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At least 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Mechanical Characteristics of Additively Manufactured ODS 316L and 316H Alloys with and Without Post-build Processing

This research aims to explore an accelerated development path for oxide dispersion-strengthened (ODS) alloys by integrating additive manufacturing (AM) technologies with recent advances in ODS materials and traditional manufacturing methods. Novel AM and post-build processing routes have been developed for ODS austenitic alloys, specifically Fe-Cr-Ni alloys like 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the effects of process variables on microstructure and properties, aiming for an economically feasible route property optimization. Traditionally, ODS alloy production involves multi-day high-energy mechanical milling of alloy powder with yttria (Y 2 O 3 ) followed by powder consolidation via extrusion or other methods and additional thermomechanical processing (TMP) for property control. Here, to address these challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes focusing on AM and traditional TMP methods. The new ODS alloy processing routes have achieved up to a 400% increase in yield strength and a 60% increase in ultimate tensile strength compared to wrought stainless steels while still maintaining significant ductility and fracture toughness. This paper details the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.

Byun, Thak Sang [Oak Ridge National Laboratory (OR↗
DOE OSTI2022

Improved irradiation resistance of accident-tolerant high-strength FeCrAl alloys with heterogeneous structures

In this work, post–neutron irradiation examination is performed on advanced accident-tolerant fuel (ATF) cladding iron-chromium-aluminum (FeCrAl) alloys with ~10–13at. % Cr, ~10–12 at. % Al, ~1 at. % Mo, and minor alloying elements including Y irradiated to a damage level of 7 displacements per atom (dpa) at irradiation temperatures of 267–282 °C. A compositional dependency of the Cr and Al content is observed on the ratio of sessile and glissile dislocation loops, where the density of a$\langle$100$\rangle$ type loops is somewhat higher than the a/2$\langle$111$\rangle$ type loops. The α' precipitate number density is inversely correlated to the starting Cr concentration of the alloys of interest. The irradiation to a higher dose of 7 dpa results in a higher density of dislocation loops and α' precipitates for the same alloys at a lower irradiation dose, such as 1.8 dpa. In this work, the effect of α' precipitates on the dislocation loop density is discussed, and the presence of α' appears to inhibit the nucleation of loops. Compared with first-generation FeCrAl alloys, these advanced alloys with heterogeneous structure exhibit a lower Cr concentration in α' precipitation at the same dose level; they act as weaker obstacles deviating from the primary hardening contribution from the mature α'. Hence, the overall irradiation-induced hardening decreases; our alloys show improved radiation resistance because of their stronger sink strengths. The results presented in this paper could provide insights for the design and optimization of ATF cladding materials for future fission and space applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Machine learning elastic constants of multi-component alloys

The present manuscript explores application of machine learning methods for determining elastic constants and other derived mechanical properties of multi-component alloys. Here, a number of machine learning models, including linear regression, neural network and random forest based models, are trained and tested on a dataset of binary alloys generated using density functional theory (DFT) calculations and spanning over a large number of elemental species in the periodic table. Starting with a wide range of simple and easily accessible compositionally-averaged elemental features, a correlation-based feature selection strategy was used to systematically down-select a set of most relevant features towards the prediction of the elasticity tensor components. The true predictive performance and the associated uncertainties of the models were established by testing on unseen data and bootstrapping, respectively. A single and pair-wise feature partial dependence analysis was performed to visualize the average property trends in the multi-dimensional feature space in order to further understand the achieved predictive performance. The utility of the trained model is further demonstrated by obtaining sufficiently accurate yet highly efficient approximations for bulk modulus, Young’s modulus, shear modulus and Poisson’s ratio for alloys beyond the binary space (i.e., two-component alloys) on which the model was originally trained. More importantly, we test and validate the predictive performance of the developed model directly against the experimentally measured elastic constants of technologically relevant multi-component alloys (such as, Ni- and Ti-based alloys). Finally, utility of such a data-enabled route is demonstrated by predicting the possible range of various elastic properties for vast composition space available within the five component Ni-Cr-Fe-Mo-W alloy system in a high-throughput manner.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Stress-controlled fatigue of HfNbTaTiZr high-entropy alloy and associated deformation and fracture mechanisms

