Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “DUCTILITY”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Study of hydride reorientation and ductility of SRA ZIRLO and PRXA ZIRLO using ring compression testing (RCT)

Before dry storage, spent nuclear fuel is dried at high temperatures, which induces hydride dissolution. Radial hydride particles precipitate when cooled under a stress above a threshold stress. This process can severely degrade the ductility of cladding tubes. Zirconium alloys with different microstructures, such as grain boundary density, were quantified and studied to examine their effect on hydride reorientation. The ring compression loading mode creates a range of stress states depending on the location within the ring with respect to the applied load, producing various hydride morphologies that can be used to study the effects of microstructures on hydride reorientation. Finite element modeling was performed to calculate the hoop stress, which is the dominant stress, during hydride reorientation. These results were coupled with hydride morphology to determine the threshold stress for hydride reorientation, depending on the microstructure. In conclusion, the samples were then mechanically tested using ring compression to evaluate the ductility of zirconium alloys as a function of different hydride morphologies.

Hydride embrittlement↗
DOE OSTI2018

Microstructural strain mapping during in-situ cyclic testing of ductile iron

Highlights: • A method for quantitative study of crack formation and propagation during cyclic loading was developed. • Focused Ion Beam Milling was shown to be an effective method to generate a high quality speckle pattern for Digital Image Correlation measurements • The method enabled a high-resolution measurement of localized strain in the microstructure of ductile iron • The peak strain and the strain distribution ahead of the growing crack under load were quantified - Abstract: This paper focuses on local strain distribution in the microstructure of high silicon ductile iron during cyclic loading. In-situ cyclic test was performed on compact-tension (CT) samples inside the scanning electron microscope (SEM) to record the whole deformation and obtain micrographs for microstructural strain measurement by means of digital image correlation (DIC) technique. Focused ion beam (FIB) milling was used to generate speckle patterns necessary for DIC measurement. The equivalent Von Mises strain distribution was measured in the microstructure at the maximum applied load. The results revealed a heterogeneous strain distribution at the microstructural level with higher strain gradients close to the notch of the CT sample and accumulated strain bands between graphite particles. Local strain ahead of the early initiated micro-cracks was quantitatively measured, showing high strain localization, which decreased by moving away from the micro-crack tip. It could be observed that the peak of strain in the field of view was not necessarily located ahead of the micro-cracks tip which could be because of the (i) strain relaxation due to the presence of other micro-cracks and/or (ii) presence of subsurface microstructural features such as graphite particles that influenced the strain concentration on the surface.

36 MATERIALS SCIENCE↗
DOE OSTI2020

AA2024/SiC metal matrix composites simultaneously improve ductility and cracking resistance during elevated temperature deformation

Here this study uses the stir-casting technique to combine a semi-solid AA2024 alloy directly with finely-sized β-SiC p embedded as a powder or with mechanically alloyed granules as a delivery agent. Liquid-state primary fabrication tends to form agglomerates of reinforcement particles, whereas rolling better distributes the composite constituents. Sub-micron reinforcements of low volume fractions do not significantly increase the hardness of the composite materials. Uniaxial tensile testing at elevated temperatures over a wide range of strain rates showed simultaneous increases in the ductility and crack resistance of AA2024 + SiC p granules embedded as a powder when compared to the non-reinforced control material at lower strain rates, with the same toughness as the control material. The maximum engineering strain of 252.7 ± 19.2% was observed in AA2024/SiCp at a strain rate of 10 -4 s -1 . This improvement in properties is attributed to grain refinement in the MMCs, leading to pinning events during the straining and ductility increases. The resultant impediments to grain growth and crack propagation allow the fine-sized reinforcements to control dynamic microstructural changes during fatigue. Cube {001}<100> is a dominant texture component in AA2024, whereas the Goss {011}<100> and S {123}<634> components mainly represent the texture of the discontinuously reinforced aluminum matrix.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A lightweight Fe–Mn–Al–C austenitic steel with ultra-high strength and ductility fabricated via laser powder bed fusion

