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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Residual stresses in Cu matrix composite surface deposits after laser melt injection

Abstract Tungsten carbide particles reinforced metal matrix composite (MMC) coatings can significantly improve surface wear resistance owing to their increased surface hardness. However, the presence of macro‐ and micro‐residual stresses in MMC coatings can have detrimental effects, such as reducing service life. In this study, neutron diffraction was used to determine the residual stresses in spherical fused tungsten carbide (sFTC) reinforced Cu matrix composite surface deposits after laser melt injection. We also developed a thermo‐mechanical coupled finite element model to predict residual stresses. Our findings reveal that sFTC/Cu composite deposits produced with a preheating temperature of 400°C have low residual stresses, with a maximum tensile residual stress of 98 MPa in the Cu matrix on the top surface. In contrast, the sFTC/bronze (CuAl10Ni5Fe4) composite deposit exhibits very high residual stresses, with a maximum tensile residual stress in the Cu matrix on the top surface reaching 651 MPa. These results provide a better understanding of the magnitudes and distributions of residual stresses in sFTC‐reinforced Cu matrix composite surface deposits manufactured via laser melt injection.

Zhang, Xingxing↗
NASA NTRS1998

Effects of Fiber Coating Composition on Mechanical Behavior of Silicon Carbide Fiber-Reinforced Celsian Composites

Celsian matrix composites reinforced with Hi-Nicalon fibers, precoated with a dual layer of BN/SiC by chemical vapor deposition in two separate batches, were fabricated. Mechanical properties of the composites were measured in three-point flexure. Despite supposedly identical processing, the composite panels fabricated with fibers coated in two batches exhibited substantially different mechanical behavior. The first matrix cracking stresses (sigma(sub mc)) of the composites reinforced with fibers coated in batch 1 and batch 2 were 436 and 122 MPa, respectively. This large difference in sigma(sub mc) was attributed to differences in fiber sliding stresses(tau(sub friction)), 121.2+/-48.7 and 10.4+/-3.1 MPa, respectively, for the two composites as determined by the fiber push-in method. Such a large difference in values of tau(sub friction) for the two composites was found to be due to the difference in the compositions of the interface coatings. Scanning Auger microprobe analysis revealed the presence of carbon layers between the fiber and BN, and also between the BN and SiC coatings in the composite showing lower tau(sub friction). This resulted in lower sigma(sub mc) in agreement with the ACK theory. The ultimate strengths of the two composites, 904 and 759 MPa, depended mainly on the fiber volume fraction and were not significantly effected by tau(sub friction) values, as expected. The poor reproducibility of the fiber coating composition between the two batches was judged to be the primary source of the large differences in performance of the two composites.

Bansal, Narottam P.↗
DOE OSTI2016

Irradiation effects in tungsten-copper laminate composite

Tungsten-copper laminate composite has shown promise as a structural plasma-facing component as compared to tungsten rod or plate. The present study evaluated the tungsten-copper composite after irradiation in the High Flux Isotope Reactor (HFIR) at temperatures of 410-780°C and fast neutron fluences of 0.02-9.0×1025 n/m2, E>0.1 MeV, 0.0039-1.76 displacements per atom (dpa) in tungsten. Tensile tests were performed on the composites, and the fracture surfaces were analyzed with scanning electron microscopy. Before irradiation, the tungsten layers had brittle cleavage failure, but the overall composite had 15.5% elongation at 22°C. After only 0.0039 dpa this was reduced to 7.7% elongation, and no ductility was observed after 0.2 dpa at all irradiation temperatures when tensile tested at 22°C. For elevated temperature tensile tests after irradiation, the composite only had ductile failure at temperatures where the tungsten was delaminating or ductile.

Garrison, L. M.↗
DOE OSTI2018

Preparation and characterization of microwave absorbing composite materials with GSs or FeCo/GS composites

