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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

The Mechanical and Corrosion Properties of Hot-Rolled TiB{sub 2}/Ni Composites

To quickly prepare TiB{sub 2}/Ni composites at low temperatures, a method combining spark plasma sintering and hot rolling was used. This paper presents the preparation, microstructural and mechanical properties, strengthening mechanism and corrosion properties of TiB{sub 2}/Ni composites in detail. X-ray diffraction analysis shows that the texture degree of the TiB{sub 2}/Ni composites after hot rolling greatly differed from that of the as-rolled pure Ni samples. The addition of TiB{sub 2} particles limited grain growth in the Ni matrix and led to grain refinement. Dislocation strengthening, grain refinement strengthening and load transfer strengthening contributed to a 30% increase in the tensile strength compared to that of the as-rolled pure Ni. In addition, the strengthening mechanism of the mechanical property reinforcement was analyzed. The electrochemical test results demonstrate that the as-rolled pure Ni exhibited a lower corrosion current density and corrosion resistance than the other as-rolled TiB{sub 2}/Ni composites fabricated in this paper. This work demonstrates a new approach for fabricating composites in less time at lower preparation temperatures than conventional methods.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Heating Rate during Continuous Annealing on Microstructure and Mechanical Properties of High-Strength Dual-Phase Steel

The study concerns the influence of heating rate during continuous annealing on microstructure and mechanical properties of high-strength ferrite–martensite dual-phase (DP) steel. The study suggests that the superheat (ΔT), carbon diffusion and distribution were strongly influenced by increasing the heating rate, leading to different microstructure and mechanical properties of DP steel. The morphology of martensite was observed to shift from network along ferrite grain boundaries to banded structure to uniformly dispersed, and the average ferrite grain size was refined from 5.3 to 2.0 µm. When the heating rate was 300 °C/s, the steel exhibited excellent mechanical properties with tensile strength (UTS) of 982 MPa, total elongation (TEL) of 17.5%, strength–elongation balance (UTS × TEL) of 17.2 GPa%, because of finer microstructure, uniform martensite distribution and low carbon content of martensite. Moreover, the precipitation strengthening effect of NbC is an important reason for the high-strength DP steels. In addition, the variation in strain-hardening behavior and fracture mechanism of steel subjected to different heating rates is discussed in relation to the microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Impact of Cryogenic Treatment on Mechanical Behavior and Microstructure of Ti-6Al-4V ELI Biomaterial

Ti-6Al-4V with its ELI variant is a potential biomaterial for structural implants. However, its poor resistance to plastic shearing results in poor tribological properties that hinders its widespread use in biomedical implants. Cryogenic treatment being an established technique for improving wear resistance and other mechanical properties of ferrous materials is applied on Ti-6Al-4V ELI alloy. To ensure comprehensive investigations, the widely studied microstructures of Ti-6Al-4V ELI, i.e., lamellar, martensite, two variants of bimodal and mill annealed are considered in this work. Deep cryogenic treatment at the soaking temperature (− 196 °C) for 24 h soaking time followed by tempering has been applied. The impact of cryogenic treatment has been assessed in terms of changes in the mechanical behavior including wear resistance, hardness, tensile properties and impact strength. The alterations in mechanical behavior due to cryogenic treatment are correlated with microstructure evolution. Cryogenic treatment has caused significant improvement in mechanical behavior of Ti-6Al-4V ELI alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Solution Heating Rate on Quasi-static and Dynamic Mechanical Properties of Al-Mg-Si-Cu Alloy

The effect of solution heating rate on quasi-static and dynamic mechanical properties of Al-Mg-Si-Cu alloy in bake hardening state was investigated through mechanical properties, microstructure and fracture morphology characterization in the present study. The results show that solution heating rate has a strong influence on microstructure, quasi-static and dynamic mechanical properties. As solution heating rate rises, the grain microstructure transforms from the elongated grains to equiaxed grains and the fraction of low-angle grain boundaries (LAGBs) also decreases. Moreover, the equivalent average grain size first decreases, and then increases. The relationship between solution heating rate and mechanical property is monotonic, not depending on strain rate. As solution heating rate rises, the yield strength, ultimate tensile strength and elongation decrease. In contrast to quasi-static loading, dynamic loading always tends to improve strengths and elongation. In addition, compared with the quasi-static tensile specimens, the dynamic tensile specimens possess a larger number of dislocations. Regardless of strain rate and solution heating rate, all the tensile specimens exhibit the ductile fracture mode. As solution rate rises, the dimples decrease and become shallow gradually. The dimples in dynamic fracture zone are larger and deeper than those in the quasi-static fracture zone.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Deep Cryogenic Treatment on the Mechanical Properties of Spring Steels

