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DOE OSTI2021

Determining elastic anisotropy of textured polycrystals using resonant ultrasound spectroscopy

Abstract Polycrystalline materials can have complex anisotropic properties depending on their crystallographic texture and crystal structure. In this study, we use resonant ultrasound spectroscopy (RUS) to nondestructively quantify the elastic anisotropy in extruded aluminum alloy 1100-O, an inherently low-anisotropy material. Further, we show that RUS can be used to indirectly provide a description of the material’s texture, which in the present case is found to be transversely isotropic. By determining the entire elastic tensor, we can identify the level and orientation of the anisotropy originated during extrusion. The relative anisotropy of the compressive (c 11 /c 33 ) and shear (c 44 /c 66 ) elastic constants is 1.5% ± 0.5% and 5.7% ± 0.5%, respectively, where the elastic constants (five independent elastic constants for transversely isotropic) are those associated with the extrusion axis that defines the symmetry of the texture. These results indicate that the texture is expected to have transversely isotropic symmetry. This finding is confirmed by two additional approaches. First, we confirm elastic constants and the degree of elastic anisotropy by direct sound velocity measurements using ultrasonic pulse echo. Second, neutron diffraction (ND) data confirm the symmetry of the bulk texture consistent with extrusion-induced anisotropy, and polycrystal elasticity simulations using the elastic self-consistent model with input from ND textures and aluminum single-crystal elastic constants render similar levels of polycrystal elastic anisotropy to those measured by RUS. We demonstrate the ability of RUS to detect texture-induced anisotropy in inherently low-anisotropy materials. Therefore, as many other common materials have intrinsically higher elastic anisotropy, this technique should be applicable for similar levels of texture, providing an efficient general diagnostic and characterization tool.

36 MATERIALS SCIENCE↗

NASA NTRS1999

Flow Trajectories in Friction Stir Welding

In the Friction Stir Welding (FSW) process, a rotating, shouldered tool with a threaded pin is inserted under pressure along the seam of two pieces of metal which are tightly clamped together, and secured against a rigid anvil underneath. The rotating pin travels along the seam and through a combination of pressure and friction heating produces a zone of plastic deformation around the pin within the workpiece on either side of the seam. As the pin is moved in the direction of welding, the plasticised material moves around the tool and bonds together behind it. The elements of the material flow behavior are a combination of three elements. There is a rotational transport of material being carried around the tool, extrusion of material being forced around the pin on both sides into the cavity created behind it, and a lifting and dropping of material as it is stirred and mixed by the rotating action of the pin. It was assumed that rotational motion of the plastic zone is the primary mechanism for transport of material around the welding tool. A kinematic mathematical model was used to compute trajectories of material movement for various distributions of rotational slip within the plastic zone. These trajectories were then compared with the results of an experiment that produced radiographs of markers embedded in a workpiece that was welded with the FSW process. It was assumed that the copper wire markers retained their original length as the aluminum material flowed around them. The kinematic model included a constraint so that the displacements were such that the total length of the wire markers did not increase after deformation. There was good agreement between the calculated trajectories for the case of localized slip at the outer surface of the plastic deformation zone and the radiographs of the copper wire markers. The trajectories differed markedly from the radiograph traces when a distributed slip zone was assumed. It was concluded that the flow field could be described generally by a rotating plug model with slip occurring on the surface at the outer boundary of the plastic zone.

Bernstein, Edward L.↗

DOE OSTI2022

Initial Investigation of Coupled Electron-Photon Transport with SCEPTRE and RAPTURE (Rev.1.1)

