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  1. Purpose

    Surface quality and porosity significantly influence the structural and functional properties of the final product. This study aims to establish and explain the underlying relationships among processing parameters, top surface roughness and porosity level in additively manufactured 316L stainless steel.

    Design/methodology/approach

    A systematic variation of printing process parameters was conducted to print cubic samples based on laser power, speed and their combinations of energy density. Melt pool morphologies and dimensions, surface roughness quantified by arithmetic mean height (Sa) and porosity levels were characterized via optical confocal microscopy.

    Findings

    The study reveals that the laser power required to achieve optimal top surface quality increases with the volumetric energy density (VED) levels. A smooth top surface (Sa < 15 µm) or a rough surface with humps at high VEDs (VED > 133.3 J/mm3) can serve as indicators for fully dense bulk samples, while rough top surfaces resulting from melt pool discontinuity correlate with high porosity levels. Under insufficient VED, melt pool discontinuity dominates the top surface. At high VEDs, surface quality improves with increased power as mitigation of melt pool discontinuity, followed by the deterioration with hump formation.

    Originality/value

    This study reveals and summarizes the formation mechanism of dominant features on top surface features and offers a potential method to predict the porosity by observing the top surface features with consideration of processing conditions.

     
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    Free, publicly-accessible full text available July 25, 2025
  2. Abstract

    Manipulating surface charge, electric field, and plasma afterglow in a non-equilibrium plasma is critical to control plasma-surface interaction for plasma catalysis and manufacturing. Here, we show enhancements of surface charge, electric field during breakdown, and afterglow by ferroelectric barrier discharge. The results show that the ferroelectrics manifest spontaneous electric polarization to increase the surface charge by two orders of magnitude compared to discharge with an alumina barrier. Time-resolved in-situ electric field measurements reveal that the fast polarization of ferroelectrics enhances the electric field during the breakdown in streamer discharge and doubles the electric field compared to the dielectric barrier discharge. Moreover, due to the existence of surface charge, the ferroelectric electrode extends the afterglow time and makes discharge sustained longer when alternating the external electric field polarity. The present results show that ferroelectric barrier discharge offers a promising technique to tune plasma properties for efficient plasma catalysis and electrified manufacturing.

     
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  3. Abstract

    Developing stable and efficient electrocatalysts is vital for boosting oxygen evolution reaction (OER) rates in sustainable hydrogen production. High-entropy oxides (HEOs) consist of five or more metal cations, providing opportunities to tune their catalytic properties toward high OER efficiency. This work combines theoretical and experimental studies to scrutinize the OER activity and stability for spinel-type HEOs. Density functional theory confirms that randomly mixed metal sites show thermodynamic stability, with intermediate adsorption energies displaying wider distributions due to mixing-induced equatorial strain in active metal-oxygen bonds. The rapid sol-flame method is employed to synthesize HEO, comprising five 3d-transition metal cations, which exhibits superior OER activity and durability under alkaline conditions, outperforming lower-entropy oxides, even with partial surface oxidations. The study highlights that the enhanced activity of HEO is primarily attributed to the mixing of multiple elements, leading to strain effects near the active site, as well as surface composition and coverage.

     
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  4. Abstract

    Electrochemical two-electron water oxidation reaction (2e-WOR) has drawn significant attention as a promising process to achieve the continuous on-site production of hydrogen peroxide (H2O2). However, compared to the cathodic H2O2generation, the anodic 2e-WOR is more challenging to establish catalysts due to the severe oxidizing environment. In this study, we combine density functional theory (DFT) calculations with experiments to discover a stable and efficient perovskite catalyst for the anodic 2e-WOR. Our theoretical screening efforts identify LaAlO3perovskite as a stable, active, and selective candidate for catalyzing 2e-WOR. Our experimental results verify that LaAlO3achieves an overpotential of 510 mV at 10 mA cm−2in 4 M K2CO3/KHCO3, lower than those of many reported metal oxide catalysts. In addition, LaAlO3maintains a stable H2O2Faradaic efficiency with only a 3% decrease after 3 h at 2.7 V vs. RHE. This computation-experiment synergistic approach introduces another effective direction to discover promising catalysts for the harsh anodic 2e-WOR towards H2O2.

     
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  5. Abstract

    A multifaceted Mo:BiVO4(mf‐BVO) photoanode is grown on F‐doped‐SnO2substrates via achemical bath deposition, and the crystal reconstruction process of mf‐BVO is found to boost the charge transport efficiency significantly for photoelectrochemical (PEC) water splitting. The mf‐BVO exhibits columnar grains with an uncommon (121) texture with high‐index facets such as (112), (020), (132), and (204). The texture and high‐index facets facilitate rapid surface melting and grain fusion during thermal annealing, thus leading to crystal reconstructed micron‐sized BVO grains (cr‐BVO). The cr‐BVO has a photocurrent density ≈50 times larger than that of mf‐BVO. The reason is identified as the significantly improved charge transport efficiency resulting from the dopant activation (increased carrier concentration) and bulky grains (fewer defects). Additionally, the cr‐BVO exhibits improved photocorrosion resistance compared to the nanoparticle‐based BVO. After coating the oxygen evolution catalyst, the photocurrent density of cr‐BVO is further increased to 4.4 mA cm−2for water oxidation reaction at 1.23 V versus the reversible hydrogen electrode, maintaining a high and stable faradaic efficiency of over 88% for 24 h. These results demonstrate that crystal reconstruction is a facile and effective pathway to improve the charge transport efficiency, opening a new avenue for developing efficient photoelectrodes for PEC water splitting.

     
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  6. Free, publicly-accessible full text available September 1, 2025
  7. In plasma discharges, the acceleration of electrons by a fast varying electric field and the subsequent collisional electron energy transfer determines the plasma dynamics, chemical reactivity, and breakdown. Current in situ electric field measurements require reconstruction of the temporal profile over many observations. However, such methods are unsuitable for non-repetitive and unstable plasmas. Here, we present a method for creating “movies” of dynamic electric fields in a single acquisition at sample rates of 500 × 106 fps. This ultrafast diagnostic was demonstrated in radio frequency electric fields between two parallel plates in air, as well as in Ar nanosecond-pulsed single-sided dielectric barrier discharges.

     
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  8. Free, publicly-accessible full text available May 1, 2025