The stress-controlled fatigue tests are carried out at a stress ratio of 0.1 and a frequency of 10 Hz, and span both low-cycle and high-cycle regimes by varying the applied stress amplitudes. The high-cycle fatigue regime gives a fatigue strength of 497 MPa and a fatigue ratio of 0.44. At equivalent conditions, the alloy's fatigue strength is greater than all other high-entropy alloys (HEAs) with reported high-cycle fatigue data, dilute body-centered cubic alloys, and many structural alloys such as steels, titanium alloys, and aluminum alloys. Through in-depth analyses of crack-propagation trajectories, fracture-surface morphologies and deformation plasticity by means of various microstructural analysis techniques and theoretical frameworks, the alloy's remarkable fatigue resistance is attributed to delayed crack initiation in the high-cycle regime, which is achieved by retarding the formation of localized persistent slip bands, and its good resistance to crack propagation in the low-cycle regime, which is accomplished by intrinsic toughening backed up by extrinsic toughening. Additionally, the stochastic nature of the fatigue data is neatly captured with a 2-parameter Weibull model.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Hydrothermal corrosion of 2nd generation FeCrAl alloys for accident tolerant fuel cladding

As part of an effort to develop advanced fuel cladding for use in light water reactors, several FeCrAl alloys have been developed at Oak Ridge National Laboratory. A second generation of these alloys bearing additional alloying elements over the previously tested model alloys were tested in boiling water reactor (BWR) conditions to determine their resistance to hydrothermal corrosion. Coupons with alloy compositions Fe–10Cr–6Al–2Mo, Fe–13Cr–5Al–2Mo, Fe–13Cr–6Al–2Mo, Fe–13Cr–7Al–2Mo, and Fe–13Cr–5Al–2Mo–1Nb were tested in normal water chemistry (NWC) and hydrogen water chemistry (HWC) for 9 months in continuously refreshing autoclaves. Commercial FeCrAl alloy APMT and Zircaloy-2 were also tested for comparison. Among samples exposed to HWC, Fe–13Cr–7Al–2Mo performed worst with an average mass loss of 1.3 mg/cm2 over 9 months. This mass loss represents an estimated thickness loss of approximately 60 μm over 6 years. Samples exposed to NWC had very small mass losses of less than 0.15 mg/cm2 or mass gains up to 0.05 mg/cm2. Based on the results of this testing, the 2nd generation FeCrAl alloys tested exhibit low wall thickness loss and are suitable in terms of corrosion resistance for use as LWR cladding in BWR-HWC and BWR-NWC under normal operating conditions.

Raiman, Stephen↗
DOE OSTI2022

Experiment design for the neutron irradiation of $\mathrm{PM-HIP}$ alloys for nuclear reactors

Here, this article describes the design of an Advanced Test Reactor (ATR) drop-in neutron irradiation experiment aiming to directly compare the performance of nuclear structural alloys fabricated by powder metallurgy with hot isostatic pressing (PM-HIP) against conventional casting or forging. There is growing interest in PM-HIP alloys for nuclear applications because of their microstructural uniformity, superior mechanical properties, and reduced dependence on welding and machining, compared to cast/forged alloys. Nuclear code-qualification of PM-HIP alloys requires neutron irradiation testing to demonstrate performance under relevant conditions. In this experiment, six nuclear structural alloys were irradiated: Ni-based alloys 625 and 690, Grade 91 ferritic steel, SA508 pressure vessel steel, and 304L and 316L austenitic stainless steels. The experiment is assembled into seven capsules in four test trains and irradiated in three ATR inboard A positions. Both the PM-HIP and cast/forged versions of each alloy were irradiated under nearly identical conditions for comparative purposes, to target doses of 1 ± 0.2 and 3 ± 0.2 dpa at temperatures of 300 ± 50 °C and 400 ± 50 °C. A thorough description of the experiment design and thermal, structural and neutronic analyses performed to ensure the targeted irradiation conditions are met is provided. Specimens were configured as small disks, compact tension specimens and tensile bars to facilitate post-irradiation examination (PIE) that will include mechanical testing, microstructure characterization, and fracture toughness testing. Given the considerations for ASTM standardized mechanical testing, comparative fluence and temperature across specimen pairs, and comprehensive PIE planning herein, this work serves as a template for future nuclear materials qualification experiment designs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Systematic Characterization on Optical and Phonon Properties of Cs[Pb x Sn 1– x ]I 3 Alloyed Perovskites via First-Principles Modeling