The SCEPTRE1 code models coupled photon and electron transport in material media using discrete ordinates methods. The code can use different solvers in 1D and 3D in parallel, promising users the ability to run problems that are significant both in physics and computational scale. One capability that is perhaps unique at this time in the NNSA complex is SCEPTRE’s coupled photon– electron transport physics in a discrete ordinates approach. For example, incident x–rays can generate a significant electron population, whose transport can be simulated within the same code. In this context, fully–coupled means that photons can produce electrons and electrons can produce photons; uncoupled or no–coupling means photons do not produce electrons. Partial–coupling, an intermediate option in which photons can produce electrons but electrons do not produce photons, is not considered in the present work. The MCNP code can treat this physics with a Monte Carlo approach. MCNP should be viewed as complementary to SCEPTRE in both computational method (Monte Carlo versus discrete ordinates) as well as data libraries. SCEPTRE and MCNP should provide important checks on each other, especially from complementary modeling frameworks of a S n (discrete ordinates) mesh based method versus Monte Carlo particle based method. In order to learn more about SCEPTRE, and how it might inform engineering work at the Laboratory, we used it to carry out a set of initial studies. This was a series of 1D simulations of photon beams hitting Aluminum slabs. Our studies mainly used SCEPTRE directly, and made little use of the closely associated RAPTURE code (more on this below). The goals of these studies were first, to familiarize ourselves with operating the code, and second, to begin to assess the importance of coupled electron–photon transport. To support these studies, we began to develop a set of scripts to initialize inputs, run tools, process outputs, and plot results. An initial version of these scripts has been committed to the Lightning workflow repository. This memo relates the results of those studies.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2020

Pragmatic protocols for working cleanly when measuring ice nucleating particles

We report that measuring ice nucleating particles (INPs) is critical for understanding, and modeling, cloud formation, reflectivity, and precipitation patterns. However, because INPs are very rare in the atmosphere, but abundant—sometimes alarmingly so—in the dust that covers all work surfaces, contamination during processing of collected aerosol samples can be a significant hindrance to obtaining accurate measures of INPs. In preparing this technical note, we questioned the cleanliness of every collection and processing step involved in making immersion freezing measurements of INPs re-suspended from filter samples. The aim was to identify, and then minimize, all potential sources of significant contamination, including containers and tools used to store filters and prepare liquid suspensions, gloves, work surfaces, and the polymerase chain reaction (PCR) trays commonly used for sample analysis. While plasticware released few INPs, most gloves readily shed them, but this can be mitigated by using washed cleanroom vinyl or polyethylene gloves. Work surfaces, even those that had been cleaned, were prodigious reservoirs of contaminating INPs, but simply covering them with aluminum foil will provide an INP-free surface. By applying these practices, we developed a method to reduce the background level of INPs on Nuclepore™ polycarbonate filters in our tests to 0 at -25 °C and < 20 at -27 °C, making them suitable for use in all sampling environments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2012

Compositional Effects on Nickel-Base Superalloy Single Crystal Microstructures

Fourteen nickel-base superalloy single crystals containing 0 to 5 wt% chromium (Cr), 0 to 11 wt% cobalt (Co), 6 to 12 wt% molybdenum (Mo), 0 to 4 wt% rhenium (Re), and fixed amounts of aluminum (Al) and tantalum (Ta) were examined to determine the effect of bulk composition on basic microstructural parameters, including gamma' solvus, gamma' volume fraction, volume fraction of topologically close-packed (TCP) phases, phase chemistries, and gamma - gamma'. lattice mismatch. Regression models were developed to describe the influence of bulk alloy composition on the microstructural parameters and were compared to predictions by a commercially available software tool that used computational thermodynamics. Co produced the largest change in gamma' solvus over the wide compositional range used in this study, and Mo produced the largest effect on the gamma lattice parameter and the gamma - gamma' lattice mismatch over its compositional range, although Re had a very potent influence on all microstructural parameters investigated. Changing the Cr, Co, Mo, and Re contents in the bulk alloy had a significant impact on their concentrations in the gamma matrix and, to a smaller extent, in the gamma' phase. The gamma phase chemistries exhibited strong temperature dependencies that were influenced by the gamma and gamma' volume fractions. A computational thermodynamic modeling tool significantly underpredicted gamma' solvus temperatures and grossly overpredicted the amount of TCP phase at 982 C. Furthermore, the predictions by the software tool for the gamma - gamma' lattice mismatch were typically of the wrong sign and magnitude, but predictions could be improved if TCP formation was suspended within the software program. However, the statistical regression models provided excellent estimations of the microstructural parameters based on bulk alloy composition, thereby demonstrating their usefulness.

