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DOE OSTI2025

Formation mechanisms of Sn-rich δ phase and its role in strengthening Cu-10Sn manufactured by laser powder bed fusion

Cu-Sn alloys produced via laser powder bed fusion (L-PBF) additive manufacturing (AM) have gained significant attention because they combine the advantages of AM relevant to intricate component design with outstanding combinations of strength, ductility, and resistance to wear and corrosion. However, a detailed understanding of the microstructure that contributes to the enhancement of the mechanical properties of L-PBF Cu-10Sn alloys remains unclear. In particular, there is a lack of understanding of the formation mechanisms of the Sn-rich δ phase commonly observed in Cu-10Sn. This study reveals two distinct variants of the δ phase possessing unique morphological characteristics. These characteristics are attributed to the local solidification conditions inherent to the melt pool boundaries versus those at the interiors of melt pools. A phase transformation pathway that elucidates the origin of the morphological variants of the δ phase from the Sn-rich metastable phases during the cyclic heating of the AM process is proposed. We report superior mechanical properties in L-PBF Cu-10Sn compared to those of conventionally manufactured counterparts due to the synergistic contributions from grain boundaries, dislocations, and the δ phase. Notably, the δ phase alone contributes approximately 22 % to the overall strength observed in the L-PBF Cu-10Sn alloy. The discovery of two types of distinct Sn-rich δ phase offers key insights into precise microstructural control in AM Cu-Sn alloys to enhance mechanical properties, providing practical strategies for improving material performance for diverse applications in automotive, aerospace, and machinery industries.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Atomistic insights into the synergistic effects of tensile strain and hydroxyl group on increasing the thermal conductivity of monohydric alcohols as latent heat storage materials

The low thermal conductivity of linear monohydric alcohols significantly limits their performance when used as latent heat storage materials. It was found that imposing certain mechanical strains on nanomaterials with highly ordered structures can lead to appreciable thermal conductivity enhancement. To explore the potential of enhancing the intrinsic thermal conductivity of monohydric alcohols, a simplified ideal crystal model was employed for molecular arrangement in this work. The variation of atomistic heat transfer as a function of tensile strains was exploited by non-equilibrium molecular dynamics simulations. Furthermore, the influence of stretching on the vibration density of states and the corresponding molecular morphology were revealed. The results suggested that the thermal conductivity of monohydric alcohols with such simplified ideal crystalline structures can increase by about 170 % at the strain of 0.1. The distance between neighboring interfaces was found to determine the energy of inter-molecular interactions at the crystal grain boundaries. The hydrogen bonds energy has not reached the critical value when increasing tensile strains from 0 to 0.1. In contrast, the strongest van der Walls interactions for alkanes were obtained at the strain of 0.06 where the interfacial distances of alkanes have achieved their equilibrium distances. In addition, the interfacial heat transfer coefficient of ideal crystal monohydric alcohols at hydroxyl interfaces was found to be threefold than that between methyl interfaces, in consistent with the strength of inter-molecular interactions between functional groups at the interfaces.

36 MATERIALS SCIENCE↗

NASA NTRS1993

The genesis of starbursts and infrared emission in the centers of galaxies

We present 10.8-micron maps of the central regions of 21 IR-luminous galaxies. Each map, obtained using the NASA MSFC bolometer array at the IRTF, has a resolution of about 4 arcsec and spans typically 25 x 20 arcsec. Some of the galaxies have also been mapped at 12.5, 19.2, and 30/microns. The sample consists primarily of starburst galaxies but includes several Seyferts and LINERs. On average, the flux detected in each map is about 58 percent of that detected at 12 microns by IRAS. We see a variety of morphologies, including compact and elongated sources and more complex distributions exhibiting such features as kiloparsec-size rings and double lobes. The mid-IR radiation is emitted by dust particles, and for two of the galaxies we see spatial color variations attributable to the presence of very small grains and consistent with their depletion in the starbursts. The mid-IR emission traces the dust heated by the youngest stars. Comparison of the distributions of intense star formation and the dense neutral interstellar medium for eight of these galaxies demonstrates that the two are intimately linked.

Telesco, C. M.↗

NASA NTRS2002

A Solar System Perspective on Laboratory Astrophysics

Planetary science deals with a wide variety of natural materials in a wide variety of environments. These materials include metals, minerals, ices, gases, plasmas, and organic chemicals. In addition, the newly defined discipline of astrobiology introduces biological materials to planetary science. The environments range from the interiors of planets with megapascal pressures to planetary magnetospheres, encompassing planetary mantles, surfaces, atmospheres, and ionospheres. The interplanetary environment includes magnetic and electrical fields, plasma, and dust. In order to understand planetary processes over these vast ranges, the properties of materials must be known, and most of the necessary information comes from the laboratory. Observations of the bodies and materials in the Solar System are accomplished over the full range of the electromagnetic spectrum by remote sensing from Earth or spacecraft. Comets exemplify this; molecular and atomic identifications are made from the hard ultraviolet to radio wavelengths, while X-rays are emitted as comets interact with the solar wind. Gamma rays from the surfaces of the Moon and asteroids are diagnostic of the mineral and ice content of those bodies; eventually, gamma rays will also be observed by probes to comets. A number of planetary materials are available in the laboratory for extensive Study: rocks from the Moon, Mars, several asteroids, as well as dust from comets (and perhaps the Kuiper Belt) are closely studied at every level, including atomic (isotopic). Even pre-solar interstellar grains isolated from meteorites are scrutinized for composition and crystalline structure. Beyond the materials themselves, various agents and processes have altered them over the 4.6-Gy age of the Solar System. Solar radiation, solar wind particles, trapped magnetospheric particles, cosmic rays, and micrometeoroid impacts have produced chemical, physical, and morphological changes in the atmospheres and on the surfaces of all planetary bodies. These processes are not well understood, so studies in a laboratory setting are especially needed.

