3D computational fluid and particle dynamics simulations: metrics of aerosol capture by impaction filters.

Human studies provide valuable information on components or analytes recovered from exhaled breath, but there are limitations due to inter-individual and intra-individual variation. Future development and implementation of breath tests based on aerosol analysis require a clear understanding of how human factors interact with device geometry to influence particle transport and deposition. The computational fluid and particle dynamics (CFPD) algorithm combines (i) the Eulerian approach to fluid dynamics and (ii) the Lagrangian approach to single particle transport and deposition to predict how particles are carried in fluids and deposited on surfaces. In this work, we developed a 3D multiscale CFPD model to provide insight into human factors that could be important to control or measure during sampling. We designed the model to characterize the local transport, spatial distribution, and deposition of polydisperse particles in a single impaction filter of a commercial aerosol collection device. We highlight the use of decoupling numerical strategies to simultaneously quantify the influence of filter geometry, fluid flowrate, and particle size. Our numerical models showed the remarkable effect of flowrate on aerosol dynamics. Specifically, aerosol mass deposition, spatial distribution, and deposition mechanisms inside the filter. This work as well as future studies on the effect of filter geometry and human factors on aerosol collection will guide the development, standardization, and validation of breath sampling protocols for current and emerging breath tests for forensic and clinical applications.

Electrosteric Control of the Aggregation and Yielding Behavior of Concentrated Portlandite Suspensions.

Portlandite (calcium hydroxide: CH: Ca(OH)2) suspensions aggregate spontaneously and form percolated fractal aggregate networks when dispersed in water. Consequently, the viscosity and yield stress of portlandite suspensions diverge at low particle loadings, adversely affecting their processability. Even though polycarboxylate ether (PCE)-based comb polyelectrolytes are routinely used to alter the particle dispersion state, water demand, and rheology of similar suspensions (e.g., ordinary portland cement suspensions) that feature a high pH and high ionic strength, their use to control portlandite suspension rheology has not been elucidated. This study combines adsorption isotherms and rheological measurements to elucidate the role of PCE composition (i.e., charge density, side chain length, and grafting density) in controlling the extent of PCE adsorption, particle flocculation, suspension yield stress, and thermal response of portlandite suspensions. We show that longer side-chain PCEs are more effective in affecting suspension viscosity and yield stress, in spite of their lower adsorption saturation limit and fractional adsorption. The superior steric hindrance induced by the longer side chain PCEs results in better efficacy in mitigating particle aggregation even at low dosages. However, when dosed at optimal dosages (i.e., a dosage that induces a dynamically equilibrated dispersion state of particle aggregates), different PCE-dosed portlandite suspensions exhibit identical fractal structuring and rheological behavior regardless of the side chain length. Furthermore, it is shown that the unusual evolution of the rheological response of portlandite suspensions with temperature can be tailored by adjusting the PCE dosage. The ability of PCEs to modulate the rheology of aggregating charged particle suspensions can be generally extended to any colloidal suspension with a strong screening of repulsive electrostatic interactions.

Pore formation driven by particle impact in laser powder-blown directed energy deposition.

Process defects currently limit the use of metal additive manufacturing (AM) components in industries due to shorter fatigue life, potential for catastrophic failure, and lower strength. Conditions under which these defects form, and their mechanisms, are starting to be analyzed to improve reliability and structural integrity of these highly customized parts. We use in situ, high-speed X-ray imaging in conjunction with a high throughput laser, powder-blown directed energy deposition setup to observe powder particle impact behavior within the melt pool. Through fundamental observations of the stochastic, violent powder delivery in powder-blown DED, we uncover a unique pore formation mechanism. We find that a pore can form due to air-cushioning, where vapor from the carrier gas or environment is entrapped between the solid powder particle surface and liquid melt pool surface. A critical time constant is established for the mechanism, and X-ray computed tomography is used to further analyze and categorize the new type of "air-cushioning" pores. It is shown that the air-cushioning mechanism can occur under multiple laser processing conditions, and we show that air-cushioning pores are more likely to be formed when powder particles are larger than 70 µm. By quantifying the effect of powder particle impact, we identify new avenues for development of high-quality laser, powder-blown DED products. Furthermore, we deepen knowledge on defect formation in metal additive manufacturing, which is being increasingly utilized in high performance situations such as aerospace, automotive, and biomedical industries.

