Direct Energy Research Articles

Wire arc direct energy deposited multiphase steel through in situ micropowder alloying: mechanical and metallurgical studies

Purpose This study aims to investigate the effect of copper and titanium micropowder addition on the mechanical and metallurgical properties of additively manufactured low-carbon steel, aiming to produce a modified (multiphase) steel with ferritic low-carbon steel using in situ micropowder addition during wire arc direct energy deposition (WA-DED). Design/methodology/approach A robotic arm equipped with a GMA welding source deposited ER70S6 filler wire on AISI S235 substrate steel using WA-DED. Cu and Ti micropowders were interspersed between layers for microstructural modifications. Microscopy, spectroscopy, diffraction and mechanical testing were used to evaluate the properties of the deposited samples. Findings Incorporating Cu and Ti micropowders significantly enhanced the yield and tensile strength of the deposited material, showing an 83% increase in yield strength and a 33% increase in tensile strength. Microstructural analysis identified key phases such as ferrite, pearlite, bainite, retained austenite and martensite/austenite, with Cu and Ti acting as grain refiners. Nanoscaled Cu precipitates contribute to enhanced low-temperature toughness and a 150% improvement in impact strength at −30°C. Originality/value This study presents a novel approach to overcome the limitations of the available alloys (filler materials). This can be achieved by introducing in situ micropowder alloying during the WA-DED process. The micropowder addition allows altering the properties of the deposited material without changing the parent filler material itself, achieving the desired composition. With this approach, there is no need to manufacture the filler material with the preferred alloy composition separately and then carry out the deposition process.

Study on Dynamic Recrystallization under Thermal Cycles in the Process of Direct Energy Deposition for 316 L Austenitic Stainless Steel

In the process of directed energy deposition (DED), the grain structure of the deposited samples is determined by two aspects. The first is the initial solidification grain structure; the second is the effect of the upper thermal cycle on the solidified grain structure of the lower layer. Dynamic recrystallization and grain growth can be activated under suitable strain and the temperature resulting from thermal cycles. The evolution of grain size and the geometric dislocation density (GND) of austenitic stainless steel 316 L under different strains and temperatures caused by thermal cycles was investigated. It is found that dynamic recrystallization requires an appropriate level of accumulated strain, temperature, and initial grain size. Under <2% accumulated strain and 400–1200 °C conditions caused by 30 layers of thermal cycles, fully dynamic recrystallization occurs with coarse initial grains (CIG), leading to the complete coarsening of grains. However, relatively fine initial grains (FIG) under the same conditions only display partial dynamic recrystallization. The next 2–4% strain and 400–700 °C by 60 layers of thermal cycles make up the driving force of fully dynamic recrystallization, and the grains coarsen completely. Larger accumulated strain (4–6%) and lower temperature (400–600 °C) by 90 layers of thermal cycles and FIG provide more nucleation sites for dynamic recrystallization, which leads to little coarsening of grains even after fully dynamic recrystallization. Temperature, accumulated strain, and the amount of δ-ferrite promote the formation of sub-grains during dynamic recrystallization caused by thermal cycles, which leads to the increase in GND.

Tuning the optical and photophysical characteristics of DR1 through mixing with JGB

A dye mixture of Disperse red1 (DR1) and Janus green B (JGB) was prepared with different concentrations of the two dyes. The optical properties were studied for the two dyes and their mixtures in terms of the absorbance spectra. The direct optical energy gap in addition to the refractive index, extinction coefficient, dielectric constant and optical conductivity were estimated to the two dyes and their mixtures. The experimental energy gap was found to be 2.234 and 1.666 eV for DR1 and JGB respectively, while the values of the energy gaps for the mixtures were found to be ranging between these two values. On the other hand, the refractive index was found to be changed in a systematic way by changing the contents of the dye mixture. The same behavior was also observed for the dielectric constant and optical conductivity. The emission of the two dyes and their mixtures was studied in terms of fluorescence spectra using excitation wavelength of 300 nm where a change in the fluorescence intensity was observed by changing the contents of the mixture. Finally, TD-DFT simulations were performed for the two dyes and their mixture to study the electron density, electrostatic potential, energy gap and optical absorption spectrum and found to be compatible with the experimental measurements.

