP treatment and even got lower on the bottom and top regions of the PBLF samples after 20 min of reheating because of the enlarged shrinkage porosities and the coarsened morphology.

Effect of crystallographic texture and grain orientation on tribological properties of WAAM deposited IN625 alloy in weaving deposition strategy

Understanding the variation in the local microstructure and texture of the as-built fabricated by wire arc additive manufacturing (WAAM) is highly challenging. They affect the mechanical and tribological properties of the builds. The deposition patterns and the process parameters are key factors that determine the microstructures and hence other properties. In the present study, builds of Inconel 625 alloy have been manufactured through WAAM by using a weaving pattern. The microstructure and their texture at the different locations of the deposited build have been investigated through electron backscattered diffraction (EBSD) and optical microscopy. The detailed evolution mechanisms of the micro-structure of the build have been studied followed by the quantitative analysis of the grain size, misorientation angles, fraction of recrystallized and deformed grains, and textures. Later the effect of texture components on the hardness, elastic modulus, and coefficient of friction (COF) of the build has been studied by using nano-indetation and nano-scratch tests. The grain size was found to be 33 μm, 110 μm, and 66 μm at the bottom, middle, and top, respectively. The top region was dominated by Cube {001}<uvw>, Goss {011}<100>, and E {111}<110> orientations, which changed to deformed texture Brass {110}<112> and Goss {011}<100> orientations in the middle region and cube texture at the bottom. Hardness was highest at the top region 5.33 GPa, followed by 4.02 GPa in the middle region and 4.74 GPa at the bottom. The COF was highest in the middle region at 0.456, which reduced to 0.323 in the bottom region. Sheared textured grains {111}<uvw> have shown greater value of COF and hardness than the {101}< uvw> and {100}<uvw> texture grains. The study has been carried out to investigate the variation in local mechanical properties due to microstructural variations. It will help industries to design components with homogeneous mechanical properties.

Effect of DC Micro-Pulsing on Microstructure and Mechanical Properties of TIG Welded Ti-6Al-4V

This paper deals with the influence of micro-pulsed direct current on microstructure and mechanical properties of gas tungsten arc welding (GTAW) weldments of Ti-6Al-4V (Ti-64). Bead-on-plate GTA welds were made on the samples in the un-pulsed and micro-pulsed (125 Hz and 250 Hz) conditions. Post-weld heat treatment (PWHT) was performed on a few coupons at 700 °C for 3 h in an inert atmosphere, followed by furnace cooling. In the microstructure, the fusion zone (FZ), base metal (BM), and heat-affected zone (HAZ) can be easily distinguished. The top surface of the FZ has large columnar grains because of lower heat loss to the surrounding atmosphere, and the bottom region of the FZ has comparatively smaller equiaxed grains. The micro-pulsed samples’ FZ grain size was lower than that of those made without pulsing. This shows that high-frequency current has substantially refined prior β grains. The microstructure of the FZ is characterized by an acicular morphology composed of α, martensitic α′, and retained β phases. The FZ’s hardness was higher than the BM due to the presence of martensitic α′. Additionally, the hardness in the HAZ was elevated due to the formation of finer martensitic α′. Micro-pulsed DC welding led to improved mechanical properties, including higher hardness, ultimate tensile strength (UTS), and ductility compared to un-pulsed welding. This enhancement is attributed to the grain refinement achieved with micro-pulsed DC. After PWHT, the prior β grain size remained relatively unchanged compared to the as-welded condition. However, the hardness in the FZ decreased due to the decomposition of α′ into α and β phases. The ductility of all samples improved as a result of the widening of the diffusional α phase.

Study on Wear and Corrosion Resistance of Ni60/WC Coating by Laser Cladding on Reciprocating Pump Plunger: Comparison with Flame-Sprayed Plungers.

