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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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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

High strength W/TiNi micro-laminated composite with transformation-mediated ductility

A laminated W/TiNi composite is fabricated by hot pressing under vacuum and subsequent forging. The W and TiNi constituents are about 250 μm and 80 μm respectively in thicknesses and their interfaces are chemically sharp with negligible intermixing. The material exhibits two yielding plateaus and excellent strength-ductility combination during compression tests. In situ X-ray technique is employed to demonstrate that the unusual yielding phenomenon is related to the reversible thermoelastic phase transformation of TiNi layers. Furthermore, such mechanisms also contribute to the damage tolerance of the materials by inhibiting crack propagation in W.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Intrinsic and extrinsic effects on the fracture toughness of ductile metallic glasses

The potential application of metallic glasses (MGs) as structural materials demands accurate measurements of their toughness and the understanding of the underlying factors affecting it. Currently, it is challenging to precisely measure the toughness of MGs, especially ductile MGs. Measured toughness values are widely scattered, even for MGs with identical compositions. That is attributed to the combined effect of intrinsic and extrinsic factors including processing, sample geometries, and loading conditions. A fundamental understanding of the influences of these elements is thus of great significance. In the present study, molecular dynamics simulations are performed to investigate the influence of intrinsic and extrinsic effects on the fracture toughness of CuZr MGs. In particular, focused is placed on the effects of cooling rate, notch shape and size, strain rate, and temperature. The results indicate that the fracture toughness of a MG scales with the cooling rate used to prepare it. This is attributed to increased free volume content generated at high cooling rates, which enhances plastic deformation and amplifies the associated energy dissipation during plastic deformation events. Fracture toughness also increases with the strain rate, arguably due to strain rate-induced crack extension delay. Overall, the results demonstrate that the largest fracture toughness are achieved when MG samples are fabricated at high cooling rates and subjected to high strain rate deformation. In addition, results suggest that the fracture toughness decreases with increasing temperature, due to the significant decrease in strength. Here, the correlations revealed between these crucial intrinsic and extrinsic parameters and the calculated MG fracture toughness support the development of a framework to understand the root of the discrepancies in the measurement of the toughness of MGs and provide insights into the design of tough MGs for structural applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Novel NiAl-strengthened high entropy alloys with balanced tensile strength and ductility

A single phase, face-centered-cubic (FCC) Al 0.3 CoCrFeNi high entropy alloy usually has low yield strength. Here, a precipitate-strengthened Al 0.3 CoCrFeNi has been developed, exhibiting enhanced yield strength while retaining good ductility, which is attributed to a novel microstructure comprising a finely distributed, needle-like B2 phase within the grains of the FCC matrix and a granular σ phase along the grain boundaries. Such a microstructure was obtained by a two-step heat treatment of an as-cast Al 0.3 CoCrFeNi, whose parameters were determined by integrating CALPHAD-based thermodynamic calculations with microstructural characterization by atom probe tomography. In situ neutron diffraction, in conjunction with crystal-plasticity finite-element simulations, has revealed the strengthening effect owing to the load partitioning between the constituent phases. Here, this work has important implications for understanding phase stability and deformation mechanisms in multi-principal component alloys, and paves the way for developing novel microstructures in complex alloys using correlative techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A multi-length-scale investigation of the applicability of ductility laws for annealed and work-hardened copper

Small-scale mechanical testing provides unique advantages over conventional testing in investigating the mechanical response of nuclear materials. While small-scale testing enables accelerated materials research, it raises the question of comparability to large-scale properties for engineering design considerations. Among different mechanical properties for structural design considerations such as yield and ultimate tensile stress, ductility is of critical importance with respect to structural component health. The effectiveness of using small-scale mechanical testing for probing these mechanical properties is dictated by understanding how the mechanical responses translate from the microscale to the engineering scale. Therefore, a better understanding of size scaling effects via gathering and analysis of experimental data is required to bridge length-scales. Further, this work builds upon previous reports to provide statistical data on how mechanical response changes as the size of the specimens are reduced from conventional sizes. One hundred twenty mesoscale tensile coupons of oxygen-free high thermal conductivity (OFHC) copper in work-hardened and annealed state have been manufactured using micro-wire electrical discharge machining (EDM) and tested under uniaxial tension. The mesoscale specimens have dimensions dictated by pre-selected geometric ratios (i.e., gauge section length over the square root of the cross-section area) with gauge length dimensions of 3 mm (or less) and sub-millimeter gauge widths and thicknesses. The mesoscale responses were compared to bulkscale properties to reveal the effect of specimen size on the mechanical response as a function of grain size and material state for a single phase face-centered cubic metal.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A new magnesium sheet alloy and its multi-stage homogenization for simultaneously improved ductility and strength at room temperature