Investigations of inlet arrangement strategies and particle parameters on thermochemical performance in falling particle solar reactors

The reformation of methane to hydrogen and steam in a falling particle solar reactor (FPSR) is a promising method to use the solar energy, which converts solar energy into chemical energy. FPSR has higher operation temperature, higher pressure bearing capacity and more direct heat energy storage than those of traditional reactor. However, due to the short residence time of the particles, hydrogen production efficiency is reduced. Thus, inlet arrangement strategies and particle catalysts should be carefully designed to improve the thermochemical reaction performance of FPSR. In this contribution, the Eulerian-Eulerian model in CFD program (Fluent 2020 R2) is used to explore the effects of different particle inlet arrangement strategies, non-uniform particle mass flow inlet and particle size on the performance enhancement of methane steam reforming reaction. The results indicate that the two arrangement strategies show different trends in influencing hydrogen production efficiency. Besides, non-uniform particle mass flow rate also has a significant impact on hydrogen production efficiency, with the optimal arrangement conditions increasing the hydrogen production rate by 2.4831 mol/m−3(−|-) s−1. Additionally, smaller particle size demonstrates better hydrogen production efficiency, with a 0.15 mm particle size catalyst showing a 14.02 % improvement in hydrogen production efficiency compared to a 0.75 mm particle size. This contribution can provide a guidance for optimizing the heat and mass transfer performance of the falling particle solar reactor.

Radiative recombination model for BiSeI microcrystals: unveiling deep defects through photoluminescence

Abstract Pnictogen chalcohalides are semiconductors that have emerged as promising materials for energy conversion due to their exceptional optoelectronic properties. Their electronic configuration (ns2), particularly for Bi- and Sb-based compounds, can be a key factor in efficient carrier transport and defect tolerance, similarly, to Pb-perovskites. In the present study, the Bi-containing chalcohalide, bismuth selenoiodide (BiSeI) was synthesized via isothermal heat treatment of binary precursors in evacuated quartz ampoules. The synthesized BiSeI microcrystals exhibited a characteristic needle-like morphology and a near-stoichiometric composition. Both indirect and direct band gap energies of BiSeI were determined by ultraviolet–visible–near-infrared diffuse reflectance spectroscopy, with room temperature values of 1.17 eV and 1.29 eV, respectively. This study presents the first experimental investigation of the photoluminescence properties of BiSeI microcrystals resulting in a recombination model involving multiple defect states. This work provides valuable insights into the defect structure and recombination mechanisms within BiSeI, paving the way for further exploration of its potential in optoelectronic devices.

Phase composition of sputter deposited tungsten thin films

Sputter deposited tungsten thin films are studied by X-ray diffraction. Two phases can be identified: α-W and β-W based on the observed (110), and (200) and (210) Bragg reflections, respectively. With increasing film thickness (50 to 200 nm), the phase composition shifts from β-W towards α-W. No influence of the base pressure (3 × 10−3 – 3 × 10−5 Pa) on the phase composition is observed. Also the influence of the argon pressure (0.3 to 0.7 Pa) is rather weak. The strongest shift towards α-W composed thin films is obtained by increasing the discharge power (50 to 250 W). This trend is further studied by energy flux measurements using a calorimetric probe. These measurements rule out a strong change of the substrate temperature, and an impact of the energy flux scaled by the deposition rate (total energy per deposited atom). Test particle Monte Carlo simulations reveal the importance of the momentum of the reflected argon neutrals on the phase composition. The maximum energy of these species is mainly defined by the discharge voltage, and is higher than the directional dependent displacement energy of W. Despite the significant correlation between phase composition and the number of displacement per deposited atom, there is a strong scatter of the phase composition. As the deposition conditions were varied in random way, changes of the target erosion profile, and the changing discharge voltage over each series are probably partially responsible for the observed scatter. This scatter is also enhanced by the long term changes in the phase composition towards the more thermodynamic stable α-W phase.