Lightweight Fe–Mn–Al–C steels have become a topic of significant interest for the defense and automotive industries. These alloys can maintain high strength and ductility while also reducing weight in structural applications. Conventionally processed Fe–Mn–Al–C austenitic steels with high Al content (~9 wt%) demonstrate greater than 1.5 GPa strength with 35% elongation. Several recent studies have demonstrated success in fabricating steel parts using laser powder bed fusion (L-PBF) additive manufacturing (AM), which can generate near-net-shape components with complex geometries and is capable of local microstructural control. However, studies on L-PBF processing of Fe–Mn–Al–C alloys have focused on low Al content (<5 wt%) compositional regimes representing alloys that undergo transformation-induced plasticity (TRIP) and twinning-induced plasticity (TWIP). Here, in this study, we present the effects of L-PBF processing on the microstructure and mechanical properties of an Fe–30Mn–9Al–1Si-0.5Mo-0.9C austenitic steel. A process optimization framework is employed to determine an ideal L-PBF processing space that will result in >99% density parts. Implementing this framework resulted in near-fully dense specimens fabricated over a broad range of process parameters. Additionally, two bi-directional scan rotation strategies (90° and 67°) were applied to understand their effects on texture and anisotropy in this material. As-printed specimens displayed considerable work-hardening characteristics with average strengths of up to 1.3 GPa and 36% elongation in the build direction. However, solidification microcracks oriented in the build direction resulted in anisotropy in tensile strength and ductility resulting in average strengths of 1.1 GPa and 20% elongation perpendicular to the build direction. The successful L-PBF fabrication of Fe–30Mn–9Al–1Si-0.5Mo-0.9C presented here is expected to open new avenues for weight reduction in structural applications with a high degree of control over part topology.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Departing from the mutual exclusiveness of strength and ductility in nanocrystalline metals with vacancy induced plasticity

We report that strength and ductility are mutually exclusive in metallic materials. To break this relationship, we start with nanocrystalline Zirconium with very high strength and low ductility. We then ion irradiate the specimens to introduce vacancies, which promote diffusional plasticity without reducing strength. Mechanical tests inside the Transmission Electron Microscope reveal about 300% increase in plastic strain after self ion-irradiation. Molecular dynamics simulation showed that 4.3% increase in vacancies near the grain boundaries can result in about 60% increase in plastic strain. Finally, both experimental and computational results support our hypothesis that vacancies may enhance plasticity through higher atomic diffusivity at the grain boundaries.

36 MATERIALS SCIENCE↗
DOE OSTI2024

An intrinsic ductility parameter derived from anisotropic linear elasticity theory

A new indicator of intrinsic ductility (κ) is introduced based on linear elasticity. In the limit of elastic isotropy this parameter is equal to the Pugh ratio ( B / G ) plus a constant; but unlike the Pugh ratio, κ incorporates anisotropy and crystallography to improve predictive value. We identify a single ductile-to-brittle transition setpoint for κ that predicts crack-tip plasticity in atomistic simulations, experimental elongation to failure of polycrystalline elemental metals pulled in tension, and fracture energy measurements of glasses, suggesting commonality in the relationship between plasticity and fracture across all three of these cases. Statistical analysis supports the superiority of κ over B / G at predicting crack-tip plasticity in atomistic simulations and elongation to failure of polycrystalline elemental metals.

Winter, Ian S.↗
DOE OSTI2025

Photo-oxidation of semicrystalline polymers: Effect of stress triaxiality on ductility

The effect of stress triaxiality on the strain-to-fracture of as-received and photo-oxidized polyamide-6 (PA-6) was investigated using mechanical testing, synchrotron X-ray tomography, and finite element analyses. Mechanical tests were conducted on cylindrical and round notched specimens, where different notch radii were used to vary the stress triaxiality. The specimens were aged by exposure to ultra-violet (UV) radiation at 60∘, causing photo-oxidation. As-received and so-aged specimens were loaded to failure (complete loss of load carrying capacity). For both unaged and aged specimens, a higher triaxiality led to a lower strain-to-fracture. To elucidate the micromechanical damage that mediates fracture in both conditions, specimens with an intermediate notch sharpness were loaded to the peak load, unloaded, and scanned ex situ using synchrotron X-ray tomography. Damage in the unaged bar was found to occur by cavitation and was concentrated at the center of the specimen, where the triaxiality is highest. In the UV-aged bar, a network of inter-connected chemical cracks were found on the notch surface, where the triaxiality is lowest. Finite element analyses were deployed to approximate the local triaxiality at damaged regions in the unaged and UV-aged specimens using a constitutive relation for semicrystalline polymers. From these analyses, the relationship between local triaxiality and strain-to-fracture was quantified for both unaged and photo-oxidized PA-6. Both unaged and photo-oxidized PA-6 showed similar decreases in ductility with triaxiality, hinting at common ductile fracture processes.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Polystyrene Glasses under Compression: Ductile and Brittle Responses