X-ray computed tomography using partially coherent Fresnel diffraction with application to an optical fiber.

A reconstruction algorithm for partially coherent x-ray computed tomography (XCT) including Fresnel diffraction is developed and applied to an optical fiber. The algorithm is applicable to a high-resolution tube-based laboratory-scale x-ray tomography instrument. The computing time is only a few times longer than the projective counterpart. The algorithm is used to reconstruct, with projections and diffraction, a tilt series acquired at the micrometer scale of a graded-index optical fiber using maximum likelihood and a Bayesian method based on the work of Bouman and Sauer. The inclusion of Fresnel diffraction removes some reconstruction artifacts and use of a Bayesian prior probability distribution removes others, resulting in a substantially more accurate reconstruction.

Design of a 3000-Pixel Transition-Edge Sensor X-Ray Spectrometer for Microcircuit Tomography.

Feature sizes in integrated circuits have decreased substantially over time, and it has become increasingly difficult to three-dimensionally image these complex circuits after fabrication. This can be important for process development, defect analysis, and detection of unexpected structures in externally sourced chips, among other applications. Here, we report on a non-destructive, tabletop approach that addresses this imaging problem through x-ray tomography, which we uniquely realize with an instrument that combines a scanning electron microscope (SEM) with a transition-edge sensor (TES) x-ray spectrometer. Our approach uses the highly focused SEM electron beam to generate a small x-ray generation region in a carefully designed target layer that is placed over the sample being tested. With the high collection efficiency and resolving power of a TES spectrometer, we can isolate x-rays generated in the target from background and trace their paths through regions of interest in the sample layers, providing information about the various materials along the x-ray paths through their attenuation functions. We have recently demonstrated our approach using a 240 Mo/Cu bilayer TES prototype instrument on a simplified test sample containing features with sizes of ∼ 1 µm. Currently, we are designing and building a 3000 Mo/Au bilayer TES spectrometer upgrade, which is expected to improve the imaging speed by factor of up to 60 through a combination of increased detector number and detector speed.

Three-Dimensional Particle Shape Analysis Using X-ray Computed Tomography: Experimental Procedure and Analysis Algorithms for Metal Powders.

Measuring the size distribution of the particles in a powder is a common activity in science and industry. Measuring the shape distribution of the particles is much less common. However, the shape and size of powder particles are not independent quantities. All known size/shape measurement techniques either assume a spherical shape or measure the shape in two dimensions only. The X-ray computed tomography (XCT) based method presented here measures both size and shape in 3D without making any assumptions. Starting from a 3D image of particles, the method can mathematically classify particles according to shape, for example particles composed of several smaller particles welded together as opposed to single particles that are not necessarily spherical. Of course, defining a single number as the "size" or "shape" of a random non-spherical particle is not possible in principle, leading to many ways to estimate particle size and shape via various interlinked parameters, which can all be generated from this complete 3D characterization in the form of averages and distributions. The necessary experimental procedures, mathematical analysis, and computer analysis are described and an example is given for a metal powder. The technique is limited to particles that can be imaged by XCT with a minimum of about 1000 voxels per particle volume.

Temperature-Induced Aggregation in Portlandite Suspensions.

Temperature is well known to affect the aggregation behavior of colloidal suspensions. This paper elucidates the temperature dependence of the rheology of portlandite (calcium hydroxide: Ca(OH)2) suspensions that feature a high ionic strength and a pH close to the particle's isoelectric point. In contrast to the viscosity of the suspending medium (saturated solution of Ca(OH)2 in water), the viscosity of Ca(OH)2 suspensions is found to increase with elevating temperature. This behavior is shown to arise from the temperature-induced aggregation of polydisperse Ca(OH)2 particulates because of the diminution of electrostatic repulsive forces with increasing temperature. The temperature dependence of the suspension viscosity is further shown to diminish with increasing particle volume fraction as a result of volumetric crowding and the formation of denser fractal structures in the suspension. Significantly, the temperature-dependent rheological response of suspensions is shown to be strongly affected by the suspending medium's properties, including ionic strength and ion valence, which affect aggregation kinetics. These outcomes provide new insights into aggregation processes that affect the temperature-dependent rheology of portlandite-based and similar suspensions that feature strong charge screening behavior.