Electrochemical Reactivity of Hydrogen Storage Materials: Exploring Borohydride and Hydrazinium Salt Mixtures

Electrochemical characterization of hydrogen storage materials was conducted in a non-aqueous environment to investigate the direct electrochemical release and consumption of hydrogen and the potential for regeneration. We first address the challenge of minimal solubility of the synthetic precursors, sodium borohydride (NaBH4) and hydrazinium bromide (N2H5Br), in both organic and inorganic solvents. We next determine and calibrate a reference electrode formulation compatible with our non-aqueous media and analytes that demonstrates a stable reference potential. We employ cyclic voltammetry (CV) to characterize the precursors and mixtures thereof. Each CV peak is assigned to a corresponding electrochemical reaction. Using the rate-dependent CV method and Randles–Ševčík equation, we calculate the diffusion coefficient of each chemical (NaBH4 and N2H5Br). Analysis of the CVs, coupled with 11B NMR analysis, reveals a room temperature chemical transformation of NaBH4 and N2H5Br mixtures into hydrazine borane (N2H4BH3). These results are particularly significant, considering the limited information available on the electrochemical characterization of metal borohydride and hydrazinium salt in non-aqueous media. This work establishes a foundation for adapting a non-aqueous electrochemical system to further study the borohydride family of chemistries and to design and develop electrochemical devices for direct electrical and chemical energy interconversion with hydrogen storage materials.

Broadband polarization-adjustable antenna realized by waveguide circular polarizers.

A broadband polarization-adjustable antenna realized by two waveguide circular polarizers is proposed in this paper. The antenna consists of a rectangular-to-circular transition waveguide, two identically structured rectangular slot circular polarizers, and a conical horn, all connected in sequence. By rotating the two circular polarizers to specific angles, the antenna can switch among four polarization modes: horizontal polarization, vertical polarization, left-hand circular polarization, and right-hand circular polarization. The antenna polarization adjustment principle is thoroughly analyzed. Taking the X-band polarization-adjustable antenna as an example, simulation and optimization were performed, and a prototype was fabricated and measured. The antenna's reflection coefficient is below -18 dB across all polarization modes from 9.2 to 10GHz. In linear polarized modes, gains exceed 10.5 dBi. For circular polarized modes, the gains align with those of linear modes, with an axial ratio of less than 1 dB in the operating frequency band. The measured results are consistent with the simulation results, confirming its excellent polarization adjustment performance and potential for high power microwave applications.

Research on a broad-band X-band high power relativistic klystron amplifier

This paper introduces a high-power broadband X-band klystron amplifier that achieves an output power of 157 MW and a 3 dB operating bandwidth of 6.7%. The amplifier employs an explosive emission diode with high impedance, which balances the requirements of high power and broadband. The multi-gap input and output cavities are designed to operate at two different longitudinal modes within the operating frequency band, resulting in a flat absorption rate and output efficiency. Moreover, an eight-stage stagger-tuned bunching section is implemented to achieve a uniform fundamental harmonic current modulation depth across the frequency band. Simulation results indicate that when the diode voltage is 550 kV and the beam current is 550 A, the amplifier can achieve a maximum power of 157 MW with an efficiency of 51.9% at the central frequency of 9.8 GHz. Furthermore, within the 3 dB operating bandwidth of 6.7% (670 MHz), the power output remains higher than 80 MW. This novel klystron amplifier structure exhibits exceptional performance in terms of bandwidth, power, and efficiency, thus validating the effectiveness of the design in enhancing bandwidth and providing a solid foundation for the broadband design of high-power microwave sources.