Polystyrene of different molecular weights and their binary mixtures are studied in terms of their various mechanical responses to uniaxial compression at different temperatures. PS of Mw = 25 kg/mol is completely brittle until it is above its glass transition temperature Tg. In contrast, upon incorporation of a high molecular weight component, PS mixtures turn from barely ductile a few degrees below its Tg to ductile over 40 below Tg. In the upper limit, a PS of Mw = 319 kg/mol yields and undergoes plastic flow, even at T = 70 C. The observed dependence of mechanical responses on molecular weight and molecular weight distribution can be adequately rationalized by the idea that yielding and plastic compression are caused by chain networking.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Brittle-to-Ductile Transition Temperature Decreases at the Microscale in Muscovite Mica

Characterizing the structural and chemical transitions of muscovite mica across various scales and thermal profiles is essential for ensuring the reliability of high-voltage power insulation, aerospace thermal barriers, and nanoscale semiconductor substrates under extreme operational stress. Here, we investigate notch fracture toughness $K^{n}_{Ic}$ of muscovite mica as a function of feature size w and temperature T with microscale shear testing. $K^{n}_{Ic}$ decreased and then stayed constant as w increased, likely from fabrication-induced changes to the microstructure and roughness. Moreover, $K^{n}_{Ic}$ initially decreased and then increased as temperature T increased, with the reversal in trend indicative of a brittle-to-ductile transition. Complementary Raman spectroscopy and molecular dynamics showed that the observed trends were due to an increase in bond lengths and a decrease in critical stresses/strains. In comparing the microscale results to macroscale counterparts, it was surmised that the decrease in brittle-to-ductile transition temperature was due to an increase in the dehydroxylation rate.

DelRio, Frank W. [Sandia National Laboratories (SN↗
DOE OSTI2013

Designing tensile ductility in metallic glasses

Effectiveness of a second phase in metallic glass heterostructures to improve mechanical properties varies widely. Unfortunately, methods to fabricate such heterostructures like foams and composites do not allow controlled variation of structural features. Here we report a novel strategy, which allows us to vary heterostructural features independently, thereby enabling a systematic and quantitative study. Our approach reveals the optimal microstructural architecture for metallic glass heterostructures to achieve tensile ductility. Critical design aspect is a soft second phase, which is most effective when spacing between the second phase assumes the critical crack length of the metallic glass. This spacing should coincide with the second phase’s size, and beyond, the specific second phase morphology of the heterostructure is crucial. These toughening strategies are only effective in samples that are large compared with the spacing of the second phase. The identified design aspects provide guidance in designing tensile ductility into metallic glasses.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Dual heterogeneous structures lead to ultrahigh strength and uniform ductility in a Co-Cr-Ni medium-entropy alloy

Alloys with ultra-high strength and sufficient ductility are highly desired for modern engineering applications but difficult to develop. Here we report that, by a careful controlling alloy composition, thermomechanical process, and microstructural feature, a Co-Cr-Ni-based medium-entropy alloy (MEA) with a dual heterogeneous structure of both matrix and precipitates can be designed to provide an ultra-high tensile strength of 2.2 GPa and uniform elongation of 13% at ambient temperature, properties that are much improved over their counterparts without the heterogeneous structure. Electron microscopy characterizations reveal that the dual heterogeneous structures are composed of a heterogeneous matrix with both coarse grains (10~30 μm) and ultra-fine grains (0.5~2 μm), together with heterogeneous L1 2 -structured nanoprecipitates ranging from several to hundreds of nanometers. The heterogeneous L1 2 nanoprecipitates are fully coherent with the matrix, minimizing the elastic misfit strain of interfaces, relieving the stress concentration during deformation, and playing an active role in enhanced ductility.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Phase-field framework with constraints and its applications to ductile fracture in polycrystals and fatigue