Electromagnetic resonance analysis of asymmetric carbon nanotube dimers for sensing applications.

In this work, we study the electromagnetic scattering characteristics of asymmetric carbon nanotube (CNT) dimers with rigorous computational experiments. We show that the configurational asymmetry in the CNT dimer assembly creates a unique field distribution in the vicinity of the dimer, which in turn generates two distinct resonances representing the bonding and anti-bonding modes. The sensitivity of these two modes towards CNT lengths, orientations, and shapes, is studied. We also show the ability of asymmetric CNT dimer for the contactless detection of nanoparticles (NP). The presence of a NP in the vicinity of the CNT dimer perturbs the dimer's field distribution and causes unequal shifts in the bonding and anti-bonding resonances depending on the NP location, material, size and shape. By studying the differences in these resonance shifts, we show that the relative location and orientation of the NP can be reconstructed. The computational experiments performed in this work have the potential to guide the use of asymmetric CNT dimers for novel sensing applications.

How clay particulates affect flow cessation and the coiling stability of yield stress-matched cementing suspensions.

The remarkable increase in the flow resistance of dense suspensions can hinder 3D-printing processes on account of flow cessation in the extruder, and filament fragility/rupture following deposition. Understanding the nature of rheological changes that occur is critical to manipulate flow conditions or to dose flow modifiers for 3D-printing. Therefore, this paper elucidates the influences of clay particulates on controlling flow cessation and the shape stability of dense cementing suspensions that typically feature poor printability. A rope coiling method was implemented with varying stand-off distances to probe the buckling stability and tendency to fracture of dense suspensions that undergo stretching and bending during deposition. The contributions of flocculation and short-term percolation due to the kinetics of structure formation to deformation rate were deconvoluted using a stepped isostress method. It is shown that the shear stress indicates a divergence with a power-law scaling when the particle volume fraction approaches the jamming limit; φ → φj ≈ φmax. Such a power-law divergence of the shear stress decreases by a factor of 10 with increasing clay dosage. Such behavior in clay-containing suspensions arises from a decrease in the relative packing fraction (φ/φmax) and the formation of fractally-architected aggregates with stronger interparticle interactions, whose uniform arrangement controls flow cessation in the extruder and suspension homogeneity, thereby imparting greater buckling stability. The outcomes offer new insights for assessing/improving the extrudability and printability behavior during slurry-based 3D-printing process.

Dispersing nano- and micro-sized portlandite particulates via electrosteric exclusion at short screening lengths.

In spite of their high surface charge (zeta potential ζ = +34 mV), aqueous suspensions of portlandite (calcium hydroxide: Ca(OH)2) exhibit a strong tendency to aggregate, and thereby present unstable suspensions. While a variety of commercial dispersants seek to modify the suspension stability and rheology (e.g., yield stress, viscosity), it remains unclear how the performance of electrostatically and/or electrosterically based additives is affected in aqueous environments having either a high ionic strength and/or a pH close to the particle's isoelectric point (IEP). We show that the high native ionic strength (pH ≈ 12.6, IEP: pH ≈ 13) of saturated portlandite suspensions strongly screens electrostatic forces (Debye length: κ-1 = 1.2 nm). As a result, coulombic repulsion alone is insufficient to mitigate particle aggregation and affect rheology. However, a longer-range geometrical particle-particle exclusion that arises from electrosteric hindrance caused by the introduction of comb polyelectrolyte dispersants is very effective at altering the rheological properties and fractal structuring of suspensions. As a result, comb-like dispersants that stretch into the solvent reduce the suspension's yield stress by 5× at similar levels of adsorption as compared to linear dispersants, thus enhancing the critical solid loading (i.e., at which jamming occurs) by 1.4×. Significantly, the behavior of diverse dispersants is found to be inherently related to the thickness of the adsorbed polymer layer on particle surfaces. These outcomes inform the design of dispersants for concentrated suspensions that present strong charge screening behavior.

Dynamic Laser Absorptance Measured in a Geometrically Characterized Stainless-Steel Powder Layer.

