To gain unparalleled insights into materials synthesis, microstructural evolution, and defect genesis for electron beam powder bed fusion (EB-PBF) additive manufacturing (AM), we argue that characterization of materials and microstructures must take place in-situ and at relevant time scales. To this end, we will leverage direct, in-situ measurement of electron interactions and charge transfer within materials during EB-PBF AM in real-time.

Materials science for nuclear security applications is a key component. Ensuring the functionality of components for nuclear security applications, replacement of components for existing systems and enhancing performance while reducing costs are key elements based on smart materials design and a comprehensive understanding of the materials degradation mechanisms in service conditions.

There is a dire need for rapid screening of materials and design for the hydrogen economy. Refractory molybdenum alloys are unaffected by hydrogen and are thus prime candidates for regenerative cooling systems, both for aerospace and land-based applications. The objective of this proposed project is to develop a data-driven framework to enable a new manufacturing paradigm for novel refractory alloys for advanced heat exchanger (HX) applications via additive manufacturing (AM). This integrated digital framework will enable the rapid establishment of AM processing science with the focus on targeting desired microstructural /component features and final material properties.

NC State will work with SRNL Engineers to develop copper components for electron beam melting powder bed fusion additive manufacturing.

Stem cells are present in all multicellular organisms and are considered the building blocks for different cell types and tissues. Deciphering the processes by which stem cells are specified and differentiate is critical to producing specific cell-types and even organ-like structures from induced pluripotent stem cells in both animals and plants. However, in most mammalian systems, the lack of definitive stem cell markers, the inaccessibility of these cells, and cell movement confound analysis of these cells. These limitations can be overcome by using the model plant Arabidopsis as an experimental system. Moreover, because plant cells do not move and stem cells divide in a stereotypical manner, the root offers a spatially oriented lineage from stem cells to their differentiated progeny and provides an excellent system in which to identify emergent properties underlying cell specification, determination, and differentiation. Furthermore, disruption of the stereotypical cellular arrangement of the root via either physical, mechanical, or laser ablation, can inform us about the underlying rules of cellular reprogramming and reestablishment of morphogen patterning. Interrogating this self-organizing capacity, however, has thus far been limited by the challenge of manipulating individual cells within their local microenvironment. Nowadays, the precise placement of cellular materials can be programmatically assembled in 3D space in nearly any arrangement using 3D-bioprinting capabilities. Despite this great advantage, 3D-printing technologies have been limited to animal cells, and have not been yet exploited to plant cells, which offer an amenable system (i.e plant cells can be easily isolated and manipulated and their tissues are organized into cell layers where entire cell lineages are spatially restricted). Thus, we propose that by arranging, at high-resolution, plant cells in predetermined architectures (e.g precise -through 3d printing- placement of cell types, which recapitulate gradients and influence cell behavior), using fluorescent reporters to quantify small molecule gradients (e.g auxin and gibberellin biosensors) and performing single cell gene expression profile and network modeling we will be able to: 1) Understand, simplify, and test the critical spatial and temporal establishment of patterning and interactions among cells; 2) Determine the rules by which morphogen gradients are established across cells to predict differentiation and growth; 3) Identify mechanisms regulating stem cell regulation and the differentiation of their progeny into specific tissues.

We propose to additively manufacture a solid, near-net shape, pure W thimble with a metallurgically bonded porous W armor using Electron Beam Powder Bed Fusion (EB-PBF). New generation EB-PBF systems include a 5,000 MW/m2 peak power density, 6kW beam and vacuum build temperatures as high as 1050oC, making EB-PBF well suited to printing tungsten above the ductile-to-brittle-transition temperature with reduced residual stress. Currently, EB-PBF is used for serial production of safety-critical TiAl turbine blades used in the GE9x engine. Considering that TiAl has similar low-temperature cracking issues as tungsten, EB-PBF is extremely well suited to reliably fabricating PFCs using equipment with a high level of technological maturity.

It is proposed to acquire and install a Diffusion Bonding Hot Press Furnace for processing advanced materials such as ceramics, composites, refractory metals and composite metal foams for research and training on various topics of materials processing, evaluation and treatment. The system will be used to perform processing of panels of various sizes up to 1ft x 1ft. Currently the only system similar to this unit in the entire area is an old (over 50 years old) hot press with a very small chamber size and malfunctioning hydraulic press that is in PI������������������s lab. Due to the lack of capacity of this machine, the PIs are unable to process large parts or advanced materials that require higher temperature or pressure for manufacturing (such as ceramics and refractory metals). This press can be a valuable tool not only to support all PIs������������������ research, but also to support all users of NCSU on-campus Center for Additive Manufacturing and Logistics (CAMAL) and other universities in the area such as Duke university. CAMAL center currently houses five metal additive manufacturing machines that are used for a variety of research projects. However, it is lacking such large chamber press with high temperature capabilities for processing and post processing treatments of advanced ceramics, metallic and composite materials. Since the unit will housed in a shared facility, it will be easy for access both as an educational tool and a research tool for users not only at the college of engineering, but also all other colleges across the campus as well as outside users from both academia and industry. The advantages of this system over all other units are the distinctly larger chamber along with higher service temperatures and clean, efficient, and fast heating and cooling rate with a simultaneous heating and pressing. Additionally, it may be used in vacuum and in partial pressure inert gas atmosphere. Moreover, proper operation of the furnace may be mastered in a few hours which is necessary for such equipment that is going to be used by various users and students both as an educational and a research tool.

North Carolina State University, Ohio State University, Oakland University, and University of New Hampshire are applying for a planning grant to establish a multi-university IUCRC Center for Industrial Metal Forming. The mission of the proposed Center is to perform cutting-edge, pre-competitive fundamental research in metal forming science and engineering in collaboration with industrial members to drive innovation and competitiveness in U.S. advanced manufacturing processes. CIMF will employ Industrial Internet of Things (IIoT), sensor technologies, novel numerical modeling and experimental techniques to enable advancements in material utilization, weight reduction and improved dimensional stability of formed components, extending the life of metal forming dies and increasing the productivity of industrial metal forming processes.

Membership Documents for ge additive to Join Consortium

Scalable and cost-effective fabrication of creep-resistant oxide dispersion strengthened (ODS) steel is critical for constructing blankets in future fusion reactors that operate above 900K for economic power conversion cycles. The current ODS steel fabrication route requires mechanical alloying (MA) of precursor ODS steel powder for over 40 hours and highly skilled thermal-mechanical processing (TMP), which are cost-prohibitive and lack consistent part to part reliable performance for certification. For the first time, Pacific Northwest National Laboratory (PNNL) and its partners will combine MA-free synthesis of precursor ODS steel powder and advanced manufacturing methods, including first-of-its-kind shear assisted processing and extrusion (ShAPE) and additive manufacturing (AM) methods of laser directed energy deposition (DED) and electron beam melting (EBM), to fabricate ODS steel tubes, plates, and complex parts with scalability. This will reduce cost for MA-free ODS steel components by 50% or more and yield reliable performance with creep resistance above 900K that can be certified for reactor use. In addition, PNNL������������������s friction stir welding (FSW) machine, having the highest stiffness in the US, is capable of joining ODS steel components for fusion blanket mock-up structures without compromising oxide distribution.