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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

An innovative radial gradient material design using hot isostatic pressing for applications in extreme environments

Functionally graded materials (FGMs) are highly advanced continuous or discontinuous structures whose structural and material properties vary along a singular geometric dimension either in the axial or radial direction. Here, the radial gradient FGM design makes for an optimal structural design to incorporate a bi-metallic structure with a copper-based high entropy alloy (Cu-HEA) with good mechanical properties and high irradiation resistance, and Chromium (Cr) with great corrosion resistance. This study focuses on the experimental design of a metal powder loading mechanism to fabricate a bi-metallic radial gradient structure using Cu-HEA and 99.9 % pure Cr metal powders. The powder loading strategy uses custom-designed concentric cylindrical dividers to separate the individual compositions. Two benchtop trial runs were performed for design optimization. The optimized design was then implemented to eventually load the HEA and Cr powders for consolidation via powder metallurgy hot isostatic pressing (PM-HIP). The electron microscopy analysis reveals the successful fabrication of the radial gradient structure with the chemical mapping analysis, demonstrating the gradual composition shift from the HEA at the center to the pure-Cr at the periphery via a three-step gradient.

High Entropy Alloys (HEAs)↗
DOE OSTI2023

A novel design of transitional layer structure between reduced activation ferritic martensitic steels and tungsten for plasma facing materials

Plasma-facing components (PFCs) are among the most critical gaps for fusion energy to establish technical and economic feasibility. Tungsten as a first wall/blanket material in PFCs requires to be integrating with reduced activation ferritic martensitic (RAFM) steels as a structural component. Currently, major drawbacks are the requirement of brazing, the formation of a brittle interface, and a large difference between the coefficients of thermal expansion of tungsten and steel. Here, a novel transitional multilayer structure was designed and investigated to join tungsten and RAFM steels using three interlayers. The composition of each interlayer was selected based on computational thermodynamics and diffusion kinetics to ensure a body-centered cubic (bcc) single-phase structure and prevent the formation of a brittle intermetallic phase region in the temperature range of 600–1150 °C. Although the transitional layer structure was designed for additive manufacturing, spark plasma sintering (SPS) as proof of concept was used to bond the individual layers. Interfaces were investigated using scanning and transmission electron microscopy methods but no layered intermetallic phase was observed. Nanoindentation maps across the interface suggest major hardness differences at the interface between tungsten and the vanadium interlayer, as well as the interface between RAFM steel and the FeCrAl interlayer.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Testing fast reactor fuels in a thermal reactor: Comparison of transmutation metallic fuel alloys behavior by scanning electron microscopy

To optimize nuclear waste repository performance, the destruction of minor actinide elements, particularly Np and Am, in a neutron fast spectrum reactor is possible by incorporating these elements into nuclear fuel. Evaluating the performance of minor actinide containing fuel is of paramount importance to enabling this technology. However, such a task is challenging without an available domestic fast spectrum test reactor. A comparison of fuel performance tested in an available domestic thermal reactor at the Idaho National Laboratory, the Advanced Test Reactor, and in a fast spectrum reactor in France (Phénix) is presented here in this study. This study evaluates the capability of using a cadmium shrouded test position to mimic the power profile along the fuel radius present in fast spectrum reactors so that thermally driven phenomenon (e.g., constituent redistribution) can be evaluated in a thermal reactor and determined to be prototypical of a fast reactor. Thus, optical microscopy and scanning electron microscopy has been performed on irradiated 35U-29Pu-4Am-2Np-30Zr fuel samples (where the number preceding the element is the weight percent concentration) from the two mentioned reactors that present similar irradiation temperatures and power conditions. The results indicate that fuel performance phenomena are reproducible in the two irradiation conditions. The redistribution of Zr occurred in the same manner for the two samples. Similar partitioning of U-Pu-Zr phases was observed, and the behavior of Am was similar in the analyzed specimens. Finally, the overall microstructure evolution seems not to be affected by minor actinides addition compared to expected behavior of conventional U-19Pu-10Zr ternary metal fuels for both specimens. Slight differences in fuel cladding chemical interaction were, however, observed. This difference is likely driven by difference in cladding composition rather than irradiation conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Examining the creep strengthening nanoprecipitation in novel highly reinforced heat resistant steels