Here, understanding the optical properties and phonon thermodynamic features of materials enables the determination of their viability for optoelectronic applications including optical-based gas sensors. Metal halide perovskites ABX 3 as well as their mixed alloys can be attractive in applications of this kind. In particular, the formation of alloyed perovskites A[B x B’ 1–x ]X 3 modulates the functional characteristics that can overtake the single-halide ABX 3 . To this end, we use the first-principles simulations to model the effect of B-site alloying on the optical and phonon properties of cubic Cs[Pb x Sn 1–x ]I 3 (x = 0.75, 0.50, and 0.25). We identified the systematic shifts of optical properties as a function of alloying concentration, such as dielectric constants, refraction indices, and absorption coefficients. It was also found that a linear correlation exists between the optical constants and the band gaps of these materials, which satisfies the Penn model. Modeling of phonons in Cs[Pb x Sn 1–x ]I 3 showed that dissipating the dynamically unstable phonons can be feasible at a carefully chosen alloying concentration, which are originally present in their single-halide Pb- and Sn-ends. Our findings pave a way to optimize the alloying conditions of the alloyed perovskite systems of interest for tuning their optical and phonon stability characteristics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Efficient Modeling of Structural, Electronic, and Optical Properties of Silver and Gold Metal Nanoclusters and Alloys Using Optimized SCC-DFTB Parameters

Computation of optical properties using conventional time-dependent density functional theory (TD-DFT) is time-consuming and memory-intensive. In this study, we investigate the accuracy and efficiency of the density functional tight binding (DFTB) framework with newly optimized Slater–Koster (SK) parameters for modeling the structural, electronic properties, and absorption spectra of silver and gold nanoclusters and their alloys. Our investigation of the ground state (GS) properties demonstrates that the newly developed GS-SK parameters enable DFTB to closely approximate DFT-calculated bond lengths for octahedron, tetrahedron, icosahedra, and truncated octahedron with sizes Ag n /Au n (n = 19, 20, 38, 55), nanoclusters and Ag 20 /Au 20 nanoalloys, with a maximum deviation of approximately 0.15 Å. Formation energy results indicate that the GS-SK parameters can closely estimate changes in formation energies with alloy composition, and the comparison of electronic structures for Ag 20 , Au 20 , and AgAu alloy nanoclusters using the DFTB approximation reveals good agreement in the projected density of states (DOS) profiles and energy levels. A second set of SK parameters, ES-SK, has been developed to describe excited state (ES) properties, including the absorption spectra of silver octahedron Ag 19 , tetrahedral Ag n (n = 20, 56, 84), truncated octahedron Ag 38 , and icosahedra Ag 55 closed-shell clusters and their gold and alloy counterparts over a broad range of alloy compositions. This parametrization uses TD-DFTB calculations and fine-tunes the d and p eigenvalues by comparing them to reference absorption spectra from first-principles TD-DFT. This enables the generation of absorption spectra that closely match the reference spectra when plasmon excitation is dominant, as demonstrated by studying the plasmonic properties of icosahedral Ag n and Au n (n = 309 and 561) nanoparticles. This includes the rapid loss in plasmon quality when Au partially replaces Ag in alloy clusters. Furthermore, these results provide a foundation for addressing computational bottlenecks in plasmonics and with new prospects for applications in the quantum plasmonics for bimetallic alloys.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