Highlights: • It is found that adding GSs or FeCo/GSs composite into the sample SiC/NR can greatly increase RL and the absorbing peak shifts to low-frequency with increasing the adding amount. • The optimum adding amount of GSs is 2%. The sample GS-200-2% possesses the lowest RL value of −31.27 dB at 7.6 GHz. • The optimum adding amount of FeCo/GSs composite is 3%. The sample AGS-450-3% possesses the lowest RL value of −20.67 dB at 7.8 GHz. - Abstract: This study mainly explored the synthesis method of graphene sheets (GSs) and FeCo/graphene sheet (FeCo/GS) composites and evaluated the microwave absorbing characteristics of composite materials containing GSs or FeCo/GS composites. First, graphite oxide (GO) was synthesized by the modified Hummers method. The synthesized GO was further used to synthesize GSs and FeCo/GS composites. Afterward, GSs or FeCo/GS composites were mixed with silicon carbide (SiC) and natural rubber (NR) to prepare microwave absorbing materials with thicknesses of 2 mm. Finally, identification and characterization of these samples were performed by XRD, FE-SEM, TEM, TGA, ESCA, RS, AFM and VNA. GSs were synthesized successfully at a low annealing temperature of 200 °C, and their thicknesses were between 0.848 nm and 2.115 nm, which corresponds to 2–6 stacked layers of graphene. FeCo/GS composites were also synthesized successfully at three different annealing temperatures. The nanoparticles of metals and metal oxides were well-dispersed on the surfaces of and the spaces between GSs. It was found that adding GSs or FeCo/GS composites into the SiC/NR sample can greatly increase reflection loss (RL) and that the absorbing peak shifts to lower frequencies as the concentration of added particles increases. The optimum concentration of added GSs was 2 wt.%. The GS-200-2% sample possessed the lowest RL value of −31.27 dB at 7.6 GHz. The optimum concentration of added FeCo/GS composites was 3 wt.%. The AGS-450-3% sample possessed the lowest RL value of −20.67 dB at 7.8 GHz.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Effect of phase composition of calcium silicate phosphate component on properties of brushite based composite cements

The composite cement mixtures were prepared by mixing brushite (B) with, the amorphous hydrated calcium silicate phosphate (CSPH) or annealed calcium silicate phosphate (CSP composed of Si-saturated hydroxyapatite, wollastonite and silica) phases and water as liquid component. The contents of the silicate-phosphate phase in composites were 10.30 and 50 wt%. The significant effect of both the Ca/P ratio and different solubility of calcium silicate phosphate component in starting cement systems on setting time and phase composition of the final composite cements was demonstrated. The compressive strength of the set cements increased with the filler addition and the highest value (~ 48 MPa) exhibited the 50CSP/B cement composite. The final setting times of the composite cements decreased with the CSPH addition from about 25 to 17 min in 50CSHP/B and setting time of CSP/B composites was around 30 min. The higher content of silica in cements caused the precipitation of fine hydroxyapatite particles in the form of nanoneedles or thin plates perpendicularly oriented to sample surface. The analysis of in vitro cement cytotoxicity demonstrated the strong reduction in cytotoxicity of 10CSPH/B composite with time of cultivation (a low cytotoxicity after 9 days of culture) contrary to cements with higher calcium silicate-phosphate content. These results were attributed to the different surface topography of composite substrates and possible stimulation of cell proliferation by the slow continuously release of ions from 10CSPH/B cement. - Highlights: • Ca/P ratio and solubility of calcium silicate-phosphate components affect the self-setting properties of cements. • Strong relationship between the composite in vitro cytotoxicity and surface microtopography was demonstrated. • Plate-like morphology of coarser particles allowed cells to better adhere and proliferate as compared with nanoneedles.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Thermo-Oxidative Stability of Graphite/PMR-15 Composites: Effect of Fiber Surface Modification on Composite Shear Properties

Experiments were conducted to establish a correlation between the weight loss of a polyimide (PMR- 15) matrix and graphite fibers and the in-plane shear properties of their unidirectional composites subjected to different isothermal aging times up to 1000 hr at 316 C. The role of fiber surface treatment on the composite degradation during the thermo-oxidative aging was investigated by using A4 graphite fibers with three surface modifications: untreated (AU-4), surface treated (AS-4), and surface treated and sized with an epoxy-compatible sizing (AS-4G). The weight loss of the matrix fibers, and composites was determined during the aging. The effect of thermal aging was seen in all the fiber samples in terms of weight loss and reduction in fiber diameter. Calculated values of weight loss fluxes for different surfaces of rectangular unidirectional composite plates showed that the largest weight loss occurred at those cut surfaces where fibers were perpendicular to the surface. Consequently, the largest amount of damage was also noted on these cut surfaces. Optical observation of the neat matrix and composite plates subjected to different aging times revealed that the degradation (such as matrix microcracking and void growth) occurred in a thin surface layer near the specimen edges. The in-plane shear modulus of the composites was unaffected by the fiber surface treatment and the thermal aging. The shear strength of the composites with the untreated fibers was the lowest and it decreased with aging. A fracture surface examination of the composites with untreated fibers suggested that the weak interface allowed the oxidation reaction to proceed along the interface and thus expose the inner material to further oxidation. The results indicated that the fiber-matrix interface affected the composite degradation process during its thermal aging and that the the weak interface accelerated the composite degradation.