We report that a new Mg-2Zn-0.3Ca-0.2Ce-0.1Mn (ZXEM2000) alloy and a multi-stage homogenization process have been designed and developed based on CALculation of Phase Diagram (CALPHAD) modeling results and experimental validation. The new sheet alloy offers an excellent combination of ductility (about 29% elongation) and yield strength (157 MPa), promising room-temperature forming applications. Microstructure characterization reveals that the exceptional properties of this alloy are mainly attributed to the weak basal texture, fine average grain size and high density of nano-scale Mn and Mg 6 Zn 3 Ca 2 precipitates achieved through multi-stage heat treatment and thermomechanical processing.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effects of Molecular Weight Reduction on Brittle–Ductile Transition and Elastic Yielding Due to Noninvasive γ Irradiation on Polymer Glasses

By exposing specimens to the irradiation, we show that polymer glasses including bisphenol A polycarbonate (PC) and poly(methyl methacrylate) (PMMA) turn from ductBy causing chain scission with the irradiation, we examine the origin of mechanical stress produced from cold drawing of four ductile polymer glasses (PC, PMMA, polystyrene, and poly(2,6-dimethyl-1,4-phenylene oxide)). We elucidate the origin of the residual stress embedded in the glassy state from the cold-drawing of these polymer glasses into the strain hardening regime by investigating the elastic yielding behavior of these colddrawn specimens. In contrast to the emergent retractive stress observed during annealing of the cold-drawn specimens above their storage temperature but still well below their glass transition temperatures, we find significantly lower retractive stress level and longer induction time for the retractive stress to show up when these specimens undergo sufficient dosage of the irradiation whose effect on the molecular weight and its distribution has been measured with gel permeation chromatography.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Iron-Catalyzed Cross-[2 + 2] Cycloaddition of Butadiene and α,ω-Dienes for Ductile and Chemically Recyclable Poly(oligocyclobutanes)

Poly(divinyloligocyclobutanes) (pDVOCBs) are a distinct class of butadiene-derived, chemically recyclable polyolefins prepared from iron-catalyzed [2 + 2] cycloaddition followed by ruthenium-catalyzed ADMET polymerization. These polymers are highly crystalline, with high melting temperatures and unique rotator phases. The high degree of crystallinity in these materials not only leads to high stiffness over a broad temperature range but also results in brittle failure for polymers of modest molecular weights. Iron-catalyzed cross-[2 + 2] cycloaddition of butadiene and α,ω-dienes was accomplished, where the number of methylene units between the four-membered rings was systematically varied. Subsequent ADMET polymerization of the resulting telechelic oligomers provided a new class of chemically recyclable polyolefins that exhibit distinct thermomechanical properties. Specifically, methylene units induce changes in crystallinity that, in combination with the increased molecular weight, favored the formation of stable necks upon tensile deformation, with ∼10× enhanced ductility and improved toughness compared to pDVOCB. Through combined experimental and computational studies, the effects of methylene spacers on the crystal-to-rotator transition of the cyclobutane polymers were established. Ultimately, these methylene-modified cyclobutane polymers expand the range of properties and potential applications of this class of recyclable polyolefins.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Ductility mechanisms in complex concentrated refractory alloys from atomistic fracture simulations

The striking variation in damage tolerance among refractory complex concentrated alloys is examined through the analysis of atomistic fracture simulations, contrasting behavior in elemental Nb with that in brittle NbMoTaW and ductile Nb45Ta25Ti15Hf15. We employ machine-learning interatomic potentials (MLIPs), including a new MLIP developed for NbTaTiHf, in atomistic simulations of crack tip extension mechanisms based on analyses of atomistic fracture resistance curves. While the initial behavior of sharp cracks shows good correspondence with the Rice theory, fracture resistance curves reveal marked changes in fracture modes for the complex alloys as crack extension proceeds. In NbMoTaW, compositional complexity appears to promote dislocation nucleation relative to pure Nb, despite theoretical predictions that the alloy should be relatively more brittle. In Nb45Ta25Ti15Hf15, alloying alters the fracture mode compared to elemental Nb, promoting crack tip blunting and enhancing resistance to crack propagation.

