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DOE OSTI2025

Meshfree simulation and prediction of recrystallized grain size in friction stir processed 316L stainless steel

Friction stir processing (FSP) is a promising solid-phase microstructural modification technique that can repair and enhance damaged stainless steel surfaces exposed to harsh environments. The quality of the repaired material is closely correlated to the recrystallized grain size in the stir zone (SZ), which is influenced by the thermomechanical conditions dictated by FSP process parameters. Thus, establishing a reliable relationship between these parameters and recrystallized grain size in the SZ is crucial for optimizing repair quality. However, existing experimental approaches often rely on indirect temperatures measured far from the SZ, along with rough strain rate estimations, which are imprecise and time-consuming. Meanwhile, existing mesh-based modeling methods usually face numerical challenges when dealing with the large material deformations inherent in FSP. Here, to address these issues, this study introduces a meshfree process model for FSP based on the smoothed particle hydrodynamics (SPH) method, aimed at predicting process conditions under different parameters. The model is validated using experimental data from 11 combinations of tool traverse and rotation speeds on 316 L stainless steel. Correlations between process parameters, material flow, temperature, strain, strain rate, and recrystallized grain size are revealed through SPH simulations and electron backscatter diffraction (EBSD) imaging. The results show that in situ SZ temperatures range from 1071 to 1322°C, which exceed the tool temperature by over 300°C. Furthermore, SZ temperature, strain rate, and grain size increase monotonically with higher tool temperature and faster traverse speed. A relationship is then established between the model-predicted Zener-Hollomon parameter and the recrystallized grain size based on EBSD data, expressed as ln(d) = -0.364 ln(Z) + 14.673. Finally, this relationship exhibits satisfactory accuracy with errors of less than 26.9% in predicting grain sizes at various SZ locations, which offers valuable insights for optimizing FSP repair processes for 316 L stainless steel.

316L stainless steel↗

DOE OSTI2025

Effects of Grain Size and Interstitial Content on Recrystallization in Nb after Cold Rolling

A fully recrystallized microstructure with a fine grain size can improve the performance of superconducting radio-frequency (SRF) cavities produced from high-purity Nb (ASTM B393–18 Type 5 Nb) while providing mechanical strength. Recrystallization depends on impurity content, initial microstructure, deformation state, and annealing conditions. To better understand how fine-grained, fully recrystallized microstructures may be produced, the recrystallization behaviors of Type 5 and Type 2 Nb materials were studied. Type 5 Nb specimens were produced with both fine and coarse initial grain sizes. All were cold rolled and then annealed under vacuum for one hour to determine the rolling reductions and temperatures required for recrystallization. The recrystallized fraction exceeded 95% in fine-grained Type 5 Nb rolled to a 30% or greater thickness reduction and then annealed at 800 °C or higher. The coarse grained Type 5 Nb required greater rolling reductions to produce any recrystallized grains at 800 °C. The higher interstitial content of the Type 2 Nb required a temperature of 1000 °C or higher to reach a recrystallized fraction greater than 95% in specimens rolled to a 60% reduction. Recrystallization is more easily achieved during annealing at a given temperature for a set time by increasing rolling reduction, decreasing interstitial content, and decreasing initial grain size prior to cold rolling. In conclusion, to avoid grain growth following recrystallization, which increases grain size, the minimum time and temperature necessary for complete recrystallization should be applied.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS2016

Snow Grain Size Retrieval over the Polar Ice Sheets with the Ice, Cloud and Land Elevation Satellite (ICESat) Observations