Madhukar, Madhu S.↗
DOE OSTI2025

Multi-site Milling Strategy Reveals Significant Variation in Biomass Composition of Switchgrass ( Panicum virgatum ) Grown at Ten Locations

Cell wall composition influences biomass use as a forage and as a feedstock for biofuel and chemical conversion. To examine the influence of environment on composition of switchgrass (Panicum virgatum L.), we utilized a multi-environment experiment consisting of clones of switchgrass genotypes grown at up to ten locations in the continental US. We tested the influence of different milling treatments on biomass composition trait predictions via near-infrared reflectance spectroscopy (NIRS). We found that most compositional trait predictions (29/34) were significantly different (P < 0.05) when a single lot of biomass was subjected to disparate milling treatments, i.e., knife milling vs. knife milling with an additional cyclone milling. Further, depending on the plant material tested, three to eight compositional trait predictions vary (P < 0.05) when identical biomass was knife milled at different sites followed by cyclone milling at a single site, including for traits such as Klason lignin, nitrogen, and carbon. In some cases, variation due to milling site exceeded environmentally induced compositional variation of a single switchgrass genotype grown at different sites. From these observations, we recommend a protocol with two sequential millings that decouples growth environment from a particular mill. Utilizing this approach, we found that 46/46 biomass composition traits from the warm season herbaceous forage and switchgrass bioethanol NIRS equations vary significantly (P < 0.001) in clones of a switchgrass genotype (WBC) grown at ten sites, with the growth site representing the largest average source of variation (41%). This multi-site milling approach can be used to examine environmental and gene-by-environment influences on composition with the goal of optimizing cell wall composition in different environments for biomass utilization.

09 BIOMASS FUELS↗
DOE OSTI2021

Copper carbon composite wire with a uniform carbon dispersion made by friction extrusion

Copper-carbon composites are a group of materials with excellent mechanical, electrical, thermal, and tribological properties. However, bulk size copper-carbon composites made by the traditional manufacturing processes, like rolling or extrusion, fall short of reaching some of these properties predicted by theory or demonstrated only by samples at centimeter scale or smaller. The two main challenges to the successful scaling-up are: 1) to uniformly disperse carbon in the metal matrix; 2) to avoid degradation due to oxidation or reaction from overheating. In this work, we first demonstrate friction extrusion as a new method to make bulk-size void-free copper-carbon composite wires with homogenized carbon dispersion. Three different carbon varieties, graphite powder, graphene nanopowder, and carbon nanotubes, were added to the copper matrix with the concentration ranging from 0.5 wt% to 15 wt%. Special tooling, processing parameters, and procedures were developed, especially for high carbon content samples. Ten-fold reductions of both copper grain size and carbon particle size were achieved and attributed to the high shear deformation. Energy dispersive X-ray spectrometry indicates the carbon powder was refined to a sub-micron level and uniformly dispersed in the copper matrix. Compared with that of pure copper, the thermal capacity of the composite wire increases by 30 % while density reduces by 29 %.

Friction extrusion, Metal matrix composite, Graphe↗
DOE OSTI2014

A Composite Modeling Analysis of the Deformation Behavior of Medium Manganese Steels

The deformation behavior of medium manganese steels was evaluated with uniaxial tensile testing and the results were correlated with predictions of a composite model shown previously to provide design insight into the development of multi-phase steels with third-generation advanced high strength steel (3GAHSS) properties. An equilibrium thermodynamic-based methodology to design microstructures containing systematic amounts of metastable austenite with controlled stability against transformation is presented. The analysis is based on Mn enrichment of austenite during intercritical annealing of medium Mn (7 and 10 wt pct.) low carbon (0.1 and 0.15 wt pct) steels. The steels were produced as laboratory heats that were hot and cold rolled prior to annealing. After annealing the microstructures consisted primarily of either a matrix of fine grained ferrite with austenite contents between 32.6 and 45.2 wt pct (7Mn, 0.1C steels) or a matrix of martensite with various amounts of austenite in the higher Mn steel. The different intercritical annealing conditions produced steels with wide variations in austenite contents and austenite compositions (Mn and C contents) resulting in steels with significant variations in austenite stability. Predictions based on the composite analysis with different assumed flow behaviors for the individual constituents and stability functions for the meta-stable austenite are presented and shown to accurately predict strength-ductility combinations over a range of austenite volume fractions for the 7Mn steel. Applicability of the composite analysis is extended to consider the deformation behavior of the 10Mn steel and evaluate other possible microstructural combinations leading to 3GAHSS properties.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Facile electrostatic self-assembly of silicon/reduced graphene oxide porous composite by silica assist as high performance anode for Li-ion battery