Reciprocating pumps are widely used in the current oil extraction process, and the plunger is a vulnerable part of these pumps that directly determines the service life of the reciprocating pump. To improve the service life of plungers, Ni60/WC coatings were applied to the surface of 45-steel plungers via laser cladding technology to improve wear and corrosion resistance. Defect-free and dense Ni60/WC coatings were successfully applied to the plunger surface with strong metallurgical bonding between the coating and the substrate. The coating consists mainly of a γ-(Ni, Fe) phase, which contains isotropic and isotropic-like crystals, dendritic crystals, and columnar crystals in the top, middle, and bottom regions of the coating, respectively. The service performance of the laser cladding coating was compared to the flame-sprayed plunger, which is widely used, and the laser cladding coating has a microhardness of up to 821.8 HV0.5, which is higher than that of the flame-sprayed coating (545.5 HV0.5) and the 45-steel substrate (200 HV0.5). The laser cladding coating has a lower friction coefficient and a smaller volumetric wear rate, and the corrosion current density and corrosion rate in the NaCl solution are 2.52 × 10-7 A/cm2 and 2.96 × 10-3 mmPY, respectively, which indicates superior corrosion resistance to the flame-sprayed coating and the substrate. The laser cladding of reciprocating pump plunger surfaces has a significantly improved comprehensive performance and is a promising way to increase the service life of reciprocating pumps.

Numerical simulation of fluid flow characteristics and ultrasonic cavitation performance in novel-designed stirred tank sonoreactor

A novel-designed stirred tank sonoreactor was developed to well solve large-scale dispersion of nanoparticles in liquid phase system. The fluid flow characteristics and ultrasonic cavitation performance in the sonoreactor were numerically simulated by CFD method. By comparing the pressure, cavitation bubble and velocity distribution under different situations, it is found that larger ultrasonic amplitude, relatively smaller ultrasonic frequency, higher saturated vapor pressure and lower viscosity of liquid medium are beneficial to ultrasonic cavitation. Besides, the acoustic flow action is strengthened with the increase of ultrasonic frequency and decrease of gas-liquid mixture's average density. For the designed sonoreactor, it is critical that high-frequency transducers should be determined near the bottom and upper region of the kettle, and large-amplitude transducers can be confirmed in the middle position. The research findings will provide theoretical and technical supports for developing state-of-the-art sonoreactors and optimizing ultrasonic process parameters in the industrialized preparation of nanocomposites.

Laser directed energy deposition remanufacturing of LPBF-processed TA15 parts: Hybrid process interface induced microstructure inheritance and mechanical performance

The laser additive hybrid manufacturing technology, which combines the precision of Laser Powder Bed Fusion (LPBF) and the flexibility of Laser Directed Energy Deposition (LDED), provides an effective solution for efficient forming and remanufacturing of large, complex components. The bonding zone (BZ) between LPBF and LDED forming regions is crucial for the final component performance. This study utilized LDED to remanufacture annealed LPBF substrates and investigated the microstructure and mechanical properties of TA15 alloy remanufactured parts. Results shows that a gradient microstructure forms at the bonding zone (BZ), where the bottom region exhibits a mixed structure including transitional β phase (βt), lamellar α and secondary α phase (αs). The top region shows a "ghost structure" of fine needle-like α phases. The mechanical property matched the microstructure well, as the hardness in the upper BZ reaches up to 463 MPa, whereas the LFZ exhibits the lowest hardness at 401 MPa. As the angle between the LDED region edge and tensile direction increases, the tensile strength first increases and then stabilizes, while elongation increases initially and then decreases. At a tilt angle of 60°, the strength peaks at 1098 MPa; at a 30° angle, the elongation reaches a maximum of 10.336%. All samples fracture at the LPBF zone, indicating that the formation of fine lamellar α phases in the BZ contributes to its higher strength compared to LPBF substrate and LDED deposition zones.

Structural and excitonic properties of the polycrystalline FAPbI3 thin films, and their photovoltaic responses

