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Results for “Densification”

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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

In-situ 3D visualization of composite microstructure during polymer-to-ceramic conversion

One route for producing fiber-reinforced ceramic-matrix composites entails repeated impregnation and pyrolysis of a preceramic polymer in a fiber preform. The process relies crucially on the development of networks of contiguous cracks during pyrolysis, thereby allowing further impregnation to attain nearly-full densification. The present study employs in-situ x-ray computed tomography (XCT) to reveal in three dimensions the evolution of matrix structure during pyrolysis of a SiC-based preceramic polymer to 1200 °C. Observations are used to guide the development of a taxonomy of crack geometries and crack structures and to identify the temporal sequence of their formation. A quantitative analysis is employed to characterize effects of local microstructural dimensions on the conditions required to form cracks of various types. Complementary measurements of gas evolution and mass loss of the preceramic polymer during pyrolysis as well as changes in mass density and Young's modulus provide context for the physical changes revealed by XCT. Furthermore, the findings provide a foundation for future development of physics-based models to guide composite fabrication processes.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Ultrahigh temperature in situ transmission electron microscopy based bicrystal coble creep in Zirconia II: Interfacial thermodynamics and transport mechanisms

This work uses a combination of stress dependent single grain boundary Coble creep and zero-creep experiments to measure interfacial energies, along with grain boundary point defect formation and migration volumes in cubic ZrO 2 . These data, along with interfacial diffusivities measured in a companion paper are then applied to analyzing two-particle sintering. The analysis presented here indicates that the large activation volume, v * = v f + v m primarily derives from a large migration volume and suggests that the grain boundary rate limiting defects are delocalized, possibly due to electrostatic interactions between charge compensating defects. The discrete nature of the sintering and creep process observed in the small-scale experiments supports the hypothesis that grain boundary dislocations serve as sources and sinks for grain boundary point defects and facilitate strain during sintering and Coble creep. Model two-particle sintering experiments demonstrate that initial-stage densification follows interface reaction rate-limited kinetics.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Bulk nanocrystalline Al alloys with hierarchical reinforcement structures via grain boundary segregation and complexion formation

Grain size engineering, particularly reducing grain size into the nanocrystalline regime, offers a promising pathway to further improve the strength-to-weight ratio of Al alloys. Unfortunately, the fabrication of nanocrystalline metals often requires non-equilibrium processing routes, which typically limit the specimen size and require large energy budgets. In this study, multiple dopant elements in ternary Al alloys are deliberately selected to enable segregation to the grain boundary region and promote the formation of amorphous complexions. Three different fully dense bulk nanocrystalline Al alloys (Al-Mg-Y, Al-Fe-Y, and Al-Ni-Y) with small grain sizes were successfully fabricated using a simple powder metallurgy approach, with full densification connected directly to the onset of amorphous complexion formation. All the compositions demonstrate densities above 99% with grain sizes <60 nm following consolidation via hot pressing at 585 °C. The very fine grain structure results in excellent mechanical properties, as evidenced by nanoindentation hardness values in the range of 2.2-2.8 GPa. Detailed microstructural characterization verifies the segregation of all dopant species to grain boundaries as well as the formation of amorphous complexions, which suggests their influential role in aiding effective consolidation and endowing thermal stability in the alloys. Moreover, nanorods with a core-shell structure are also observed at the grain boundaries, which likely contribute to the stabilization of the grain structure while also strengthening the materials. Lastly, intermetallic particles with sizes of hundreds of nanometers form in all systems. As a whole, the results presented here demonstrate a general alloy design strategy of segregation and boundary evolution pathway that enables the fabrication of multiple nanocrystalline Al alloys with hierarchical microstructures and improved performance.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effects of bridging fibers on the evolution of lamellar architecture during H 2 /H 2 O redox cycling of Fe-foams