Snow grain size is an important parameter for cryosphere studies. As a proof of concept, this paper presents an approach to retrieve this parameter over Greenland, East and West Antarctica ice sheets from surface reflectances observed with the Geoscience Laser Altimeter System (GLAS) onboard the Ice, Cloud, and land Elevation Satellite (ICESat) at 1064 nanometers. Spaceborne lidar observations overcome many of the disadvantages in passive remote sensing, including difficulties in cloud screening and low sun angle limitations; hence tend to provide more accurate and stable retrievals. Results from the GLAS L2A campaign, which began on 25 September and lasted until 19 November, 2003, show that the mode of the grain size distribution over Greenland is the largest (approximately 300 microns) among the three, West Antarctica is the second (220 microns) and East Antarctica is the smallest (190 microns). Snow grain sizes are larger over the coastal regions compared to inland the ice sheets. These results are consistent with previous studies. Applying the broadband snow surface albedo parameterization scheme developed by Garder and Sharp (2010) to the retrieved snow grain size, ice sheet surface albedo is also derived. In the future, more accurate retrievals can be achieved with multiple wavelengths lidar observations.

ice↗

DOE OSTI2025

Different methods of estimating riverbed sediment grain size diverge at the basin scale

Introduction: The distribution of sediment grain size in streams and rivers is often quantified by the median grain size (D50), a key metric for understanding and predicting hydrologic and biogeochemical function of streams and rivers. Manual D50 measurements are time-consuming and ignore larger grains, while approaches to model D50 based on catchment characteristics may over-generalize and miss site-scale heterogeneity. Machine learning-enabled object detection methods like You Only Look Once (YOLO) provides an alternative that enables estimation of D50 that is faster than manual measurements and more site-specific than predictions based on catchment characteristics. Methods: To understand the potential role of object detection methods for improving understanding of D50, we compared D50 estimates made manually, predicted from catchment characteristics, and using a YOLO-enabled approach across the Yakima River Basin. Results: We found distinct differences between methods for D50 averages and variability, and relationships between D50 estimates and basin characteristics. Discussion: We discuss the advantages and limitations of object detection methods versus current methods, and explore potential future directions to combine D50 methods to better estimate spatiotemporal variation of D50, and improve incorporation into basin-scale models.

grain size distribution↗

NASA NTRS1973

Lunar soil grain size distribution

A comprehensive review has been made of the currently available data for lunar grain size distributions. It has been concluded that there is little or no statistical difference among the large majority of the soil samples from the Apollo 11, 12, 14, and 15 missions. The grain size distribution for these soils has reached a steady state in which the comminution processes are balanced by the aggregation processes. The median particle size for the steady-state soil is 40 to 130 microns. The predictions of lunar grain size distributions based on the Surveyor television photographs have been found to be quantitatively in error and qualitatively misleading.

Carrier, W. D., III↗

NASA NTRS2008

Mapping Snow Grain Size over Greenland from MODIS

This paper presents a new automatic algorithm to derive optical snow grain size (SGS) at 1 km resolution using Moderate Resolution Imaging Spectroradiometer (MODIS) measurements. Differently from previous approaches, snow grains are not assumed to be spherical but a fractal approach is used to account for their irregular shape. The retrieval is conceptually based on an analytical asymptotic radiative transfer model which predicts spectral bidirectional snow reflectance as a function of the grain size and ice absorption. The analytical form of solution leads to an explicit and fast retrieval algorithm. The time series analysis of derived SGS shows a good sensitivity to snow metamorphism, including melting and snow precipitation events. Preprocessing is performed by a Multi-Angle Implementation of Atmospheric Correction (MAIAC) algorithm, which includes gridding MODIS data to 1 km resolution, water vapor retrieval, cloud masking and an atmospheric correction. MAIAC cloud mask (CM) is a new algorithm based on a time series of gridded MODIS measurements and an image-based rather than pixel-based processing. Extensive processing of MODIS TERRA data over Greenland shows a robust performance of CM algorithm in discrimination of clouds over bright snow and ice. As part of the validation analysis, SGS derived from MODIS over selected sites in 2004 was compared to the microwave brightness temperature measurements of SSM\I radiometer, which is sensitive to the amount of liquid water in the snowpack. The comparison showed a good qualitative agreement, with both datasets detecting two main periods of snowmelt. Additionally, MODIS SGS was compared with predictions of the snow model CROCUS driven by measurements of the automatic whether stations of the Greenland Climate Network. We found that CROCUS grain size is on average a factor of two larger than MODIS-derived SGS. Overall, the agreement between CROCUS and MODIS results was satisfactory, in particular before and during the first melting period in mid-June. Following detailed time series analysis of SGS for four permanent sites, the paper presents SGS maps over the Greenland ice sheet for the March-September period of 2004.

