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Results for “Field assisted sintering”

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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A universal all-solid synthesis for high throughput production of halide perovskite

Abstract Halide perovskites show ubiquitous presences in growing fields at both fundamental and applied levels. Discovery, investigation, and application of innovative perovskites are heavily dependent on the synthetic methodology in terms of time-/yield-/effort-/energy- efficiency. Conventional wet chemistry method provides the easiness for growing thin film samples, but represents as an inefficient way for bulk crystal synthesis. To overcome these, here we report a universal solid state-based route for synthesizing high-quality perovskites, by means of simultaneously applying both electric and mechanical stress fields during the synthesis, i.e., the electrical and mechanical field-assisted sintering technique. We employ various perovskite compositions and arbitrary geometric designs for demonstration in this report, and establish such synthetic route with uniqueness of ultrahigh yield, fast processing and solvent-free nature, along with bulk products of exceptional quality approaching to single crystals. We exemplify the applications of the as-synthesized perovskites in photodetection and thermoelectric as well as other potentials to open extra chapters for future technical development.

36 MATERIALS SCIENCE↗
DOE OSTI2021

idaholab/malamute

MALAMUTE combines MOOSE module functionality with realistic materials and geometries for arbitrary-Eulerian-Lagrangian (ALE) and level-set based laser melting and welding applications and electric-field assisted sintering (EFAS) applications.

Icenhour, Casey [Idaho National Lab. (INL), Idaho ↗
DOE OSTI2021

Moose Application Library For Advanced Manufacturing Utilities

MALAMUTE combines MOOSE module functionality with realistic materials and geometries for arbitrary-Eulerian-Lagrangian (ALE) and level-set based laser melting and welding applications and electric-field assisted sintering (EFAS) applications.

Lindsay, AlexanderD.↗
DOE OSTI2022

Microstructural Transitions during Powder Metallurgical Processing of Solute Stabilized Nanostructured Tungsten Alloys

Exploiting grain boundary engineering in the design of alloys for extreme environments provides a promising pathway for enhancing performance relative to coarse-grained counterparts. Due to its attractive properties as a plasma facing material for fusion devices, tungsten presents an opportunity to exploit this approach in addressing the significant materials challenges imposed by the fusion environment. Here, we employ a ternary alloy design approach for stabilizing W against recrystallization and grain growth while simultaneously enhancing its manufacturability through powder metallurgical processing. Mechanical alloying and grain refinement in W-10 at.% Ti-(10,20) at.% Cr alloys are accomplished through high-energy ball milling with transitions in the microstructure mapped as a function of milling time. We demonstrate the multi-modal nature of the resulting nanocrystalline grain structure and its stability up to 1300 °C with the coarser grain size population correlated to transitions in crystallographic texture that result from the preferred slip systems in BCC W. Field-assisted sintering is employed to consolidate the alloy powders into bulk samples, which, due to the deliberately designed compositional features, are shown to retain ultrafine grain structures despite the presence of minor carbides formed during sintering due to carbon impurities in the ball-milled powders.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Electromagnetics and Advanced Manufacturing Simulation Development within the MOOSE Ecosystem

The MOOSE electromagnetics module (EMM) was developed to provide a general simulation tool for modeling a wide range of problems encountered in computational electromagnetics and enable MOOSE and MOOSE-based application coupling to Maxwell's equations to solve a wide class of new problems. Development of the electromagnetics module has also enabled development of new advanced manufacturing models in the MOOSE ecosystem, including that of the electric field-assisted sintering (EFAS) process. Recent results from this effort show good agreement with experimental results, and these two capabilities will be used in future projects to develop models for novel materials development and manufacturing for extreme environments.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Microstructure development of novel composite heating elements for steel decarbonization

The iron and steel industry is critical for the modern world but is also responsible for 7% of the total energy sector CO2 emissions. It is a difficult industry to decarbonize due to the high temperature heat required for the production of steel, such as reheating steel slabs to ~1250 °C for hot rolling. Electrification of this process using resistive heating is currently not possible due to the poor creep resistance of MoSi2 heating elements, which need to be operated well below their maximum temperatures when mounted horizontally. To solve this problem, novel MoSi2 composite heating elements with SiBCN ceramic reinforcements are being developed using high energy ball milling and electric field assisted sintering (EFAS). The microstructure and density of the composites after sintering depends on the sintering parameters chosen. Herein we present the effects of EFAS sintering parameters on the microstructure and density of the MoSi2-SiBCN composites.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Report on the Assessment of Ion Irradiations on High Entropy Alloys

