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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Versatile Sequential Casting Processing for Highly Efficient and Stable Binary Organic Photovoltaics

Forming an ideal bulk heterojunction (BHJ) morphology is a critical issue governing the photon to electron process in organic solar cells (OSCs). Complementary to the widely-used blend casting (BC) method for BHJ construction, sequential casting (SC) can also enable similar or even better morphology and device performance for OSCs. Here, BC and SC methods on three representative donor:acceptor (D:A) blends are utilized, that is, PM6:PC 71 BM, PM6:IT-4F and PM6:L8-BO. Higher power conversion efficiencies (PCEs) in all cases by taking advantage of beneficial morphology from SC processing are achieved, and a champion PCE of 18.86% (certified as 18.44%) based on the PM6:L8-BO blend is reached, representing the record value among binary OSCs. The observations on phase separation and vertical distribution inspire the proposal of the swelling–intercalation phase-separation model to interpret the morphology evolution during SC processing. Further, the vertical phase segregation is found to deliver an improvement of device performance via affecting the charge transport and collection processes, as evidenced by the D:A-ratio-dependent photovoltaic properties. Besides, OSCs based on SC processing show advantages on device photostability and upscale fabrication. Finally, this work demonstrates the versatility and efficacy of the SC method for BHJ-based OSCs.

14 SOLAR ENERGY↗
DOE OSTI2018

Anti-biofilm Activity of Solvent-Cast and Electrospun Polyhydroxyalkanoate Membranes Treated with Lysozyme

Biofilms consist of groups of microorganisms that adhere to surfaces, such as wound and implant surfaces, making it difficult to prevent or remove their formation by antibiotic treatment, due to the innate resistance of the biofilm. Effective treatments of medical biofilms are limited. Polyhydroxyalkanoate (PHA) is a biodegradable and biocompatible polymer that is a suitable alternative to petroleum based polymers for use as a raw material for medical applications. In this study, membranes of the copolymer poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) [P(HB-co-HHx)] containing different HHx monomer contents were used due to its porosity and flexibility, and different sheets were prepared by solvent-casting and electrospinning methods. The sheets were loaded with lysozyme in order to measure the maximum amount of protein adsorption and to examine the ability of immobilized enzyme to inhibit biofilm formation and detach previously established biofilms. Our results have shown maximum loading of 16.1 µg enzyme per 9.5 mm{sup 3} discs, and these sheets are effective for inhibiting biofilm formation. Also, lysozyme loaded, eletrospun sheets were observed to more effectively inhibit biofilm formation, as compared to solvent-cast sheets. Based on this study, P(HB-co-HHx) sheets are a suitable material for being used as a potential raw material for fabrication of wound dressings to be used in anti-biofilm treatments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Formation Mechanism of Surface Crack in Low Pressure Casting of A360 Alloy

A surface crack defect is normally found in low pressure castings of Al alloy with a sudden contraction structure. To further understand the formation mechanism of the defect, the mold filling process is simulated by a two-phase flow model. The experimental results indicate that the main reason for the defect deformation is the mismatching between the height of liquid surface in the mold and pressure in the crucible. In the case of filling, a sudden contraction structure with an area ratio smaller than 0.5 is obtained, and the velocity of the liquid front increases dramatically with the influence of inertia. Meanwhile, the pressurizing speed in the crucible remains unchanged, resulting in the pressure not being able to support the height of the liquid level. Then the liquid metal flows back to the crucible and forms a relatively thin layer solidification shell on the mold wall. With the increasing pressure in the crucible, the liquid level rises again, engulfing the shell and leading to a surface crack. As the filling velocity is characterized by the damping oscillations, surface cracks will form at different heights. The results shed light on designing a suitable pressurizing speed for the low pressure casting process.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Single Crystal Casting with Fluidized Carbon Bed Cooling: A Process Innovation for Quality Improvement and Cost Reduction