MacKay, Rebecca A.↗

NASA NTRS2009

Comparison of Transport Codes, HZETRN, HETC and FLUKA, Using 1977 GCR Solar Minimum Spectra

The HZETRN deterministic radiation transport code is one of several tools developed to analyze the effects of harmful galactic cosmic rays (GCR) and solar particle events (SPE) on mission planning, astronaut shielding and instrumentation. This paper is a comparison study involving the two Monte Carlo transport codes, HETC-HEDS and FLUKA, and the deterministic transport code, HZETRN. Each code is used to transport ions from the 1977 solar minimum GCR spectrum impinging upon a 20 g/cm2 Aluminum slab followed by a 30 g/cm2 water slab. This research is part of a systematic effort of verification and validation to quantify the accuracy of HZETRN and determine areas where it can be improved. Comparisons of dose and dose equivalent values at various depths in the water slab are presented in this report. This is followed by a comparison of the proton fluxes, and the forward, backward and total neutron fluxes at various depths in the water slab. Comparisons of the secondary light ion 2H, 3H, 3He and 4He fluxes are also examined.

Heinbockel, John H.↗

NASA NTRS1997

2195 Aluminum-Copper-Lithium Friction Plug Welding Development

Technology developments and applications of friction plug welding is presented. This friction repair welding technology is being studied for implementation on the Space Transportation System's Super Light Weight External Tank. Single plug repairs will be used on a vast majority of weld defects, however, linear defects of up to several inches can be repaired by overlapping plug welds. Methods and results of tensile, bend, simulated service, surface crack tension and other tests at room and cryogenic temperatures is discussed. Attempts to implement Friction Plug Welding has led to both tool and process changes in an attempt to minimize expansive tooling and lengthy implementation times. Process control equipment and data storage methods intended for large scale production will also be addressed. Benefits include increased strength and toughness, decreased weld repair time, automated and highly reliable process, and a lower probability of having to re-repair defect locations.

Takeshita, Rike P.↗

DOE OSTI2023

Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis

Aerospace flight panels must provide high strength with low mass. For aluminum panels, it is common practice to begin with a wrought plate and remove the majority of the material to attain the desired structure, comprising a thinner plate with the desired pattern of reinforcement ribs. As an alternative, this study implements hybrid manufacturing, where aluminum is first deposited on a baseplate only at the rib locations using additive friction stir deposition (AFSD). Structured light scanning is then used to measure the printed geometry. This geometry is finally used as the stock model for computer numerical control (CNC) machining. This paper details the hybrid manufacturing process that consists of: AFSD to print the preform, structured light scanning to generate the stock model and tool path, three-axis CNC machining, and post-process measurements for part geometry and microstructure.

42 ENGINEERING↗

NASA NTRS1994

Containerless liquid-phase processing of ceramic materials

Containerless melting and solidification provides a powerful tool for investigation and synthesis of ceramic and glass materials. The work described in this article explored and extended the limits of ground-based experimentation by using aero-acoustic and aerodynamic levitation in combination with laser beam heating and melting to investigate ceramic and glass processing. Results of liquid-phase processing experiments on calcia-gallia and calcia-gallia-silica glass-forming mixtures, aluminum oxide, and ceramic superconductors are summarized. The work is discussed in the context of low gravity experimental and materials synthesis requirements and opportunities.

Weber, J. K. R.↗

NASA NTRS2011

Use of Cold Radiometers in Several Thermal/Vacuum Tests

We have developed a low cost low temperature broadband radiometer for use with low temperature tests as a diagnostic tool for measuring stray thermal radiation and remote measurement of material properties. So far these radiometers have been used in two large thermal/vacuum tests for the James Webb Space Telescope (JWST) Project. In the first test the radiometers measured stray radiation in a test of part of the JWST sunshield, and in the second test the radiometers were used to measure the reflectivity and specularity of black Z307 painted aluminum walls on a 25 K cooled shroud. These results will be presented as well as plans for future tests to measure the residual energy through a baffled aperture in the shroud and other stray thermal energy measurements.

