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Cakmak, Ercan

Publications and source records attributed to Cakmak, Ercan.

54 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

In-situ x-ray computed tomography analysis of fracture mechanisms in ultrasonic additively manufactured Al-6061 alloy

The deformation and failure mechanisms in an ultrasonic additively manufactured Al-6061 alloy are studied using in-situ x-ray computed tomography during tensile deformation as well as ex-situ characterization with scanning electron microscopy. The role of pre-existing voids between the build layers on the failure mechanism is discussed with a focus on individual foil failures and void coalescence.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Processing and microstructure of ZrB 2 –SiC composite prepared by reactive spark plasma sintering

In-situ formation of ZrB 2 –SiC composites was investigated by reactive spark plasma sintering of precursor powders according to the reaction B4C + 2ZrC + 3Si → 3SiC + 2ZrB 2 . The reaction and process presented here involves a diffusion reaction between B4C and ZrC which facilitates the formation of ZrB 2 , while liquid phase sintering of silicon facilitates atomic diffusion and combines with free C from the B4C and ZrC reaction to form SiC within minutes of heating and there were some residual unreacted precursor materials. An interpenetrating matrix of ZrB 2 –SiC was formed that shows increased fracture toughness (6.03 ± 0.45 MPa m 1/2 ) despite relatively low density (95 %).

36 MATERIALS SCIENCE↗
DOE OSTI2021

Wear Mechanism Analysis of a New Rotary Shear Biomass Comminution System

A new biomass comminution system, Crumbler rotary shear, was developed to process fuel-grade biomass. The rotary shear is more efficient than the traditional hammer mill in comminuting high-moisture biomass and producing more uniform particles with minimal fines. However, the milling unit experiences significant wear in processing dirty woodchips. This study investigated the wear mechanisms of the rotary shear system based on analysis of the minerals carried by woodchips and characterization of actual worn components. Abrasive wear was found to be the dominant effect, and localized adhesive wear (material transfer), microfracture (chipping), and plastic deformation were additional effects. Connections have been made between the wear progression of key cutting components and the particle size change of biomass extrinsic minerals. On the basis of the wear mechanism understanding, mitigations based on advanced tool materials and optimized tool geometric designs are being developed for improving the tool life and cutting efficiency.

09 BIOMASS FUELS↗
DOE OSTI2021

Alumina-based filters made via binder jet 3D printing of alumina powder, colloidal silica infiltration, and sintering

Alumina-based, porous filter media was made via a binder jet 3D printing process consisting of an alumina powder printing step with subsequent heating, colloidal silica infiltration, drying, and sintering to consolidate particles yet retain a net open porous microstructure. The composites made were alumina-silica or alumina-mullite, where the silica sintering aid was used to densify and join the alumina particles. The resulting composite structures had open porosities in the 25–31 vol% range as measured by Archimedes density. Pressure drops were measured across the filter media at constant flow rates to compare disc shapes and complex, 3D printed filters based on the N95 design requirements. Complex, 3D-printed alumina composites were produced with acceptable pressure drops for N95 implementation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Compatibility of FeCrAlMo in Flowing Pb-Li at 600°C to 700°C

A series of monometallic thermal convection loops (TCLs) has been conducted to determine the maximum temperature where FeCrAl alloys have compatibility with eutectic lead lithium (Pb-Li) for a dual-coolant fusion blanket. Pre-oxidizing commercial alloy APMT (Fe-21Cr-5Al-3Mo) for 2 h at 1000°C to form a surface α-Al 2 O 3 layer was very effective in reducing the mass loss of specimens in the hot and cold legs of the most recent TCL that was operated for 1000 h with a peak temperature of 700°C. However, unlike previous experiments, the postexposure room temperature ductility of many of the APMT specimens was degraded to <10% total elongation, and many of the specimens at the highest temperature (>680°C) were severely damaged or were not recovered. Furthermore, wide-angle X-ray scattering found that the pre-formed α-Al 2 O 3 scale transformed to a mixture of trigonal and tetragonal LiAlO 2 . The overall results suggest that the maximum temperature for FeCrAl is limited to <700°C.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Development of a Reconstruction Methodology Based on X-Ray Computed Tomography to Generate Realistic 3D Concrete Microstructures in MOSAIC