Leaf springs are mechanical elements responsible for supporting the vertical load on heavy duty vehicles. For this critical structural component, the required mechanical performance depends mainly on chemical composition and heat treatment. SAE 5160 and SAE 6140 steels are widely used as springs, because after heat treatments, the strength requirements of impact and fatigue are obtained. 51CrV4-ACF steel is another spring steel option which also exhibits excellent mechanical properties. The objective of this work was to study the influence of conventional heat treatments and cryogenic treatment on properties involving fatigue and impact resistance of spring steels. Furthermore, fracture toughness was measured for these materials, and the fracture surfaces were analyzed. The results showed that the cryogenic cycles used did not provide positive effects on spring steel performance. On the other hand, the chemical composition and the application of cleanliness technology promoted higher mechanical strength: Fracture toughness of 51CrV4-ACF was 100% higher than SAE 5160 steel.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mechanical Property Evaluation of CuNb Composites Manufactured with High-Pressure Torsion

Copper is under consideration as the optimum material for both high heat flux applications and high pulsed magnets. One challenge is that copper has low strength which is problematic to deployment in these applications. One solution is to alloy copper with BCC elements to improve its mechanical properties. However, the limited solubility of the BCC elements in copper requires high deformation processes to be used in order to manufacture these 3D composites. Here, high energy ball milling combined with high pressure torsion was used to manufacture 3D Cu-Nb composites. After the consolidation the mechanical properties of the composites were measured using micro- and nanohardness testing at room and elevated temperature. The results indicated that after 10 turns during the high-pressure torsion consolidation, the mechanical properties of the composites were completely saturated displaying uniform properties across the manufactured disk. Performing the high pressure torsion at temperature further improved consolidation of the disk. The high temperature nanoindentation also indicated a change in the deformation mechanism between 200 and 500 ºC.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Probing the Mechanical Performance of Micro-architected Porous Structures Through In Situ Characterization and Analysis

Micropores play critical roles in both natural and man-made materials. Such pores take on a variety of shapes and sizes ranging from spherical to irregular sphere-like voids with diameters spanning from the nanometer to millimeter scales. When porous structures are mechanically loaded, the pores direct the stress around their free surfaces, altering the material’s mechanical response relative to fully dense materials. In this study, for the first time, we create micro-architected porous samples using nanolithography and investigate the role of pore morphology by conducting a series of in situ micropillar compression tests in scanning electron microscopy. The findings demonstrate that porosity is the primary factor influencing the mechanical response of these micro-architected materials, as often seen on a macroscopic level. Additionally, we observed that pore geometry had a significant impact on Young’s modulus, yield stress, and strain energy density as a secondary parameter. Then, the extracted Young’s modulus was compared to macroscopic empirical models and determined the analytical models sufficiently described the impact of porosity in the microscopic scale but failed to capture the impact of second-order parameters. Furthermore, these results suggest how porous materials can be tailored to achieve desired mechanical properties based on the engineering applications of interest.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The Linkage Between Electro-Chemical Mechanical Instabilities in Battery Materials

Battery chemistry must be diversified to achieve a sustainable energy landscape by effectively utilizing renewable energy sources. Alkali metal-ion, all-solid-state, metal–air batteries, and multivalent batteries offer unique cost, safety, raw material abundance, energy, and power density solutions. However, realizing these “beyond Li-ion batteries” must uncover their working principles and performance & property relationships. In this aspect, mitigating chemo-mechanical instabilities in the structure and surface of the electrodes plays a crucial role in their performance. Unfortunately, the coupling between electrochemical and mechanical interactions is often poorly understood due to a lack of operando characterization. Here, this review article explains the working principles of curvature measurement and digital image correlation for measuring stress and strain generations in battery materials. We provided specific examples of how these operando mechanical measurements shed light on instabilities in alkali metal ion electrodes, solid electrolytes, Li-O 2 batteries, and aqueous Zn-ion batteries. Operando mechanical measurements offer an effective way to map changes in the physical fingerprint of the battery materials, therefore providing crucial information to elucidate instabilities in battery materials.