A map of single-phase high-entropy alloys

High-entropy alloys have exhibited unusual materials properties. The stability of equimolar single-phase solid solution of five or more elements is supposedly rare and identifying the existence of such alloys has been challenging because of the vast chemical space of possible combinations. Herein, based on high-throughput density-functional theory calculations, we construct a chemical map of single-phase equimolar high-entropy alloys by investigating over 658,000 equimolar quinary alloys through a binary regular solid-solution model. We identify 30,201 potential single-phase equimolar alloys (5% of the possible combinations) forming mainly in body-centered cubic structures. We unveil the chemistries that are likely to form high-entropy alloys, and identify the complex interplay among mixing enthalpy, intermetallics formation, and melting point that drives the formation of these solid solutions. We demonstrate the power of our method by predicting the existence of two new high-entropy alloys, i.e. the body-centered cubic AlCoMnNiV and the face-centered cubic CoFeMnNiZn, which are successfully synthesized.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Corrosion evaluation of Al-Cu-Mn-Zr cast alloys in 3.5% NaCl solution

Corrosion behavior of cast Al-Cu-Mn-Zr (ACMZ) and RR350 alloys was compared to a cast 319 alloy in 3.5 wt.% NaCl. After 168 h immersion, ACMZ and RR350 alloys suffered from preferential attack adjacent to intermetallic particles decorated at grain boundaries while the attack in 319 occurred in eutectic Al-Si dendritic boundaries. Electrochemical data allowed semiquantitative comparison of alloy resistance to corrosion initiation, and ACMZ type alloys, including RR350 and three alloys with higher Cu, were considered more resistant than 319 due to the absence of deleterious Si particles. In case of 319, such Si particles presumably drove higher micro-galvanic influence to initiate and sustain Al corrosion. With lower susceptibility to corrosion initiation, ACMZ alloys should exhibit higher or at minimum similar resistance compared to cast 319.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Microstructure and properties of additively manufactured Al–Ce–Mg alloys

Additive manufacturing of aluminum alloys is largely dominated by a near-eutectic Al-Si compositions, which are highly weldable, but have mechanical properties that are not competitive with conventional wrought Al alloys. In addition, there is a need for new Al alloys with improved high temperature properties and thermal stability for applications in the automotive and aerospace fields. In this work, we considered laser powder bed fusion additive manufacturing of two alloys in the Al–Ce–Mg system, designed as near-eutectic (Al–11Ce–7Mg) and hyper-eutectic (Al–15Ce–9Mg) compositions with respect to the binary L → Al + Al 11 Ce eutectic reaction. The addition of magnesium is used to promote solid solution strengthening. A custom laser scan pattern was used to reduce the formation of keyhole porosity, which was caused by excessive vaporization due to the high vapor pressure of magnesium. The microstructure and tensile mechanical properties of the alloys were characterized in the as-fabricated condition and following hot isostatic pressing. The two alloys exhibit significant variations in solidification structure morphology. These variations in non-equilibrium solidification structure were rationalized using a combination of thermodynamic and thermal modeling. Both alloys showed higher yield strength than AM Al-10Si-Mg for temperatures up to 350 °C and better strength retention at elevated temperatures than additively manufactured Scalmaloy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Ab-initio Cu alloy design for high-gradient accelerating structures

