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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 OSTI2012

Technical Basis for Gas-Phase Vadose Zone Remediation Technologies at Hanford: A Review - 12186

In situ vadose zone remediation approaches are being evaluated as potential options to mitigate the transport of inorganic and radionuclide contaminants from the vadose zone to the groundwater. Some of the candidate approaches are based on changing the contaminant or subsurface conditions in a way that slows downward migration of the contaminants through the vadose zone using amendments delivered in the gas-phase. Two promising approaches that have undergone testing at Hanford include soil desiccation to address technetium-99 contamination and ammonia-induced sequestration of uranium. For soil desiccation, a dry gas is injected to desiccate a targeted portion of the subsurface and thereby decrease contaminant movement by removing moisture and decreasing the hydraulic conductivity of the desiccated zone. Ammonia-induced sequestration of uranium relies on changing the pore water chemistry, primarily through pH changes, to induce dissolution and precipitation processes that decrease the amount of mobile uranium in the vadose zone. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Scaling gas-phase treatment of vadose-zone contaminants for field application at the Hanford site - 15133

In situ vadose zone remediation approaches are being evaluated as potential options to mitigate the transport of inorganic and radionuclide contaminants from the vadose zone to the groundwater at the U.S. Department of Energy's Hanford site. Some of the candidate approaches are based on changing the contaminant or subsurface conditions in a way that slows downward migration of the contaminants through the vadose zone using amendments delivered in the gas-phase. Ammonia-vapor treatment of uranium relies on induced sediment dissolution and precipitation processes that decrease the amount of mobile uranium in the vadose zone. Previous laboratory studies have demonstrated the decrease in uranium mobility caused by ammonia treatment. As part of development efforts for the ammonia technology, scale-up issues were identified and have been addressed through a series of laboratory and modeling efforts. Key scale-up elements are scoping calculations to support treatment design and understanding ammonia transport. Recent research has extended the concept of geochemical manipulation by ammonia to investigate a combined-gas treatment for sequestering Tc-99 in the vadose zone. The technique uses a combination of geochemical Tc-99 reduction with hydrogen sulfide gas and induced sediment mineral dissolution and precipitation with ammonia vapor, creating conditions for deposition of stable precipitates that decrease the mobility of Tc-99. Laboratory experiments have demonstrated the effectiveness of this treatment under a variety of operational and sediment conditions important to the scale-up and evaluation of potential addition field applications. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Evaluating Contaminant Transport in the Vadose Zone to Support Remedy Decisions at Aqueous-Waste Disposal Sites - 16195

Inorganic contaminants in aqueous waste disposed at land surface have a potential to contaminate groundwater. However, contaminant concentrations are attenuated during transport through the vadose zone. Quantifying contaminant attenuation and the resulting temporal concentration profile of in underlying groundwater is important for assessing the need for, and type of, remediation in the vadose zone and groundwater. An approach was developed for evaluating vadose zone transport and attenuation of aqueous wastes containing inorganic (non-volatile) contaminants that were disposed at land surface (i.e., directly to the ground in cribs, trenches, tile fields, etc.) and their effect on underlying groundwater. The approach provides a structured method to estimate transport of contaminants through the vadose zone and the resulting temporal profile of groundwater contaminant concentrations. A series of numerical model simulations was applied to investigate how different factors affect contaminant transport in the vadose zone and the conditions for which individual factors are important. This analysis demonstrated that, while water flow and contaminant transport can be complex during aqueous-waste disposal, conditions will change over time after disposal ceases and fewer factors will control the contaminant transport rate and resulting temporal profile of groundwater contaminant concentrations. Data verifying that these conditions have been reached can be provided by a few key metrics such as the vertical profile of moisture content, the temporal profile of recharge at the site, and basic information about waste disposal and subsurface properties. Under these conditions, and with information about specific contaminant transport parameters (e.g., for partitioning), estimates of contaminant transport can be made and used to support remedy decisions. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Subsurface Radionuclide Transport: Northeastern Negev Desert Vadose Zone Model Development - 19285