25 ENERGY STORAGE↗
DOE OSTI2019

Interactions between myocardial sympathetic denervation and left ventricular mechanical dyssynchrony: A CZT analysis

Background: A correlation between left ventricular (LV) dyssynchrony (LVD) and impaired myocardial sympathetic tone has been hypothesized. We sought to assess the interactions between regional LV sympathetic innervation, perfusion, and mechanical dyssynchrony. Methods: Eighty-three patients underwent evaluation of LV perfusion and sympathetic innervation on {sup 99m}Tc-tetrofosmin/{sup 123}I-metaiodobenzylguanidine ({sup 123}I-MIBG) imaging. The summed rest score and summed {sup 123}I-MIBG score (SS-MIBG) were computed. The extent of “innervation/perfusion” mismatch was defined as the number of denervated LV segments with relatively preserved perfusion. LVD was evaluated on phase analysis and the wall with latest mechanical activation identified. Results: LVD was revealed in 36 (43%) patients. Patients with LVD had more abnormal values of SRS (21 ± 9 vs 10 ± 8, P < 0.001) and SS-MIBG (29 ± 9 vs 17 ± 11, P < 0.001) than those without LVD. The presence of LVD also clustered with a higher burden of “innervation/perfusion” mismatch (P = 0.019). On per-wall analysis, LV walls with delayed mechanical activation showed a higher burden of “innervation/perfusion” mismatch (2.3 ± 1.4 segments) than normally contracting walls (1.3 ± 1.2 segments; P < 0.001). On multivariate analysis, the extent of “innervation/perfusion” mismatch was the only predictor of delayed mechanical activation (P = 0.029). Conclusions: Patients with LVD show an elevated burden of “innervation/perfusion” mismatch that is concentrated at the level of the most dyssynchronous walls.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2024

Microstructural Coarsening Kinetics and Mechanical Property Changes in Long-Term Aged Sn–Pb–Sb Solder Joints

Tin-lead-antimony (50Sn–47Pb–3Sb wt.%) soldered assemblies were mechanically tested approximately 30 years after initial production and found to have solder joints of reduced strength. The microstructure of this solder alloy exhibits a ternary eutectic structure with Sn-rich, Pb-rich, and SnSb phases. Accelerated aging was performed to evaluate solder microstructural coarsening and associated strength of laboratory solder joints to correlate these properties to the “naturally aged” solder joints. Isothermal aging was conducted at room temperature, 55, 70, 100, and 135 °C and aging times that ranged from 0.1 to 365 days. The coarsening kinetics of the Pb-rich phase were determined through optical microscopy and image analysis methods established in previous studies on binary Sn–Pb solder. A kinetic equation was developed with time exponent n of 0.43 and activation energy of 24000 J/mol, suggesting grain boundary diffusion or other fast diffusion pathways controlling the microstructural evolution. Compression testing and Vickers microhardness showed significant strength loss within the first 20–30 days after soldering; then, the microstructure and mechanical properties changed more slowly over long periods of time. Further, by combining accelerated aging data and the microstructure-based kinetics, strength predictions were made that match well with the properties of the actual soldered assemblies naturally aged for 30 years. However, aging at the highest temperature of 135 °C produced anomalous behavior suggesting that extraneous aging mechanisms are active. Therefore, data obtained at this temperature or higher should not be used. Overall, the combined microstructural and mechanical property methods used in this study confirmed that the observed reduction in strength of ~ 30-year-old solder joints can be accounted for by the microstructural coarsening that takes place during long-term solid-state aging.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Atomic-scale mechanisms of void strengthening in tungsten

Neutron and heavy-ion irradiation of tungsten produces nanometer-size vacancy voids, gas-filled bubbles and dislocation loops. These defect features can affect mechanical properties and the impact can be quite significant because of their high density. Understanding the basic mechanisms of mechanical properties degradation is necessary for predicting radiation effects. Predictions can be made using discrete dislocation dynamics or/and finite element approaches which, however, need local interaction mechanisms as inputs. Such knowledge can be provided only by atomic-scale modeling. This paper reports the results of an extensive atomic-scale modeling study of the interactions between moving edge dislocations and voids in tungsten. Furthermore, the main focus is on the effects of the void size and ambient temperature. Critical resolved shear stress was calculated for voids up to 9 nm in diameter. Atomistic results are compared with the theoretical approach and with those obtained earlier for voids in body centered cubic (bcc) iron. An important role of the void surface has been revealed.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Deformation mechanisms of a 20Mn TWIP steel investigated by in situ neutron diffraction and TEM