Here we studied the creep strengthening nanoprecipitation in novel heat resistant steels strengthened by a high density of stable nanoprecipitates. The results show that the high number density of MX nanoprecipitates within the martensitic laths in these steels comes from the great amount of MX former elements present in their chemical compositions and the high dislocation density generated by the martensitic transformation that takes place during cooling after austenitization. These dislocations act as nucleation sites for these nanoprecipitates during the tempering applied after the austenitization and quenching. Atom probe tomography measurements show that these nanoprecipitates are rich in Nb, V, Cr and N for the HDSN1 and HDSN2 steels and V, Cr and N for the HDSN3 steel. The distribution of the nanoprecipitates within the martensitic laths suggests that the creep strengthening produced by the Nb, V, Cr and N nanoprecipitates in the HDSN1 and HDSN2 steels is more effective at pinning dislocations at high temperature than that obtained in the HDSN3 steel by the V, Cr and N nanoprecipitates. However, the high amount of W in the HDSN3 steel enhances the solid solution strengthening at high temperatures, resulting in a similar high temperature strength for all HDSN steels.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Spatially resolved phase transformation mapping in 410 stainless steel during additive manufacturing visualized via real-time infrared data

Here, in this study, we demonstrate that spatially resolved cooling curves derived from real-time infrared (IR) thermography during additive manufacturing (AM) can capture spatial variations in phase transformation temperatures through cooling curve analysis (CCA). Using this approach, we show that during laser hot-wire deposition of 410 stainless steel (410SS), the martensite start temperature (M s ) evolves dynamically throughout the build. The M s temperature is spatially nonuniform, ranging from 185 °C to 348 °C, with the lowest values toward the build center and higher values toward the upper region of the deposit. In the lower portion of the build, no M s inflection is detected via CCA, consistent with transformation occurring earlier during thermal cycling followed by tempering during subsequent thermal cycles. These trends in M s are corroborated by characterizing the microstructure by electron backscatter diffraction (EBSD). Traditionally, M s is assumed to be constant, and a single interpass temperature is applied during both deposition and residual stress modeling. Our results demonstrate that IR-derived cooling curves provide a route to spatially and temporally resolved transformation temperature tracking for dynamic interpass control and improved residual-stress modeling.

Additive manufacturing↗
DOE OSTI2026

Evaluation of high-temperature properties of binary, eutectic Ni-X alloys (X = B, Ca, Ce, La, Y, Zr)

We investigated the high-temperature behavior of binary eutectic nickel-base alloys with low-solubility elements, towards developing alloys with new combinations of structural and functional (e.g. thermal or corrosion) properties. Based on thermodynamic screening, we cast binary near-eutectic Ni-B, Ni-Ca, Ni-Ce, Ni-La, Ni-Y, and Ni-Zr alloys and characterized their microstructure and high-temperature properties. All alloys (except Ni-Ca) contain a fine eutectic microstructure, containing submicron alternating lamellae of γ-Ni and continuous intermetallic phases. The eutectic microstructure did not significantly coarsen at 700°C (except for Ni-B), but measurably coarsened in all alloys at 900°C, most quickly in Ni-B, followed by Ni-Ce, Ni-La, Ni-Y, and Ni-Zr. Coarsening in these alloys occurs by fault migration; diffusion within the intermetallic, and its interfacial energy, likely influence coarsening kinetics. At room-temperature, all alloys possess negligible ductility due to the continuous, brittle intermetallic. At 700 and 900°C, the Ni-Zr alloy showed the best combination of strength and ductility. Oxidation experiments at 900°C on Ni-Zr and Ni-Ce revealed heavy internal oxidation of the continuous intermetallic phase. Overall, the Ni-Zr alloy showed good high-temperature coarsening resistance and strength, though ductility and oxidation resistance require improvement for use in structural applications. Possible routes for improving alloy properties via additive manufacturing are discussed.