Superalloy gas turbine blades are being produced by investment casting and directional solidification. A new process, Fluidized Carbon Bed Cooling (FCBC), has been developed and is now being optimized in a prototype casting unit with 10 kg pouring weight. In early test runs with still rather simple mold cluster geometries, a reduction of the primary dendrite arm spacing of around 40 pct compared to the standard radiation cooling process (HRS) could be demonstrated. The improvement is mainly attributed to higher temperature gradients driving solidification, made possible by a functioning Dynamic Baffle. Compared to earlier development efforts in the literature, contamination of the melt and damage to the equipment are avoided using carbon-based fluidized bed materials and the so-called “counter pressure concept.”.

36 MATERIALS SCIENCE↗
DOE OSTI2018

An Integrated Study on the Evolution of Inclusions in EH36 Shipbuilding Steel with Mg Addition: From Casting to Welding

Inclusion evolution behaviors, in terms of composition, size, and number density, and associated influence on the microstructures of the as-cast slabs, rolled plates, and simulated welded samples of plain EH36 and EH36-Mg shipbuilding steels have been systematically investigated. The results indicate that the inclusions in the as-cast plain EH36 are almost Al-Ca-S-O-(Mn) complex oxides with sizes ranging from 1.0 to 2.0 μm. After Mg addition, a large amount of individually fine MnS precipitates and Mg-containing Ti-Al-Mg-O-(Mn-S) complex inclusions are generated, which significantly refine the microstructure and are conducive to the nucleation of acicular ferrite in the rolled and welded sample. Moreover, after rolling and welding thermal simulation, the number of individual MnS decreases gradually due to its precipitation on the surface of Ti-Al-Mg-O oxides.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Ladle Changeover Condition on Transient Three-Phase Flow in a Five-Strand Bloom Casting Tundish

The transient three-phase flow behavior in a five-strand bloom casting tundish during the ladle changeover process considering a constant casting speed was investigated by the VOF model, and the effect of ladle throughput rate, shroud immersion depth, turbulence inhibitor structure and ladle changeover time on the turbulent flow, and level fluctuations during the filling process were analyzed to optimize the flow pattern in the tundish during ladle changeover. The results showed that the exposed area of molten steel in the impact zone increases as the ladle throughput rate increases during the filling process and that the exposure of molten steel is eliminated when the ladle throughput rate is 1.5Q{sub steady}. As the immersion depth of the shroud increases, a slight decrease in slag entrainment happens, while the exposed area of molten steel first decreases and then increases. The shroud immersion depth should be 310 mm. When the optimized turbulence inhibitor is used, the wave crests of the steel level are greatly reduced, the height of the level fluctuation is alleviated with the maximum value decreasing from 33 mm to approximately 10 mm, and the exposure of molten steel is eliminated. When the ladle changeover time is between 2 and 3 minutes, the exposed area of molten steel during the stable period of the filling process is in the range from 150 to 170 cm{sup 2}, which is substantially less than the exposed area of 500 cm{sup 2} when the ladle changeover time is 4 minutes. Therefore, the ladle changeover time should be controlled within 3 minutes. The flaw detection disqualification rate caused by ladle changeover operation is decreased from 43.8 to 25.8 pct of the total disqualified steel rails after optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Porosity Prediction in A356 Wheel Casting