The deformation mechanisms and associated microstructure changes during tensile loading of an annealed twinning-induced plasticity (TWIP) steel with the chemical composition of Fe–20Mn–3Si–3Al–0.045C (wt.%) were systematically investigated using in situ time-of-flight (TOF) neutron diffraction in combination with postmortem transmission electron microscopy (TEM). The initial microstructure of the investigated alloy consists of equiaxed austenitic grains with the initial α´-phase of ~7% in volume. In addition to dislocation slip, twinning and two kinds of martensitic transformations from the austenite to α´- and epsilon martensites were observed as the main deformation modes during the tensile deformation. In situ neutron diffraction provides a powerful tool to establish the deformation mode map for elucidating the role of different deformation modes in different strain regions. The critical stress is 520 MPa for the martensitic transformation from the austenite to α´-martensite, whereas a higher stress (>600 MPa) is required for actuating the deformation twin and/or the martensitic transformation from -martensite. Both epsilon- and α´-martensites act as the hard phases whereas mechanical twinning contributes to both strength and ductility of the studied steel. TEM observations confirmed that the twinning process was facilitated by the parent grains orientated with <111> or <110> parallel to the loading direction. The nucleation and growth of twins are attributed to the pole and self-generation formation mechanisms, as well as the stair-rod cross-slip mechanism.

in situ neutron diffraction↗
DOE OSTI2015

Mechanical and Electrical Performance of Thermally Stable Au-ZnO films

The mechanical properties, thermal stability, and electrical performance of Au–ZnO composite thin films are determined in this work. The co-deposition of ZnO with Au via physical vapor deposition leads to grain refinement over that of pure Au; the addition of 0.1 vol.% ZnO reduces the as-grown grain size by over 30%. The hardness of the as-grown films doubles with 2% ZnO, from 1.8 to 3.6 GPa as measured by nanoindentation. Films with ZnO additions greater than 0.5% show no significant grain growth after annealing at 350 °C, while pure gold and smaller additions do exhibit grain growth and subsequent mechanical softening. Films with 1% and 2% ZnO show a decrease of approximately 50% in electrical resistivity and no change in hardness after annealing. A model accounting for both changes in the interface structure between dispersed ZnO particles and the Au matrix captures the changes in mechanical and electrical resistivity. Furthermore, the addition of 1–2% ZnO co-deposited with Au provides a method to create mechanically hard and thermally stable films with a resistivity less than 80 nΩ-m. Our results complement previous studies of other alloying systems, suggesting oxide dispersion strengthened (ODS) gold shows a desirable hardness–resistivity relationship that is relatively independent of the particular ODS chemistry.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Origin, parameters, and underlying deformation mechanisms of propagating deformation bands in irradiated 316L stainless steel

Lüders-type propagating deformation bands were observed in specimens of irradiated 316L stainless steel samples removed from Spallation Neutron Source target vessels after service. Mechanical testing with digital image correlation (DIC) and in-situ tensile testing with scanning electron microscopy electron backscatter diffraction showed that the observed Lüders-type behavior was not related to the known transformation-induced plasticity or twinning-induced plasticity behavior. Instead, the phenomenon occurs at small local strain values before a significant amount of martensite or deformation twins appear in the microstructure. Microstructural analysis and in-situ mechanical test results suggest Lüders-type band formation and propagation were related to the appearance and evolution of defect-free channels—analogous to slip bands. A modified Swift equation with a Ludwigson-like component was offered to rationalize the phenomenon and model the strain-softening processes at small strain values. Finally, the results indicate complex microstructural processes and deformation mechanisms were active at small strain values and underline the benefits of advanced mechanical test approaches such as DIC.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Compositional effects on cure kinetics, mechanical properties and printability of dual-cure epoxy/acrylate resins for DIW additive manufacturing

Interest in 3D printing of thermoset resins has increased significantly in recent years. One approach to additive manufacturing of thermoset resins is printing dual-cure resins with direct ink write (DIW). Dual-cure resins are multi-component resins which employ an in situ curable constituent to enable net-shape fabrication while a second constituent and cure mechanism contribute to the final mechanical properties of the printed materials. In this work, the cure kinetics, green strength, printability, and print fidelity of dual-cure epoxy/acrylate thermoset resins are investigated. Resin properties are evaluated as a function of acrylate concentration and in situ UV exposure conditions. The acrylate cure kinetics are probed using photo-differential scanning calorimetry and the impacts of resin composition and UV cure profile on the acrylate extent of conversion are presented. Continuous and pulsed UV cure profiles are shown to affect total conversion due to variances in radical efficiency at different UV intensities and acrylate concentrations. The effects of acrylate concentration on the kinetics of the epoxy thermal cure and the final mechanical properties are also investigated using dynamic mechanical analysis and three-point bend measurements. The glass transition temperature is dependent on formulation, with increasing acrylate content decreasing the T g . However, the room temperature shear moduli, flexural moduli, strength, strain-to-failure, and toughness values are relatively independent of resin composition. The similarity of the final properties allows for greater flexibility in resin formulation and in situ cure parameters, which can enable the printing of complex parts that require high green strength. We found that the in situ UV print intensities and exposure profiles that are necessary to achieve the best print quality are not, in most cases, the conditions that maximize conversion of the acrylate network. Lastly, this highlights the importance of developing optimized resin compositions which enable complete cure of the acrylate network by promoting acrylate dark cure or thermal cure.