The overarching goal of the research presented is to build a subsurface radionuclide transport model for the vadose zone in the northeastern Negev desert of Israel, in order to assist in evaluating its suitability for radioactive waste subsurface disposal. The Negev desert provides a unique geologic setting because of its arid conditions, deep vadose zone and the layered stratigraphy consisting of sandstones, limestones, chalks, shales, marls, phosphorites, clays and cherts. These lithologies form intercalated layers of impermeable and permeable rocks, some with a high adsorption capacity for radionuclides. This paper consists of year one results of a joint US-Israeli collaboration to construct a generic radionuclide transport model of the vadose zone of the northeastern Negev region, Israel. The work aims to (1) evaluate potential vadose zone sites for a nuclear waste disposal site in Israel, and (2) promote the exchange of information and experience in subsurface waste siting and management. First year results include a) measured hydrogeologic rock properties for rock and core samples taken from the Negev desert, Israel, b) sorption and kinetic data for uranium U(VI) on phosphorite, chalk, sandstone and oil-shale lithologies, and c) an updated geologic, stratigraphic, and hydrologic subsurface framework for the northeastern Negev region. Preliminary results on uranium adsorption for key subsurface lithologies are encouraging in terms of the potential suitability of the Negev vadose zone to act as an efficient medium for the retardation of radionuclides. The findings provide impetus for continued experimentation and the development of a northeastern Negev subsurface flow and transport model. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Applications of Hyporheic Zone Sampling for Assessing VOC Plume Engineered Remediation and Natural Attenuation Effectiveness - 20414

Determining the efficacy of engineered remedial actions and/or natural attenuation as an acceptable EPA Record of Decision (ROD) must address long-term temporal and spatial variability. Since final plume downslope destinations are aquifers and related surface streams and rivers, hyporheic zone sampling is essential. Comprehensive hyporheic sampling documents plume groundwater remediation prior to upwelling into stream benthic strata and natural attenuation within this dynamic zone itself. Our intensive sampling of the Savannah River Site (SRS) Chemical, Metals, and Pesticides (CMP) Pits VOC plume-fringe from 2005 to 2018 documented PCE natural attenuation and effectiveness of In Situ Thermal Treatment (ISTT). Most plume hyporheic upwelling was delimited to a 20 m inflow reach along Pen Branch. Our study utilized corroborative sampling methodologies: ambient hole-water grab samples: passive diffusion bags (PDB); and hole-core sediment samples to confirm station to station spatial and temporal trends. VOC hot spot detections were confirmed from both groundwater and soil core samples. VOC pathways through the Pen Branch hyporheic zone were assessed at hole-installation using sequential soil samples from augered cores and grab-samples of hole-bottom water. Longer term, composite water samples were collected from PDBs deployed for a minimum two-week equilibration period. Soil samples were collected from the 15 and 65 cm core levels in December 2017 and June 2018 at six stations. Additional core depths of 40 and 85 cm were sampled in June 2018 at the highest VOC station (5DB80). All samples were analyzed in an EPA certified lab by purge and trap GC-MS. Effectiveness of previous ISTT and soil vapor extraction (SVE) for this CMP Pits PCE plume, was clearly documented by significant downward trends in VOC at hyporheic zone stations prior to December 2015. Achieving final stage conversions of PCE daughter products to ethene and CO{sub 2} may be limited depending upon suitable interactions between hyporheic zone sediment morphology, hydrology, and redox conditions. Because declines in VOC daughter products at our hyporheic stations may also be caused by physical actions of dilution and dispersion rather than true biochemical dechlorination, full quantification of natural attenuation requires the use of compound-specific isotope ratio analysis (CSIA) and microbial 16S rRNA with qPCR. To assist these next-phase efforts, a natural attenuation index (NAI) was used to help produce quicker, more cost-effective decision making for locating CSIA and microbial sampling efforts. The NAI used natural logarithm transformed GC-MS results for station VOC degradation compounds versus VOC parent compounds. Wide differences were observed between stations. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Use of an Alternative Conceptual Model of Vadose Zone Heterogeneity to Evaluate Past Tank Leaks and Other Unplanned Releases within a Tank Farm at the Hanford Site - 20061