Operation of normal conducting accelerator structures at high accelerating gradients is beneficial for many accelerator applications in basic science, industry, medicine, and National Security. RF breakdown is the major factor that limits the achievable accelerating gradients. Previous experiments on copper (Cu) have demonstrated that RF breakdown probability can be significantly decreased by hardening the material and alloying Cu with solutes such as silver (Ag). In this paper, we propose a figure-of-merit (FOM) that characterizes the ability of Cu alloys to withstand high-gradients. The FOM represents a trade-off between hardening through solid solution strengthening and the additional thermal stress induced by incremental RF pulse heating resulting from changes in electronic properties induced by alloying. We performed high-throughput ab initio calculations and computed the FOM for a large number of binary Cu alloys. Several promising candidate alloys for high-gradient accelerating structures were identified, such as CuAg, CuCd, CuHg, CuAu, CuIn, and CuMg. CuAg alloys have previously exhibited low RF breakdown rates in experiments. The results provide guidance for selecting alloys for the future high-gradient normal conducting accelerating structures operating at very high gradients.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Machine learning guided optimal composition selection of niobium alloys for high temperature applications

Nickel- and cobalt-based superalloys are commonly used as turbine materials for high-temperature applications. However, their maximum operating temperature is limited to about 1100 °C. Therefore, to improve turbine efficiency, current research is focused on designing materials that can withstand higher temperatures. Niobium-based alloys can be considered as promising candidates because of their exceptional properties at elevated temperatures. The conventional approach to alloy design relies on phase diagrams and structure–property data of limited alloys and extrapolates this information into unexplored compositional space. In this work, we harness machine learning and provide an efficient design strategy for finding promising niobium-based alloy compositions with high yield and ultimate tensile strength. Unlike standard composition-based features, we use domain knowledge-based custom features and achieve higher prediction accuracy. We apply Bayesian optimization to screen out novel Nb-based quaternary and quinary alloy compositions and find these compositions have superior predicted strength over a range of temperatures. We develop a detailed design flow and include Python programming code, which could be helpful for accelerating alloy design in a limited alloy data regime.

Mohanty, Trupti (ORCID:0000000342701430)↗
DOE OSTI2024

Interpolation of compound semiconductor alloy parameters from those of their constituents

Several methods have been proposed for interpolation of the value of physical parameters of quaternary alloys from those of their constituent ternary and binary sub-alloys. These expressions agree when non-linear bowing terms are not required; they differ in how the bowing terms of the bounding ternaries should be utilized. Common interpolation expressions for quaternaries can be generalized into two groups: (1) those that use a linear interpolation of the nearest ternary parameter values and (2) those that interpolate over binary values with a bowing term derived from the bounding ternaries. The second group of methods is equivalent to a polynomial expansion over the alloy’s interpolation space. For compound semiconductor alloys, the geometry of the composition space is the direct sum of the group-III and group-V mixture sub-spaces. The mixture sub-spaces are best described using barycentric coordinates on a regular simplex. A general polynomial expansion of the value of an alloy parameter using barycentric coordinates for the group-III and group-V simplex spaces is described along with an algorithm to generate interpolation expressions for alloys with arbitrary numbers of elements, including quinary and senary alloys. It is shown that a polynomial expansion produces values in closer agreement with the direct gap of quaternaries lattice-matched to common substrates than do approaches using an interpolation of the ternary values, despite a prominent recommendation to the contrary. Finally, a quaternary correction term is described that improves the predicted direct bandgap energies of GaInAsSb for compositions near those lattice matched to InP, InAs, and GaSb.

Olesberg, Jonathon T. [Sandia National Laboratorie↗
DOE OSTI2020

Thermomechanical Processing of Uranium Alloys with 10 and 50 Weight Percent Zirconium