The relationship between real powder distributions and optical coupling is a critical building block for developing a deeper physical understanding of laser-additive manufacturing and for creating more reliable and accurate models for predictable manufacturing. Laser-light absorption by a metal powder is distinctly different from that of a solid material, as it is impacted by additional parameters, such as particle size, shape distribution, and packing. Here, we use x-ray computed tomography to experimentally determine these parameters in a thinly spread austenitic stainless-steel powder on a metal substrate, and we combine these results with optical absorptance measurements during a 1 ms stationary laser-light exposure to simulate the additive-manufacturing process. Within the thinly spread powder layer, the particle volume fraction changes continuously from near zero at the powder surface to a peak value of 0.72 at a depth of 235 µm, with the most rapid increase taking place in the first 100 µm. The relationship between this particle volume fraction gradient and optical absorptance is investigated using an analytical model, which shows that depth-averaged absorptance measurements can measure the predicted average value, but will fail to capture local effects that result from a changing powder density. The time-averaged absorptance remains at levels between 0.67 and 0.80 across a two orders of magnitude range in laser power, which is significantly higher than that observed in solid stainless-steel experiments. The dynamic behavior of the absorptance, however, reveals physical phenomena, including oxidation, melting, and vapor cavity (keyhole) formation, as well as quantifying the effect of these on the absorbed energy.

AMB2018-03: Benchmark Physical Property Measurements for Material Extrusion Additive Manufacturing of Polycarbonate.

Material extrusion (MatEx) is finding increasing applications in additive manufacturing of thermoplastics due to the ease of use and the ability to process disparate polymers. Since part strength is anisotropic and frequently deviates negatively with respect to parts produced by injection molding, an urgent challenge is to predict final properties of parts made through this method. A nascent effort is underway to develop theoretical and computational models of MatEx part properties, but these efforts require comprehensive experimental data for guidance and validation. As part of the AM-Bench framework, we provide here a thorough set of measurements on a model system: polycarbonate printed in a simple rectangular shape. For the precursor material (as-received filament), we perform rheology, gel permeation chromatography, and dynamical mechanical analysis, to ascertain critical material parameters such as molar mass distribution, glass transition, and shear thinning. Following processing, we conduct X-ray computed tomography, scanning electron microscopy, depth sensing indentation, and atomic force microscopy modulus mapping. These measurements provide information related to pores, method of failure, and local modulus variations. Finally, we conduct tensile testing to assess strength and degree of anisotropy of mechanical properties. We find several effects that lead to degradation of tensile properties including the presence of pore networks, poor interfacial bonding, variations in interfacial mechanical behavior between rasters, and variable interaction of the neighboring builds within the melt state. The results provide insight into the processing-structure-property relationships and should serve as benchmarks for the development of mechanical models.

Multi-Energy X-Ray Tomography of an Optical Fiber: The Role of Spatial Averaging.

Using a commercial X-ray tomography instrument, we have obtained reconstructions of a graded-index optical fiber with voxels of edge length 1.05 µm at 12 tube voltages. The fiber manufacturer created a graded index in the central region by varying the germanium concentration from a peak value in the center of the core to a very small value at the core-cladding boundary. Operating on 12 tube voltages, we show by a singular value decomposition that there are only two singular vectors with significant weight. Physically, this means scans beyond two tube voltages contain largely redundant information. We concentrate on an analysis of the images associated with these two singular vectors. The first singular vector is dominant and images of the coefficients of the first singular vector at each voxel look are similar to any of the single-energy reconstructions. Images of the coefficients of the second singular vector by itself appear to be noise. However, by averaging the reconstructed voxels in each of several narrow bands of radii, we can obtain values of the second singular vector at each radius. In the core region, where we expect the germanium doping to go from a peak value at the fiber center to zero at the core-cladding boundary, we find that a plot of the two coefficients of the singular vectors forms a line in the two-dimensional space consistent with the dopant decreasing linearly with radial distance from the core center. The coating, made of a polymer rather than silica, is not on this line indicating that the two-dimensional results are sensitive not only to the density but also to the elemental composition.

The Influence of X-Ray Computed Tomography Acquisition Parameters on Image Quality and Probability of Detection of Additive Manufacturing Defects.

