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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Effect of Thermal Aging and Test Temperatures on Fracture Toughness of SS 316(N) Welds

The effect of thermal aging and test temperatures on fracture toughness (J{sub 0.2}) of SS 316(N) weld material has been studied based on J-R curve evaluations. The aging of the welds was carried out at temperatures 370, 475 and 550 °C and for durations varying from 1000 to 20,000 h. The fracture toughness (J-R curve) tests were carried out at 380 and 550 °C for specimens after all aging conditions, including as-weld condition. The initiation fracture toughness (J{sub 0.2}) of the SS 316(N) weld material has shown degradation after 20,000-h aging durations and is reflected in all the test temperatures and aging temperatures. The fracture toughness after different aging conditions and test temperatures, including as-weld condition, was higher than the minimum specified value for this class of welds.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and Wear Resistance of FeCrBSi Plasma-Sprayed Coating Remelted by Gas Tungsten Arc Welding Process

Herein, an FeCrBSi coating was fabricated via plasma spray on AISI1045 steel, and subsequently, a gas tungsten arc welding (GTA) process was employed to remelt the coating. The microstructure, microhardness, fracture toughness and surface roughness of the coating before and after remelting were investigated, as well as the wear resistance was tested by a UMT-3-type sliding wear apparatus. The results showed that, upon remelting, most defects in the as-sprayed coating were effectively eliminated, the surface roughness decreased by 43%, and the coating–substrate interface bonding changed from mechanical to metallurgical. The phase composition of the as-sprayed coating was primarily α-Fe and a small amount of hard Fe{sub 3}B phase, while the remelted coating consisted of α-Fe and (Fe,Cr){sub 23}C{sub 6} and a small quantity of CrB. In addition, remelting the coating was found to induce a 287.6% increase in the fracture toughness, a 33.4% increase in the average microhardness, and a 47.5% decrease in the wear volume, while the failure mechanism changed from abrasive wear to fatigue wear upon remelting. Therefore, GTA remelting of plasma-sprayed coating was found to be a feasible method to obtain a coating with good wear resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Replacement of Nitrided 33CrMoV Steel with ESR Hot Work Tool Steels for Motorsport Applications: Microstructural and Fatigue Characterization

In this work tensile strength, fatigue resistance and fracture toughness of two electroslag remelted (ESR) tool steels and of 33CrMoV12 ESR steel (both in quenched and tempered condition, as well as nitrided condition) were evaluated. The role of hardness, residual stresses and inclusion sizes on the fatigue behavior was investigated. Tool steels have a tensile strength between about 1900 and 2300 MPa, fracture toughness between 35 and 33 MPa√m, while fatigue strength ranges between 725 and 992 MPa. The tensile strength and fracture toughness of the 33CrMoV12 ESR are, respectively, 1365 MPa and about 150 MPa√m. Nitriding induces a significant increase in fatigue strength from 560 to 980 MPa. These results highlight that appropriate ESR tool steels could replace nitrided steels.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Computational Modeling of Fracture Toughness of Al-Si and Al-Zn-Mg-Cu Alloys with Detected Porosity

This article presents the results of an experimental and numerical analysis of the fracture resistance of cast aluminum alloys subjected to variable loads over time based on the fracture mechanics method. The subjects of the analysis were the AlSi9 and AlZn6MgCu alloys (usually used for plastic processing) in which the presence of porosities in the form of separate or dispersed voids was revealed experimentally. The material for the experimental procedures was obtained directly from a casting or from casting samples. Depending on the type of the defect detected, different numerical models were proposed. The results of the numerical calculations were verified experimentally. Static tensile tests, fatigue low-cycle tests, fracture mechanics tests, fatigue crack propagation tests, a microscopic examination of the sample fracture area, and an x-ray tomographic analysis were all performed. A correlation of the results between the numerical analysis and the experimental work has been found. On the basis of the proposed calculation models, the fatigue life of castings of the analyzed alloys can be predicted in the case of concentrated and dispersed defects.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Effects of Sc Addition on the Microstructure and Mechanical Properties of Be-Al Alloy Fabricated by Induction Melting