Ekaputra, Clement [ORNL] (ORCID:0000000307166479)↗
DOE OSTI2022

Machine learning prediction on the fractional free volume of polymer membranes

Fractional free volume (FFV) characterizes the microstructural level features of polymers and affects their properties including thermal, mechanical, and separation performance. Experimental measurements and theoretical analyses have been used to quantify the FFV of polymers, but challenges remain because of their limitations. Experimental measurements are laborious and based on semi empirical equations, while Bondi’s group contribution theory involves ambiguities like the determination of van der Waals volume and the choice of factor values in the theoretical equation. To efficiently evaluate the FFV of polymers, this study utilizes high-throughput molecular dynamics (MD) simulations to build a large dataset regarding polymer’s FFV. Based on this large dataset, we further build machine learning (ML) models to establish the composition-structure relation. Inspired by group contribution theory which correlates polymer’s functional groups to FFV, our ML models correlate polymer’s substructures or physico-chemical indexes to FFV. Here, our study first benchmarks the MD simulation protocol to obtain reliable FFV of polymers and then carries out high-throughput MD simulations for more than 6,500 homopolymers and 1,400 polyamides. Such a large and diverse dataset makes the well-trained ML models more generalizable, compared with the group contribution theory. The efficiency of a feed forward neural network model is further demonstrated by applying it to a hypothetical polyimide dataset of more than 8 million chemical structures. The predicted FFVs of hypothetical polyimides are further validated by MD simulations. The obtained FFVs of the 8 million polymers, plus their previously reported gas separation performances, demonstrate the promising capability of ML virtual screening for the discovery of polymer membranes with exceptional permeability/selectivity.

36 MATERIALS SCIENCE↗
DOE OSTI2021

On the exceptionally high ductility of Mg–2Zn-0.3Ca-0.2Ce-0.1Mn alloy

A newly developed Mg–2Zn-0.3Ca-0.2Ce-0.1Mn (in weight %, ZXEM2000) wrought alloy exhibits an exceptionally high tensile ductility (29% ± 1.4% tensile elongation) along the rolling direction at room temperature. In this work, we investigated the fundamental plastic deformation mechanisms that can contribute to the high ductility of ZXEM2000. Scanning electron microscopy and transmission electron microscopy were carried out at selected strain levels to characterize the microstructural evolution. Compared with the deformed microstructures from the hot-rolled pure Mg and Mg–3Al–1Zn alloy at similar conditions, our results revealed that the high ductility of ZXEM2000 could be attributed to four key factors: weaker texture, fine grain size, reduced twinning, and increased cross-slip frequency of < c +a > dislocation. Furthermore, these direct observations offer a key insight into improving ductility of magnesium alloys for future alloy design and development.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Quasi-static and dynamic response of a Cu/Nb composite following equal channel angular extrusion

The article presents a study of the plastic properties of a Cu–18%Nb composite following equal channel angular extrusion under both low- and high-strain rate loadings. The microstructures are characterized by optical and scanning electron microscopy as well as electron backscatter diffraction. Comparisons are also made with a Cu–50%Nb laminate made by accumulative roll bonding. Textures obtained within the respective phases in the extruded composite closely mimic those previously reported for the pure components alone (Cu, Nb). Grain sizes of the major phase (Cu) exhibit broad distributions, due largely to partial recrystallization during the extrusion process. Further re-crystallization is obtained within localized deformation bands produced at high strain rates (3 × 10 3 s –1 ). While the degree of anisotropy and the strain rate sensitivity of the composite response are similar to those of pure Cu after extrusion, the strength levels of the composite are somewhat greater, falling broadly between those obtained in the pure components after extrusion to comparable plastic strains. Furthermore, the implications for selection of composite composition and processing for achieving higher strengths are briefly discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Additive manufacturing of a metastable high entropy alloy: Metastability engineered microstructural control via process variable driven elemental segregation