Fe/Fe 3 O 4 redox cycling via cyclic H 2 /H 2 O exposure at 800 °C is studied in lamellar Fe foams with 15 vol% fibers, created by freeze-casting. Fibers were integrated in the foams to mitigate densification during cycling by mechanically supporting neighboring lamellae, thus preventing buckling and sintering at contact points. Three fiber types are examined: short (0.1 mm) and long (1–2 mm) stainless-steel fibers, and long zirconia fibers. Long fibers bridge lamellae and have a marked effect on the architecture by increasing the initial interlamellar porosity (from < 60 to > 85%), with a corresponding decrease in foam shrinkage during initial reduction and sintering (from > 80 to < 55% volumetric loss). Though performance improves as compared to fiber-free foams, fiber effectiveness against damage decreases with cycling: after 10 redox cycles, porosity falls from 85 to 50% for foams with long fibers. One novel degradation mechanism is identified: fiber engulfment. This mechanism occurs over successive redox cycles, as material from the lamellae cyclically engulfs (as Fe 3 O 4 ) and withdraws (as Fe) from the fibers, with a net transport from lamellae to fibers after each cycle. Finally, this cyclic coarsening mechanism alters foam architecture from bridged-lamellar (with evenly distributed porosity) to mixed lamellar/fibrous (with unevenly distributed porosity).

36 MATERIALS SCIENCE↗
DOE OSTI2025

Understanding coarsening of a post-corrosion microstructure in a molten salt by combining phase-field modeling and in situ tomography

Alloys corroding in molten salt have been observed to form bicontinuous, nanoporous microstructures via dealloying, which subsequently undergo coarsening due to facile transport in high-temperature conditions. In this work, we describe a methodology to elucidate the underlying transport mechanisms during coarsening of a bicontinuous microstructure via quantitative comparisons between phase-field simulations and four-dimensional in situ experiments, in this case X-ray nanotomography of the coarsening of a dealloyed 80 wt% Ni-20 wt% Cr microwire in molten KCl-MgCl 2 at 800°C. We conduct phase-field simulations initialized from experimental data to model coarsening via three different transport mechanisms: surface diffusion, solid bulk diffusion, and liquid bulk diffusion. These simulations reproduce key features of the experiment, such as the densification of the outer layer of the dealloyed wire and the reduction in radius over time. We quantitatively compare different microstructural characteristics between the simulations and experiment and extract temporal scaling factors that optimally match the time scales of the simulations to that of the experiment. This allows us to evaluate morphological similarity between the simulations and experiment and relate the experimental coarsening kinetics to fundamental material properties. We find that surface diffusion is most likely to be the dominant coarsening mechanism, and its kinetics imply a surface diffusivity of D S = 8.9 x 10 -20 m 3 /s, which is within the range of reported values for Ni-vacuum interfaces at 800°C. However, the difference between the experiment and the surface diffusion simulation increases substantially at late times, suggesting that other mechanisms, such as the dissolution of residual Cr, may be at play.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Scaling microstructural processes in the sintering of ionic ceramics

A multi-scale framework, combining a multiphase field formulation and large deformation mechanics, was developed as a stepping stone to perform the data analytics of the microstructural level kinetics of a sintering solid. Relevant microstructural information from this framework, such as grain, stress, and porosity statistics, was scaled up to describe the macroscopic level sintering kinetics. Here, the developed formulation was applied to describe the electric field assisted sintering of Y 2 O 3 . Microstructural inhomogeneities in a multi-granular solid result in the formation of a field of compressive stress networks, which interleave with low compression and weakly tensile regions, defining a scaffolding for sintering concentration regions to develop. A Poisson effect-induced lateral stress network is also naturally self-induced as a result of the mechanical constraints imposed by the sintering apparatus. For long sintering times, localized shear stresses enhancing mass flow along grain boundaries and internal surfaces develop. Three-sided pores are removed by either vacancy transport to the surrounding pores, or move towards the external surfaces through grain boundary diffusion. Four- and higher order-sided pores stabilize because an equal amount of vacancies are gained and lost through the connecting grain boundaries. Grain dewetting contributes to pore coalescence, suggesting that pore kinetics and grain growth are coupled and should be analyzed in concert. The combined sintering and grain growth kinetics define six regimes of sintering behavior: (1) T, the transient regime; (2) E$_Υ$, the surface energy dominated, early sintering regime, where the grain growth exponent, p = 1, and the stress concentration factor, $f$ ~ $1/\hat{ρ}^{4.6}$; (3) E S , the stress dominated, early sintering regime, where p = 1 and $f$ ~ $1/\hat{ρ}^{4}$; (4) I$_Υ$, the surface energy dominated, intermediate sintering regime, where p = 2 and $f$ ~ $1/\hat{ρ}^{4.6}$; (5) I S , the stress dominated, intermediate sintering regime, where p = 2 and $f$ ~ $1/\hat{ρ}^{4}$; and (6) L, the late sintering regime, where p = 3 and $f$ ~ 1. At the macroscopic level, the rapid densification and suppression of grain growth observed in the electric field assisted sintering process is a consequence of the compounding effects of the underlying stress-, transport-, and interfacial-energy-induced energy minimization kinetics, as predicted by the multi-scale framework.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2011