Despite being passive components, concrete structures represent a major capital investment in nuclear power plants. However, some concrete components are critical for the safety and long-term operation of the reactors: the concrete containment building protects the reactors from external aggression. The concrete biological shield (CBS) contains the radiation exiting the reactor to protect equipment and personnel. Depending on the design, the CBS also has a function for supporting the reactor’s systems. This function needs to be ensured in-service and during accident scenarios. After several decades of use, the CBS is exposed to high-energy irradiation over an extended operation time, exceeding the fluence level currently considered detrimental for the concrete’s structural properties. Such conditions occur at different times depending on the reactor’s operation and design. Nevertheless, from the perspective of subsequent license application, it is mandatory to assess the potential effects of prolonged irradiation on concrete. Unlike steel components, concrete structures are built with local constituents (cement, sand, and coarse aggregates) to avoid prohibitive transportation costs. Thus, concrete performance is determined by the tolerance or the susceptibility of its constituents against any aging mechanism. The tolerance against irradiation of the CBSs may vary greatly among the 56 nuclear power plants and 93 nuclear power reactors that form the current US light-water reactor fleet. Irradiation-induced degradation is mainly a result of amorphization-induced expansions of the silicated minerals present in the aggregates. The neutron irradiation–induced expansion varies from one rock-forming mineral to another: well framework–structured silicates (e.g., quartz and feldspars) exhibit higher swelling than chained (e.g., pyroxene) or isolated silicates (e.g., garnet). Silicates make up nearly 90% of the Earth’s crust. Other common minerals present in construction aggregates are carbonates found, for example, in limestone. Irradiated carbonates exhibit only very minor expansions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

A Tracer Study on sCO2 Corrosion with Multiple Oxygen-Bearing Impurities

Abstract Several modern power production systems utilize supercritical CO 2 (sCO 2 ), which can contain O 2 and H 2 O as impurities. These impurities may degrade the compatibility of structural alloys through accelerated oxidation. However, it remains unclear which of these impurities plays a bigger role in high-temperature reactions taking place in sCO 2 . In this study, various model and commercial Fe‐ and Ni‐based alloys were exposed in 300 bar sCO 2 at 750 °C to low levels (50 ppm) of O 2 and H 2 O for 1,000 h. 18 O-enriched water was used to enable the identification of the oxygen source in the post-exposure characterization of the samples. However, oxygen from the water did not accumulate in the scale, which consisted of Cr 2 O 3 in the cases where a protective oxide formed. A 2wt.% Ti addition to a Ni-22%Cr model alloy resulted in the formation of thicker oxides in sCO 2 , while a 1wt.% Al addition reduced the scale thickness. A synergistic effect of both Al and Ti additions resulted in an even thicker oxide than what was formed solely by Ti, similar to observations for Ni-based alloy 282.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Investigating the effect of different shielding gas mixtures on microstructure and mechanical properties of 410 stainless steel fabricated via large scale additive manufacturing

Metal Big Area Additive Manufacturing (mBAAM) offers the potential to fabricate large scale tools at high deposition rates (15 lb/h+). 410 martensitic steel is a potential tooling material, owing to its low cost, good machinability and reasonable printability. During the mBAAM process, the shielding gas can have a significant impact on the material properties as well as the process cost. Therefore, the current study aims to understand the effect of different shielding gas mixtures on large-scale additive manufacturing of 410 martensitic stainless steel. We show that an argon mixture with 3% nitrogen gas produced the best performance in terms of maximum hardness and tensile strength, with much less scatter in tensile strength. He-Ar-CO 2 or tri-mix shielded samples showed a low tensile strength with wide scatter, due to stabilized delta ferrite in microstructure during printing. Both tri-mix and Ar-CO 2 shielded samples showed slightly higher porosity. Thus, we recommend the use of argon-3% nitrogen as a shielding gas mixture for processing 410 steel for tool applications, based on the relatively low cost of this gas mixture and the resulting higher hardness, higher dimensional stability, and lower porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Surface-modified and oven-dried microfibrillated cellulose reinforced biocomposites: Cellulose network enabled high performance

Microfibrillated cellulose (MFC) is widely used as a reinforcement filler for biocomposites due to its unique properties. However, the challenge of drying MFC and the incompatibility between nanocellulose and polymer matrix still limits the mechanical performance of MFC-reinforced biocomposites. In this study, we used a water-based transesterification reaction to functionalize MFC and explored the capability of oven-dried MFC as a reinforcement filler for polylactic acid (PLA). Remarkably, this oven-dried, vinyl laurate–modified MFC improved the tensile strength by 38 % and Young’s modulus by 71 % compared with neat PLA. Our results suggested improved compatibility and dispersion of the fibrils in PLA after modification. This study demonstrated that scalable water-based surface modification and subsequent straightforward oven drying could be a facile method for effectively drying cellulose nanomaterials. We find that the method helps significantly disperse fibrils in polymers and enhances the mechanical properties of microfibrillar cellulose-reinforced biocomposites.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Hydrogen Diffusivity Measurements of YH 1.87 Moderator Material with Incoherent Quasielastic Neutron Scattering

