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Fundamental Aspects of Selective Melting Additive Manufacturing Processes

Van Swol, Frank B.; Miller, James E.

Certain details of the additive manufacturing process known as selective laser melting (SLM) affect the performance of the final metal part. To unleash the full potential of SLM it is crucial that the process engineer in the field receives guidance about how to select values for a multitude of process variables employed in the building process. These include, for example, the type of powder (e.g., size distribution, shape, type of alloy), orientation of the build axis, the beam scan rate, the beam power density, the scan pattern and scan rate. The science-based selection of these settings con- stitutes an intrinsically challenging multi-physics problem involving heating and melting a metal alloy, reactive, dynamic wetting followed by re-solidification. In addition, inherent to the process is its considerable variability that stems from the powder packing. Each time a limited number of powder particles are placed, the stacking is intrinsically different from the previous, possessing a different geometry, and having a different set of contact areas with the surrounding particles. As a result, even if all other process parameters (scan rate, etc) are exactly the same, the shape and contact geometry and area of the final melt pool will be unique to that particular configuration. This report identifies the most important issues facing SLM, discusses the fundamental physics associated with it and points out how modeling can support the additive manufacturing efforts.

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TYPE SAND Report YEAR 2014
DOIOSTI

Performance and Energy Implications for Heterogeneous Computing Systems: A MiniFE Case Study

Barrett, Richard F.; Tang, Li; Hu, X.S.

Heterogeneous computing systems, which employ a mix of general-purpose (GP) processors and accelerators such as graphics processing units (GPUs) or Field Programmable Gate Arrays (FPGAs), have the potential to offer much higher performance and lower energy usage than homogeneous systems. However, designing heterogeneous computing systems to achieve high performance and low energy usage is a challenging task. Designs that offer higher performance do not necessarily lead to lower energy consumption. Furthermore, mapping of applications to different computing devices can play a key role in performance and energy tradeoff. In this report, we present a detailed performance and energy study of executing a specific mini-application on different heterogeneous systems. The results show that hardware choices, application implementations, and mapping of applications to hardware can all significantly impact system performance and energy consumption and that the impact on performance and energy can be quite different. This study forms a basis for modeling the interdependencies of program structures and hardware execution units, which could be used to guide design space exploration.

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TYPE SAND Report YEAR 2014
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Supplemental Information Source Document Waste Management

Foulk, James W.

This Supplemental Information Source Document for Waste Management was prepared in support of future analyses including those that may be performed as part of the Sandia National Laboratories, New Mexico (SNL/NM) Site-Wide Environmental Impact Statement. This document presents information about waste management practices at SNL/NM, including definitions, inventory data, and an overview of current activities.

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TYPE Other Report YEAR 2014
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A Scalable Solution Framework for Stochastic Transmission and Generation Planning Problems. Draft

Munoz, Francisco D.; Watson, Jean-Paul

Current commercial software tools for transmission and generation investment planning have limited stochastic modeling capabilities. Because of this limitation, electric power utilities generally rely on scenario planning heuristics to identify potentially robust and cost effective investment plans for a broad range of system, economic, and policy conditions. Several research studies have shown that stochastic models perform significantly better than deterministic or heuristic approaches, in terms of overall costs. However, there is a lack of practical solution approaches to solve such models. In this paper we propose a scalable decomposition algorithm to solve stochastic transmission and generation planning problems, respectively considering discrete and continuous decision variables for transmission and generation investments. Given stochasticity restricted to loads and wind, solar, and hydro power output, we develop a simple scenario reduction framework based on a clustering algorithm, to yield a more tractable model. The resulting stochastic optimization model is decomposed on a scenario basis and solved using a variant of the Progressive Hedging (PH) algorithm. We perform numerical experiments using a 240-bus network representation of the Western Electricity Coordinating Council in the US. Although convergence of PH to an optimal solution is not guaranteed for mixed-integer linear optimization models, we find that it is possible to obtain solutions with acceptable optimality gaps for practical applications. Our numerical simulations are performed both on a commodity workstation and on a high-performance cluster. The results indicate that large-scale problems can be solved to a high degree of accuracy in at most two hours of wall clock time.

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TYPE Other Report YEAR 2014
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SNL/CA Facilities Management Design Standards Manual

Rabb, David; Clark, Eva

At Sandia National Laboratories in California (SNL/CA), the design, construction, operation, and maintenance of facilities is guided by industry standards, a graded approach, and the systematic analysis of life cycle benefits received for costs incurred. The design of the physical plant must ensure that the facilities are "fit for use," and provide conditions that effectively, efficiently, and safely support current and future mission needs. In addition, SNL/CA applies sustainable design principles, using an integrated whole-building design approach, from site planning to facility design, construction, and operation to ensure building resource efficiency and the health and productivity of occupants. The safety and health of the workforce and the public, any possible effects on the environment, and compliance with building codes take precedence over project issues, such as performance, cost, and schedule.

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TYPE Other Report YEAR 2014
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Accelerated discovery of elpasolite scintillators

Doty, F.P.; Yang, Pin; Zhou, Xiaowang

Elpasolite scintillators are a large family of halides which includes compounds reported to meet the NA22 program goals of <3% energy resolution at 662 keV1. This work investigated the potential to produce quality elpasolite compounds and alloys of useful sizes at reasonable cost, through systematic experimental and computational investigation of crystal structure and properties across the composition space. Discovery was accelerated by computational methods and models developed previously to efficiently identify cubic members of the elpasolite halides, and to evaluate stability of anion and cation exchange alloys.