Washington State Department of Ecology (Ecology) requested that U.S. Department of Energy (DOE)-Office of River Protection (ORP) consider an evaluation of effects of fine-grained thin sediment layers on transport with a separate alternative conceptual model in its evaluation of the potential impact of tank leaks and other unplanned releases within the tank farm at the Hanford Site. For this alternative model, Ecology recommended that the model be developed based on the general framework of fine-grained units identified by a stakeholder group in their interpretations of variability in moisture content data collected in the vicinity of Waste Management Area (WMA) C. In discussions with DOE-ORP, Ecology acknowledged that the underlying data and interpretations of the occurrence and lateral continuity of the fine-grained thin layers identified by a stakeholder group are uncertain. However, DOE-ORP agreed to Ecology's recommendation and has provided support for the requested evaluation that involved development of an alternative model based on the general framework of the unpublished report by the stakeholder. DOE-ORP considered this evaluation to be a hypothetical evaluation of vadose zone heterogeneities at WMA C. General observations from the range of simulation cases examined in the evaluation of the effects of hypothetical vadose zone heterogeneities at WMA C are as follows. - The movement of the center of mass of the simulated plumes was generally vertically downward below the source for all simulations, including those that incorporated the hypothetical fine-grained units. - All simulations that incorporated hypothetical heterogeneity produced additional plume spreading over what was produced in simulations using Equivalent Homogeneous Media (EHM) model(s)a. The spreading resulted in a broadening of the fringes of the plume, resulting in a wider region of low concentration, but lower peak concentrations associated with the center of mass of the plume. - Simulations that used the silty-sand hydraulic properties, suggested by Ecology for the hypothetical fine-grained units, generally produced similar spreading and slightly lower peak mass flux at the water table when compared to the EHM modeling results. a The EHM-based models used at WMA C do not explicitly include small-scale fine-grained heterogeneities used in the model advocated by Ecology. - Simulations that used the silty-sand hydraulic properties, suggested by Ecology for the hypothetical fine-grained units, generally produced less spreading and an earlier arrival of mass flux at the water table when compared to the use of another set of hydraulic properties from a silty-sand sample collected at a nearby disposal facility. - The EHM representation of the vadose zone generally produced higher peak mass flux and an earlier occurrence of peak fluxes at the water table compared to all analyses incorporating additional hypothetical heterogeneity. Results of this alternative model evaluation of past leaks provided some insight into the transport effects of vadose zone heterogeneities at WMA C that helped resolve Ecology's comments and issues related to the effects of vadose zone heterogeneities on past leaks and losses from the WMA C tank farms area. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Mechanical Properties of Nominally Ductile and Brittle Zones within the Caney Shale Formation

We present a case study from the Caney Shale, which is an emerging hydrocarbon-bearing formation in Oklahoma. Open hole logs lead to a nominal distinction of five zones in an exploration well, two of which are designated “ductile” and three of which are designated as less ductile “reservoir” zones. Subsequently, a detailed mechanical characterization was carried out on core plugs taken from each of these zones. Results show nominally “ductile” zones are weaker in terms of UCS, tensile strength, fracture toughness, and confined compressive strength. However, by a variety of brittleness indices, it is found the nominal “ductile” regions do not behave as expected. They are weaker, but not consistently more ductile. Furthermore, some brittleness indices lead to contradictory conclusions. For example, zones which would be considered the most brittle according to the proportion of nonlinear stress-strain behavior prior to failure and/or by indices based on elastic properties would be considered the least brittle according to their internal friction angle.

