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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

A Geometric Approach to Modeling Microstructurally Small Fatigue Crack Formation: Simulation and Prediction of Crack Nucleation in AA 7075-T651 - 2

The objective of this paper is to develop further a framework for computationally modeling microstructurally small fatigue crack growth in AA 7075-T651 [1]. The focus is on the nucleation event, when a crack extends from within a second-phase particle into a surrounding grain, since this has been observed to be an initiating mechanism for fatigue crack growth in this alloy. It is hypothesized that nucleation can be predicted by computing a non-local nucleation metric near the crack front. The hypothesis is tested by employing a combination of experimentation and nite element modeling in which various slip-based and energy-based nucleation metrics are tested for validity, where each metric is derived from a continuum crystal plasticity formulation. To investigate each metric, a non-local procedure is developed for the calculation of nucleation metrics in the neighborhood of a crack front. Initially, an idealized baseline model consisting of a single grain containing a semi-ellipsoidal surface particle is studied to investigate the dependence of each nucleation metric on lattice orientation, number of load cycles, and non-local regularization method. This is followed by a comparison of experimental observations and computational results for microstructural models constructed by replicating the observed microstructural geometry near second-phase particles in fatigue specimens. It is found that orientation strongly influences the direction of slip localization and, as a result, in uences the nucleation mechanism. Also, the baseline models, replication models, and past experimental observation consistently suggest that a set of particular grain orientations is most likely to nucleate fatigue cracks. It is found that a continuum crystal plasticity model and a non-local nucleation metric can be used to predict the nucleation event in AA 7075-T651. However, nucleation metric threshold values that correspond to various nucleation governing mechanisms must be calibrated.

Hochhalter, Jake D.↗
NASA NTRS1980

On the feasibility of quantitative ultrasonic determination of fracture toughness: A literature review

The three main topics covered are: (1) fracture toughness and microstructure, (2) quantitative ultrasonic and microstructure; and (3) scattering and related mathematical methods. Literature in these areas is reviewed to give insight to the search of a theoretical foundation for quantitative ultrasonic measurement of fracture toughness. The literature review shows that fracture toughness is inherently related to the microstructure and in particular, it depends upon the spacing of inclusions or second particles and the aspect ratio of second phase particles. There are indications that ultrasonic velocity attenuation measurements can be used to determine fracture toughness. The leads to a review of the mathematical models available in solving boundary value problems related to microstructural factors that govern facture toughness and wave motion. A framework towards the theoretical study for the quantitative determination of fracture toughness is described and suggestions for future research are proposed.

Fu, L. S.↗
DOE OSTI2024

In Situ Study on Fracture Behavior of Thick-Section Friction Stir-Welded AA 5083 Alloy

Friction stir welding (FSW) produces a gradient microstructure with distinct metallurgical zones. Here, the present study focuses on characterizing the fracture behavior during uniaxial loading across thick-section FSW joint in nonheat-treatable 5083 aluminum alloy. The hardness variation is linked to microstructural features across the weld zones through correlative microscopy. Notably, the heat-affected zone (HAZ) exhibits a lower hardness of 75 HV, while the thermomechanically affected zone (TMAZ) and stir zones (SZ) display a hardness of around 79HV. A marginal difference in hardness in HAZ prompts strain localization in HAZ on the advancing side of the weld, resulting in offset in fracture from the SZ, which is captured through in situ monitoring of the tensile test. Further, the postdeformation analysis reveals crack propagation along the maximum shear stress plane due to the coalescence of microvoids resulting from the fracturing and debonding of second-phase particles. Overall, this study provides valuable insight for optimizing the FSW process of AA 5083 alloy for thick-section applications.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Quantitative characterization of spatial distribution of particles in materials: Application to materials processing