Compositional paradigm shift in high entropy alloys (HEAs) provided new opportunities for microstructural engineering, whereas process control during laser powder bed fusion (LPBF) additive manufacturing (AM) enable fine microstructure tailoring. Metastability engineering in transformation induced plasticity (TRIP) HEAs by addition of minor alloying elements is an attractive strategy for fine microstructural tuning. This study explored in detail the microstructural evolution during LPBF AM of a metastable Fe 40 Mn 20 Co 20 Cr 15 Si 5 (at.%) dual phase HEA (CS-HEA). LPBF processing window for CS-HEA was established based on quantitative analysis and experiments. Based on melt pool overlap lack of fusion pores were observed at lower energy densities (J) of $\textit{J}$ ≤ 31.25 J/mm 3 and key-hole formation by melt pool destabilization in case of $\textit{J}$ ≥ 75 J/mm 3 . The microstructure of CS-HEA consists of metastable FCC-γ and HCP-ε phases; LPBF process parameters governed the final phase fraction in the alloy which has been correlated to metastability alteration of the high temperature γ phase. Final microstructural engineering was devised by LPBF process control which enabled cooling rate manipulation to guide Mn and Si segregation at the cell boundaries, thereby controlling the matrix metastability and final phase fraction. Additionally, high resolution transmission electron microscopy (TEM) revealed disparity in stacking fault morphology in CS-HEA with LPBF process variable alterations associated with local variations in chemical composition and stacking fault energy. Further, the phase evolution with process parameters also affected the nanomechanical behavior of the alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Two-layer cathode architecture for high-energy density and high-power density solid state batteries

Solid state batteries with high-energy density and high-power density require the development of thick and energy dense cathodes. Structured cathode electrodes with a double-layer configuration were enabled using a freeze tape casting technique. A bottom dense layer was utilized to enhance the energy density whereas a top porous layer with vertically aligned walls was utilized to enhance the power density. The porous structure of the power layer was achieved by ice templating this layer on top of the densified energy layer of the cathode. This configuration was found to better utilize the active material of the cathodes and was optimized using numerical simulation and computer modeling. Cells with Li metal anode and LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) at approximately 5 and 20 mg/cm 2 were cycled at 70 °C at different C-rates. Poly(ethylene oxide) (PEO) with lithium bis-trifluoromethanesulfonimide (LiTFSI) was used for the catholyte and the solid-state electrolyte. The structured cathodes exhibited more than double capacity values as well as better Coulombic efficiency compared to non-structured (single-layer) thick cathodes. In conclusion, synchrotron X-ray tomography and scanning electron microscopy were used to characterize the microstructure of the cathodes.

25 ENERGY STORAGE↗
DOE OSTI2021

Developing an experimental-computational framework to investigate the deformation mechanisms and mechanical properties of Al-8Ce-10Mg alloys at micro and macroscales

There is a promising future for the use of aluminum-cerium-magnesium alloys in a broad range of applications, including devices that operate at high temperatures. With cerium currently considered a waste product of rare earth mining validation studies of possible applications are essential to reduce the environmental waste. Here, a computational-experimental framework is developed to investigate the role both the intermetallic and matrix have on the mechanical properties of these alloys. A set of experiments, including SEM/EBSD imaging, nanoindentation, in-situ SEM tensile testing, and in-situ SEM-DIC tests are performed to characterize the microstructure and mechanical properties of these alloys. Furthermore, the elastic, plastic, and failure deformation mechanisms of the microstructure, and their correlation with the bulk scale mechanical properties are investigated. Experimental results are also used to calibrate parameters for a crystal plasticity finite element model, by performing a computational framework that minimizes the error between the computational and experimental results. This model is then utilized to investigate how the area percentage of intermetallics and the crystallographic texture control the mechanical properties of the alloy. Simulation results show that an increase in the percentage of intermetallics increase the strength but decrease the ductility of the alloy. Also, a change in material texture improves strength and reduces damage that leads to material failure. The development of the crystal plasticity model, as discussed in this work, opens opportunities for future investigations of similar aluminum-cerium-magnesium alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Precipitation behavior near shrinkage porosity in a large sand casting of Haynes 282 alloy