This study investigated the alloying effects of 0.4 wt.% Sc on the microstructure, mechanical properties, and fracture behavior of a cast Be-Al alloy prepared by vacuum induction melting. The micromechanics of Sc-containing secondary-phase particles (SPs) were characterized by nanoindentation, and the fracture behavior of the alloy was investigated via tensile fractography and optical metallography. The addition of 0.4 wt.% Sc significantly modified the alloy microstructure by decreasing the secondary dendritic arm spacing (SDAS), weakening the dendritic structure of Be, and producing an equiaxed/cellular alloy microstructure with refined Be grains. Sc alloying increased the Vickers hardness by 36%, elastic modulus by 28%, yield strength by 35%, ultimate strength by 52%, but decreased the elongation from 3.6 to 2.9%. Sc-containing SPs had a higher elastic modulus, yield strength, microhardness, and a lower plasticity index than the Be and Al matrices, resulting in interface separation during the fracture process. SPs located at the Be/Al interfaces did not act as microcrack sources for the matrices, whereas highly faceted SPs within the Be grains induced microcrack formation and decreased the elongation. The failure mode of the cast Be-Al-0.4Sc alloy still involved the brittle cleavage failure of Be regions and ductile dimple failure of Al regions, which was not the case with the cast Be-Al alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Interfacial Strength Evaluation of Oxide Films on Carbon Steel by Using the Laser Shock Adhesion Test

We investigate the adhesion strength (interfacial strength) of the oxide film formed on a carbon steel substrate by using a laser shock adhesion test (LaSAT). A rolled carbon steel (SS400) plate is first heated at high temperature (700 °C) under the atmosphere (heat treatment) to cause the formation of oxide films about 20-50 μm thick on the steel surface. The film consisted of multiple layers, including wustite (FeO), magnetite (Fe{sub 3}O{sub 4}), and hematite (Fe{sub 2}O{sub 3}). Next, the x-ray diffraction method was used to measure the residual stress in the film. We find that compression stress develops in the film because of a mismatch of thermal strain in between the film and substrate after the heat treatment. With LaSAT, strong elastic wave generates by a pulsed laser ablation of the substrate backside, and results in interfacial fractures in the oxide films. To monitor the normal (out-of-plane) displacement of the top surface film, a laser ultrasonic interferometer is simultaneously utilized, such that we detect film delamination and determine the critical laser energy for interfacial fracture to obtain the critical stress (interfacial strength). Furthermore, additional pulsed laser irradiation is conducted against a pre-delaminated specimen in order to examine the growth of delamination area and evaluate the interfacial fracture toughness. Finally, elastic wave propagation in the sample is computed using the finite element method (FEM) in order to evaluate the interfacial stress field, accurately. For the FEM, multiple layers in the oxide film are modeled, and the residual stress due to thermal strain mismatch is introduced. The FEM computations reveal the stress distribution around the interface and evaluate the critical stress and critical stress intensity factor for delamination. We thus quantitatively evaluate the interfacial strength and interfacial fracture toughness of the oxide film formed on carbon steel. The mechanism of interfacial fracture is also discussed on the basis of microstructures in a film with multiple layers. This result may be useful for understanding the adhesion quality of oxide film during the hot-rolling process.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Comparative Study of the Geometric Effects on Fracture Behaviors of Side-Grooved and Plain-Sided Compact Tension Specimens

This paper investigates the fracture response and crack-tip constraint of two typical compact tension specimens. They are pre-cracked plain-sided and side-grooved specimens. In order to clarify the significant effects of geometric parameters on the crack-tip stress fields, an extensive series of detailed 3D elastic–plastic finite element analyses have been carried out. Taking the standard ratio of geometric parameters as a basis, several non-standard geometric parameters are adopted in the calculation for comparison, including specimen thickness, width, crack length. Accordingly, the variation of local J-integral and crack-tip opening displacement have been vigorously investigated over the crack front. Most importantly, the crack-tip stress fields are analyzed in detail with the emphasis on the stress triaxiality and opening mode stress. Furthermore, the crack-tip plastic strain and deformation are compared under small-scale yielding and large-scale yielding between plain-sided and side-grooved specimens, and the constraint parameter Q is employed to explain the distribution of the near-tip plastic strain. Through the vigorous research work, the variation of fracture behavior caused by geometric parameters is reasonably explained and understood.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Post-forming Room Temperature Brittle Fracture in a High-Strength Low-Alloy Steel Sheet After Various Forming Modes