Most engineering materials contain second phase particles or fibers which serve to reinforce the matrix phase. The effect of reinforcements on material properties is usually analyzed in terms of the average volume fraction and spacing of reinforcements, quantities which are global microstructural characteristics. However, material properties can also depend on local microstructural characteristics; for example, on how uniformly the reinforcing phase is distributed in the material. The analysis method will then be applied to a materials processing problem to discover how processing parameters can be selected to maximize redistribution of the reinforcing phase during processing. Several mathematical analysis methods could be adapted to the problem of characterizing the distribution of particles in materials. A tessellation-based method was selected. In the first phase of the investigation, a software package was written to automate the analysis. Typical results are shown. The analysis technique allows the degree to which particles are clustered together, the size and spacing of particle clusters, and the particle density in clusters to be found. The analysis methods were applied to computer-generated distributions and to a few real particle-containing materials. Methods for analyzing a nonuniform particle distribution in a material can be applied to two broad classes of materials science problems: understanding how the resulting particle distribution affects properties. The analysis method described is applied to a materials processing problem: how to select extrusion conditions to maximize the redistribution of reinforcing particles that are initially nonuniformly distributed. In addition, the tessellation-based method to analyze star distributions in spiral galaxies was adapted, illustrating the diverse types of problems to which the analysis method can be applied.

Parse, J. B.↗
NASA NTRS1988

Transparent metal model study of the use of a cellular growth front to form aligned monotectic composite materials

The purpose of this work was to resolve a scientific controversy in the understanding of how second phase particles become aligned during unidirectional growth of a monotectic alloy. A second aspect was to make the first systematic observations of the solidification behavior of a monotectic alloy during cellular growth in-situ. This research provides the first systematic transparent model study of cellular solidification. An interface stability diagram was developed for the planar to cellular transition of the succinonitrile glycerol (SNG) system. A method was developed utilizing Fourier Transform Infrared Spectroscopy which allows quantitative compositional analysis of directionally solidified SNG along the growth axis. To determine the influence of cellular growth front on alignment for directionally solidified monotectic alloys, the planar and cellular growth morphology was observed in-situ for SNG between 8 and 17 percent glycerol and for a range of over two orders of magnitude G/R.

Kaukler, William F.↗
NASA NTRS1977

Alloy design with oxide dispersoids and precipitates

The mechanical behavior of particle-strengthened alloys is reviewed. On the basis of this knowledge, it is concluded that second-phase particles, coherent or incoherent, can enhance the flow strength, creep resistance, and stress-rupture life of alloys. Unfortunately, particles are usually not beneficial alloy-design elements if enhanced uniaxial ductility, plane-strain ductility, stress-rupture ductility, and toughness are called for. Such properties as fatigue-crack propagation resistance appear to require, for example, both high strength and high ductility, a situation which can come to pass only when the perennial conflict between strength and ductility is resolved in particle-strengthened systems in particular and in any other material system in general. Wherever possible, the role of coherent and incoherent particles in alloy design is distinguished.

Tien, J. K.↗
DOE OSTI2023

Understanding and control of Zener pinning via phase field and ensemble learning

Zener pinning refers to the dispersion of fine particles which influences grain size distribution via movement of grain boundaries in a polycrystalline material. Grain size distribution in polycrystals has a significant impact on their properties including physical, chemical, mechanical, and optical to name a few. We explore the use of Phase-field modeling and machine-learning techniques to understand and improve the control of grain size distribution via Zener pinning in polycrystalline materials. We develop a machine learning model that determines the relative importance of various parameters to exercise microstructure control via Zener pinning. Our workflow combines high-throughput phase-field simulations and machine learning to address the computational bottlenecks associated with large-scale simulations as well as identify features necessary for microstructure control in polycrystals. A random forest (RF) regression model was developed to predict grain sizes based on five Phase-field model parameters, achieving an average prediction error of 0.72 nm for the training data and 1.44 nm for the test data. The importance of the input parameters is analyzed using the SHapley Additive exPlanations (SHAP) approach which reveals that diffusivity, volume fraction, and particle diameter are the most important parameters in determining the final grain size. These findings will allow us to select the best second-phase particles, optimize grain size distributions and thus design microstructures with the desired properties. The developed method is a highly versatile and generalizable approach that can be used to assess the combined effects of individual features in the presence of multiple variables.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Pion-decay radiation and two-phase acceleration in the June 3, 1982 solar flare