X-ray computed tomography (XCT) is a promising nondestructive evaluation technique for additive manufacturing (AM) parts with complex shapes. Industrial XCT scanning is a relatively new development, and XCT has several acquisition parameters that a user can change for a scan whose effects are not fully understood. An artifact incorporating simulated defects of different sizes was produced using laser powder bed fusion (LPBF) AM. The influence of six XCT acquisition parameters was investigated experimentally based on a fractional factorial designed experiment. Twenty experimental runs were performed. The noise level of the XCT images was affected by the acquisition parameters, and the importance of the acquisition parameters was ranked. The measurement results were further analyzed to understand the probability of detection (POD) of the simulated defects. The POD determination process is detailed, including estimation of the POD confidence limit curve using a bootstrap method. The results are interpreted in the context of the AM process and XCT acquisition parameters.

Comparison of Models for Heat Transfer in High-Density Fibrous Insulation.

This study evaluated different models for calculating the effective thermal conductivity of fibrous insulation by comparing predicted values with certified values of Standard Reference Material 1450c, Fibrous Glass Board. This comparison involved the coupled effects of radiation and conduction heat transfer. To support these comparisons, the fiber diameter distribution was measured using X-ray computed tomography, and this distribution was used in several heat transfer models considered in this paper. For the evaluation of the radiative heat transfer, the diffusion approximation, the Schuster-Schwarzschild approximation, and the Milne-Eddington approximation were considered. The conduction of the gas and the fibers was treated by the kinetic theory and a semi-empirical model, respectively. Two models were considered for the evaluation of the radiative properties: the large specular reflecting approach and the application of Mie theory for media composed of infinite cylinders.

AMB2018-04: Benchmark Physical Property Measurements for Powder Bed Fusion Additive Manufacturing of Polyamide 12.

Laser sintering (LS) of polyamide 12 (PA12) is increasingly being adopted for industrial production of end-use parts, yet the complexity of this process coupled with the lack of organized, rigorous, publicly available process-structure-physical property datasets exposes manufacturers and customers to risks of unacceptably poor part quality and high costs. Although an extensive scientific literature has been developed to address some of these concerns, results are distributed among numerous reports based on different machines, materials, process parameters, and users. In this study, a single commercially important LS PA12 feedstock has been processed along four build dimensions of a modern production LS machine, characterized by a wide range of physical techniques, and compared to the same material formed by conventional melt processing. Results are discussed in the context of the literature, offering novel insights including distributions of particle size and shape, localization of semicrystalline phase changes due to LS processing, effect of chemical aging on melt viscosity, porosity orientation relative to LS build axes, and microstructural effects on tensile properties and failure mechanisms. The resulting datasets will be made publicly available to modelers and practitioners for the purpose of improving certifiability and repeatability of end-use parts manufactured by LS.

Preliminary X-ray CT investigation to link Hounsfield unit measurements with the International System of Units (SI).

PURPOSE: This paper lays the groundwork for linking Hounsfield unit measurements to the International System of Units (SI), ultimately enabling traceable measurements across X-ray CT (XCT) machines. We do this by characterizing a material basis that may be used in XCT reconstruction giving linear combinations of concentrations of chemical elements (in the SI units of mol/m3) which may be observed at each voxel. By implication, linear combinations not in the set are not observable. METHODS AND MATERIALS: We formulated a model for our material basis with a set of measurements of elemental powders at four tube voltages, 80 kV, 100 kV, 120 kV, and 140 kV, on a medical XCT. The samples included 30 small plastic bottles of powders containing various compounds spanning the atomic numbers up to 20, and a bottle of water and one of air. Using the chemical formulas and measured masses, we formed a matrix giving the number of Hounsfield units per (mole per cubic meter) at each tube voltage for each of 13 chemical elements. We defined a corresponding matrix in units we call molar Hounsfield unit (HU) potency, the difference in HU values that an added mole per cubic meter in a given voxel would add to the measured HU value. We built a matrix of molar potencies for each chemical element and tube voltage and performed a singular value decomposition (SVD) on these to formulate our material basis. We determined that the dimension of this basis is two. We then compared measurements in this material space with theoretical measurements, combining XCOM cross section data with the tungsten anode spectral model using interpolating cubic splines (TASMICS), a one-parameter filter, and a simple detector model, creating a matrix similar to our experimental matrix for the first 20 chemical elements. Finally, we compared the model predictions to Hounsfield unit measurements on three XCT calibration phantoms taken from the literature. RESULTS: We predict the experimental HU potency values derived from our scans of chemical elements with our theoretical model built from XCOM data. The singular values and singular vectors of the model and powder measurements are in substantial agreement. Application of the Bayesian Information Criterion (BIC) shows that exactly two singular values and singular vectors describe the results over four tube voltages. We give a good account of the HU values from the literature, measured for the calibration phantoms at several tube voltages for several commercial instruments, compared with our theoretical model without introducing additional parameters. CONCLUSIONS: We have developed a two-dimensional material basis that specifies the degree to which individual elements in compounds effect the HU values in XCT images of samples with elements up to atomic number Z = 20. We show that two dimensions is sufficient given the contrast and noise in our experiment. The linear combination of concentrations of elements that can be observed using a medical XCT have been characterized, providing a material basis for use in dual-energy reconstruction. This approach provides groundwork for improved reconstruction and for the link of Hounsfield units to the SI.