Lyapustin, Alexei↗

NASA NTRS2021

An Investigation of the Grain Size and Adhesion Strength of High-Speed Impact Ice

Ice accumulation on aircraft from supercooled water droplets (impact icing) can increase drag and decrease lift, leading to a decrease in fuel efficiency and a potential for unsafe situations. Anti-icing materials and coatings are of high interest to prevent aircraft icing. Because no anti-icing material suitable for in-flight situations has been realized, icing models aim to predict the accumulation and shape of the ice to understand its effects. In both cases, understanding the physical mechanism behind ice adhesion and shedding is necessary. A recent literature review has shown that the apparent ice adhesion strength to any specific material varies over several orders of magnitude across studies and test methods. One of the reasons for this high variance is likely to be the varying microstructure of the ice used for different studies. Although the microstructure of impact ice has been studied in the past, those conditions were not relevant to that of in-flight aircraft icing. The microstructure of the ice formed will determine both its bulk and surface properties, yet it has been overlooked in the ice adhesion community. Here, we use optical microscopy to study the non-uniform ice crystal grain size in impact ice accreted in NASA Glenn Research Center’s Icing Research Tunnel at various icing conditions. Similar to other environmental conditions studied in the literature, we show an increase in grain size at larger distances from the growth interface; however, the data shows substantially larger grains than what was expected from the prior literature. Ice accrued at lower temperatures has a smaller grain size at all distances from the growth interface. No change in grain size was noticed when varying only the wind speed. A correlational analysis shows that smaller grain sizes at the growth interface corresponded to an increase in the apparent ice adhesion strength when the adhesive failure was interfacial, but not when the failure was cohesive. These results may explain the overall trend in the literature of increasing apparent adhesion strength with decreasing temperature. Incorporating microstructure trends for various environmental conditions in icing models may increase the certainty in predicting ice adhesion strength and shedding, and will provide a better basis for comparison between adhesive tests on ice produced in different facilities and at different storage times.

• Ice Fabric↗

NASA NTRS2012

Fatigue Failure Modes of the Grain Size Transition Zone in a Dual Microstructure Disk

Mechanical property requirements vary with location in nickel-based superalloy disks. In order to maximize the associated mechanical properties, heat treatment methods have been developed for producing tailored grain microstructures. In this study, fatigue failure modes of a grain size transition zone in a dual microstructure disk were evaluated. A specialized heat treatment method was applied to produce varying grain microstructure in the bore to rim portions of a powder metallurgy processed nickel-based superalloy disk. The transition in grain size was concentrated in a zone of the disk web, between the bore and rim. Specimens were extracted parallel and transversely across this transition zone, and multiple fatigue tests were performed at 427 C and 704 C. Grain size distributions were characterized in the specimens, and related to operative failure initiation modes. Mean fatigue life decreased with increasing maximum grain size, going out through the transition zone. The scatter in limited tests of replicates was comparable for failures of uniform gage specimens in all transition zone locations examined.

Gabb, Timothy P.↗

NASA NTRS1992

Generic grain size distribution for liquid phase sintering

In order to develop an empirical model to represent a generic grain size distribution for liquid phase sintering, experimental data and theoretical models are analyzed using the plot of standard normal vs normalized size. From the experimental 3D grain size plot, the most representative line is deduced. The line best fits the Lifshitz-Slyozov encounter modified model except for the small size ranges of the lower 15 percent of the distribution. It is shown that grain coalescence might be a cause for this departure from theory.