Aligned Carbon Nanotube Reinforced Silicon Carbide Composites by Chemical Vapor Infiltration

Owing to their exceptional stiffness and strength1 4, carbon nanotubes (CNTs) have long been considered to be an ideal reinforcement for light-weight, high-strength, and high-temperature-resistant ceramic matrix composites (CMCs)5 10. However, the research and development in CNT-reinforced CMCs have been greatly hindered due to the challenges related to manufacturing including poor dispersion, damages during dispersion, surface modification, densification and sintering, weak tube/matrix interfaces, and agglomeration of tubes at the matrix grain boundaries5,11. Here we report the fabrication of high-quality aligned CNT/SiC composites by chemical vapor infiltration (CVI), a technique that is being widely used to fabricate commercial continuous-filament CMCs12 15. Using the CVI technique most of the challenges previously encountered in the fabrication of CNT composites were readily overcome. Nanotube pullouts, an important toughening mechanism for CMCs, were consistently observed on all fractured CNT/SiC samples. Indeed, three-point bending tests conducted on individual CNT/SiC nanowires (diameters: 50 200 nm) using an atomic force microscope show that the CNT-reinforced SiC nanowires are about an order of magnitude tougher than the bulk SiC. The tube/matrix interface is so intimate and the SiC matrix is so dense that a ~50-nm-thick SiC coating can effectively protect the inside nanotubes from being oxidized at 1600 C in air. The CVI method may be extended to produce nanotube composites from a variety of matrix

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2018

Development of mesopores in superfine grain graphite neutron-irradiated at high fluence

Microstructural changes induced by neutron irradiation of superfine grain graphite G347A (Tokai Carbon, Japan) were examined by nitrogen adsorption at 77 K and by three microscopy techniques (SEM, TEM and FIB-SEM tomography). The specimens were irradiated at doses of up to 30 dpa, covering stages before and after the turnaround fluence at three temperatures (300, 450, 750 °C) of their irradiation envelope. The initial graphite densification at low fluences did not produce any detectable effect in the pore size range (<350 nm) measured by gas adsorption. However, graphite irradiated at high fluences, after turnaround, showed severe structural changes. At all three temperatures and high irradiation fluences, gas adsorption revealed significant increase of the volume of narrow mesopores (<5–20 nm) and up to five times increase of BET surface area, both in linear relationship with the relative volume expansion. Analysis of microscopy images showed multiplication of fine macropores (>50 nm) at high irradiation fluences and more structural changes on multiple scales, from nanometers to microns. As a result, this work demonstrates the unique ability of gas adsorption techniques to analyze open pores with sizes between sub-nanometer and sub-micron in bulk nuclear graphite, with supporting microscopy results.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Microstructural and bulk property changes in hardened cement paste during the first drying process

This paper reports the microstructural changes and resultant bulk physical property changes in hardened cement paste (hcp) during the first desorption process. The microstructural changes and solid-phase changes were evaluated by water vapor sorption, nitrogen sorption, ultrasonic velocity, and {sup 29}Si and {sup 27}Al nuclear magnetic resonance. Strength, Young's modulus, and drying shrinkage were also examined. The first drying process increased the volume of macropores and decreased the volume of mesopores and interlayer spaces. Furthermore, in the first drying process globule clusters were interconnected. During the first desorption, the strength increased for samples cured at 100% to 90% RH, decreased for 90% to 40% RH, and increased again for 40% to 11% RH. This behavior is explained by both microstructural changes in hcp and C–S–H globule densification. The drying shrinkage strains during rapid drying and slow drying were compared and the effects of the microstructural changes and evaporation were separated.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effect of pulverized fuel ash and CO{sub 2} curing on the water resistance of magnesium oxychloride cement (MOC)