The effects of various sheet forming modes on the post-forming room temperature fracture behavior of a 550-MPa yield strength high-strength low-alloy (HSLA) steel are investigated. In-plane biaxial stretching, plane strain (cold rolling), uniaxial tension, cylindrical cup drawing, and in-plane compression (IPC) are examined up to a von Mises effective prestrain ε{sub eff} = 0.7. Most of the results pertain to sub-size Charpy-type impact specimens prepared from the prestrained material. After sufficiently large prestrains, the fracture behavior is highly anisotropic. Low-energy fracture modes, namely cleavage and intergranular fracture, occur after all modes of prestraining along plane directions that are perpendicular to the principal compressive prestrain. These planes are parallel to the sheet surface after biaxial stretching and cold rolling and correspond to brittle splits extending into the primary, ductile fracture surface. After cup drawing, the brittle planes are oriented perpendicular to the circumferential compressive prestrain. This results in very low energy fractures propagating in the length direction of a fully drawn cup. After in-plane compression, brittle fracture occurs along planes that are perpendicular to the compression direction. The fracture toughness for a crack propagating along such a plane after IPC to ε{sub eff} = 0.38 was very low (12.7 MPa √m), much lower than in the undeformed condition (247 MPa√m). Changes in grain shape and in crystallographic texture caused by the various prestraining modes, as well as the microstructural damage at non-metallic inclusions and carbides, are examined to try to understand the fracture behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Multifunctional application of nanoscratch technique to characterize cementitious materials

This study aims to further explore the multifunctional applicability of nanoscratch technique to cementitious materials for comprehensive characterization. Based on the investigation of deformation, applied force, and fracture toughness of hardened cement paste during scratching, the methods of phase identification, fracture toughness of individual phase, and the interfacial transition zone (ITZ) thickness quantification were proposed and discussed. After redefining the vertical loading rate of scratching, the slope of the square scratching depth vs. scratching length is recognized as a reliable parameter to distinguish the individual phases for the first time. A fracture toughness-based method is proposed to quantify the thickness of ITZ between clinker and hydrates. Meanwhile, the applicability of phase identification by the scratch method is discussed for different transverse scratching speeds and the vertical loading rates. The findings will benefit the investigation and mechanism understanding of cementitious materials at the microscale by utilizing nanoscratch technique.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Hydromechanical modelling to evaluate impact of fault structure on CO 2 migration in stacked storage system

Faulting processes produce a complex fault damage zone (FDZ) having permeability variations over several orders of magnitude within a very short distance. In this study we use an example normal fault system from a depleted oil field in southern Louisiana with multiple stacked sand beds along the fault structure. Geostatistical techniques are used to introduce heterogeneities of several orders of magnitude over very short distances that honor the across- and along-fault architecture of the system. A total of 15 cases are simulated to account for the impact of a fragmented core, an intact core and a naturally fractured core on inter-sand leakage rates. The presented results show the complex nature of CO 2 migration within the fault structure, where an interplay between overcoming the fault core’s high capillary entry pressure and stress propagation in the vertical direction dictates the leakage direction and rates. It is observed that hydromechanical evolution of fracture flow properties may result in significant leakage from the storage zone. In one case with small caprock thickness, a loss of 18% of the total injected mass is observed. The results presented highlight some unique features of representative fault related leakage in stacked sand systems and thus will be beneficial for storage integrity analysis in these systems.

58 GEOSCIENCES↗
DOE OSTI2012

Fracture strength and elastic modulus as a function of porosity for hydroxyapatite and other brittle materials Part I

Porous brittle materials are used as filters, catalyst supports, solid oxide fuel cells and biomedical materials. However the literature on the Weibull modulus, m, versus volume fraction porosity, P, is extremely limited despite the importance of m as a gauge of mechanical reliability. In Part I of this study, m is determined for 441 sintered hydroxyapatite (HA) specimens fractured in biaxial flexure for 0.08 P 0.62. In this study, we analyze a combined data set collected from the literature that represents work from a total of 17 different research groups (including the present authors), eight different materials and more than 1560 oxide and non-oxide specimens, the m versus P plot is Ushaped with a wide band of m values for P < 0.1 (Region I) and P > 0.55 (Region III), and a narrower band of m values in the intermediate porosity region of 0.1 < P < 0.55 (Region II). The limited range of m ( 4 < m < 11) in Region II has important implications since Region II includes the P range for the majority of the applications of porous brittle materials. Part II of this study focuses on the P dependence of the mean fracture strength,< f >, and the Young s modulus E for the HA specimens tested in Part I along with literature data for other brittle materials. Both < f > and E are power law functions of the degree of densification, , where = 1 P/PG and PG is the green (unfired) porosity.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2014

Nanostructured gadolinium-doped ceria microsphere synthesis from ion exchange resin: Multi-scale in-situ studies of solid solution formation