This work focuses on casting and thermomechanical processing for moderate sized (500-1000g) 10% by weight and 50% by weight uranium-zirconium alloys. Three castings of uranium – 10wt% zirconium and a fourth casting of uranium – 50wt% zirconium were completed using different castings processes. The first casting process relied on only induction mixing within the VIM system thereby eliminating the need for an arc-melting feedstock preparation step. The second casting process used the arc-melting process prior for feedstock to the same VIM system. In this study, the induction mixing process alone with a graphite crucible appears insufficient for the fabrication of UZr alloys. Graphite is suitable with the use of master alloy UZr feedstock produced by arc-melting. There was a moderate increase of approximately 100 ppm of carbon within the U10Zr alloys. However, there was a near 1000 ppm increase of carbon in the U50Zr alloy. This carbon content is considered too high for forming processes, and therefore, warrants the use of a ceramic crucible for UZr castings near 50wt% zirconium. Zirconia does not appear suitable for UZr castings near 50wt% zirconium. The use of Beryllia or Thoria may be a more suitable option. However, due to the significantly lower liquidus and lower zirconium content, Zirconia crucibles do appear viable for carbon reduction in the U10Zr system. Two thermomechanical processes are also studied in this work - hot extrusion of the U50Zr system and heat treatment in an argon atmosphere. This work demonstrated that extrusion of the U50Zr alloy near 680°C is a viable choice even with +1000 ppm carbon. Extrusion of the U50Zr system near 630°C was unsuccessful and does not appear viable unless significant force and tooling strength is available. There appears to be a moderate increase in extrudate hardness when compared to as-cast. Heat-treatment reduced the hardness of as-cast alloys in the U10Zr castings as well as resolve some variance in the microstructures. However, for the U50Zr billet that did not successfully extrude at 630°C, heat treatment at 900°C for 96 hours did not have a significant impact on hardness or microstructure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Development of High-Performance Ni-base Alloys for Gas Turbine Wheels Using a Coprecipitation Approach (Final Technical Report)

In this project, a synergistic approach involving experiments informed by modelling was used to develop γ'/γ'' coprecipitation-strengthened Ni-base superalloys for land-based gas turbine wheels. In thick sections of such turbine wheels, the slow cooling rate normally observed, as well as variations in cooling rate could potentially result in drastically inhomogeneous and coarsened microstructure. Thus, ten alloy compositions were selected based on coprecipitation and sluggish γ’ growth and coarsening during three iterations of alloy development, assisted by extensive CALPHAD modeling. Phase equilibrium calculations, informed by the characterization of early alloys, were successful in predicting suitable aging treatments to obtain bimodal coprecipitate distribution in several alloys. These aging treatments were applied to the subsequent round of alloys and the resulting microstructures were characterized in detail. Two different cooling rates were used during each of these heat treatments to simulate the range of cooling rates observed in a thick section forging. The microstructures were used to calibrate a multi-phase field model (MPF), which was used to study the formation mechanisms of various coprecipitate morphologies observed in the experiments. Following this, the most promising alloys in each round were selected and studied using high temperature tensile and creep tests. Considering that a slower cooling rate would lead to a strength debit, while a faster cooling rate might lead to a decline in creep rupture life of a full-scale wheel, tensile tests were carried out for slower cooled samples, while creep tests were carried out for faster cooled samples. The deformation microstructures were then characterized using advanced characterization techniques such as Diffraction Contrast-Scanning Transmission Electron Microscopy (DC-STEM) and Electron Channeling Contrast Imaging (ECCI). Further, a mean-field creep model was developed and calibrated using these experimental findings to predict long-term creep behavior of these coprecipitation-strengthened alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Assessment of Aging Degradation Mechanisms of Alloy 709 for Sodium Fast Reactors