36 MATERIALS SCIENCE↗
DOE OSTI2017

A numerical manifold method model for analyzing fully coupled hydro-mechanical processes in porous rock masses with discrete fractures

A numerical manifold method (NMM) model was developed for fully coupled analysis of hydro-mechanical (HM) processes in porous rock masses with discrete fractures. Using an NMM two-cover-mesh system of mathematical and physical covers, fractures are conveniently discretized by dividing the mathematical cover along fracture traces to physical cover, resulting in a discontinuous model on a non-conforming mesh. In this model, discrete fracture deformation (e.g. open and slip) and fracture fluid flow within a permeable and deformable porous rock matrix are rigorously considered. For porous rock, direct pore-volume coupling was modeled based on an energy-work scheme. For mechanical analysis of fractures, a fracture constitutive model for mechanically open states was introduced. For fluid flow in fractures, both along-fracture and normal-to-fracture fluid flow are modeled without introducing additional degrees of freedom. When the mechanical aperture of a fracture is changing, its hydraulic aperture and hydraulic conductivity is updated. At the same time, under the effect of coupled deformation and fluid flow, the contact state may dynamically change, and the corresponding contact constraint is updated each time step. Therefore, indirect coupling is realized under stringent considerations of coupled HM effects and fracture constitutive behavior transfer dynamically. To verify the new model, examples involving deformable porous media containing a single and two sets of fractures were designed, showing good accuracy. Finally, the model was applied to analyze coupled HM behavior of fractured porous rock domains with complex fracture networks under effects of loading and injection.

58 GEOSCIENCES↗
DOE OSTI2025

MURR LEU structural and thermal hydraulics analyses: Part II – Impacts of irradiation thermo-mechanical behavior on thermal hydraulics safety analyses

A series of structural analyses have been performed to support the conversion of the University of Missouri Research Reactor (MURR) from the use of highly enriched uranium (HEU; ≥20 wt% U-235) to low-enriched uranium (LEU; <20 wt% U-235) fuel. The irradiation thermo-mechanical analysis evaluated the effects of fuel swelling, irradiation creep, thermal expansion, as well as thermal resistance from the oxide layer growth for the MURR LEU element in prototypic thermal and irradiation conditions as presented in Part I of this article. Overall, this irradiation thermo-mechanical analysis predicts smaller gap thickness reductions in previously limiting regions, and larger reductions in the middle of the outermost end channels where power density is not typically a maximum. Due to substantial differences between the channel gap reductions assumed for the previous safety analyses and those predicted by the irradiation thermo-mechanical analysis, a need to evaluate their impact on the thermal hydraulics safety analyses arose. This article presents the results from the steady-state safety analysis for normal operation as well as the two most limiting accident scenarios. The calculation models were revised in order to account for the spatial and temporal variation of the channel gap thicknesses. The results show that sufficient safety margins are still maintained for normal operation as well as during the postulated accident transients. This work provides a methodology of incorporating the irradiation thermo-mechanical behavior of plate-type fuel into the thermal hydraulics safety analyses.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Twin-screw granulation: Mechanistic understanding of the effect of material properties on key granule quality attributes through the analysis of mixing dynamics and granulation rate mechanisms

This study focuses on understanding the effect of material properties on granule quality attributes through the analysis of mixing dynamics and granulation rate mechanisms. Powder wettability, binder viscosity, and liquid-to-solid (L/S) ratio were the factors that were investigated in this study. Further, the mixing occurring inside the twin-screw granulator (TSG) was quantitatively assessed by obtaining the axial dispersion coefficient from the experimentally measured residence time distribution (RTD) curves. It was observed that the quality of the nuclei fed to the kneading zone significantly affected the mixing dynamics. The quality of nuclei was governed by nucleation kinetics, which in turn was principally affected by the liquid saturation of the nuclei and the ratio of drop penetration time and encounter time, which in turn were affected by the L/S ratio and binder viscosity respectively. The hydrophobicity of the blend mainly affected the extent of nucleation. The type of nuclei entering the kneading zone and mixing dynamics in the TSG also determined whether the granulation growth mechanism was “layering-dominant” or “viscous-dominant”. It was also shown that the resultant granule quality attributes were a reflection of the growth mechanisms. Ultimately, a mechanistic link between material properties, mixing dynamics, granulation rate mechanisms, and granule quality attributes was established.

36 MATERIALS SCIENCE↗

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