Silicon(Si)/graphene composite has been regarded as one of the most promising candidates for next generation anode materials with high power and energy density in lithium ion batteries. Introduction of graphene in Si anodes could improve the electronic conductivity, suppress the severe volume expansion of Si, and facilitate the formation of stable solid electrolyte interphase, etc. However, traditionally mechanical mixing of Si and graphene cannot realize uniform distribution of Si particles on the graphene sheets, which would largely weaken the effectiveness of the graphene in the composite. In this work, nano-Si/reduced graphene oxide porous composite (p Si/rGO) has been fabricated by a facile electrostatic self-assembly approach via using SiO2 as the sacrificial template. Compared with the simply mechanically mixed nano-Si and rGO (Si/rGO), the nano-Si particles could be more uniformly dispersed among the rGO sheets in the p Si/rGO, which significantly increases its electronic conductivity. Moreover, the drastic volume expansion of nano-Si during repeated lithiation/delithiation cycles also has been effectively accommodated by the large number of pores left after removing the SiO2 template in the composite. Thus, the p Si/rGO presented largely enhanced electrochemical performances, showing a high reversible capacity up to 1849?mA?h?g-1 at 0.2?A?g-1 with good capacity retention, and high rate capability (535?mA?h?g-1 at 2?A?g-1).

Silicon, Reduced graphene oxide, Electrostatic sel↗
NASA NTRS1978

Impetus of composite mechanics on test methods for fiber composites

Significant contributions of the three major areas of composite mechanics to the development of test methods are illustrated with selected examples. The areas of composite mechanics include composite micromechanics, composite macromechanics, and laminate theory. The examples can be considered to be representative of the contribution of composite mechanics to the development of composite test methods. The specific examples describe contributions such as criteria for selecting resin matrices for improved composite strength, the 10 deg off-axis tensile test, procedures for configuring hybrids, and the concept of 'reduced bending rigidities'. The pertinent composite mechanics equations associated with each contribution are given and supplemented by tabular and/or graphical data which illustrate the significance of the contribution.

Chamis, C. C.↗
NASA NTRS1998

Effect of Composite Fabrication on the Strength of Single Crystal Al2O3 Fibers in Two Fe-Base Alloy Composites

Continuous single-crystal Al2O3 fibers have been incorporated into a variety of metal and intermetallic matrices and the results have consistently indicated that the fiber strength had been reduced by 32 to 50% during processing. Two iron-based alloys, FeNiCoCrAl and FeAlVCMn, were chosen as matrices for Al2O3 fiber reinforced metal matrix composites (MMC) with the goal of maintaining Al2O3 fiber strength after composite processing. The feasibility of Al2O3/FeNiCoCrAl and Al2O3/FeAlVCMn composite systems for high temperature applications were assessed in terms of fiber-matrix chemical compatibility, interfacial bond strength, and composite tensile properties. The strength of etched-out fibers was significantly improved by choosing matrices containing less reactive elements. The ultimate tensile strength (UTS) values of the composites could generally be predicted with existing models using the strength of etched-out fibers. However, the UTS of the composites were less than desired due to a low fiber Weibull modulus. Acoustic emission analysis during tensile testing was a useful tool for determining the efficiency of the fibers in the composite and for determining the failure mechanism of the composites.

Draper, Susan L.↗
DOE OSTI2025

Compositionally-driven surface nanostructuring on refractory compositionally complex alloys under low energy helium bombardment

Additive manufacturing enables user-defined control of the compositional complexity, opening new design spaces for complex concentrated alloys (CCAs). Refractory CCAs may offer enhanced performance in the divertor region of a fusion reactor environment where plasma-facing materials will be subject to high temperatures, low energy He and D particles, and 14 MeV neutrons. In this work, specimens with the nominal composition of NbTaMoTi, NbTaMo, NbTaTi, and NbTa were fabricated via directed energy deposition (DED) then bombarded with 40 eV He ions to a fluence of 2x10 26 m −2 at ∼ 1000 K. Post irradiation, the surface morphology and composition were examined with electron microscopy and x-ray photoelectron spectroscopy to offer information on the spatial distribution of surface nano-structuring. Sub-surface He bubbles driving the nano-structuring were examined with electron microscopy techniques. Analysis indicates the local composition directly influences the He bubble and tendril size, while the region with the highest complexity showed the shortest nano-structuring. Molecular Dynamics simulations complement the experimental results, showing comparable helium bubble growth and migration as a function of compositional complexity. This work demonstrates the compositional dependence of surface nanostructure formation of compositionally complex alloys, important for future design of complex plasma facing materials in fusion reactors.

Complex concentrated alloys↗