Influence of milling interventions on the geometry of wall-shaped structures in hybrid wire-arc direct energy deposition

The Hybrid Wire-Arc Direct Energy Deposition (Hybrid Wire-Arc DED) process integrates Wire-Arc Direct Energy Deposition (Wire-Arc DED) with machining (typically milling) interventions, offering the potential for creating intricate geometries and finished surfaces. However, if milling is employed as a hybrid intervention rather than as a final part-finishing process, the interplay between these processes remains under-investigated. This paper examines the influence of milling interventions on the geometry of a wall-shaped structure, quantified by the transverse cross-sectional width, built using a Hybrid Wire-Arc DED. Through experiments on mild steel, the underlying causes of observed wall-width variations are analyzed. Initial observations suggested that thermo-mechanical deformations from milling influence the width variations. However, evidence indicates the significant role of additional remelting cycles experienced by the milled surface layer during subsequent layer depositions. The study also reveals that the observed increase in wall width for each milling intervention occurs at approximately the same depth below the milled surface. A mechanistic explanation for this observation is given. Crucially, the findings suggest that unless milling is done at higher frequencies, like after each layer deposition, the resultant unevenness might render the Hybrid Wire-Arc DED process less efficient in terms of surface quality and dimensional accuracy than its non-hybrid counterpart.

Improvement of gradient microstructure and properties of wire-arc directed energy deposition titanium alloy via laser shock peening

Wire-arc directed energy deposition (WADED) technology has been widely used in the remanufacturing of titanium alloy structural components benefited from with the advantages such as high deposition efficiency and low cost. However, due to the coarse and anisotropic microstructure, the complex internal stresses and processing-induced rough surface significantly reduce fatigue performance and reliability of the remanufactured structural components. In this work, surface modification of titanium alloy WADED repair component was carried out via laser shock peening (LSP), and its gradient structure, microhardness, residual stress and fatigue performance and enhancement mechanism were systematically investigated. Results indicated that the different microstructure of each region led to different responses under the action of LSP, which was related to the change of dislocation density. LSP induced crystal defects such as high-density dislocations, twins and stacking faults on the surface. A variety of crystal defects gradually decreased with the depth from the strengthened surface, formed a gradient microstructure and significantly affected the microhardness and residual stress of the repaired components. The surface hardness and compressive residual stress of the repaired components were greatly increased after LSP and the hardened layer and compressive residual stress depth affected layer were 600 μm and 800 μm, respectively. The average fatigue life of the additive repair component increased by 197 % under the synergistic effect of compressive residual stress and gradient microstructure.

Secured energy data transaction for prosumers under diverse cyberattack scenarios

Due to the increasing use of renewable energy sources and the advancement of smart grid technology, bilateral energy transactions between prosumers have attracted significant interest as a potential solution for efficient and decentralized energy distribution. Prosumers can establish direct energy exchanges by utilizing internet of things (IoT) technologies and arrangements with smart metering capabilities, eliminating the need for middlemen and allowing for more effective use of renewable energy sources. However, these direct energy exchanges between prosumers can be susceptible to cyber-threats, which hinder secure and effective energy transactions while protecting privacy. To enable safe and seamless energy transactions among prosumers and the grid, the cyber-security of IoT devices should be of paramount significance as a possible solution. Therefore, this paper focuses on securing the energy transactions among prosumers facilitated by smart meters. It aims to address potential threats against data integrity, confidentiality, and availability from the prosumers’ point of view and develop a comprehensive framework for securing energy transactions based on artificial intelligence (AI). The proposed structured roadmap not only identifies compromised trading data but also prevents prosumers from reacting to it by replacing the contaminated as well as missing trading data. A comparative analysis on AI-based algorithms indicates that decision tree (DT) outperforms support vector machine (SVM) and multi-layer perceptron (MLP) for the proposed framework to profile the corrupted trading data identification and categorization in order to provide effective outcomes. Additionally, the proposed framework adopts a deep learning (DL)-based model for the replacement of compromised trading data. All the numerical analyses, along with extensive simulation results, justify, the efficacy of the proposed framework.