Abstract Modeling of ductile fracture in polycrystalline structures is challenging, since it requires integrated modeling of cracks, crystal plasticity, and grains. Here we extend the typical phase-field framework to the situations with constraints on the order parameters, and formulate two types of phase-field models on ductile fracture. The Type-I model incorporates three sets of order parameters, which describe the distributions of cracks, plastic strain, and grains, respectively. Crystal plasticity is employed within grain interiors accommodated by J 2 plasticity at grain boundaries. The applications of the Type-I model to single crystals and bicrystals demonstrate the influences of grain orientations and grain boundaries on crack growth. In the Type-II model, J 2 plasticity is assumed for the whole system and grain structures are neglected. Taking advantage of the efficiency of the fast Fourier transform, our Type-II model is employed to study low cycle fatigue. Crack closure and striation-like patterning of plastic strain are observed in the simulations. Crack growth rate is analyzed as a function of the J -integral, and the simulated fatigue life as a function of plastic strain agrees with the Coffin–Manson relation without a priori assumption.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Tailoring planar slip to achieve pure metal-like ductility in body-centred-cubic multi-principal element alloys

Uniform tensile ductility (UTD) is crucial for the forming/machining capabilities of structural materials. Normally, planar-slip induced narrow deformation bands localize the plastic strains and hence hamper UTD, particularly in body-centred-cubic (bcc) multi-principal element high-entropy alloys (HEAs), which generally exhibit early necking (UTD < 5%). Here we demonstrate a strategy to tailor the planar-slip bands in a Ti-Zr-V-Nb-Al bcc HEA, achieving a 25% UTD together with nearly 50% elongation-to-failure (approaching a ductile elemental metal), while offering gigapascal yield strength. The HEA composition is designed not only to enhance the B2-like local chemical order (LCO), seeding sites to disperse planar slip, but also to generate excess lattice distortion upon deformation-induced LCO destruction, which promotes elastic strains and dislocation debris to cause dynamic hardening. Further, this encourages second-generation planar-slip bands to branch out from first-generation bands, effectively spreading the plastic flow to permeate the sample volume. Moreover, the profuse bands frequently intersect to sustain adequate work-hardening rate (WHR) to large strains. Our strategy showcases the tuning of plastic flow dynamics that turns an otherwise-undesirable deformation mode to our advantage, enabling an unusual synergy of yield strength and UTD for bcc HEAs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Strong yet ductile nanolamellar high-entropy alloys by additive manufacturing

Additive manufacturing produces net-shaped components layer by layer for engineering applications. The additive manufacture of metal alloys by laser powder bed fusion (L-PBF) involves large temperature gradients and rapid cooling, which enables microstructural refinement at the nanoscale to achieve high strength. However, high-strength nanostructured alloys produced by laser additive manufacturing often have limited ductility. In this work, we use L-PBF to print dual-phase nanolamellar high-entropy alloys (HEAs) of AlCoCrFeNi 2.1 that exhibit a combination of a high yield strength of about 1.3 gigapascals and a large uniform elongation of about 14 percent, which surpasses those of other state-of-the-art additively manufactured metal alloys. The high yield strength stems from the strong strengthening effects of the dual-phase structures that consist of alternating face-centred cubic and body-centred cubic nanolamellae; the body-centred cubic nanolamellae exhibit higher strengths and higher hardening rates than the face-centred cubic nanolamellae. The large tensile ductility arises owing to the high work-hardening capability of the as-printed hierarchical microstructures in the form of dual-phase nanolamellae embedded in microscale eutectic colonies, which have nearly random orientations to promote isotropic mechanical properties. The mechanistic insights into the deformation behaviour of additively manufactured HEAs have broad implications for the development of hierarchical, dual- and multi-phase, nanostructured alloys with exceptional mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Response and representation of ductile damage under varying shock loading conditions in tantalum