Idaho National Laboratory (INL) initiated a joint international effort with the Czech Republic to explore the feasibility of manufacturing High Entropy Alloys for high-temperature nuclear applications using Additive Manufacturing. This effort was funded at INL by the United States Department of Energy’s Office of Nuclear Energy under the Advanced Reactor Technologies and Advanced Materials and Manufacturing Technologies (AMMT) Program. The High Entropy Alloys were specifically designed for the corrosive and irradiation environments as experienced in gas fast reactors, molten salt reactors, and fusion power. These alloys were manufactured by multiple processes to determine the impact of manufacturing processes on the performance of the alloys in corrosive and irradiation environments. Preliminary results show that MoNbTiV and MoNbTi alloys exhibit no degradation after multiple corrosion tests. These MoNbTiV and MoNbTi alloys were also evaluated after irradiation experiments were conducted at the Michigan Ion Beam Laboratory at the University of Michigan, which is the focus of this milestone report. For these irradiation experiments, the MoNbTiV and MoNbTi alloys manufactured by arc melting and Electric Field Assisted Sintering (EFAS) were tested at 500 C at a dose of 30 dpa to evaluate the microstructural stability and decomposition.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Microstructural Characteristics, Mechanical Properties, and Corrosion Behavior of Field-Assisted Diffusion Welded Alloy 617

This study investigated the microstructural characteristics, mechanical response, and corrosion resistance of Alloy 617 diffusion welded by electric field-assisted sintering (EFAS). The microstructure exhibited good grain boundary (GB) migration across the interface and flat interface in the samples bonded at different conditions. Graded grain size was observed, with grain coarsening being more significant near sample surface due to EFAS-induced temperature gradient. Tensile testing revealed that the specimens fractured in the matrix away from the interface. The peak strength of 807 MPa was obtained in the samples welded at 1000°C. The materials obtained at 1100°C exhibited reduced tensile strength but improved ductility. Strain maps revealed by digital image correlation showed the flat interfaces were less ductile compared to the matrix. The hardness reduced near sample surfaces due to enlarged grains induced by temperature gradient. The interfaces with GB migration exhibited improved corrosion resistance in molten salt compared to the flat interfaces.

36 - MATERIALS SCIENCE↗
DOE OSTI2023

Embedding of Fiber Optic Sensors in Stainless Steel for Sensing in Harsh Environments

Structural health monitoring is critical for components working in harsh environments to assess their safety and integrity. This can be realized with advanced sensors, such as fiber optic sensors, embedded in these components. Recent studies have used ultrasonic consolidation (UC) and laser-based additive manufacturing (AM) techniques to embed fiber optic sensors in metals. However, sensor embedding using these techniques has been challenging, with gaps and voids around the embedded fiber. Successful embedding of fiber optic sensors requires good contact between the fiber and the matrix to eliminate potential gas/liquid leaks in critical systems such as in nuclear and aerospace services. Defect-free fiber/matrix bond is also essential for accurate measurement of parameters of interest, such as temperature and strain. This study developed a novel fiber embedding technique based on electric field-assisted sintering (EFAS). Sapphire optical fibers with diameters of 125 µm and 250 µm were embedded in stainless steel (SS) 316L using EFAS. The embedding was completed by sintering SS 316L powders at a pressure of 50MPa, hold time of 5 min, and temperatures of 1000°C, 1100°C, and 1200°C. Joule heating mechanism during EFAS enabled rapid sintering of the SS 316L powder with resulting sample densities over 99%. Microscopy analysis performed on the cross-sections revealed a defect-free bond between the embedded fiber and SS 316L. The good integrity of the embedded fiber was evidenced by optical transmittance measurement. Optical attenuation of the fiber before and after embedment was examined in the near-infrared region. Scanning electron microscopy was employed to investigate the grain morphology of SS 316L near the embedded fiber. Hardness distribution in the sintered part was also investigated to study the effect of the embedded fiber on the mechanical properties of the as-fabricated component. The results indicated that EFAS was able to embed fiber in SS with good fiber functionality and part quality.