German, R. M.↗

NASA NTRS1983

Frost grain size metamorphism - Implications for remote sensing of planetary surfaces

The effective grain size of a material on a planetary surface affects the strength of absorption features observed in the reflectance of a particulate surface. In the case of a planetary surface containing volatile ices, the absorption characteristics can change in connection with processes leading to a change in the grain size of the material. The present investigation is concerned with an evaluation regarding the occurrence of such processes and the implications for remote sensing applications. It is found that quantitative modeling of the kinetics of grain growth and destruction by thermal and nonthermal processes can provide a means to reconcile apparent optical paths in the volatile portions of planetary surfaces with the physical history of those surfaces. Attention is also given to conditions in the case of the Pluto/Triton system, Uranus and Saturnian satellites, and the Galilean system.

Clark, R. N.↗

NASA NTRS1996

Retrieval of Surface Snow Grain Size and Melt Water from AVIRIS Spectra

The Earth's energy balance and hydrology are affected by the distribution and characteristics of snow cover on the surface. Snow grain size and snow melt influence surface albedo and hydrology. A model of snow reflectance that depends on both grain size and surface melt water was developed to derive these parameters from remote spectral measurements. This reflectance model is based on a discrete ordinate radiative transfer approach that uses Mie calculations of snow optical properties, which are based on the complex refractive index of ice and water. This snow model was linked to an atmospheric radiative transfer code and a nonlinear least squares fitting algorithm. The resulting combined algorithm was applied to an AVIRIS snow data set acquired over Mammoth Mountain, California. Maps of grain size and surface snow melt were generated that are consistent with the expected ranges and distributions for conditions at the site.

Green Robert O.↗

NASA NTRS1978

Core 74001/2 - Grain size and petrology as a key to the rate of in-situ reworking and lateral transport on the lunar surface

A suite of samples from the double drive tube 74001/2 has been studied. Material from this core mainly consists of orange and black droplets interpreted to be volcanic pyroclastic ejecta. Grain size analysis indicates that this material is very homogeneous in its grain size properties. It is also the finest and best sorted suite of soil samples in the lunar collection having a mean grain size of 40 microns and a mean standard deviation of 1.75 phi. The upper 5.5 cm of this core has apparently undergone in situ reworking by meteorites over a period of about 10 million years. This reworked zone contains 'exotic' grains including basalt, mineral fragments, vitric breccias, and agglutinates. One type of agglutinate is unique and has been made primarily from orange and black glass droplets melted and welded together by micrometeorite impacts. Other agglutinates are made mainly from basaltic fragments and minerals. The amount of 'exotic' material added to the core combined with an estimate of the location of the source areas for the 'exotic' material allows us to estimate that a maximum of about 0.36 gm per sq cm of regolith surface is added from a radius of about 1 meter in 10 million years. Furthermore, no more than about 0.01 gm per sq cm of regolith surface is added from a radius of about 100 meters in 10 million years.

Mckay, D. S.↗

NASA NTRS1980

Determination of the total grain size distribution in a vulcanian eruption column, and its implications to stratospheric aerosol perturbation

The total grain distribution of tephra from the eruption by the Fuego volcano in Guatemala on Oct. 14, 1974 was determined by grain size analysis. The region within each isopach has a grain distribution which was weighted proportionally to its percentage volume; the total distribution had a median grain size of 0.6 mm and a sorting coefficient of 2.3. The ash composed of fine particles did not fall in the volcano area as part of the recognizable tephra blanket; the eruption column reached well into the stratosphere to the height of 10-12 km above sea level, with mass flux rate estimated altitudes of 18-23 km

Murrow, P. J.↗

NASA NTRS1986

Ultrasonic Verification of Metal-Grain Size

Ultrasonic attenuation as function of frequency determined for metal sample having known mean grain diameter. Once function determined for one sample of material, scaled to determine mean grain size of other samples of materials. Results suggest ultrasonic approach viable for verifying effects of heat treatments that vary grain size. Uses of this technology include nondestructive ultrasonic verification size heat treatments and other online inspection systems.