The response of polycrystalline metals, which possess adequate mechanisms for plastic deformation under extreme loading conditions, is often accompanied by the formation of pores within the structure of the material. This large deformation process is broadly identified as progressive with nucleation, growth, coalescence, and failure the physical path taken over very short periods of time. These are well known to be complex processes strongly influenced by microstructure, loading path, and the loading profile, which remains a significant challenge to represent and predict numerically. In the current study, the influence of loading path on the damage evolution in high-purity tantalum is presented. Tantalum samples were shock loaded to three different peak shock stresses using both symmetric impact, and two different composite flyer plate configurations such that upon unloading the three samples displayed nearly identical “pull-back” signals as measured via rear-surface velocimetry. While the “pull-back” signals observed were found to be similar in magnitude, the sample loaded to the highest peak stress nucleated a connected field of ductile fracture which resulted in complete separation, while the two lower peak stresses resulted in incipient damage. The damage evolution in the “soft” recovered tantalum samples was quantified using optical metallography, electron-back-scatter diffraction, and tomography. These experiments are examined numerically through the use of a model for shock-induced porosity evolution during damage. The model is shown to describe the response of the tantalum reasonably well under strongly loaded conditions but less well in the nucleation dominated regime. As a result, numerical results are also presented as a function of computational mesh density and discussed in the context of improved representation of the influence of material structure upon macro-scale models of ductile damage.

36 MATERIALS SCIENCE↗
DOE OSTI2026

A strong and ductile Super Kovar alloy via fully coherent nanoprecipitates

Emerging high-precision technologies demand materials with exceptional dimensional stability and mechanical robustness, as even microscopic thermomechanical deformation can cause functional failure. However, a fundamental trilemma exists: High strength, ductility, and low thermal expansion are mutually exclusive, as strengthening-induced lattice distortions compromise the spin-lattice coupling, which is essential for low thermal expansion. Here, we overcome this trilemma by designing “Super Kovar,” an Fe-Ni-Co-Al-Ta alloy, featuring fully coherent nanoprecipitates. It unifies a 1.0-gigapascal ultimate tensile strength and ∼39% elongation with a Kovar-grade thermal expansion of 3.81 × 10−6 K−1 (100 to 410 K). The key is a dense dispersion of L12 nanoprecipitates that form an almost strain-free coherent interface with the ferromagnetic matrix. Beyond providing precipitation strengthening, these coherent interfaces suppress intrinsic phonons of nanoprecipitates via elastic coupling while avoiding magnetic domain pinning to preserve the Invar effect of the matrix. This reduces the thermal expansion of the precipitates by 56% and achieves a fourfold enhancement in the strength-ductility product, establishing a paradigm for dimensionally stable, ultrastrong alloys.

Yu, Chengyi [University of Science and Technology ↗
DOE OSTI2021

Gradient cell–structured high-entropy alloy with exceptional strength and ductility

We report that similar to conventional materials, most multicomponent high-entropy alloys (HEAs) lose ductility as they gain strength. In this study, we controllably introduced gradient nanoscaled dislocation cell structures in a stable single-phase HEA with face-centered cubic structure, thus resulting in enhanced strength without apparent loss of ductility. Upon application of strain, the sample-level structural gradient induces progressive formation of a high density of tiny stacking faults (SFs) and twins, nucleating from abundant low-angle dislocation cells. Furthermore, the SF-induced plasticity and the resultant refined structures, coupled with intensively accumulated dislocations, contribute to plasticity, increased strength, and work hardening. These findings offer a promising paradigm for tailoring properties with gradient dislocation cells at the nanoscale and advance our fundamental understanding of the intrinsic deformation behavior of HEAs.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Investigation of High-temperature Oxidation Kinetics and Residual Ductility of Oxidized Samples of Sponge-based E110 Alloy Cladding Tubes

Two-sided oxidation experiments were recently conducted at 1000-1200°C in flowing steam with samples of sponge-based Zr-1Nb alloy E110. Although the old electrolytic E110 tubing exhibited a high degree of susceptibility to nodular corrosion and experienced breakaway oxidation rates in relatively short time, the new sponge-based E110 has demonstrated steam oxidation behavior comparable to Zircaloy-4. The sponge-based E110 followed the parabolic law, and the derived oxidation rate constant is in good agreement with the Cathcart-Pawel (CP) correlation at 1100-1200°C. For 1000°C oxidation, the weight-gain of sponge-based E110 is much lower than Zircaloy-4. No breakaway oxidation was observed at 1000°C up to 8000 s. Ring compression tests were conducted to evaluate the residual ductility of oxidized samples at room temperature and at 135°C. All sponge-based E110 specimens were still ductile at 135°C after being oxidized up to 20% equivalent cladding reacted at 1000-1200°C. Metallographic examinations were performed on oxidized E110 specimens to correlate material performance with microstructure.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