Benge, Margaret↗
DOE OSTI2022

Development of a vadose zone advanced monitoring system: Tools to assess groundwater vulnerability

Performing repeat pore-fluid sampling over long time-scales can provide valuable information on unsaturated zone contaminants and their potential flux to ground water. This information can be used to manage groundwater remedies and identify contaminants that need to be sequestered in the vadose zone to minimize flux to ground water. Pore-water samples are commonly used to obtain contaminant concentrations within the vadose zone, but existing methods are limited as they only provide a single sample at one location and time. The vadose zone advanced monitoring system (VZAMS) has been designed to integrate multiple technologies into a single down-borehole system that allows for sampling of pore fluids (liquid and gas) to provide information about contamination and hydraulic conditions at multiple depths (~0.3-m intervals) within a cased borehole. Testing has been completed at the laboratory scale to verify the sampling elements of VZAMS, including geochemical testing for representative contaminants known to exist at the Hanford Site, located in southeastern Washington State. Physical tests focused on the ability of the sampler to draw fluid under unsaturated conditions. Initial geochemical testing showed that the stainless steel material used with the porous cuff may affect the sampled concentrations of redox-sensitive contaminants under very dry conditions. Additional laboratory testing demonstrated that the VZAMS components are able to collect representative samples for substances of interest under expected field conditions. In this paper, the design and functionality of a novel instrument are demonstrated in support of subsequent testing in the field.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Comparative Study of Oxides Formed on Fusion Zone and Base Metal of Laser Welded Zr-1.0Sn-1.0Nb-0.1Fe Alloy

Numerous studies have primarily focused on the corrosion mechanism of zirconium alloy base metal. However, the corrosion resistance of weld beads or seams is of vital importance in the degradation of structural components in the reactor. In the present work, the corrosion resistance of the fusion zone and base metal of laser welded zirconium alloy joints was comparatively investigated. The microstructure morphologies, phase structures and strain fields of oxide films formed on fusion zone and base metal were observed and analyzed. The oxide thickness of the fusion zone was thicker than that of the base metal with prolonged corrosion. Compared to the base metal, the lower density of dislocations and level of strain values in the oxide film of the fusion zone indicated that the stress in the oxide film was lower. The phase transition from the tetragonal ZrO{sub 2} to the monoclinic ZrO{sub 2} could be suppressed due to the high level of stress, resulting in the better corrosion resistance of the base metal. Moreover, the second phase particles and non-βZr phase in the base metal contributed to the better corrosion resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Ab Initio Analysis of Guinier–Preston–Bagaryatsky Zone Nucleation in Al-Cu-Mg Alloys

Due to the inherit difficulties associated with microstructure characterization in the early stages of aging, the origin of rapid hardening in Al-Cu-Mg alloys remains a poorly understood and controversial issue. This works addresses the precipitation processes in the early stages by ab-initiomodeling of GPB zone nucleation. We derive the structural nature of GPB zone nuclei and establish that the nucleation starts with 1D-GPB1 crystals, which represent thermodynamically stable configurations at the size scale previously associated only with solute clusters. It is also established that the 1D-GPB1 can form very rapidly due a simple structural transition from FCC based configurations (clusters). The formation of GPB zones in the early stages of aging is validated by comparison with previous experimental measurements. Based on previous experimental evidence, it is postulated that GPB zones rather than solute clusters may be able to rationalize the rapid hardening in the Al-Cu-Mg alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Maximizing oil production from water alternating gas (CO 2 ) injection into residual oil zones: The impact of oil saturation and heterogeneity