DiPirro, M.↗

DOE OSTI2023

Neutron Absorber Plate Characterization Plan for Criticality Experiments Design

After being used in nuclear installations, depleted fuel can still be highly reactive and must be handled securely to prevent any radiological or criticality concerns. In particular, spent fuel from use in nuclear power reactors must be stored and transported in specifically designed containers using neutron absorber materials to prevent criticality. Various neutron absorber material types exist and are manufactured by various entities, as thoroughly described in the Handbook of Neutron Absorber Materials for Spent Nuclear Fuel Storage and Transportation Applications written by EPRI. Presently, one of the most modern and most widely used types of neutron absorber material contains particles of boron carbide, or B 4 C, embedded in aluminum matrix: Boralcan, manufactured by Rio Tinto. It is very important for the community to know as much as possible about such neutron absorber materials. Therefore, in the recent years, a US Department of Energy National Nuclear Security Administration–Nuclear Criticality Safety Program funded project initiated design of an experiment that places Boralcan neutron-absorbing plates in an established critical assembly using low-enriched uranium fuel at the Sandia Pulsed Reactor Facility/Critical Experiments (SPRF/CX) apparatus at Sandia National Laboratories. The goal of the experiment is to produce high-quality benchmark data to submit to the International Criticality Safety Benchmark Evaluation Project (ICSBEP), for use in validating calculational tools and nuclear data by criticality safety analysts. The project, named IER-554, is currently in its final design stage, following a successful preliminary design. In the work documented in the design study, ten critical configurations using Boralcan neutron absorber plates were designed, and the experiment was proven to be feasible, with a predicted low k eff uncertainty around 100 pcm. An overview of the modeled cutout of the critical assembly with a Boralcan plate is shown in Figure 1, representing one of the configurations planned for the critical experiments. Before the plates are inserted in the critical assembly, it is necessary to know more about their composition and uniformity. This summary focuses on the plate characterization plans. Each plate will undergo (1) neutron transmission measurements at different locations to determine the 10 B areal density and (2) an in-depth x-ray computed tomography (XCT) examination to obtain the exact Sizes and distribution of the B4C powder particles inside the plates. In parallel, plate modeling studies are performed with a goal to determine the validity of the currently used approximation of modeling the neutron absorber plates as a homogeneous mixture of Aluminum 1100 alloy and B4C— instead of explicitly modeling the B4C particles. By using the experimental 10 B areal density measurements, and the exact size and location of the B4C particles obtained by XCT, a plate model can theoretically be built that reproduces the plate with extremely high fidelity. The results of this modeling study could increase the confidence of the criticality safety community in its modeling methods when using this type of neutron absorber material, and the industry could use these validations to change the boron loading credit limits from the U.S. Nuclear Regulatory Commission standard review plan for dry cask storage of spent nuclear fuel. The modeling calculations are performed with SCALE 6.3.0 using the KENO V.a sequence for criticality calculations with the ENDF/B-VIII.0 continuous-energy cross section library.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy

Additive friction stir deposition (AFSD) is a solid-state metal additive manufacturing technique, which utilizes frictional heating and plastic deformation to create large deposits and parts. Much like its cousin processes, friction stir welding and friction stir processing, AFSD has seen the most compatibility and use with lower-temperature metals, such as aluminum; however, there is growing interest in higher-temperature materials, such as titanium and steel alloys. In this work, we explore the deposition of an ultrahigh-temperature refractory material, specifically, a tantalum–tungsten (TaW) alloy. The solid-state nature of AFSD means refractory process temperatures are significantly lower than those for melt-based additive manufacturing techniques; however, they still pose difficult challenges, especially in regards to AFSD tooling. In this study, we perform initial deposition trials of TaW using twin-rod-style AFSD with a high-temperature tungsten–rhenium-based tool. Many challenges arise because of the high temperatures of the process and high mechanical demand on AFSD machine hardware to process the strong refractory alloy. Despite these challenges, successful deposits of the material were produced and characterized. Mechanical testing of the deposited material shows improved yield strength over that of the annealed reference material, and this strengthening is mostly attributed to the refined recrystallized microstructure typical of AFSD. These findings highlight the opportunities and challenges associated with ultrahigh-temperature AFSD, as well as provide some of the first published insights into twin-rod-style AFSD process behaviors.