The June 3, 1982 flare is unique in the wealth of observed neutron, gamma-ray and energetic-particle emission that it produced. Using calculations of high-energy emissions to fit the various time-dependent gamma-ray fluxes, a self-consistent interaction model for the June 3 flare is constructed in which the observed fluxes are produced by two distinct particle populations with different acceleration and interaction time histories as well as different but time-independent energy spectra. The two populations are associated with first- and second-phase particle acceleration, respectively.

Ramaty, R.↗
DOE OSTI2021

Improvements to the Powder Processing of near-Final Shape alnico Magnets

Alnico permanent magnets (PMs), a recent PM system of interest as an attractive rare earth-free PM alternative, have advantageous high operating temperature and magnetic saturation with the potential for utilization in electric machines, e.g. interior-PM motors found in electric vehicles, if current directional solidification methods can be replaced by a true mass production approach. Recently, two unique alnico compositions, termed Full-Co and Co-lean, with improved coercivity, were gas atomized, compression molded, and vacuum sintered (4h at 1240°C) to high densities of 97.8% and 99.3%, respectively. However, the Co-lean remained fine grained isotropic magnets and the Full-Co grains were not textured, lowering magnetic strength in spite of attempts to grow large textured grains by a stress-biased solid state grain alignment method to convert them to high energy anisotropic magnets. It was hypothesized that oxidation during de-binding in air left many prior particle boundary oxides within the sintered microstructure that hindered grain growth and texturing during the stress-biased texturing procedure and prevented the desired abnormal grain growth (AGG). Here we explored a vacuum de-binding step that was linked (in-place) to vacuum sintering and found that the Co-lean exhibited faster uniform grain growth that doubled the average grain size (40 μm to 80 μm). Linked vacuum de-binding and sintering of Full-Co produced some AGG after only 1 h of 1240°C sintering. A new direction for promoting AGG (and stress-biased texturing) in alnico is being explored that utilizes a fundamental analysis of systems with second phase particles that either inhibit or boost grain growth. This effort explores the influence of vacuum de-binding linked to a series of lower sintering temperatures at a fixed time (4h) to see if oxide particle size and volume fraction can be changed to promote AGG conditions in alnico. Surprising qualitative results indicate that AGG may be promoted for vacuum sintering at less than 1200°C.

Rinko, Emily↗
DOE OSTI2020

A Model of Grain Boundary Complexion Transitions and Grain Growth in Yttria-Doped Alumina

In this work, we present a physically-parameterized microstructure evolution model for the Yttria-doped alumina system. Yttria-doped alumina is a well-known ceramic system which undergoes first-order phase-like transitions at grain boundaries, which can radically alter interface properties. The change in interfacial properties in turn can radically change microstructure outcomes during processing, including the induction of abnormal grain growth modes. In this work, we develop a simulation that evolves alumina microstructure as a function of yttria concentration and temperature. In the window studied, we achieve strong agreement with reviewed experimental results in identifying the windows for large grains, small grains, abnormal grain growth, and complexion transition kinetics. We then apply the model to study and demonstrate how the possible inclusion of second-phase particles or uneven solute distribution profiles will impact microstructure evolution. It is found that particles do not significantly affect abnormal grain growth in the window studied (but do lead to reduced grain size through pinning effects). It is found that even modest amounts of solute inhomogeneity will result in substantial changes in microstructure outcomes, frequently leading to clusters of abnormal grains. This model largely corroborates the expectations and hypotheses made from recent experimental studies in oxide-doped alumina systems. Further, it is found that there exists a peak transition fraction for the system at which abnormal grain size tends to be maximized.