36 - MATERIALS SCIENCE↗
DOE OSTI2023

Modeling and Simulation of Advanced Manufacturing Techniques using MOOSE and MALAMUTE

Advanced manufacturing techniques offer increased geometry complexity, energy and material usage efficiency improvements, and an expanded palette of materials as compared to conventional manufacturing approaches. Advanced-manufacturing-produced parts can experience wide variations in the final microstructure, and these microstructure variations significantly impact the parts’ performance. In this chapter, we present recent code developments within Multiphysics Object-Oriented Simulation Environment (MOOSE) and in the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE). Here we demonstrate applying these modeling and simulation codes to two advanced manufacturing process types: advanced sintering techniques and laser-based additive manufacturing techniques. The multiphysics and multiscale capabilities of these codes enable prediction of the microstructure evolution resulting from variations in the Advanced manufacturing process parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2021

On the Arrhenius-like behavior of conductivity during flash sintering of 3 mol% yttria stabilized zirconia ceramics

Here, we discuss the Arrhenius behavior of electrical conductivity σ during flash sintering of 3 mol% yttria stabilized zirconia (3YSZ). In situ x-ray diffraction is used to determine sample temperature. Sintering contribution to σ is excluded by investigating the flash event on a dense ceramic. We show that total conductivity follows an Arrhenius-like equation in both dense and green samples, even during Stage II of flash. The non-linearity often verified during flash sintering of 3YSZ is therefore related to the furnace temperature instead of the sample temperature when building the ln(σ) vs. 1/T plots. Furthermore, we verified a change in the activation energy for conduction prior to the ignition of the flash event and discussed the possible mechanisms. For instance, the decrease in activation energy from Stage I to II in the dense sample is attributed to a contribution from electronic carriers.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The onset of selective laser flash sintering in undoped and doped lanthanum chromite

Previous studies have shown that selective laser flash sintering (SLFS) can be initiated in dielectrics that exhibit ionic or electronic conduction at high temperature. These materials required high laser powers to reach the temperatures where electrical conduction is sufficient to initiate SLFS. In this study, SLFS in lanthanum chromite (LC), an intrinsic electronic conductor with high conductivity, and lanthanum strontium chromite (LSC), which is doped to further increase electronic conductivity, were investigated with a focus on understanding the initiation mechanisms. Results show that the initiation of SLFS in LC and LSC occurs when electronic charge carriers are activated and flow to the electrode where the current is measured. A combination of carriers produced at the electrode, temperature-activated intrinsic charge carriers, and extrinsic charge carriers present in LSC due to doping are responsible for the facile initiation of SLFS.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Accelerated thermal property mapping of TRISO advanced nuclear fuel

TRistructural ISOtropic (TRISO) fuel is a leading-edge nuclear fuel form representing a departure from the more traditional nuclear fuel forms utilized in the reactor fleet of today. Rather than a monolithic fuel pellet of uranium dioxide, integral fuel forms containing TRISO fuel are composed of thousands of microencapsulated uranium-bearing fuel kernels and individually coated with multiple layers of pyrolytic carbon and silicon carbide. These multilayered ceramic coatings serve as an environmental barrier to ensure radioactive and chemically reactive fission products are contained within the reactor fuel elements, but also participate in the transfer of heat generated in the nuclear fuel to the coolant – the primary purpose of a nuclear reactor. Since traditional thermal property measurement techniques, such as laser flash analysis, would be unable to resolve the thermal properties of the individual TRISO coating layers, a simplified frequency-domain thermoreflectance technique has been developed to rapidly map the thermal properties of TRISO particles. Using this technique, the thermal properties of TRISO particles have been mapped from room temperature up to 1000 °C to examine the spatial variation and temperature-dependency of the thermal properties within each layer. Additionally, spatial-domain thermoreflectance was used to examine the anisotropy of the thermal properties for each layer at different locations within a single TRISO particle, and across multiple TRISO particles to assess the intra- and inter-particle uniformity of thermal properties, respectively. To elucidate the underlying causes for the measured variations in thermal properties, scanning electron microscopy and Raman spectroscopy were used to examine variations in microstructure and chemical bonding within the different coating layers. Results from this work are then compared with previous examinations of TRISO fuel particles and microstructurally driven mechanisms for the variations in the measured thermal properties of the different carbonaceous layers are discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

3D Printed Carbon Fiber Reinforced Carbon: An energy efficient alternative to graphite EFAS tooling

Carbon fiber preforms are printed in a Quasi-Isotropic layup, where the fibers are aligned to the X and Y axes, and ±45° in plane. Thermal and electrical conductivity values along the fiber axes are comparable to graphite but are extremely low through the Z axis. Low conductivity (high resistivity) in the axis of current flow enables more efficient Joule heating.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Electrical, thermal, and mechanical properties of spatially tailored fiber orientations in 3D printed carbon-carbon composites for EFAS/SPS

Using C-C synthesized at INL from continuous fiber 3D printed preforms, tooling was fabricated, tested, and compared to graphite. The anisotropic properties of the C-C material were leveraged to make stronger and more energy efficient tooling. Future work involves tailoring the fiber orientations to create targeted heating zones and thermal gradients.

36 MATERIALS SCIENCE↗