On the cyclic deformation behavior of wire-based directed energy deposited Fe-Ni Invar alloy

Fe-basis alloys with Ni concentrations of approximately 36 wt.-% are widely used for components with high requirements on mechanical properties and dimensional accuracy. Due to the remarkably low coefficient of thermal expansion, these so-called Invar alloys provide for dimensional accuracy over a wide temperature range. Generally, additive manufacturing technologies have already been qualified for processing of Invar alloys in terms of maintaining mechanical as well as functional properties. However, the mechanical behavior under cyclic loading still is not comprehensively understood. Therefore, the present study focuses on the fatigue properties of the Fe-Ni36 Invar alloy manufactured by wire-based directed energy deposition (DED) employing either an electric arc (DED-Arc) or a laser beam (DED-LB) as energy source. Here, a wire-based DED-LB Invar condition is comprehensively studied for the first time in open literature. For initial assessment, specimens were analyzed using optical and scanning electron microscopy as well as computed tomography and tensile testing. Here, the DED-LB material is characterized by a heterogeneous grain size distribution, less pronounced crystallographic texture as well as increased tensile strength and ductility compared to the DED-Arc counterparts. Despite increased strength and ductility, the DED-LB Invar consistently shows inferior fatigue properties. This behavior is discussed based on microstructural heterogeneity, cyclic deformation response, process-induced porosity and the contribution of plastic strain. Furthermore, investigations on the thermal expansion behavior show that the DED Invar retains its outstanding thermal properties, respectively.

Synthesis, Spectral Analysis, and DFT Studies of the Novel Pyrano[3,2-c] quinoline-based 1,3,4-thiadiazole for Enhanced Solar Cell Performance

In this study, we synthesized a novel compound, 3-(5-amino-1,3,4-thiadiazol-2-yl)-6-ethyl-4-hydroxy-2H-pyrano[3,2-c]quinoline-2,5(6H)-dione (ATEHPQ), through a condensation reaction between 6-ethyl-4-hydroxy-2,5-dioxo-5,6-dihydro-2H-pyrano[3,2-c]quinoline-3-carboxaldehyde and thiosemicarbazide, followed by oxidative cyclization. We characterized ATEHPQ using elemental analysis, IR, 1H and 13C NMR spectroscopy, and mass spectrometry. Density Functional Theory (DFT) calculations with the B3LYP/6-311++G(d,p) basis set were employed to optimize the molecular geometry and analyze global reactivity descriptors, including HOMO-LUMO energies. The Molecular Electrostatic Potential (MEP) map was used to identify reactive sites, and drug-likeness studies indicated potential pharmaceutical applications. Notably, ATEHPQ showed a higher first hyperpolarizability (βtot) compared to urea, suggesting its suitability for nonlinear optical applications. We also determined the Miller indices for ATEHPQ’s preferred orientations using a specialized program. Williamson–Hall analysis revealed an average crystal size of 26.08 nm and a lattice strain of 6.3 × 10−3. The thin films exhibited three distinct absorption peaks at 2.8, 3.41, and 4.21 eV, with a direct energy gap of 2.43 eV. Dispersion parameters from the single oscillator model provided oscillator and dispersion energies of 3.12 eV and 14.21 eV, respectively, with a high-frequency dielectric constant of 4.71. The ATEHPQ thin films, when combined with n-Si, demonstrated significant improvements in photovoltaic performance: the open-circuit voltage (Voc) rose from 0.13 V to 0.521 V, the short-circuit current (Isc) increased from 0.253 mA to 2.94 mA, the fill factor (FF) improved from 0.238 to 0.33, and the efficiency (η) grew from 0.71% to 4.64% with increased illumination intensity. These results highlight the excellent photovoltaic and photodetection capabilities of ATEHPQ thin films, underscoring their potential for advanced optoelectronic and solar cell applications.

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.