Grain Growth, Grain Boundary Complexion, abnormal ↗
DOE OSTI2023

Development and characterization of a low-density TiNbZrAlTa refractory high entropy alloy with enhanced compressive strength and plasticity

A new refractory high entropy alloy (RHEA) is designed by combining refractory elements Nb and Ta with Ti, Zr, and Al, resulting in a (TiNbZr) 89 (AlTa) 11 alloy composition with a low-density of 6.0 g/cm 3 . The novel RHEA features a BCC matrix with B2 and Zr 5 Al 3 nano precipitates, exhibiting a compressive yield strength of ~890 MPa and specific yield strength of ~148.3 MPa g -1 cm 3 . Remarkably, the alloy demonstrates excellent compressive plasticity of ~70% at 298 K. As the temperature increases to 873 K, 1073 K, and 1273 K, the yield strength of the RHEA gradually decreases to ~610 MPa, ~ 210 MPa, and ~ 60 MPa, respectively. These results indicate that this novel RHEA showcases a combination of good specific strength and plasticity. Post-compression, B2, and Zr 5 Al 3 phases are observed. In conclusion, the second-phase particles dispersed throughout the grains hinder dislocation motion and contribute to the formation of sub-grain boundaries during hot compression.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Conversion of real-world aluminum scrap streams into high-performance Al–Mg–Si–Cu automotive alloys using shear assisted processing and extrusion

The conversion of post-consumer aluminum (Al) scrap into usable Al alloys without adding primary Al is challenging because of excess impurities. In this work, >99% post-consumer Twitch, used beverage cans (UBCs), and remelt scrap ingots (RSIs) were used as feedstock materials. As-cast and solution heat-treated feedstock billets were extruded using Shear Assisted Processing and Extrusion (ShAPE) at ~510°C, followed by press quenching. To explore the development of the microstructure, texture, and underlying mechanisms and how they contribute to the overall strengthening in as-extruded and artificially aged samples, scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) were used to collect microstructure and texture data. The enhanced strength and ductility were corroborated with the microstructural features and crystallographic texture. Simple shear $\textrm{A}/\bar{\textrm{A}}$, $\textrm{A}_1^*/\textrm{A} _2^*$ texture components along with weak $\textrm{C}$ and $\textrm{B}/\bar{\textrm{B}}$ texture components were formed during extrusion; the texture was strengthened after heat treatment. The refined second-phase particles helped to retain the deformed microstructure and texture. The contributions of dislocation and precipitate strengthening were maximized when billets were solution-heat-treated prior to extrusion. This is attributed to the formation of effective supersaturated solid solutions during the ShAPE process, which precipitate out during the peak age treatment. Overall, the highest yield strength of 305 MPa, ultimate tensile strength of 350 MPa, and elongation of 12% were achieved in artificially aged samples, which are comparable to those of Al 6082-T6.

Al alloy↗
DOE OSTI2022

Microstructural Characterization of As-Cast MP-1 Experiment U-10Mo Alloy

The Mini-Plate-1 (MP-1) test is the first in a series of fuel testing campaigns with the purpose of achieving regulatory qualification for the U-10Mo monolithic plate-type fuel system. The objective of MP-1 is to assess fuel performance behavior of fuel plates fabricated by a commercial fuel fabricator (BWX Technologies, Inc.) and make sure that the fuel maintains mechanical integrity and geometric stability and behaves in a stable and predictable manner. As a part of MP1 fabrication campaign several castings were prepared. The castings were vacuum induction melted using HEU pieces mixed with a master alloy made up of DU and molybdenum pieces. The Master Alloy was poured by a commercial vendor. There was little mixing during melting. A three-plate mold was utilized to form three U-10Mo plates per melt pour. The work described here shows that the resulting microstructure varies greatly from one cast plate to another, and from the top to the bottom of each cast plate. The extent of variation in microstructural features such as grain size, second phase particle (SPP) distribution and morphology, microsegregation of constituents within the dendritic microstructure, porosity, and casting abnormalities are presented and discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Effect of Initial Microstructure on the Toughness of Coarse-Grained Heat-Affected Zone in a Microalloyed Steel