Residual oil zones (ROZs) are widespread reservoirs, characterized by oil at residual saturation, either underlying oil fields (brownfield) or lateral (greenfield) to such fields. These reservoirs have the potential to produce volumes of oil sufficiently significant to make appreciable impacts on the US’s oil reserves and associated incidental CO 2 sequestration. The objective of this study is to improve our understanding the impact of heterogeneous and low oil saturations, in brownfield ROZs, on the effectiveness of water alternating gas (WAG) injection strategies. ROZs occur in the Permian Basin and elsewhere, and operators are using CO 2 injection for enhanced oil recovery (EOR) in these zones. The consensus model for the formation of ROZs is that they were formed by the effect of faster regional aquifer flow, acting over millions of years. Both the magnitude of oil saturation and the spatial distribution of oil differ from water-flooded main pay zones (MPZs). To explore the most effective injection strategies, we conducted simulations of CO 2 injection into synthetic geologic reservoirs. These simulations focused on injection into reservoirs subject to either man-made waterflooding or long-term natural waterflooding. By exploring the impact of varying: oil saturation; well patterns; reservoir heterogeneity; and permeability anisotropy, we attempt to quantify the factors that most influence the effectiveness of WAG injection. WAG ratios (the ratio of injected water and CO 2 , in reservoir volumes) of interest are those that either minimize the net CO 2 utilization ratios or maximize oil production rates. In general, the most effective WAG ratios for ROZs, are consistently less than those observed undergoing CO 2 injection in the same geologic reservoir models after traditional (man-made) waterflooding. This work demonstrates that most favorable WAG ratios for oil production in ROZs are different from those in traditional MPZs because of oil saturation differences. Therefore, CO 2 injection into both zones or directly copying WAG injection designs from MPZs to ROZs might not maximize oil production.

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2024

Unified cohesive zone model (UCZM) for fracturing and fragmenting solids

Here, a Unified Cohesive Zone Model (UCZM), which inherits most of the advantages while overcoming the shortcomings of existing Cohesive Zone Models (CZMs), is proposed. Similar to the traditional extrinsic CZM approach, UCZM dynamically inserts the cohesive elements into the system based on local material states (e.g., stress, strain). However, the transition from continua to discontinua is smoothly achieved, thereby eliminating the “time-discontinuous” issue seen in the extrinsic CZM. Moreover, within the novel UCZM framework, the point of transition from continua to discontinua is controllable through the introduction of crack initialization criteria. As a result, the UCZM allows any material models (e.g., elastic, plastic, damage models) for continuum solids and for discrete fracture behavior to work together. In essence, both an enhanced extrinsic cohesive zone model and an intrinsic cohesive zone model can be represented by the proposed unified model. The proposed UCZM has been verified through different numerical examples. The work demonstrates that the UCZM is a highly effective approach for modeling fracture and fragmentation processes in solids.

42 ENGINEERING↗
DOE OSTI2026

3D seismic imaging of a fracture damage zone controlling reservoir compartmentalization at the Raft River EGS using multi-azimuth walkaway VSP

Accurate imaging of steeply dipping fracture zones in crystalline enhanced geothermal systems (EGS) is critical for constraining permeability architecture and guiding stimulation design. However, such structures remain poorly resolved by conventional surface seismic methods. We present a fully three-dimensional (3D) elastic-waveform inversion-migration workflow applied to multi-azimuth walkaway vertical seismic profiling (VSP) data acquired in a deviated borehole at the Raft River EGS. The workflow integrates first-arrival traveltime tomography, multi-scale elastic waveform inversion (EWI), and elastic least-squares reverse-time migration (ELSRTM) to recover high-resolution compressional-and shear-wave velocity models and to image structural discontinuities in the crystalline basement. The results reveal a laterally continuous low-velocity anomaly, with shear-wave velocity reductions of 25-30%, consistent with fractureinduced mechanical weakening. Two steeply dipping discontinuities bound a 50-80 m wide fracture damage zone. Independent constraints from microseismic clustering and geochemical compartmentalization corroborate the geometry and structural significance of this feature. Synthetic modeling further confirms that structures of this scale are resolvable (~30 m). These findings indicate that the Narrows structure is a distributed fracture damage zone rather than a discrete fault plane. By resolving fracture-zone geometry at the tens-of-meters scale using a single borehole, this workflow provides a practical and transferable approach for improving structural characterization, reducing uncertainty in permeability architecture, and supporting reservoir modeling and stimulation design in fractured crystalline EGS reservoirs.