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TYPE Other Report YEAR 2014
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Results of stainless steel canister corrosion studies and environmental sample investigations

Bryan, C.R.; Enos, David

This progress report describes work being done at Sandia National Laboratories (SNL) to assess the localized corrosion performance of container/cask materials used in the interim storage of used nuclear fuel. The work involves both characterization of the potential physical and chemical environment on the surface of the storage canisters and how it might evolve through time, and testing to evaluate performance of the canister materials under anticipated storage conditions. To evaluate the potential environment on the surface of the canisters, SNL is working with the Electric Power Research Institute (EPRI) to collect and analyze dust samples from the surface of in-service SNF storage canisters. In FY 13, SNL analyzed samples from the Calvert Cliffs Independent Spent Fuel Storage Installation (ISFSI); here, results are presented for samples collected from two additional near-marine ISFSI sites, Hope Creek NJ, and Diablo Canyon CA. The Hope Creek site is located on the shores of the Delaware River within the tidal zone; the water is brackish and wave action is normally minor. The Diablo Canyon site is located on a rocky Pacific Ocean shoreline with breaking waves. Two types of samples were collected: SaltSmart™ samples, which leach the soluble salts from a known surface area of the canister, and dry pad samples, which collected a surface salt and dust using a swipe method with a mildly abrasive ScotchBrite™ pad. The dry samples were used to characterize the mineralogy and texture of the soluble and insoluble components in the dust via microanalytical techniques, including mapping X-ray Fluorescence spectroscopy and Scanning Electron Microscopy. For both Hope Creek and Diablo Canyon canisters, dust loadings were much higher on the flat upper surfaces of the canisters than on the vertical sides. Maximum dust sizes collected at both sites were slightly larger than 20 μm, but Phragmites grass seeds ~1 mm in size, were observed on the tops of the Hope Creek canisters. At both sites, the surface dust could be divided into fractions generated by manufacturing processes and by natural processes. The fraction from manufacturing processes consisted of variably-oxidized angular and spherical particles of stainless steel and iron, generated by machining and welding/cutting processes, respectively. Dust from natural sources consisted largely of detrital quartz and aluminosilicates (feldspars and clays) at both sites. At Hope Creek, soluble salts were dominated by sulfates and nitrates, mostly of calcium. Chloride was a trace component and the only chloride mineral observed by SEM was NaCl. Chloride surface loads measured by the Saltsmart™ sensors were very low, less than 60 mg m–2 on the canister top, and less than 10 mg m–2 on the canister sides. At Diablo Canyon, sea-salt aggregates of NaCl and Mg-SO4, with minor K and Ca, were abundant in the dust, in some cases dominating the observed dust assemblage. Measured Saltsmart™ chloride surface loads were very low (<5 mg m–2); however, high canister surface temperatures damaged the Saltsmart™ sensors, and, in view of the SEM observations of abundant sea-salts on the package surfaces, the measured surface loads may not be valid. Moreover, the more heavily-loaded canister tops at Diablo Canyon were not sampled with the Saltsmart™ sensors. The observed low surface loads do not preclude chloride-induced stress corrosion cracking (CISCC) at either site, because (1) the measured data may not be valid for the Diablo Canyon canisters; (2) the surface coverage was not complete (for instance, the 45º offset between the outlet and inlet vents means that near-inlet areas, likely to have heavier dust and salt loads, were not sampled); and (3) CISCC has been experimentally been observed at salt loads as low as 5-8 mg/m2. Experimental efforts at SNL to assess corrosion of interim storage canister materials include three tasks in FY14. First, a full-diameter canister mockup, made using materials and techniques identical to those used to make interim storage canisters, was designed and ordered from Ranor Inc., a cask vendor for Areva/TN. The mockup will be delivered prior to the end of FY14, and will be used for evaluating weld residual stresses and degrees of sensitization for typical interim storage canister welds. Following weld characterization, the mockup will be sectioned and provided to participating organizations for corrosion testing purposes. A test plan is being developed for these efforts. In a second task, experimental work was carried out to evaluate crevice corrosion of 304SS in the presence of limited reactants, as would be present on a dustcovered storage canister. This work tests the theory that limited salt loads will limit corrosion penetration over time, and is a continuation of work carried out in FY13. Laser confocal microscopy was utilized to assess the volume and depth of corrosion pits formed during the crevice corrosion tests. Results indicate that for the duration of the current experiments (100 days), no stifling of corrosion occurred due to limitations in the amount of reactants present at three different salt loadings. Finally, work has been carried out this year perfecting an instrument for depositing sea-salts onto metal surfaces for atmospheric corrosion testing purposes. The system uses an X-Y plotter system with a commercial airbrush, and deposition is monitored with a quartz crystal microbalance. The system is capable of depositing very even salt loadings, even at very low total deposition rates.

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TYPE Presentation YEAR 2014
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Results 50301–50400 of 99,299
Results 50301–50400 of 99,299