Faormamadinium based perovskites have been proposed to replace the methylammonium lead tri-iodide (MAPbI3) perovskite as the light absorbing layer of photovoltaic cells owing to their photo-active and chemically stable properties. However, the crystal phase transition from the photo-activeα-FAPbI3to the non-perovksiteδ-FAPbI3still occurs in un-doped FAPbI3films owing to the existence of crack defects, which degrads the photovoltaic responses. To investigate the crack ratio (CR)-dependent structure and excitonic characteristics of the polycrystalline FAPbI3thin films deposited on the carboxylic acid functionalized ITO/glass substrates, various spectra and images were measured and analyzed, which can be utilized to make sense of the different devices responses of the resultant perovskite based photovoltaic cells. Our experimental results show that the there is a trade-off between the formations of surface defects and trapped iodide-mediated defects, thereby resulting in an optimal crack density or CR of the un-dopedα-FAPbI3active layer in the range from 4.86% to 9.27%. The decrease in the CR (tensile stress) results in the compressive lattice and thereby trapping the iodides near the PbI6octahedra in the bottom region of the FAPbI3perovskite films. When the CR of the FAPbI3film is 8.47%, the open-circuit voltage (short-circuit current density) of the resultant photovoltaic cells significantly increased from 0.773 V (16.62 mA cm-2) to 0.945 V (18.20 mA cm-2) after 3 d. Our findings help understanding the photovoltaic responses of the FAPbI3perovskite based photovoltaic cells on the different days.

A novel conceptual design for self-healing of cracked cementitious composites incorporating two bacteria-based capsules

Expanded polystyrene (EPS) is a low-density material prone to float during composite mixing and vibration. Inspired by this, a two-bacteria-capsule system was reported in this study to enhance the self-healing capacity of cracked mortar. Specifically, the BC-A capsule, containing aerobic bacteria, EPS, and superabsorbent polymer (SAP), and the BC-N capsule, containing anaerobic bacteria and SAP, are prepared through granulation using polyethylene glycol. Sulphoaluminate cement and epoxy resin are used to encapsulate the core materials. The BC-A capsules automatically float in the composite preparation process, while the BC-N capsules are distributed in the middle and bottom regions due to extrusion effect. Upon capsule rupture, the two types of bacteria are released in regions favorable for biomineralization, corresponding to the principle that oxygen concentration reduces along the crack depth. The self-healing behaviour was evaluated as well as the healing products were characterized. The results showed that the capsules cracked simultaneously with the composite and the coating effectively avoided premature release of the self-healing materials. Cementitious composites containing double capsules achieved 90 % closure of cracks with initial widths of 50–600 μm. The three-dimensional healing capacity was significantly enhanced, particularly in terms of impermeability and strength recovery ratio. The main healing products in the cracks were calcite and swollen SAP. The swollen SAP provided nucleation sites and enough water for biomineralization in the healing process.

Mechanical and Metallurgical Characteristics of Wire-Arc Additive Manufactured HSLA Steel Component Using Cold Metal Transfer Technique

Recently, the application of wire-arc additive manufacturing (WAAM) for the production of metallic products is gaining traction. WAAM is associated with the direct energy deposition technique and therefore has a higher deposition rate (approximately 4 kg/h). For this reason, it is of greater interest than powder-based additive manufacturing techniques. Industrial applications such as marine and offshore structures and pressure vessels for space programs commonly utilize high-strength low-alloy (HSLA) steel. HSLA steel components produced by casting methods exhibit defects due to oxidation. Therefore, cold metal transfer (CMT)-WAAM was adopted in this study to fabricate HSLA steel components. The metallurgical properties were analyzed using microscopic and diffraction techniques. The effects of the evolved microstructures on mechanical properties, such as strength, microhardness, and elongation to fracture, were evaluated. To analyze and test the structure, two regions were selected, namely, top and bottom. Microstructural analyses revealed that both regions were primarily composed of acicular ferrite, polygonal ferrite, and bainitic structures. The bottom region exhibited superior mechanical properties compared with the top region. The improved strength at the bottom region can be ascribed to the formation of a high density of dislocations and finer grains.

Stress evolution in rocks around tunnel under uniaxial loading: Insights from PFC3D-GBM modelling and force chain analysis