A FLUENT™-based thermal-fluid-compositional model has been developed and applied to a low-pressure, die-cast, A356 aluminum alloy wheel to explore the effects of macro-segregation of hydrogen and late-stage liquid encapsulation on pore formation during solidification. Based on the evolution of temperature, pressure, and hydrogen concentration in the liquid output from FLUENT, the porosity size distribution has been predicted at a number of locations in a commercially produced wheel using an in-house micro-porosity model. The porosity model incorporates pore nucleation kinetics based on hydrogen supersaturation, and two modes of pore growth: the first, occurring at low solid fractions is based on hydrogen diffusion; and the second, occurring at high solid fractions is based on conservation of volume. Samples from a commercially cast wheel have been analyzed using X-ray micro-tomography to provide basic validation of the micro-porosity model. The predicted results showed that the evolution in pressure has the dominant effect on pore growth, but only under conditions where pores have nucleated prior to late-stage liquid encapsulation. Otherwise, the cooling rate appears to have the dominant effect. The accuracy of the model is discussed in terms of the predicted pore size distribution and number density of pores. Areas for continued development are presented.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Application of Al-2La-1B Grain Refiner to Al-10Si-0.3Mg Casting Alloy

This paper reports the application and microstructure refining effect of an Al-2La-1B grain refiner in Al-10Si-0.3Mg casting alloy. Compared with the traditional Al-5Ti-1B refiner, Al-2La-1B refiner shows better performances on the grain refinement of Al-10Si-0.3Mg alloy. Transmission electron microscopy analysis suggests that the crystallite structure features of LaB6 are beneficial to the heterogeneous nucleation of α-Al grains. Regarding the mechanical performances, tensile properties of Al-10Si-0.3Mg casting alloy are prominently improved, due to the refined microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Low Solution Temperature Heat Treatment of AlSi{sub 9}Cu{sub 3}(Fe) High-Pressure Die-Casting Actual Automotive Components

Usually, high-pressure die-casting (HPDC) components cannot be heat-treated at high temperature without the occurrence of surface blisters, which are unacceptable for surface finish and may reduce the mechanical properties. In this context, the purpose of the present paper was to analyze the effectiveness of special low solution temperature T6 heat treatment in overcoming this limit for HPDC AlSi{sub 9}Cu{sub 3} alloy. Very low solution temperatures (< 450 °C, followed by 165 °C aging) to prevent the occurrence of blisters were combined with commonly used times (from 1 to 16 h) ensuring the feasibility of industrial application. Treatments were conducted on samples extracted from actual castings to evaluate the typical defects encountered in common production. Properties were analyzed by means of visual inspection, microstructural observations, image analysis, hardness, tensile tests and fractography. The results showed that it is possible to use solubilization temperatures below 450 °C for several hours in a T6 treatment to give strengthening without relevant blistering in AlSi{sub 9}Cu{sub 3} alloy. The optimum match of properties was provided by a solution treatment at 430 °C for 4 h followed by an aging at 165 °C for 8 h, which gave a yield increase of ~ 50 MPa, an increase in ductility and the best Quality Index value.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effects of Mg Content on the Fatigue Strength and Fracture Behavior of Al-Si-Mg Casting Alloys

In order to investigate the influence of Mg content on the fatigue properties in Al-Si-Mg alloy, uniaxial tensile tests and rotating bending fatigue tests were conducted on two Al-7Si-Mg casting alloys, with different Mg contents of 0.3 and 0.6 wt.%. The fracture surfaces of the specimens were observed by scanning electron microscopy, and the fatigue crack growth process was obtained by the replica method. The results indicate that the increase in Mg content enhances the yield strength and tensile strength of the alloy, whereas it reduces its elongation. There is an obvious knee point in the S–N curves of Al-7Si-0.6Mg alloy while that of Al-7Si-0.3Mg alloy shows continuous decrease. The fatigue strength at 5 × 10{sup 5} cycles is 60 MPa for Al-7Si-0.3Mg alloy and 80 MPa for Al-7Si-0.6Mg alloy. For the two types of specimens, the fatigue failure can initiate from crystal slip and casting defects. The replica results suggest that cracks in Al-7Si-0.6Mg alloy grow more slowly than that in Al-7Si-0.3Mg alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of Vanadium on Modification of Iron-Rich Intermetallics and Mechanical Properties in A356 Cast Alloys with 1.5 wt.% Fe