The precipitation behavior of L1 2 structure Ni 3 (Al,Ti)-type γ' precipitates near shrinkage porosity in a large sand casting of Haynes 282 alloy has been investigated by scanning/transmission electron microscopy in conjunction with energy dispersive x-ray spectroscopy. The experimental results revealed that in the carbonitride-rich region close to the shrinkage porosity, γ' precipitates could still form with comparable sizes though at lower volume density than those in the general cast Ni matrix. The resulting γ' precipitates had a very high Al/Ti ratio. Close to oxide-rich pore surfaces, an absence of γ' precipitates was observed due to Al and Ti depletion by forming Al oxides and Ti carbonitrides, respectively. This work suggests that Al rather than Ti plays a dominant role in the formation of γ' precipitates in porous regions in cast Haynes 282 alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Transmission electron microscopy with in-situ ion irradiation: Facilities and community

Whilst there is a clear scientific and technological need for the technical capabilities of transmission electron microscopes with in-situ ion irradiation, it also requires a collaborative community of international researchers to support such facilities in successfully meeting this demand. Instruments of this type serve to provide fundamental understanding of the mechanisms which drive changes in materials important to nuclear fission and fusion energy, the semiconductor industry, quantum information systems, space travel, astronomy, geology and many more applications. As these areas continue to evolve and the instrumentation possibilities expand, the capacity of in-situ ion irradiation facilities must also develop hand-in-hand with the user community to deliver an ever-greater diversity of high-fidelity extreme-environment experimentation. Future directions for the field, such as miniaturization from MEMS/microfluidic devices and advanced controls with ML-based analysis, continuously emerge to advance both the hardware and software which support the coupling of TEMs with ion beams. This review sets out to provide up-to-date insights into the community and advancement of current, and development of future, facilities which have the potential to further unlock access to the nanoscale exploration of coupled extreme environments crucial to many of the important science and engineering challenges we face today.

In-situ irradiation↗
DOE OSTI2020

Ultrastructure of Critical-Gel-like Polyzwitterion–Polyoxometalate Complex Coacervates: Effects of Temperature, Salt Concentration, and Shear

The structure of unconventional complex coacervates, such as polymer-nonpolymer complex coacervates, remains less investigated than that of the conventional coacervates formed between oppositely charged polyelectrolytes with symmetric charge species. Yet, their microscopic structural organization is important to further elucidate the mechanism of liquid-liquid-phase separation processes upon complexation. In this work, we characterize the microstructural organization of complex coacervates formed between inorganic polyoxometalate (POM) and polyzwitterion by small-angle X-ray scattering (SAXS) with in situ temperature and shear control. Furthermore, despite the apparent transparent and homogeneous morphology of dense coacervates as observed by optical microscopy, our previous results (Macromolecules 2018, 51, 22, 9405-9411) suggest that dense polyzwitterion-POM coacervates exhibit critical-gel-like networks containing both complex-poor region (mesh pore) and complex-rich region (connective network). SAXS results as reported in this work support that the complex-rich region is actually in the form of loosely packed POM aggregates linked by polyzwitterion, designated as complex particles. The structure of aggregating complex particles is further examined against varied composition and salt concentrations, temperature, and shear, thanks to the high X-ray scattering contrast of POMs from that of other components in the coacervates. The complex particles in the dense coacervates appear to grow with more tightly packed POM aggregates with increasing POM-to-polyzwitterion concentration ratio, in contrast to more loosely packed POM aggregates with decreasing salt concentration. Conversely, increasing temperature could result in smaller complex particles containing more loosely packed POM aggregates, consistent with temperature-dependent viscoelasticity of dense coacervates. Furthermore, such POM-based hybrid dense coacervates exhibit intriguing strain-hardening behavior, resulting from shear-enhanced POM packing inside the complex particles. Distinct from the shear-thinning behavior of most conventional crosslinked polymeric networks, the strain-hardening property combined with thermal- and salt-responsive characteristics of polyzwitterion-POM coacervates could broaden the applications of hybrid organic-inorganic macroion coacervates as smart functional materials working under extreme environmental conditions.

36 MATERIALS SCIENCE↗