Generazio, E. R.↗

NASA NTRS1991

Effects of grain size and shape in modeling reflectance spectra of mineral mixtures

The effects of grain size and shape on the reflectance spectra of mineral mixtures are investigated to improve a reflectance model called the isograin model, whose prototype was proposed by M. Kinoshita in 1985. The sample powder was assumed to consist of an infinite number of layers, each of which has the same thickness with the grain size d.

Hiroi, T.↗

NASA NTRS1980

Chemical and isotopic fractionation by grain size separates

Fractionation of refractory elements according to grain size is argued to occur during their growth. Two major modes should exist: (1) during thermal condensation sequences whenever the condensing phase (e.g. Mg2SiO4) does not alloy with the precondensed phase (e.g. MgAl2O4); (2) during accretion of gaseous atoms in the nonequilibrated interstellar medium. Processes dynamically sorting grains according to size (e.g. sedimentation) therefore are potentially capable of achieving fractionations normally attributed to separations of dust and gas. This paper considers the first mode during supernova condensation; however, it also can occur in an equilibrium solar condensation sequence owing to an overlooked freedom in that simplified description.

Clayton, D. D.↗

NASA NTRS1976

Geochemistry of grain-size fractions of soils from the Taurus-Littrow valley floor

Results are presented for a study in which high-precision instrumental neutron activation analysis was applied to determine the abundances of seven rare-earth and nine other elements in two grain-size fractions (90 to 150 microns and less than 20 microns) of eight soils from the Taurus-Littrow Valley floor and one Apollo 11 bulk-soil fraction with grain sizes of less than 1 mm. Compositional differences between the two size fractions of two valley-floor soils are examined, and mixing of soil components is investigated. It is found that a five-component mixing model describes very adequately the chemical composition of bulk soils with grain sizes of less than 1 mm as mixtures of local Apollo 17 rock types (basalt, anorthositic gabbro, noritic breccia), orange glass, and meteorites, but does not describe well the chemical compositions of the other two size fractions. A ten-component model is used to show that the compositions of those two size fractions can be well represented as mixtures of the five components if the mineralogy and chemical composition of the basalt component are allowed to vary in the size fractions.

Korotev, R. L.↗

NASA NTRS2010

Fatigue Resistance of the Grain Size Transition Zone in a Dual Microstructure Superalloy Disk

Mechanical property requirements vary with location in nickel-based superalloy disks. To maximize the associated mechanical properties, heat treatment methods have been developed for producing tailored microstructures. In this study, a specialized heat treatment method was applied to produce varying grain microstructures from the bore to the rim portions of a powder metallurgy processed nickel-based superalloy disk. The bore of the contoured disk consisted of fine grains to maximize strength and fatigue resistance at lower temperatures. The rim microstructure of the disk consisted of coarse grains for maximum resistance to creep and dwell crack growth at high temperatures up to 704 C. However, the fatigue resistance of the grain size transition zone was unclear, and needed to be evaluated. This zone was located as a band in the disk web between the bore and rim. Specimens were extracted parallel and transverse to the transition zone, and multiple fatigue tests were performed at 427 and 704 C. Mean fatigue lives were lower at 427 C than for 704 C. Specimen failures often initiated at relatively large grains, which failed on crystallographic facets. Grain size distributions were characterized in the specimens, and related to the grains initiating failures as well as location within the transition zone. Fatigue life decreased with increasing maximum grain size. Correspondingly, mean fatigue resistance of the transition zone was slightly higher than that of the rim, but lower than that of the bore. The scatter in limited tests of replicates was comparable for all transition zone locations examined.

Gabb, T. P.↗