Formation of Fe-rich intermetallics and mechanical properties of vanadium-modified A356 cast alloys with 1.5 wt.% Fe were investigated using image analysis, scanning electron microscopy, differential scanning calorimetry, and a tensile test. The results showed that V content has no apparent influence on α-Al grain size in A356 alloys with high Fe content. Also, 0.8 wt.% V is beneficial for improving mechanical properties in A356 cast alloys with high Fe content. Specifically, these results can be attributed to the formation of Chinese script or block α-Fe phases, refined needle-like β-Fe (Al{sub 5}FeSi), and decreased porosities. An excessive amount of V deteriorates mechanical properties of alloys because it leads to VSi{sub 2} formation, large sized iron-rich intermetallics, and increased porosities.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Ti and REE on Primary Crystallization and Wear Resistance of Chromium Cast Iron

The article presents the results of primary crystallization, wear resistance and SEM studies of chromium cast iron inoculated with ferrotitanium and rare earth elements as a mischmetal inoculating mixture. Thermal-derivative analysis method was used to conduct studies of primary crystallization in two types of testers, namely ATD-C and ATD-Is, reflecting two different cooling speeds. Wear resistance tests were performed with the use of modified pin-on-disk method on Tribotester 3-POD device, where the samples were moving in circular motion in metal-mineral friction system. Silicon carbide was used as a counter sample. The studies allowed to determine the influence of selected inoculants on the microstructure and wear resistance of the studied samples. All characteristic crystallization temperatures of samples casted into ATD-Is testers increased, as well as wear resistance of each inoculated samples compared to the non-inoculated sample. It was proven that TiC and REE compounds are effective inoculants for chromium carbides and that REE compounds can work as underlay for TiC crystallization.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Interaction of Strain Refined Precipitates and Recrystallized Grains in Nb-Ti Microalloyed Steel during Continuous Casting, Hot-Core Heavy Reduction Rolling, and Reheating Process

Hot-core heavy reduction rolling (HHR{sup 2}) is an energy-saving process that directly rolls continuously cast slabs at the end of solidification that have a large temperature gradient. Here, we elucidated the interaction of strain refined precipitates and recrystallized grains in Nb-Ti microalloyed steel during continuous casting, hot-core heavy reduction rolling, and reheating process. Furthermore, theoretical models were established to calculate recrystallization driving force and pinning force at temperatures in the range of 850-1300 °C by a two-stage interrupted compression test using a Gleeble-3800 thermomechanical simulator. The study indicated that a random dispersion of strain refined precipitates with a size range of ~ 6-10 nm was obtained in the hot-core heavy reduction rolled slab, which was different from the coarse and uneven distribution of precipitates in a conventional slab. Upon reheating, the austenite grains in the hot-core heavy reduction rolled slab were significantly refined and evenly distributed along the thickness direction. This is attributed to the random dispersion of strain refined precipitates formed in the HHR{sup 2} process.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Aqueous Corrosion Behavior of Cast CoCrFeMnNi Alloy

CoCrFeMnNi high-entropy alloy demonstrates good mechanical properties and can be further strengthened by thermomechanical processes. A sample alloy prepared by vacuum casting in a graphite mold was further investigated for its corrosion resistance. One-millimeter thin strips of cast alloy were used to investigate its corrosion behavior at room temperature. Linear potentiodynamic tests of the alloy in sodium chloride solution confirmed uniform corrosion property comparable to stainless steel AISI 304. However, a positive cyclic hysteresis loop indicated susceptibility to pitting corrosion. In sodium hydroxide solution, metastable pit formation was observed, while sulfuric acid solution passivated the alloy. In both cases, the alloy did not show any spontaneous pitting tendency.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Development of Pore-Free Ti-Si-C MAX/Al-Si Composite Materials Manufactured by Squeeze Casting Infiltration