In the current nano-sized material revolution, the main limitations to a large-scale deployment of nanomaterials involve health concerns related to nano-dissemination via air. Developing new chemical routes benefiting from nano-size advantages while avoiding their hazards could overcome these limitations. Addressing this need, a chemical route leading to soft nano-particle agglomerates, i.e., macroscopic precursors presenting the ability to be decomposed into nano-sized materials, was developed and applied to Ce{sub 0.8}Gd{sub 0.2}O{sub 2−δ}. Using cerium/gadolinium-loaded ion exchange resin, the Ce{sub 0.8}Gd{sub 0.2}O{sub 2−δ} solid solution formation as a function of temperature was studied in-situ through X-ray diffraction, X-ray absorption spectroscopy and Raman spectroscopy. Temperatures corresponding to the organic skeleton decomposition and to the mixed oxide crystallization were identified. An optimal heat treatment, leading to nanostructured soft agglomerates, was established. Microsphere processing capabilities were evaluated and particle size distribution measurements were recorded. A very low fracture strength was calculated, and a nanometric particle size distribution (170 nm) was determined. - Graphical abstract: The elaboration of micro-spherical precursors leading to the formation of nano-oxide soft agglomerates was studied and approved through the use of ion exchange resin loaded with cerium and gadolinium. The formation of the solid solution was followed through in-situ measurements such as XAS, XRD, Raman, TGA and DSC. Key temperatures were identified for the formation of the mixed-oxide. Following this study, the microstructure and particle size of oxide microspheres formed highlight the formation of soft nano-arrangments. - Highlights: • Soft microspherical agglomerates able to be decomposed into nano-sized materials. • In situ study of cerium/gadolinium-loaded ion exchange resin conversion in oxide. • In situ multi-scale study through Raman spectroscopy, XAS and HT-XRD. • Monodisperse nanometric particle synthesis suitable for ceramic processing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2011

Phase transformation and wear studies of plasma sprayed yttria stabilized zirconia coatings containing various mol% of yttria

Plasma sprayable grade zirconia powders doped with various mol% of yttria (0, 2, 3, 4, 6, 8 and 12 mol%) were synthesized by a chemical co-precipitation route. The coprecipitation conditions were adjusted such that the powders possessed good flowability in the as calcined condition and thus avoiding the agglomeration step like spray drying. Identical plasma spray parameters were used for plasma spraying all the powders on stainless steel plates. The powders and plasma sprayed coatings were characterized by X-ray diffractometry, Scanning Electron Microscopy and Raman spectroscopy. Zirconia powders are susceptible to phase transformations when subjected to very high temperatures during plasma spraying and XRD is insensitive to the presence of some non crystalline phases and hence Raman spectroscopy was used as an important tool. The microstructure of the plasma sprayed coatings showed a bimodal distribution containing fully melted and unmelted zones. The microhardness and wear resistance of the plasma sprayed coatings were determined. Among the plasma sprayed coatings, 3 mol% yttria stabilized zirconia coating containing pure tetragonal zirconia showed the highest wear resistance. - Research Highlights: {yields} Preparation plasma sprayable YSZ powders without any agglomeration process and plasma spraying {yields} Phase transformation studies of plasma sprayed YSZ coatings by XRD and Raman spectroscopy {yields} Microstructure of the plasma sprayed coatings exhibited bimodal distribution {yields} Plasma sprayed 3 mol% YSZ coating exhibited the highest wear resistance {yields} Higher wear resistance is due to the higher fracture toughness of tetragonal 3 mol% YSZ phase.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Effect of tungsten addition on the toughness and hardness of Fe{sub 2}B in wear-resistant Fe-B-C cast alloy

The effects of tungsten additions of 0%, 1.12%, 2.04%, and 3.17% (in wt.%) on the morphology, fracture toughness and micro-hardness of Fe{sub 2}B in Fe-B-C cast alloy were investigated. The results indicate that, with the increase of tungsten addition, the morphology and distribution of Fe{sub 2}B have no change and a new W-containing phase, except the (Fe, W){sub 2}B with a certain tungsten solution, does not form, and that the fracture toughness of Fe{sub 2}B increases first and then decreases, while the hardness increases first and then has a little change. Compared with the fracture toughness (3.8 MPa{center_dot}m{sup 1/2}) of Fe{sub 2}B without tungsten addition, the toughness at 2.04 wt.% tungsten can be improved by about above 80% and achieves about 6.9 MPa{center_dot}m{sup 1/2}, and variation characteristics of hardness and toughness of Fe{sub 2}B were also testified by viewing the indentation marks and cracks on the Fe{sub 2}B, respectively. - Highlights: Black-Right-Pointing-Pointer Poor toughness of Fe2B decreases obviously the wear resistance of the alloy. Black-Right-Pointing-Pointer As W content increases, Fe2B's toughness increases first and then decreases. Black-Right-Pointing-Pointer As W content increases, Fe2B's hardness first increases and then has little change. Black-Right-Pointing-Pointer The toughness at 2.04 % W can be improved by above 80% more than that at 0% W.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Effect of cold drawing ratio on γ′ precipitation in Inconel X-750