Computational methods↗
DOE OSTI2017

Statistical study of ductility-dip cracking induced plastic deformation in polycrystalline laser 3D printed Ni-based superalloy

Ductility-dip cracking in Ni-based superalloy, resulting from heat treatment, is known to cause disastrous failure, but its mechanism is still not completely clear. A statistical study of the cracking behavior as a function of crystal orientation in a laser 3D-printed DL125L Ni-based superalloy polycrystal is investigated here using the synchrotron X-ray microdiffraction. The dislocation slip system in each of the forty crystal grains adjacent to the 300 μm long crack has been analyzed through Laue diffraction peak shapes. In all these grains, edge-type geometrically necessary dislocations (GNDs) dominate, and their dislocation line directions are almost parallel to the crack plane. Based on Schmid's law, the equivalent uniaxial tensile force direction is revealed normal to the trace of the crack. A qualitative mechanism is thus proposed. Thermal tensile stress perpendicular to the laser scanning direction is elevated due to a significant temperature gradient, and thus locations in the materials where the thermal stress exceeds the yield stress undergo plastic deformation mediated by GND activations. As the dislocations slip inside the crystal grains and pile up at the grain boundaries, local strain/stress keeps increasing, until the materials in these regions fail to sustain further deformation, leading to voids formation and cracks propagation.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Reduced partitioning of plastic strain for strong and yet ductile precipitate-strengthened alloys

When a material that contains precipitates is deformed, the precipitates and the matrix may strain plastically by different amounts causing stresses to build up at the precipitate-matrix interfaces. If premature failure is to be avoided, it is therefore essential to reduce the difference in the plastic strain between the two phases. Here, we conduct nanoscale digital image correlation to measure a new variable that quantifies this plastic strain difference and show how its value can be used to estimate the associated interfacial stresses, which are found to be approximately three times greater in an Fe-Ni 2 AlTi steel than in the more ductile Ni-based superalloy CMSX-4 ® . It is then demonstrated that decreasing these stresses significantly improves the ability of the Fe-Ni 2 AlTi microstructure to deform under tensile loads without loss in strength.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Engineering transformation pathways in an Al 0.3 CoFeNi complex concentrated alloy leads to excellent strength–ductility combination

Guided by thermodynamic modeling, engineering phase transformation pathways via thermo-mechanical processing, in a complex concentrated alloy/high entropy alloy (HEA) of composition Al 0.3 CoFeNi, lead to a novel multi-scale microstructure consisting of fine-scale FCC + L1 2 grains mixed with B2 + BCC grains. The two-step pathway comprises initial decomposition of the parent single-phase FCC to form a fine-grained FCC + B2 microstructure, which further decomposes in the second step into the complex four-phase mixture, exhibiting an excellent combination of tensile yield stress of ~1490 MPa, ultimate tensile strength of ~1663 MPa, with a good ductility of ~12% at room temperature. This paper reports a novel multi-phase microstructure in a HEA/CCA similar to the microstructure observed in dual-phase stainless steel. This report exemplifies the novelty of HEA/CCA compositional space.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A new ductile, tougher resin for impregnation of superconducting magnets

A major remaining challenge for Nb 3 Sn high field magnets is their training due to random temperature variations in the coils. The main objective of our research is to reduce or eliminate it by finding novel impregnation materials in replacement of the epoxies currently used. An organic olefin-based thermosetting dicyclopentadiene resin, C 10 H 12 , commercially available in Japan as TELENE® by RIMTEC, was used to impregnate a short Nb 3 Sn undulator coil developed by ANL and FNAL. This magnet reached short sample limit after only two quenches, compared with ∼100 when CTD-101K® was used. Ductility, i.e. the ability to accept large strains, and toughness were identified as key properties to achieve these results. In addition, we have been investigating whether mixing TELENE with high heat capacity ceramic powders such as Gd 2 O 3 , Gd 2 O 2 S, and HoCu 2 , increases the specific heat (C p ) of impregnated Nb3Sn superconducting magnets. The viscosity, heat capacity, thermal conductivity, and other physical properties of TELENE with high-C p powder fillers were measured in this study as a function of temperature and magnetic field. The TELENE-87 wt%Gd 2 O 2 S had a peak in C p between 4.3 K and 5.3 K at fields between 0 and 8 T. We have also investigated the effect on the mechanical properties of pure and mixed TELENE under 10 MGy of gamma ray irradiation at the Takasaki Advanced Radiation Research Institute in Takasaki, Japan. TELENE-87 wt%Gd 2 O 2 S exhibited exceptional radiation resistance. Impregnating an undulator coil with TELENE mixed with Gd 2 O 2 S powder will verify whether the coils' thermal stability further improves, or whether its low diffusivity will require engineering the material with high-thermal conductivity components. Short magnet training will lead to better magnet reliability, lower magnet margins, lower risk and substantial saving in accelerators' commissioning costs. Part of this study is supported by the U.S.-Japan Science and Technology Cooperation Program in high energy physics operated by MEXT in Japan and DOE in the U.S.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2017