In underground engineerings, the evolution of the stress state in the surrounding rocks can effectively reveal its fracture mechanism. To precisely describe this microscopic information, the present study utilizes the three-dimensional Grain-based model based on Particle Flow Code (PFC3D-GBM) to construct a square numerical specimen with a pre-existing hole representing a tunnel and subjected it to uniaxial loading. In this model, different types of mineral structures and internal force chain networks are distinguished at a three-dimensional scale. Furthermore, the evolution of force chain networks in the top, bottom, left and right regions around the tunnel is quantitatively characterized. The anti-fracture capability depending on stress state of various structures is calculated and then the fracture mechanism from the point of anti-fracture capability is discussed. The research results indicate that at at the beginning of loading, some red force chains with higher level have appeared on both sides of the tunnel. As the load goes on, red force chain network extending from both sides of the tunnel to the upper and lower ends of the specimen have emerged. The average value and sum value of all force chains show an increasing trend before the peak load and a decreasing trend after the peak load. The average value of force chains within a specific structure can accurately reflect the microscopic mechanical properties of that structure. The average values of force chains on the left and right sides of the tunnel are higher, both in terms of starting points and ascending rates, than those in the upper and lower regions of the tunnel. The orientation distribution of all force chains is relatively uniform, but force chains with higher level are generally align with the loading direction. The fundamental reason for the high degree of fragmentation on the left and right sides of the tunnel is that these regions bear more external load than the upper and lower regions, rather than being inherently more prone to fracture.

The Solar FUV-UV Spectra Measurement Experiment in the Near Space by High Altitude Balloon

An experiment measuring the solar far-ultraviolet-ultraviolet (FUV-UV) irradiance with spectral resolution better than 0.1 nm in the wavelength range from 170 to 400 nm was carried out by the “HongHu-6” high-altitude balloon that flew to the bottom region of the near-space in September 2022. This experiment was based on the fact that solar FUV-UV penetrates through a complex cross-section window of the upper atmosphere, from outer to near space. The solar FUV-UV deposits energy in the upper atmosphere, which provides a key to answer scientific questions on the most important energy contributor to overall heating sources of the near space and how the near-space environment responds to solar activities. In the wavelength range between 150 and 210 nm, irradiance maps from active regions of the solar corona, the comparative small cross-section of molecular oxygen allows certain wavelengths of the band to arrive at altitudes between 20 and 30 km above the ground, indicating solar flares could directly impact the bottom region of the near space. Solar UV irradiance in the wavelength range 210 – 400 nm is absorbed by the upper atmosphere as a function of wavelength, and energy is deposited vertically in the lower regions of the near space. This experiment historically provides measurement data to fill a gap in the wavelength shorter than 280 nm in the lower regions of the near space. The solar FUV-UV spectrometer (SUVS) is a compact instrument based on improved Roland circle optics to adapt to the “HongHu-6” balloon payload platform. In this paper, we introduce the scientific goals of the solar FUV-UV spectrum measurement experiment, provide information on the SUVS instrument preflight calibration, and present the first results from the flight data.

Multi-scale three-dimensional simulation of the solidification microstructure evolution in laser welding of aluminum alloys under dynamic spatial thermal cycling

Laser welding process involves three-dimensional (3D) highly dynamic spatial thermal cycling that results in intricate microstructure evolution in different zones. Understanding of the 3D topological evolution of microstructure under spatial thermal cycling is crucial for effective control in solidification processes. In this paper, a 3D multiphase-field model combined with accelerated methods and multi-scale coupling algorithms was developed for high-precision prediction of the dynamic microstructure evolution in laser welding. The heat flow distribution during laser welding varied significantly, with the cooling rates of 1.7–1.9 × 104 K/s at the middle region and 7.5–9.0 × 104 K/s at the bottom region. Considering the effects of 3D heat flow, a large angle may appear between the grains' primary growth direction and the cross-sectional plane, thereby the ultimate morphology through 2D analysis may lead to distortion from reality. The simulation of 3D microstructure evolution during distinct regions results showed that the grains at the bottom region exhibited larger characteristic dimensions (Length/Height >2.5, Length/Width >2.0) and columnar shape, while the middle region tended to form equiaxed structures. The grain size statistics revealed that the grains in the middle region exhibited larger scale due to their smaller GR (G: temperature gradient, R: growth rate) values. The simulation results were in good agreement with the electro-back-scattered diffraction testing results and the theoretical analysis.

Hybrid Nanoparticle-Enhanced Fluid Flow and Heat Transfer Behaviors in a Parabolic Cavity with a Heat Source

AbstractNatural convection of nanofluids holds considerable importance in both scientific research and engineering applications due to their exceptional heat transfer capabilities, which occur spontaneously without the need for additional energy input. In this paper, the natural convection of nanofluid inside a parabolic cavity containing a hot obstacle is studied numerically. The shape of the hot obstacle is selected as either circular or elliptical. Additionally, the effects of the Rayleigh number, nanoparticle volume fraction, and the position of the heat source are investigated. The computational fluid dynamics model was computed using COMSOL Multiphysics. It is observed that the average Nusselt number tends to increase with both the Rayleigh number and the volume fraction of nanoparticles in the fluid. When the heat source moves from the bottom region to the top area, the heat transfer performance of the heat source increases. When Ra ≤ 105, the cases with circular heat sources exhibit better heat transfer performance than those with elliptical heat sources. However, at Ra = 106, the average Nusselt number of the elliptical heat source is higher than that of the circular one.