Inconel X-750 is a Ni-based precipitation-hardened superalloy having large tensile and fracture strengths. In the study, X-750 wires were cold drawn to different extents. Small angle neutron scattering was employed to quantitatively measure the size and volume fraction of the γ′ phase as a function of the cold drawing ratio (DR) and aging temperature. The presence and size of γ′ precipitates were confirmed by transmission electron microscopy. The drawing ratio had an important effect on the volume fraction of the γ′ precipitates. However, the size of the precipitates was independent on the drawing ratio. The specimen with the minimum drawing ratio (DR0) produced the largest volume fraction of γ′ as compared with large drawing ratio (DR) specimens such as DR17 and DR42. The small volume fraction of the γ′ phase for a sizeable drawing ratio was associated with the large amount of nucleation sites for secondary carbides, M{sub 23}C{sub 6}, and the fast diffusion path, i.e., dislocation, needed to form M{sub 23}C{sub 6}. A Cr depletion zone around the secondary carbides raised the solubility of γ′. Therefore, the significant drawing ratio contributing to the large volume fraction of the secondary carbides decreased the volume fraction of the γ′ precipitates in Inconel X-750. - Highlights: • The volume fraction of secondary carbides increased with the drawing ratio. • The volume fraction of γ′ decreased as the drawing ratio increased. • The drawing ratio affected the γ′ volume fraction with no variation of the γ' size. • The volume fraction of γ′ was affected by the secondary carbide volume fraction.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Digital image analysis to quantify carbide networks in ultrahigh carbon steels

A method has been developed and demonstrated to quantify the degree of carbide network connectivity in ultrahigh carbon steels through digital image processing and analysis of experimental micrographs. It was shown that the network connectivity and carbon content can be correlated to toughness for various ultrahigh carbon steel specimens. The image analysis approach first involved segmenting the carbide network and pearlite matrix into binary contrast representations via a grayscale intensity thresholding operation. Next, the carbide network pixels were skeletonized and parceled into braches and nodes, allowing the determination of a connectivity index for the carbide network. Intermediate image processing steps to remove noise and fill voids in the network are also detailed. The connectivity indexes of scanning electron micrographs were consistent in both secondary and backscattered electron imaging modes, as well as across two different (50 × and 100 ×) magnifications. Results from ultrahigh carbon steels reported here along with other results from the literature generally showed lower connectivity indexes correlated with higher Charpy impact energy (toughness). A deviation from this trend was observed at higher connectivity indexes, consistent with a percolation threshold for crack propagation across the carbide network. - Highlights: • A method for carbide network analysis in steels is proposed and demonstrated. • ImageJ method extracts a network connectivity index from micrographs. • Connectivity index consistent in different imaging conditions and magnifications. • Impact energy may plateau when a critical network connectivity is exceeded.

36 MATERIALS SCIENCE↗
DOE OSTI2018

An improved three-point bending test method for the investigation of nanosecond laser dicing of ultrathin Si dies with Cu stabilization layer

Highlights: • A selective chemical etching method has been developed for removal of metallization layers on ultrathin Si dies for three-point bending test. • The complex elastoplastic stress distribution in the die is simplified to an elastic stress distribution. • The die sidewall fracture strength can be determined using the standard three-point bending tensile stress equation. • The characteristic fracture strengths of ultrathin Si dies were correlated to the laser-induced microstructures of the die sidewall. - Abstract: The sidewall fracture strength of ultrathin Si dies with frontside and backside metallization layers cannot be determined directly from three-point bending (3PB) test. The complex 3PB elastoplastic stress distribution makes it difficult to determine the die sidewall fracture strength by analytical method or finite element analysis due to various theoretical and practical constraints. In this work, a selective chemical etching method has been developed for complete removal of the frontside and backside metallization layers on the ultrathin die without affecting the critical microstructure and strength of the die sidewall induced by laser dicing. By removing all the metallization layers on the die, the complex 3PB elastoplastic stress distribution is simplified to an elastic stress distribution. This enables a straightforward calculation of the die sidewall fracture strength using the standard 3PB tensile stress equation for a homogeneous linear elastic material with a rectangular cross section. Two chemical etchants were evaluated and found to be suitable but FeCl{sub 3} is preferred because of the much faster etching time. With this improved 3PB test method, the effect of nanosecond laser dicing on ultrathin Si dies with backside Cu layer was investigated. The die frontside and backside characteristic fracture strengths of ultrathin Si dies with varying backside Cu thickness were determined and correlated to TEM analyses of the compositions and microstructures at the fracture origins.

36 MATERIALS SCIENCE↗