Yttrium hydride is an optimal choice of moderator material for thermal neutron spectrum reactors requiring small core volumes. The Transformation Challenge Reactor (TCR) program at Oak Ridge National Laboratory (ORNL) aims to develop an additively manufactured microreactor core by leveraging recent advances in materials, manufacturing, data analytics, and high-fidelity modeling and simulation. Yttrium hydride was selected as the moderator material for TCR due to its high moderating power, which enables the spatially efficient reactor design and thermal stability that is superior when compared with zirconium hydride. Hydrogen desorption from yttrium hydride is expected at elevated temperatures, posing safety and performance concerns. As a lifetime component in advanced reactors, appropriate strategies to mitigate hydrogen release from yttrium hydride over long-term reactor operation are required. Understanding hydrogen mobility in yttrium hydride provides the scientific basis for developing a hydrogen barrier for hydride moderator and predicting the hydrogen redistribution within the material during various operational conditions. This study investigated the hydrogen motion in YH 1.87 as a function of temperature ranging from 200 to 1,173 K using incoherent quasielastic neutron scattering (IQNS) at the Spallation Neutron Source (SNS). The results are presented and discussed in terms of hydrogen self-diffusion coefficients, activation energy for translational hydrogen motion, and hydrogen jump distances. Based on the IQNS data, YH 1.87 is found to be stable at high temperatures with no translational H motion below 1,023 K within the IQNS detection limits. In the temperature range of 1,073–1,173 K, hydrogen diffusivity in YH 1.87 is $D = 4.57 X 10^{⁻3} [m^2/s] exp (⁻\frac{1.73[eV]}{RT}$). The hydrogen concentration’s dependence on hydrogen diffusivity is also discussed in this report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

High-performance molded composites using additively manufactured preforms with controlled fiber and pore morphology

Here, large-scale multimaterial preforms produced by additive manufacturing (AM) underwent compression molding (CM) to produce high-performance thermoplastic composites reinforced with short carbon fibers. AM and CM techniques were integrated to control the fiber orientation (microstructure) and to reduce void content for the improved mechanical performance of the composite. The new integrated manufacturing technique is termed “additive manufacturing-compression molding” (AM-CM). For the present study, the most common materials were used for large-scale printing, i.e., acrylonitrile butadiene styrene (ABS), carbon fiber (CF)–filled ABS (CF/ABS) and glass fiber (GF)–filled ABS (GF/ABS). Three different manufacturing processes; (a) AM (b) extrusion compression molding (ECM), and (c) AM-CM were used to prepare four different panel configurations: (1) neat ABS, (2) CF/ABS, (3) overmold (CF/ABS over neat ABS), and (4) sandwich (neat ABS between two CF/ABS layers). The mechanical properties (tensile and flexural strength and modulus, and Izod impact energy) of samples prepared via all three manufacturing processes were compared. X-ray microcomputer tomography was employed to evaluate the fiber orientation distribution and the volumetric porosity content. The preform maintained high fiber alignment (≈ 82% of fibers within the range of 0–20° in the deposition direction), and the volumetric porosity was reduced by 50% from 3.79% to 1.91% after compression. The alignment of long pores along the deposition direction was also observed. The mechanical properties are discussed with correlation to the fiber alignment and void content in the samples. CF/ABS samples prepared by AM-CM showed significant improvement of 11.15%, 35.27%, 28.6%, and 74.3% in the tensile strength, tensile modulus, flexural strength, and flexural modulus, respectively, when compared with samples prepared by ECM. Unique aspects of this study are the demonstration of large-scale multimaterial AM and the use of multimaterials as preforms to make high-performance composites.

36 MATERIALS SCIENCE↗
DOE OSTI2020

On the nonlinear temperature dependence of residual stresses in solid oxide fuel cells

The residual stresses in a dense yttria-stabilized zirconia (YSZ) layer bonded to a porous NiO-YSZ substrate were measured by X-ray diffraction in air between 25°C and 900°C. In this work, it was found that the residual stresses on the outer surface of the YSZ layer were compressive, that their magnitude increased with decreasing temperature, and that the temperature dependence was nonlinear particularly at temperatures below 600°C. An elastic model that incorporates micromechanics and laminate theory was formulated to successfully predicts the nonlinearity of the temperature dependence of the residual stresses by accounting for the effect of the order-disorder transition experienced by YSZ around 600°C and the magnetic transition of NiO at the Néel temperature around 265°C, on the properties of these materials. The implications of the results for the reliability of solid oxide fuel cells are discussed.