This project was initiated in October 2015 to investigate the creep and creep-fatigue behavior of Alloy 709 for structural components in Gen IV sodium cooled fast spectrum reactors. The goal of this project is to develop an understanding of the mechanisms responsible for the behavior of austenitic stainless steel alloy 709 under accelerated testing conditions to confidently predict long term creep and creep-fatigue behavior at the times (500,000 hours) and temperatures (550°C) of interest for fast reactor structural applications. Alloy 709 has exhibited significantly better creep resistance than Alloy 316H, which is currently specified in design of fast reactor structural components. However, the alloy has not been code qualified for elevated temperature nuclear design. The elevated temperature microstructure stability and creep and creep-fatigue behavior need to be better understood so service life can be accurately predicted. Alloy 709 was developed for fossil boiler applications, which operate at a higher temperature than the nuclear components. Thus, there is a strong need to characterize its creep and creep-fatigue behavior at these lower temperatures and corresponding longer service lifetimes. The overall objective of this project is to develop sufficient understanding of the mechanisms responsible for behavior of Alloy 709 under accelerated testing conditions to confidently predict long term creep and creep-fatigue behavior at the times (500,000 hours) and temperatures (550°C) of interest for fast reactor structural applications. The following report summarizes the findings of the creep-fatigue and creep behavior with respect to the research questions identified during the course of the project. Additionally, the training and professional development that occurred through the project and the products resulting from the project are summarized.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Shear Assisted Processing and Extrusion (ShAPE) of Aluminum Alloy 7075, 2024, and Al-12.4TM

The most common aluminum alloys utilized in the aerospace industry are 7075 and 2024 due to their high strength-to-weight ratio compared to advanced high strength steels and other aluminum alloys. Despite excellent performance, these aluminum alloys have seen limited use outside of the aerospace industry due in part to high cost. If high-performance aluminum extrusions could be made more cost effectively by eliminating energy intensive process steps typical of conventional extrusion, then numerous opportunities exist for more widespread adoption. A key reason for the high cost of 7075 and 2024 extrusions (25-75% higher than 6061) is their slow extrusion speed. 7075 and 2024 are limited to 2 m/min and 3.5 m/min respectively, in contrast to 6061 which can be extruded at 20–80 m/min. In addition to slow speed, aluminum alloys require numerous thermal treatments throughout the extrusion process including homogenization and pre-heating prior to extrusion, and solution heat treating and artificial aging after extrusion. Each of these steps contribute to the total energy consumed during manufacturing of extruded components. This project investigates the use of ShAPE to improve extrusion speed and reduce, or even eliminate, the typical thermal treatments for high strength aluminum alloys, all while improving material performance. The overarching goal of this project was to demonstrate that Shear Assisted Processing and Extrusion (ShAPE) can manufacture high-performance aluminum alloy tubing with lower manufacturing energy and improved mechanical properties compared to conventional extrusion. Unlike conventional extrusion where the billet is rammed against a stationary die using a strictly linear motion, the ShAPE process superimposes a rotational shear force by spinning the die while the billet is plunged. Compared to conventional linear extrusion, the ShAPE process imparts significantly more strain into the feedstock material, which enables the formation of novel microstructures. These microstructures manifest an array of property and process improvements for extrusion of high-performance aluminum alloys. The following accomplishments were achieved for this project: Extrusion of 7075 at 12.2 meters/min compared to 2 meters/min for conventional extrusion; Elimination of 7075 billet homogenization (430 °C for 20 hours) which is required prior to conventional extrusion; Elimination of 7075 billet pre-heating (400 °C for 1 hour) in a separate furnace which is required prior to conventional extrusion; Achieved 7075-T6with yield strength = 595 MPa, ultimate tensile strength = 531MPa, and elongation = 17.4% for extrusions made from unhomogenized billets. Exceeds the ASTM and ASM standard, and typical industry values; Achieved 7075-T5 (i.e., no solution heat treatment) with yield strength = 588 MPa, ultimate tensile strength = 535 MPa, and elongation = 14.8% for extrusions made from homogenized billets; Extrusion of 2024 at 7.4 meters/min compared to 3.5 meters/min for conventional extrusion; Achieved 2024-T8510 yield strength = 522 MPa, ultimate strength = 510MPa, and elongation = 7.1% for extrusions made from wrought billets. Exceeds the ASTM and ASM standard, and typical industry values; Extrusion of Al-12.4TM high-performance aluminum powder directly into tubing, in a single step, which eliminates process steps typical of powder metallurgy extrusion.

36 MATERIALS SCIENCE↗