36 MATERIALS SCIENCE↗

NASA NTRS1995

Risks and reliability of manufacturing processes as related to composite materials for spacecraft structures

Fabricating primary aircraft and spacecraft structures using advanced composite materials entail both benefits and risks. The benefits come from much improved strength-to-weight ratios and stiffness-to-weight ratios, potential for less part count, ability to tailor properties, chemical and solvent resistance, and superior thermal properties. On the other hand, the risks involved include high material costs, lack of processing experience, expensive labor, poor reproducibility, high toxicity for some composites, and a variety of space induced risks. The purpose of this project is to generate a manufacturing database for a selected number of materials with potential for space applications, and to rely on this database to develop quantitative approaches to screen candidate materials and processes for space applications on the basis of their manufacturing risks including costs. So far, the following materials have been included in the database: epoxies, polycyanates, bismalemides, PMR-15, polyphenylene sulfides, polyetherimides, polyetheretherketone, and aluminum lithium. The first four materials are thermoset composites; the next three are thermoplastic composites, and the last one is is a metal. The emphasis of this database is on factors affecting manufacturing such as cost of raw material, handling aspects which include working life and shelf life of resins, process temperature, chemical/solvent resistance, moisture resistance, damage tolerance, toxicity, outgassing, thermal cycling, and void content, nature or type of process, associate tooling, and in-process quality assurance. Based on industry experience and published literature, a relative ranking was established for each of the factors affecting manufacturing as listed above. Potential applications of this database include the determination of a delta cost factor for specific structures with a given process plan and a general methodology to screen materials and processes for incorporation into the current conceptual design optimization of future spacecrafts as being coordinated by the Vehicle Analysis Branch where this research is being conducted.

Bao, Han P.↗

DOE OSTI2020

Validation of MCNP Critical Benchmark Models of PU-MET-FAST-016

A new centralized repository of high-quality MCNP models of critical benchmark experiments is currently under development at Los Alamos National Laboratory (LANL). The repository is the combined effort of the Nuclear Criticality Safety, Nuclear Data, and Monte Carlo code development/application organizations at LANL. The initial set of benchmark models in the repository are derived from the Whisper Suite provided with MCNP6.2 and are evaluated against the benchmark experiments described in the International Criticality Safety Benchmark Evaluation Project (ICSBEP) Handbook. The goal is to build a single LANL benchmark collection that is up to date with the latest ICSBEP revision, has a formal review and revision process, is contained in an open-source repository, and utilizes new Python tools for improved input and output file review. This paper describes the validation of the models associated with PU-MET-FAST-016, “Flooded 3X3X3 Arrays of 3-kg Plutonium (Pu) Metal Cylinders – Phase I”. In this critical experiment, twenty-seven 3-kg Pu metal cylinders with a height of 46.33 ± 0.15 mm and diameter of 65.25 ± 0.05 mm were arranged in a cubic array. The Pu cylinders were sealed in aluminum cans, and three cans were placed in each of nine perforated aluminum sleeves, as shown in Fig. 1. The nine sleeves were supported by an aluminum frame that allowed for control of the lateral spacing of the cylinders, both in the X and Y directions. The benchmark experiment measured thirteen configurations. Of these configurations, six were modeled using MCNP.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS2002

Surface Enhancement Improves Crack Resistance

The low plasticity burnishing (LPB) process produces a deep layer of surface compression in a quick and affordable manner to produce metal surfaces free of scratches, nicks, and gouges. The process, designed for easy inclusion in the manufacturing environment, can be performed with conventional Computer Numerical Control machine tools. This allows parts to be processed during manufacturing, rather than as a post process in a separate facility. A smooth, free-rolling spherical ball suspended in a fluid allows for single-point contact. The ball comes into mechanical contact only with the surface to be burnished, and can be moved in any direction. LPB can be applied to all types of carbon and alloy steel, stainless steel, cast iron, aluminum, titanium, and nickel- based super alloys. In addition to improving a surface's resistance to fatigue and damage, treatment stops the growth of shallow cracks. The LPB process is used on the leading edges of turbine blades to improve resistance to foreign object damage and crack growth. This means significant savings for aircraft owners, since maintenance requirements to inspect for fatigue damage, replace parts, and remove corrosion damage increase the cost of operation.