25 ENERGY STORAGE↗
DOE OSTI2020

Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime

The addition of an air plasma sprayed (APS) “flash” layer on top of a high velocity oxygen fuel (HVOF) bond coating has been shown to extend the lifetime of thermal barrier coatings. A series of furnace cycle tests (FCTs) has been conducted at 1100 °C in air + 10% H 2 O to study the benefit of flash coatings on rod and disk alloy 247 specimens and provide a better mechanistic understanding of their benefit. Flash coatings of NiCoCrAlY and NiCoCrAlYHfSi both improved the FCT lifetime of rod specimens tested in 100-h cycles and disk specimens tested in 1-h cycles. In 1-h cycles, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. Both flash coatings increased the bond coating roughness compared to HVOF. During exposure, the flash layer formed an intermixed alumina-metal layer that appeared to inhibit crack formation. Using a time series of observations, the lower Y + Hf content in the Y-only flash coating appeared to reduce Al consumption. The HVOF layer acted as a source of Al for the adjacent mixed zone. A second series of specimens included a fully APS bond coating where oxide had penetrated through the entire coating to the substrate after only 100, 1-h cycles and lifetime was similar to an HVOF-only bond coating. The inner HVOF layer with the outer APS flash coating prevented this complete penetration from occurring.

Pint, Bruce↗
DOE OSTI2020

Investigation on capacity loss mechanisms of lithium-ion pouch cells under mechanical indentation conditions

Capacity loss was observed in Li-ion cells after mechanical deformation approaching the onset of internal short circuit (ISCr). In this paper, a series of indentation tests were carried out on commercial Li-ion cells of three capacities (500, 1500 and 2000 mAh). Both in-situ and ex-situ methods were used to investigate the mechanisms of indentation-induced capacity loss. We note after indentation test, the cell capacity reduced by 0.5%–6% of its original value. The incremental capacity (IC) analysis results showed that IC curves generally shifted to lower voltage region, indicating the increase in cell internal resistance. In addition, the fitting results of electrochemical impedance spectroscopy (EIS) indicated that mechanical indentation can result in a reduction in ohmic resistance and the increase in polarization resistance. Scanning electron microscopy (SEM) and X-ray computed tomography (XCT) results showed crushing of graphite, mud cracking of copper current collectors and enlarged pores in separator, which is proposed to be the main reasons for the increase in polarization resistance and permanent capacity loss. The rapid capacity loss due to mechanical abuse was compared with the long-term capacity fading.

25 ENERGY STORAGE↗
DOE OSTI2020

Internal short circuit and failure mechanisms of lithium-ion pouch cells under mechanical indentation abuse conditions: An experimental study

Electromechanical structural integrity and thermal stability dictate the safety performance of lithium-ion batteries. Progressive deformation and failure across microscopic and macroscopic lengths scales that are responsible for internal short circuit (ISC) in lithium-ion cells under mechanical abuse conditions remains elusive. In this study, a series of indentation tests were conducted on lithium-ion cells with different capacities up to the occurrence of ISC. The external response and internal configuration of these cells were investigated. It is discovered that cells with different capacities and state of charges exhibited different behaviors. Maximum temperature, which is often regarded as the most important parameter related to thermal runaway (TR), varied considerably due to the complicated contact configurations. X-ray computed tomography (XCT) showed that ISC was a collective result of shear band or other strain-localization modes in the electrode assembly, shear offsets in the granular coatings of electrodes, and the accompanying ductile fracture in the metal foils. We believe that the irregular strain-localization modes (kinks, cusps, and buckles), radical mismatches in mechanical properties of different layers, and geometric features of the indenter eventually lead to the tearing/puncture of cell separator at various locations. Furthermore, the results could provide useful guidance for the micromechanical modeling of lithium-ion cells.

25 ENERGY STORAGE↗
DOE OSTI2020

Composition-Preserving Extraction and Characterization of Biomass Extrinsic and Intrinsic Inorganic Compounds

The inorganic content of biomass impairs size reduction tool life and the conversion process. Conventional ash extraction relies on furnace combustion that inevitably alters the inorganic compounds due to oxidation and decomposition. This study developed composition-preserving methods for extracting and analyzing extrinsic and intrinsic inorganic compounds. Comprehensive characterization was carried out on selected biomass feedstocks, including corn stover, pine residue, and pine anatomical fractions, to reveal their inorganic species and morphology. The extrinsic inorganic compounds were found to be dominated by quartz, along with other minor minerals, such as albite, microcline, and gehlenite, and have particle sizes ranging from tens to hundreds of micrometers. Among the pine anatomical fractions, the needles contain the highest intrinsic silicon content while the bark trapped the most extrinsic minerals. By correlation of the total ash and extrinsic inorganic contents to the wear behavior, both the extrinsic and intrinsic inorganic compounds were concluded to have made significant contributions to the wear process. Finally, the results here validated a new approach to characterize inorganic compounds in biomass and provided fundamental insights for their potential impact on preprocessing tool wear.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