58 GEOSCIENCES↗
DOE OSTI2014

Measuring Spatial Variability of Vapor Flux to Characterize Vadose-zone VOC Sources: Flow-cell Experiments

A method termed vapor-phase tomography has recently been proposed to characterize the distribution of volatile organic contaminant mass in vadose-zone source areas, and to measure associated three-dimensional distributions of local contaminant mass discharge. The method is based on measuring the spatial variability of vapor flux, and thus inherent to its effectiveness is the premise that the magnitudes and temporal variability of vapor concentrations measured at different monitoring points within the interrogated area will be a function of the geospatial positions of the points relative to the source location. A series of flow-cell experiments was conducted to evaluate this premise. A well-defined source zone was created by injection and extraction of a non-reactive gas (SF6). Spatial and temporal concentration distributions obtained from the tests were compared to simulations produced with a mathematical model describing advective and diffusive transport. Tests were conducted to characterize both areal and vertical components of the application. Decreases in concentration over time were observed for monitoring points located on the opposite side of the source zone from the local–extraction point, whereas increases were observed for monitoring points located between the local–extraction point and the source zone. We found that the results illustrate that comparison of temporal concentration profiles obtained at various monitoring points gives a general indication of the source location with respect to the extraction and monitoring points.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Spectral induced polarization (SIP) measurements across a PFAS-contaminated source zone

There is a pressing need for the development of field-scale, in situ screening technologies for assessing variations in aqueous film forming foam (AFFF) concentrations in soils at former fire training and storage sites. Field-scale Spectral Induced Polarization (SIP) geophysical measurements were acquired on a transect crossing an AFFF source zone. Soil samples were acquired from ten locations and used to determine variations in poly- and per-fluoroalkyl substances (PFAS) concentrations in soils and soil texture. These samples were also used to create triplicate soil columns for laboratory-grade SIP measurements. Field and laboratory observations provide evidence that SIP measurements are sensitive to the concentration of AFFF constituents associated with the pore surface in soils. The phase of the SIP measurements on the laboratory samples was linearly correlated with total soil-sorbed PFAS concentration. The phase from the field SIP measurements was highest over the location of maximum PFAS concentration measured on the laboratory samples, although a significant correlation between field-measured phase and laboratory-measured total PFAS concentration was not established. The sensitivity of the SIP response to the removal of soil PFAS using a methanol wash procedure (total PFAS concentration drop of 366 ppb) adds evidence for the case for SIP characterization of AFFF source zones. The results of these studies suggest that SIP might be developed into a field-scale technology for rapid, indirect assessment of AFFF source zones. Such a technology could improve the effectiveness of AFFF source zone characterization at reduced costs.

58 GEOSCIENCES↗
DOE OSTI2014

Effect of long-term aging on microstructure and local behavior in the heat-affected zone of a Ni–Cr–Mo–V steel welded joint