Synchrotron measurements of local microstructure and residual strains in ductile cast iron

The local microstructure and distribution of thermally induced residual strains in ferrite matrix grains around an individual spherical graphite nodule in ductile cast iron (DCI) were measured using a synchrotron X-ray micro-diffraction technique. It is found that the matrix grains are deformed, containing dislocations and dislocation boundaries. Each of the residual strain components in the matrix grains exhibits a complex pattern along the circumferential direction of the nodule. Along the radial direction of the nodule, strain gradients from the interface to the grain interior are seen for some strain components, but only in some matrix grains. The observed residual strain patterns have been analysed by finite element modelling, and a comparison between the simulation and experiments is given. The present study of local residual stress by both experimental characterization and simulation provide much needed information for understanding the mechanical properties of DCI, and represent an important contribution for the microstructural design of new DCI materials.

Zhang, Y B↗
DOE OSTI2022

Ductile failure and damage localization in Al6061-T6 characterized by in situ X-ray computed tomography and neural network segmentation

Damage initiation and localization in uniaxial tension tests of an Al6061-T6 alloy are evaluated and quantified using in situ X-ray computed tomography and a neural network segmentation strategy. This segmentation strategy offers significant advantages over traditional thresholding in quantifying microstructural and damage evolution metrics. Void nucleation was observed to occur throughout the deformation process, whereas void volume did not grow significantly until later stages of deformation. Localized analysis determined that void nucleation begins in and around the necked region during the early stages of deformation, whereas limited damage nucleation occurs outside of the neck until late stages of deformation. Lastly, inhomogeneities in void and particle spacing in the initial undeformed state of the material are observed to correlate well with the location of damage localization and necking during deformation. These results provide new insights into the ductile failure of Al alloys and how preexisting defects influence damage and rupture.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Ductile failure X-prize.

Fracture or tearing of ductile metals is a pervasive engineering concern, yet accurate prediction of the critical conditions of fracture remains elusive. Sandia National Laboratories has been developing and implementing several new modeling methodologies to address problems in fracture, including both new physical models and new numerical schemes. The present study provides a double-blind quantitative assessment of several computational capabilities including tearing parameters embedded in a conventional finite element code, localization elements, extended finite elements (XFEM), and peridynamics. For this assessment, each of four teams reported blind predictions for three challenge problems spanning crack initiation and crack propagation. After predictions had been reported, the predictions were compared to experimentally observed behavior. The metal alloys for these three problems were aluminum alloy 2024-T3 and precipitation hardened stainless steel PH13-8Mo H950. The predictive accuracies of the various methods are demonstrated, and the potential sources of error are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Clustered Void Growth in Ductile Metals: Final LDRD Report

This report is a compilation of projects completing during an investigation into void growth in ductile metals. Included, are the following results. (a) We have performed a suite of tests looking at the effect of porosity on the macroscopic yield stress of the material in a plane strain framework. Results have shown the orientation of voids to have a large effect on the yield stress. (b) Preliminary simulations of a periodic three dimensional void microstructure are given along with the meshing procedure. Results show less void interaction as compared to the two dimensional case. (c) Development and implementation of an anisotropic plasticity model is detailed. The model is used to replicate anisotropic necking seen in a tensile bar experimentally tested to failure. (d) We have shown efficiency gains of 84% of a 2D solution framework compared the standard 3D framework. (e) We investigated a large number of element formulations and have shown the q1p0 element (selectively integrated hex8) to outperform all others in the context of large deformation plasticity simulations. (f) The implementation of the q1p0 element into SIERRA is provided along with results of verification and performance investigations.

36 MATERIALS SCIENCE↗
DOE OSTI2015

An attempt to calibrate and validate a simple ductile failure model against axial-torsion experiments on Al 6061-T651

This report details a work in progress. We have attempted to calibrate and validate a Von Mises plasticity model with the Johnson-Cook failure criterion ( Johnson & Cook , 1985 ) against a set of experiments on various specimens of Al 6061-T651. As will be shown, the effort was not successful, despite considerable attention to detail. When the model was com- pared against axial-torsion experiments on tubes, it over predicted failure by 3 x in tension, and never predicted failure in torsion, even when the tube was twisted by 4 x further than the experiment. While this result is unfortunate, it is not surprising. Ductile failure is not well understood. In future work, we will explore whether more sophisticated material mod- els of plasticity and failure will improve the predictions. Selecting the appropriate advanced material model and interpreting the results of said model are not trivial exercises, so it is worthwhile to fully investigate the behavior of a simple plasticity model before moving on to an anisotropic yield surface or a similarly complicated model.

42 ENGINEERING↗