Open-porous MAX phase skeletons from Ti{sub 3}SiC{sub 2} were manufactured by Microwave-Assisted Self-propagating High-temperature Synthesis (MASHS) and subsequently subjected to squeeze casting infiltration with an Al-Si lightweight casting alloy (EN AC-44200). This alloy was chosen due to its high flowability, corrosion resistance and good machinability. The manufactured composites, together with a reference sample of the original alloy, underwent testing of thermal properties, including thermal conductivity and diffusivity, specific heat and thermal expansion in the temperature range 50-500 °C, which corresponds to the expected working temperatures of the material. The fabricated AlSi/Ti{sub 3}SiC{sub 2} composites have significantly increased thermal stability, with coefficients of thermal expansion (approximately 10-11 × 10{sup −6} °C{sup −1}) half that of the original alloy. As regards mechanical properties, the instrumental Young’s modulus and Vickers hardness of the composite materials are 170.8 and 8.5 GPa, respectively. Moreover, the microstructure and phase composition, structural defects and potential impacts between constituents of the manufactured composites were characterized using SEM, TEM and STEM microscopy and EDS and XRD analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Influence of Casting Microvoids on the Constitutive Behavior of As-Quenched Al-Cu-Mn Alloy

Microvoids, a common casting defect, have a significant effect on the mechanical properties of as-quenched aluminum alloys. In this study, low-pressure casting and quenching processes were conducted on an Al-Cu-Mn alloy to investigate the porosity variation, which was characterized by using a high-precision densimeter and x-ray microtomography. Mechanical properties were tested at elevated densities varying from 2.7828 to 2.8114 g/cm{sup 3}. The Voce behavior and linear hypotheses were proposed on the relationship between the yield strength and density. A tensile constitutive model was established and validated with experimental data, and the difference between tension and compression was compared. With a decrease in density, the yield stress declined, and the tensile–compressive asymmetry increased. The ideal density, ρ{sub 0}, and the ideal saturated stress, σ{sub s}, of the as-quenched alloy were predicted. A comparison between the quantity and volume of microvoids showed that larger pores were the main factor affecting the porosity of the as-quenched alloy. The growth of single microvoid and the coalescence of several microvoids caused an increase in porosity under tensile stress.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Energy modeling and efficiency analysis of aluminum die-casting processes

Energy modeling and efficiency analysis are considered the foundation of manufacturing process optimization to improve quality and efficiency and reduce energy consumption and carbon emissions during aluminum die-casting processes. Our report introduced an energy modeling method to connect gas and electric energy consumption with production rate of aluminum die-casting processes based on data collected at workshops with various combination of machines and products. The detailed modeling process involved the development of a data-acquiring system and the comparison of various kinds of nonlinear regression methods. The resulting models were confirmed with actual production data and were also used to improve production scheduling. Furthermore, it was found that if the modeling results are reasonably used and production is accordingly well-scheduled, 10 to 15% of energy savings could be realized without sacrificing profits.

42 ENGINEERING↗
DOE OSTI2021

In situ synchrotron investigation of degenerate graphite nodule evolution in ductile cast iron

Ductile cast irons (DCIs) are of increasing importance in the renewable energy and transportation sectors. The distribution and morphology of the graphite nodules, in particular the formation of degenerate features during solidification, dictate the mechanical performance of DCIs. In situ high-speed synchrotron X-ray tomography was used to capture the evolution of graphite nodules during solidification of DCI, including degenerate features and the effect of the carbon concentration field. The degeneration of nodules is observed to increase with re-melting cycles, which is attributed to Mg-loss. The dendritic primary austenite and carbon concentration gradients in the surrounding liquid phase were found to control nodule morphology by locally restricting and promoting growth. A coupled diffusion-mechanical model was developed, confirming the experimentally informed hypothesis that protrusions form through liquation cracking of the austenite shell and subsequent localised growth. In conclusion, these results provide valuable insights into the solidification kinetics of cast irons, supporting the design of advanced alloys.

36 MATERIALS SCIENCE↗