Evolution of microstructure, micro-hardness and micro-tensile strength behavior was investigated in the heat-affected zone of a Ni–Cr–Mo–V steel welded joint after the artificial aging at 350 °C for 3000 h. After detailed characterization of microstructures in optical microscopy, scanning electron microscopy and transmission electron microscopy, it is revealed that the change of martensite–bainite constituent promotes more homogeneous microstructure distribution. The aging treatment facilitates redistribution of carbon and chromium elements along the welded joint, and the micro-hardness is increased slightly through the welds due to enrichment of carbon. The types of precipitates in the weldment mainly include M{sub 3}C, MC, M{sub 2}C and M{sub 23}C{sub 6}. The carbides in base metal, weld metal and coarse-grained heat-affected zone are prone to change from ellipsoidal to platelet form whereas more uniform spherical carbides are observed in the fine-grained zone. Precipitation and coarsening of M{sub 23}C{sub 6} near the fusion line, and formation of MC and M{sub 2}C, are responsible for the tensile strength decrease and its smooth distribution in the aged heat-affected zone. This implies that the thermal aging can relieve strength mismatch in the weldments. - Highlights: • Microstructure homogeneity improved in HAZ after long-term aging. • Tensile strength decreased in HAZ due to precipitation and coarsening of M{sub 23}C{sub 6}. • Strength mismatch in NiCrMoV steel welds was relieved after aging at 350 °C × 3000 h.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Heat-affected zone liquation crack on resistance spot welded TWIP steels

In this study, the heat affected zone (HAZ) liquation crack and segregation behavior of the resistance spot welded twinning induced plasticity (TWIP) steel have been reported. Cracks appeared in the post-welded joints that originated at the partially melted zone (PMZ) and propagated from the PMZ through the heat affected zone (HAZ) to the base metal (BM). The crack length and crack opening widths were observed increasing with heat input; and the welding current was identified to be the most influencing parameter for crack formation. Cracks appeared at the PMZ when nugget diameter reached at 4.50 mm or above; and the liquation cracks were found to occur along two sides of the notch tip in the sheet direction rather than in the electrode direction. Cracks were backfilled with the liquid films which has lamellar structure and supposed to be the eutectic constituent. Co-segregation of alloy elements such as, C and Mn were detected on the liquid films by electron-probe microanalysis (EPMA) line scanning and element map which suggests that the liquid film was enrich of Mn and C. The eutectic constituent was identified by analyzing the calculated phase diagram along with thermal temperature history of finite element simulation. Preliminary experimental results showed that cracks have less/no significant effect on the static cross-tensile strength (CTS) and the tensile-shear strength (TSS). In addition, possible ways to avoid cracking were discussed. - Highlights: • The HAZ liquation crack during resistance spot welding of TWIP steel was examined. • Cracks were completely backfilled and healed with divorced eutectic secondary phase. • Co-segregation of C and Mn was detected in the cracked zone. • Heat input was the most influencing factor to initiate liquation crack. • Cracks have less/no significant effect on static tensile properties.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Microstructure characterization of heat affected zone after welding in Mod.9Cr–1Mo steel

The microstructure of the heat affected zone after welding was investigated in Mod.9Cr–1Mo steel, using TEM and STEM-EDX. The microstructure of thin foil was observed at the fusion line, and at the positions of 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm and 3.5 mm to the base metal side of the fusion line. Martensite structure with very fine lath and high dislocation density was confirmed at all positions. Twins with a twin plane of (112) were locally observed at all positions. Elemental mapping was obtained for all positions by means of STEM-EDX. Inclusions of mainly Si were formed at the fusion line but not at the other positions. No precipitates could be detected at the fusion line or at the position of 0.5 mm. On the other hand, MX particles were observed at the positions of 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm and 3.5 mm even after welding. M{sub 23}C{sub 6} particles were also confirmed at the positions of 2.0 mm, 2.5 mm, 3.0 mm and 3.5 mm. Very fine equiaxed grains were locally observed at the positions of 2.0 mm and 2.5 mm. The Cr content of the equiaxed grains was about 12 mass%, although the martensite area included about 8 mass% Cr. - Graphical abstract: Display Omitted - Highlights: • Nonequilibrium microstructure of heat affected zone was observed after welding in Mod.9Cr–1Mo steel. • Inclusions containing Si were detected at the fusion line. • Undissolved M{sub 23}C{sub 6} and MX particles were confirmed in heat affected zone. • Twins with a twin plane of (112) were locally observed at all positions. • Very fine ferrite grains with high Cr content were observed in fine grained heat affected zone.

36 MATERIALS SCIENCE↗