Toughness of the coarse-grained-heat-affected-zone (CGHAZ) strongly depends on the prior austenite grain size. The prior austenite grain size is affected not only by chemical composition, thermal cycle, and dissolution of second-phase particles, but also by the initial microstructure. The effect of base metal microstructure (ferrite/pearlite obtained by air cooling and martensite obtained by water-quenching) on Charpy impact toughness of the CGHAZ has been investigated for different heat inputs for high-heat input welding of a microalloyed steel. A welding thermal cycle with a heat input of 100 kJ/cm and 400 kJ/cm were simulated on the MMS-300 system. Despite a similar microstructure in the CGHAZ of both the base metals, the average Charpy impact energy for the air-cooled base metal was found to be higher than the water-quenched base metal. Through thermo-kinetic simulations, it was found that a higher enrichment of Mn/C at the ferrite/austenite transformation interface of the CGHAZ of water-quenched base metal resulted in stabilizing austenite at a lower A1 temperature, which resulted in a coarser austenite grain size and eventually lowering the toughness of the CGHAZ.

36 MATERIALS SCIENCE↗
NASA NTRS1973

Composition effects on mechanical properties of tungsten-rhenium-hafnium-carbon alloys

The mechanical properties of rod and sheet fabricated from arc melted W-4Re-Hf-C alloys containing up to about 0.8 mol percent hafnium carbide (HfC) were evaluated in the as-worked condition. The DBTT's of electropolished bend and tensile specimens were independent of HfC content in this range but dependent on excess Hf or C above that required for stoichiometric HfC. Low temperature ductility was a maximum at Hf contents slightly in excess of stoichiometric. Variations in high temperature strength were also dependent on excess Hf and C. Maximum creep strengthening also occurred at Hf contents in excess of stoichiometric. Analysis of extracted second phase particles indicated that creep strength was reduced by increasing WC content in the HfC particles.

Witzke, W. R.↗
NASA NTRS1974

The effects of composition on mechanical properties of W-4Re-Hf-C alloys

Studies were made of the effects of alloy composition on the mechanical behavior of as-worked W-4Re-Hf-C alloys containing up to about 0.8 mol % Hfc. Extracted second-phase particles were analyzed and related to alloy composition and creep strength. While strengthening is attributed to HfC particles, the presence of excess hafnium or carbon (above the calculated amounts for stoichiometric HfC) in swaged W-4Re-Hf-C alloys generally causes a reduction of the high-temperature (1930 C) tensile strength; maximum creep strength is, however, indicated for alloys with a slight (about 0.05 to 0.1 at. %) excess of hafnium. Particle strengthening is reduced by WC in solid solution with HfC for allow compositions with an excess of carbon. The low-temperature ductility of worked W-4Re-Hf-C alloys appears to be far more dependent on the amount of excess C or Hf present than on the HfC particle content in the range studies.

Witzke, W. R.↗
NASA NTRS1977

Niobium-germanium superconducting tapes for high-field magnet applications

A process of fabricating superconducting Nb3Ge tapes by chemical vapor deposition (CVD) has been developed and tapes up to 10 meters long fabricated. The typical properties achieved were: critical temperature T sub c = 20 K, upper critical field H sub c2 = 29 tesla at 4.2 K, and J sub c = 3 to 4 x 10 to the 8th power A m(-2) at 4.2 K, 18 tesla. The relative depression of T sub c and H sub c2 compared with the best thin film samples sputtered on sapphire was due to the presence of Nb5Ge3 second-phase particles used as flux pinning centers and to strains induced by thermal mixmatch with Hastelloy B tape substrates. A peculiar field dependence of flux pinning force that was observed in both CVD and sputtered Nb3Ge indicated a premature pin-breaking mechanism or a phase inhomogeneity. Directions of further optimization work were defined.

Braginski, A. I.↗