This paper presents a study on the use of pulverized fuel ash (PFA) to improve the water resistance of magnesium oxychloride cement (MOC). Strength retention coefficients and volume stability were tested to evaluate the water resistance of MOC, in which the addition of PFA resulted in a remarkable improvement. The characterization of hydration products before and after water immersion was carried out using quantitative X-ray diffraction (QXRD), thermogravimetric (TG), Fourier-transformed infrared spectroscopy (FTIR) and scanning electron microscope (SEM). With the Q-XRD analysis, it was shown that the addition of PFA could result in the great increase of the amount of amorphous phase during air curing. This amorphous gel was identified as a mixture of magnesium-chloride-silicate-hydrate gel (M-Cl-S-H gel) and magnesium-chloride-hydrate gel (M-Cl-H gel) by elemental mapping scanning. It suggested that PFA could not only react with MOC to form M-Cl-S-H gel, but also change the morphology of magnesium oxychloride. The generation of insoluble M-Cl-S-H gel and M-Cl-H gel and densification of the microstructure contributed to the improvement of the water resistance of MOC. The MOC mortar expanded during air curing due to the hydration of excess MgO. Water immersion led to more expansion of MOC mortar as a result of the continuously hydration of excess MgO and the formation of Mg(OH){sub 2}. Adding PFA could increase the expansion of MOC mortar during air curing, which may because the amorphous gel could remain more water and benefit to the hydration of MgO. While, the addition of PFA could decrease the expansion of cement mortar during water immersion perhaps due to the reduction of the content of excess MgO and the insoluble amorphous-gel-layer that protect the MgO from hydration. Moreover, CO{sub 2} curing could further improve the performance of the PFA-blended MOC due to the formation of a higher content of amorphous gel.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Application of organic- and nanoparticle-modified foams in foamed concrete: Reinforcement and stabilization mechanisms

Highlights: • An ultra-stable foam was fabricated by modifying the gas–liquid interface. • A homogeneous and finer pore structure of foamed concrete was generated. • Stabilization and enhancement mechanisms were investigated. - Abstract: In this study, an ultra-stable foam used for foamed concrete was fabricated by modifying the gas–liquid interface by coupling the effects of an organic surfactant and nanoparticles. A serial of techniques was employed to study the products and microstructure development of foam and foamed concrete, respectively. The results show that nano-silica and hydroxypropyl methylcellulose can slow the coalescence and disproportionation of the bubbles by adsorbing at the air bubble surface and increasing the viscosity of cell wall paste, thus preventing gas transfer and hindering physical drainage between the gaseous and liquid phases. Also, a more homogeneous and finer pore structure is generated with the inclusion of the organic surfactant and nanoparticles. The pozzolanic reaction between the nano-silica and Ca(OH){sub 2} results in an increased C-S-H content and the densification of the cell wall structure. In addition, the stability of foamed concrete with modification and relevant stabilization mechanisms were also investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effects of anionic and nonionic surfactants on the dispersion and stability of nanoSiO2 in aqueous and cement pore solutions

It has been well recognized that the benefits and effectiveness of nanoparticles in cement-based materials could not be maximized if these are not well dispersed. To address this issue, in this study, different anionic (SDS and PCE) and nonionic surfactants (Tweens and Tritons) were used to disperse nanosilica (NS) in aqueous solution and cement pore solution. The results show that the dispersibility of NS in cement pore solution was improved, and the compressive strength of the cement-NS pastes increased linearly with critical micelle concentration (CMC) of nonionic surfactants. Among all surfactants studied, Triton X-405 led the paste to the highest increase in strength (33% at 1-day and 41% at 3-days) since it had the highest CMC. TEM and EDS analysis evidenced that this strength increase might be attributed to the nucleation of outer product CSH gel and its densification with calcite nanocrystals, attributed to Triton X-405 addition.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effects of carbonation on the retention of heavy metals in chemically activated BOF slag pastes

Basic Oxygen Furnace slag contains heavy metals, including vanadium, chromium and molybdenum. The leachability of these elements determines the industrial applicability of slag-based building products. This study investigates the post‑carbonation leaching of heavy metals from activated BOF slag pastes with the focus on the activator dosage and type (sodium and potassium citrate). Results reveal that the high degree of brownmillerite hydration boosts the leachability of heavy metals as its hydration product- hydrogarnet is less stable upon carbonation. With two leaching procedures, it is demonstrated that the carbonation resistance of pastes becomes the main attribute in preventing the leaching of heavy metals. It can be enhanced by optimising the activator dosage to facilitate the hydration of C{sub 2}S and consequent structural densification.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Influence of supplementary cementitious materials on microstructure and transport properties of spacer-concrete interface