Evolution of microstructure and mechanical property enhancement in wire-arc directed energy deposition with interlayer machining

Wire-Arc Directed Energy Deposition (Wire-Arc DED) has emerged as a promising additive manufacturing technique known for its high deposition rates. However, the variability in microstructure and mechanical properties (e.g., hardness) of the manufactured components poses significant challenges. This study delves into these issues, focusing on the influence of interlayer machining on the microstructural evolution and mechanical properties of thin-wall Wire-Arc DED structures. It is shown that as-built Wire-Arc DED structures exhibit a pronounced microstructure variation between different regions along the build direction, primarily governed by the differences in thermal history. In contrast, a Hybrid Wire-Arc DED process that integrates interlayer machining into the build process to induce severe plastic deformation leads to a microstructure characterized by refinement and homogenization, compared to a Wire-Arc DED process. This study provides insights into the impacts of plastic deformation due to machining and thermal cycling due to subsequent layer depositions on the microstructure and hardness obtained in Wire-Arc DED and Hybrid Wire-Arc DED processes, highlighting the potential of hybrid manufacturing to generate tailored microstructures to enhance the mechanical performance of functional components.

Photocatalytic activity of XInS2 (X: Ag, Cu) nanoparticles for oxidative desulfurization of diesel fuel

In this work, Ag(Cu)InS2 semiconductor nanoparticles were synthesized via microwave and solvothermal methods. The effects of synthetical parameters on the structure and morphology of the nanoparticles were characterized by XRD, SEM, TEM, UV–Vis, and EDX. The experimental results reveal that the AgInS2 compound can be crystallized in two different phases, which are tetragonal and orthorhombic. The nanoparticles size of AgInS2 is about 15-16 nm and the direct band gap energy (Eg) of 2.041. While CuInS2 has the average particle size of around 25 nm and Eg value of 3.38 eV. The catalytic activity of both AgInS2 and CuInS2 materials were performed for photocatalytic oxidative desulfurization of sulfur compounds in the commercial diesel fuel under visible light. The maximum oxidation efficiency of 98.05% was achieved for AgInS2 catalyst after 8 hours of reaction time.

Prevention of hot cracking in Ni-based superalloy via passivation layer formation during additive manufacturing

We investigated the prevention of hot cracking in a non-weldable Ni-based superalloy by utilizing a passivation layer formed through laser-based directed energy deposition. The addition of Hf to the Ni-based superalloy facilitated the formation of a passivation layer consisting of Hf oxide on the surface of the as-deposited sample. An increase in the amount (thickness) of the passivation layers with increasing Hf content resulted in a reduction in hot cracking occurrence. Specifically, the addition of 2.5 wt% Hf led to the formation of uniformly distributed fine oxides without inducing hot cracks. This passivation layer effectively inhibited the formation of coarsened Mo oxides, which typically occur during oxidation in the liquid state and contribute to the hot cracking of Ni-based superalloy. During oxidation in the liquid state, Hf diffuses out to the surface and forms a passivation layer, thereby suppressing the formation and growth of oxides to sizes large enough to induce hot cracking.

Evaluation of Band Structure of Single Crystalline Si-Rich SiSn thin Film

We evaluated the bandgap energy and optical properties of single-crystalline silicon-tin (Si1-x Sn x ) thin films utilizing Photoluminescence (PL), spectroscopic ellipsometry (SE), and X-ray photoelectron spectroscopy (XPS). The PL and SE results showed that the indirect and direct bandgap energy decrease with increasing Sn fraction. Furthermore, the change in the direct bandgap energy is larger than the indirect bandgap energy. This shows that Si1-x Sn x approaches the direct transition type. Then, the Sn fraction from the indirect-to-direct bandgap is estimated to be 47.2%. In addition, XPS results showed that the difference in valence band maximum between Si1-x Sn x and pure Si increased depending on Sn fraction. This is responsible for the decrease in the indirect and direct bandgap energy.

Stainless and low-alloy steels additively manufactured by micro gas metal arc-based directed energy deposition: microstructure and mechanical behavior

Stainless and low-alloy steels additively manufactured by micro gas metal arc-based directed energy deposition: microstructure and mechanical behavior