Analysis of Different Computational Techniques for Calculating the Polarizability Tensors of Stem Cells with Realistic Three-Dimensional Morphologies.

Recently, the National Institute of Standards and Technology has developed a database of three-dimensional (3D) stem cell morphologies grown in ten different scaffolds to study the effect of the cells' environments on their morphologies. The goal of this work is to study the polarizability tensors of these stem cell morphologies, using three independent computational techniques, to quantify the effect of the environment on the electric properties of these cells. We show excellent agreement between the three techniques, validating the accuracy of our calculations. These computational methods allowed us to investigate different meshing resolutions for each stem cell morphology. After validating our results, we use a fast and accurate Pad' approximation formulation to calculate the polarizability tensors of stem cells for any contrast value between their dielectric permittivity and the dielectric permittivity of their environment. We also performed statistical analysis of our computational results to identify which environment generates cells with similar electric properties. The computational analysis and the results reported herein can be used for shedding light on the response of stem cells to electric fields in applications such as dielectrophoresis and electroporation and for calculating the electric properties of similar biological structures with complex 3D shapes.

Giant Surface Conductivity Enhancement in a Carbon Nanotube Composite by Ultraviolet Light Exposure.

Carbon nanotube composites are lightweight, multifunctional materials with readily adjustable mechanical and electrical properties-relevant to the aerospace, automotive, and sporting goods industries as high-performance structural materials. Here, we combine well-established and newly developed characterization techniques to demonstrate that ultraviolet (UV) light exposure provides a controllable means to enhance the electrical conductivity of the surface of a commercial carbon nanotube-epoxy composite by over 5 orders of magnitude. Our observations, combined with theory and simulations, reveal that the increase in conductivity is due to the formation of a concentrated layer of nanotubes on the composite surface. Our model implies that contacts between nanotube-rich microdomains dominate the conductivity of this layer at low UV dose, while tube-tube transport dominates at high UV dose. Further, we use this model to predictably pattern conductive traces with a UV laser, providing a facile approach for direct integration of lightweight conductors on nanocomposite surfaces.

A Q-Band Free-Space Characterization of Carbon Nanotube Composites.

We present a free-space measurement technique for non-destructive non-contact electrical and dielectric characterization of nano-carbon composites in the Q-band frequency range of 30 GHz to 50 GHz. The experimental system and error correction model accurately reconstruct the conductivity of composite materials that are either thicker than the wave penetration depth, and therefore exhibit negligible microwave transmission (less than -40 dB), or thinner than the wave penetration depth and, therefore, exhibit significant microwave transmission. This error correction model implements a fixed wave propagation distance between antennas and corrects the complex scattering parameters of the specimen from two references, an air slab having geometrical propagation length equal to that of the specimen under test, and a metallic conductor, such as an aluminum plate. Experimental results were validated by reconstructing the relative dielectric permittivity of known dielectric materials and then used to determine the conductivity of nano-carbon composite laminates. This error correction model can simplify routine characterization of thin conducting laminates to just one measurement of scattering parameters, making the method attractive for research, development, and for quality control in the manufacturing environment.