Feasibility of manufacturing high-aspect-ratio hollow tubes of SS410 through wire-arc directed energy deposition

This study reports new observations from the fabrication of high-aspect-ratio hollow tubes of SS410 through wire-arc directed energy deposition (wire-arc DED) process. Characterisation work was performed on a single tube as a function of its build height. The maximum ultimate tensile strength (UTS) of 1372 MPa and maximum yield strength (YS) of 980 MPa were achieved in the middle region of the tube. The highest UTS in the middle was attributed to the low delta ferrite content. The reduction of delta ferrite was found to be linked with the repetitive heating and cooling. In contrast, the top and bottom sections exhibit a substantial presence of delta ferrite, indicating that the cyclic effects were not considerable. Nevertheless, the presence of significant ductility in the bottom region of the component indicated the occurrence of tempering effects. This observation is further supported by the lower levels of local strain observed using KAM mapping. Overall, this work proposes a novel fabrication method for producing hollow sections with superior strength and ductile properties.

Evaluation of mechanical and microstructural characteristics in different regions of wire arc additive manufactured 304L austenitic stainless steel

ABSTRACT The large structural components (304 L austenitic stainless steel) used in nuclear power plants are difficult and expensive to manufacture and machine using standard methods. Wire arc additive manufacturing (WAAM) is a low cost and high deposition method for fabricating large structural parts. Therefore, in this investigation, 304 L austenitic stainless steel (304 L ASS) cylindrical component was fabricated using WAAM technique. The mechanical and microstructural characteristics of the bottom (region ①) and top (region ②) of the WAAM 304 L ASS component are studied. The microstructure of region ① consists of austenite and ferrite with vermicular and lathy morphologies, while region ② consists of skeletal and reticular morphologies. In regions ① and ②, yield strength (YS), ultimate tensile strength (UTS), and elongation (EL) were found to be 350 ± 7 MPa, 562 ± 10 MPa, and 75 ± 1%, respectively. The impact toughness and hardness in regions ① and ② were found to be 112 ± 2 J and 183 ± 6 (Hv0.5), respectively. From the results, it is evident that the tensile properties of the WAAM 304 L ASS component were equal/greater than the values of the forged 304 L ASS material, wrought 304 L ASS alloy, and 304 L ASS filler wire.

Comprehensive Analysis of the Gradient Porous Transport Layer for the Proton-Exchange Membrane Electrolyzer.

A reasonable porous transport layer (PTL) is crucial to decreasing the mass-transfer loss in proton-exchange membrane water electrolyzers (PEMWEs). In this study, it was experimentally demonstrated that the gradient porosity PTL is beneficial in improving the performance of electrolyzers. The research comprehensively investigates the impact of gradient porosity PTL structures on the performance of the PEMWE, considering mass transfer and interfacial contact. It offers insights into the two-phase (oxygen-water) flow transport mechanisms within the PTLs using a 2D numerical model based on the actual PTL geometry. At the microscopic level, it analyzes how the interfacial contact impacts proton and electron transport mechanisms, affecting not only the contact resistance but also the number of effective catalytic sites for the oxygen evolution reaction. Experimental results demonstrate that the cis-gradient porosity PTL leads to a performance enhancement of 9.3% at 2.2 A/cm2. Numerical simulations reveal that the drivers of oxygen transport include the surface tension of the fibers and the pressure drop influenced by the local PTL porosity. Further analysis indicates that the lower oxygen saturation in the bottom region of the PTL with cis-gradient porosity favors a lower oxygen coverage area in the catalyst layers (CL) since the narrower pore space and higher capillary pressure increase the number of water flow paths into the CL. Overall, this study provides valuable insights for designing high-performance PTLs for use in electrolyzers.