Reinforcement spacers are a critical component of concrete structures. Their presence affects microstructure and transport properties of concrete cover though this is not widely appreciated. This paper presents the first study to determine whether the negative effects of spacers can be mitigated through the use of supplementary cementitious materials such as silica fume, fly ash and blast-furnace slag. Concrete samples (>200) with different spacers, binders, curing and drying regimes were prepared and tested for diffusion, permeation, absorption, electrical conductivity, carbonation and microstructure. It was found that spacers increase all transport properties, the extent depending on type of spacer, drying regime and transport mechanism. The spacer-concrete interface is weak, porous and micro-cracked, and this lowers the resistance of concrete to ingress of aggressive agents. The beneficial effects of SCMs (strength enhancement and densification) and prolonged curing (120-day) are insufficient to overcome the negative effects of spacers. Implications for durability are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Compositional inhomogeneityand segregation in (K 0.5 Na 0.5 )NbO 3 ceramics

The effects of the calcination temperature of (K 0.5 Na 0.5 )NbO 3 (KNN) powder on the sintering and piezoelectric properties of KNN ceramics have been investigated in this report. KNN powders are synthesized via the solid-state approach. Scanning electron microscopy and X-ray diffraction characterizations indicate that the incomplete reaction at 700 °C and 750 °C calcination results in the compositional inhomogeneity of the K-rich and Na-rich phases while the orthorhombic single phase is obtained after calcination at 900 °C. During the sintering, the presence of the liquid K-rich phase due to the lower melting point has a significant impact on the densification, the abnormal grain growth and the deteriorated piezoelectric properties. From the standpoint of piezoelectric properties, the optimal calcination temperature obtained for KNN ceramics calcined at this temperature is determined to be 800 °C, with piezoelectric constant d 33 =128.3 pC/N, planar electromechanical coupling coefficient k p =32.2%, mechanical quality factor Q m =88, and dielectric loss tan δ=2.1%.

36 MATERIALS SCIENCE↗
DOE OSTI2018

In-situ observation of oxygen mobility and abnormal lattice expansion in ceria during flash sintering

Flash sintering has been shown to be an effective method of sintering for many types of ceramics. However, the characteristics of flash sintering for each type of ceramic varies. When ionically conducting ceramics are sintered under a DC electric field, a strong dependence of densification with respect to position is observed. Microstructural analysis of the effect of electric field on oxygen ion conductors shows non-stoichiometry (oxygen deficiency) at the cathode which continues to build up over time under flash. In oxygen ion conductors, dominant charge carriers during flash are oxygen ions and the final density of the specimen is related to the availability of oxygen. This effect is no longer evident when using an AC power supply. In conclusion, use of AC instead of DC electric field is preferable for flash sintering of ionically conducting ceramics.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Insight into the BiFeO 3 flash sintering process by in-situ energy dispersive X-ray diffraction (ED-XRD)

The sintering mechanism of BiFeO 3 has been investigated in-situ by energy dispersive X-ray diffraction (ED-XRD) using a high-energy white collimated X-ray beam from the Advanced Photon Source (Argonne National Laboratories). Such radiation is very penetrating thereby allowing measurements of the sample even when placed inside the flash sintering set up. Additionally, the fast ED-XRD measurements permit monitoring the flash sintering process by providing information about phase composition and sample temperature in real time. Moreover, profile scans, obtained by moving the stage vertically while recording the ED-XRD spectra, permit investigating the homogeneity of the flash for the entire length of the sample. All experiments have been complemented by ex-situ studies. Here, it has been concluded that flash sintering of BiFeO 3 is a homogeneous process without any directionality effects. Furthermore, flash sintering takes place at quite low temperatures (below the Tc ≈ 830 °C), which may be related to the high quality of the samples, as pure, highly insulating ceramics without evidence of secondary phases with a homogenous nanostructured grain size distribution are obtained by this technique. Moreover, it is also evidenced that the rapid heating of the sample does not seem to justify, at least by itself, the densification process. Therefore, it appears that the electric current should play a role in the enhanced mobility during the sintering process.

36 MATERIALS SCIENCE↗