Source record↗

DOE OSTI2022

Dynamic Material Flow Analysis of Silicon Photovoltaic Modules to Support a Circular Economy Transition

Solar photovoltaics (PV) are the fastest growing renewable energy technologies for clean, cheap, and sustainable electricity generation. To prepare for rapid scale-up, the PV industry needs to project material requirements to build out all aspects of the supply chain appropriately and plan to handle large volumes of module waste. Impacts of deploying different material circularity strategies to reduce waste and conserve primary resources need to be quantified to inform sustainable material management. Here, we introduce the photovoltaic dynamic material flow analysis (PV DMFA) model based on PV electricity generation. The model quantifies material flows and stocks in the cradle-to-cradle life cycles of utility-scale c-Si PV systems in the United States through 2100. We present case studies for solar flat glass and aluminum frame materials under various scenarios to project the impacts of PV performance, reliability, and processing parameters, material circularity strategies, and module design shifts. In the absence of circularity measures, ~100 million MT of flat glass and ~12 million MT of aluminum would be needed for PV installations by 2100 to meet projected growth in domestic utility PV demand to nearly 1000 TWh in 2100. With optimistic but feasible improvements in efficiency, reliability, and circularity, material intensity and waste could be reduced by nearly 50%. Efficient module collection, minimally intrusive recycling, and careful scrap handling and cleaning could improve material circularity in the PV value chain. This model serves as a sustainability data support tool that may aid in the circular economy transition for PV systems.

circular economy↗

DOE OSTI2021

Summary of Expansions and Updates in GREET ® 2021

The GREET® (Greenhouse gases, Regulated Emissions, and Energy use in Technologies) model has been developed by Argonne National Laboratory (Argonne) with the support of the U.S. Department of Energy (DOE). GREET is a life-cycle analysis (LCA) tool, structured to systematically examine the energy and environmental effects of a wide variety of transportation fuels and vehicle technologies in major transportation sectors (i.e., road, air, marine, and rail) and other end-use sectors, and energy systems. Within the transportation sector, GREET covers road, air, water, and rail transportation sub-sectors. Recently, GREET was expanded to cover the building sector. Historically, GREET includes LCA of various materials such as steel, aluminum, cement, and different plastic types. Argonne has expanded and updated the model in various sectors in GREET 2021, and this report provides a summary of the release.

09 BIOMASS FUELS↗

NASA NTRS2014

A Multi-Parameter Approach for Calculating Crack Instability

An accurate fracture control analysis of spacecraft pressure systems, boosters, rocket hardware and other critical low-cycle fatigue cases where the fracture toughness highly impacts cycles to failure requires accurate knowledge of the material fracture toughness. However, applicability of the measured fracture toughness values using standard specimens and transferability of the values to crack instability analysis of the realistically complex structures is refutable. The commonly used single parameter Linear Elastic Fracture Mechanics (LEFM) approach which relies on the key assumption that the fracture toughness is a material property would result in inaccurate crack instability predictions. In the past years extensive studies have been conducted to improve the single parameter (K-controlled) LEFM by introducing parameters accounting for the geometry or in-plane constraint effects]. Despite the importance of the thickness (out-of-plane constraint) effects in fracture control problems, the literature is mainly limited to some empirical equations for scaling the fracture toughness data] and only few theoretically based developments can be found. In aerospace hardware where the structure might have only one life cycle and weight reduction is crucial, reducing the design margin of safety by decreasing the uncertainty involved in fracture toughness evaluations would result in lighter hardware. In such conditions LEFM would not suffice and an elastic-plastic analysis would be vital. Multi-parameter elastic plastic crack tip field quantifying developments combined with statistical methods] have been shown to have the potential to be used as a powerful tool for tackling such problems. However, these approaches have not been comprehensively scrutinized using experimental tests. Therefore, in this paper a multi-parameter elastic-plastic approach has been used to study the crack instability problem and the transferability issue by considering the effects of geometrical constraints as well as the thickness. The feasibility of the approach has been examined using a wide range of specimen geometries and thicknesses manufactured from 7075-T7351 aluminum alloy.

Zanganeh, M.↗