Cruikshank, Dale P.↗

NASA NTRS1972

Sedimentology of clastic rocks returned from the moon by Apollo 15.

A petrographic study of eleven samples of clastic rock returned from the moon by Apollo 15 suggests that two lithologies are present. The distinction between the two lithologies is based on the glass content of the rock matrices and the morphology of the detrital particles. Group I rocks have abundant, glass-rich, porous matrices and glass particles with morphologies comparable to those of glass particles in the lunar soil. The group I rocks were probably formed by welding or sintering of surficial soil deposits by impact-generated base surges of limited extent. Group II rocks have an essentially mineralic matrix and have an abundance of rounded mineral grains. Sample 15455 is the only Apollo 15 sample assigned to this group. In its general textural features, sample 15455 is comparable with the group II rocks from the Fra Mauro Formation at the Apollo 14 site. Textural features such as shock modification and rounding of mineral grains suggest that this sample is the product of a large-scale impact-generated base surge which possibly resulted from the Imbrian event.

Lindsay, J. F.↗

NASA NTRS1993

HST imaging of hydrogen-poor ejecta in Abell 30 and Abell 78 - Wind-blown cometary structures

HST Faint Object Camera images of hydrogen-poor gas in the planetary nebulae A30 and A78 have revealed remarkable 'cometary' structures in the O III 5007-A forbidden line. Most of these cometary structures, consisting of compact (0.15-0.5 arcsec) knots with radial tails several arcsec in length, are located in an equatorial plane in both nebulae. In addition, two bright, compact (0.3 arcsec) polar knots are present in A30, one of them forming a bow shock. Corresponding polar features in A78 are more diffuse. The central stars of both nebulae have energetic winds which are most likely responsible for the 'cometary' knot morphology. We interpret this morphology in terms of dense (several thousand electrons per cu cm) H-poor condensations whose outer expanding layers are swept outward by stellar winds. Photoionization modeling indicates that while dense knot cores are mostly heated by atomic photoionization, expanding tenuous gas is heated by photoelectrons ejected from abundant dust grains. Our models predict steep temperature gradients for which there is observational evidence and possible abrupt phase transitions in the expanding gas.

Borkowski, Kazimierz J.↗

NASA NTRS2011

A New View on Interstellar Dust - High Fidelity Studies of Interstellar Dust Analogue Tracks in Stardust Flight Spare Aerogel

In 2000 and 2002 the Stardust Mission exposed aerogel collector panels for a total of about 200 days to the stream of interstellar grains sweeping through the solar system. The material was brought back to Earth in 2006. The goal of this work is the laboratory calibration of the collection process by shooting high speed [5 - 30km/s] interstellar dust (ISD) analogues onto Stardust aerogel flight spares. This enables an investigation into both the morphology of impact tracks as well as any structural and chemical modification of projectile and collector material. First results indicate a different ISD flux than previously assumed for the Stardust collection period.

Zolensky, Michael E.↗

DOE OSTI2022

Stable nanovesicles formed by intrinsically planar bilayers

Quatsome nanovesicles, formed through the self-assembly of cholesterol (CHOL) and cetyltrimethylammonium bromide (CTAB) in water, have shown long-term stability in terms of size and morphology, while at the same time exhibiting high CHOL-CTAB intermolecular binding energies. We hypothesize that CHOL/CTAB quatsomes are indeed thermodynamically stable nanovesicles, and investigate the mechanism underlying their formation. A systematic study was performed to determine whether CHOL/CTAB quatsomes satisfy the experimental requisites of thermodynamically stable vesicles. Coarse-grain molecular dynamics simulations were used to investigate the molecular organization in the vesicle membrane, and the characteristics of the simulated vesicle were corroborated with experimental data obtained by cryo–electron microscopy, small- and wide-angle X-ray scattering, and multi-angle static light scattering. CHOL/CTAB quatsomes fulfill the requisites of thermodynamically stable nanovesicles, but they do not exhibit the classical membrane curvature induced by a composition asymmetry between the bilayer leaflets, like catanionic nanovesicles. Instead, CHOL/CTAB quatsomes are formed through the association of intrinsically planar bilayers in a faceted vesicle with defects, indicating that distortions in the organization and orientation of molecules can play a major role in the formation of thermodynamically stable nanovesicles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Emergent Nanostructure and Ion Transport in Polyzwitterion/Polyanion Blends

Solid polymer electrolytes (SPEs) hold great promise for the advancement of next-generation energy storage devices. However, the ion transport mechanism in SPEs remains poorly understood. In this study, we investigate blends of poly(1-(3-sulfonatopropyl)-2-vinylpyridinium) (P2VPPS) and poly(lithium (trifluoromethane)sulfonimide methacrylate) (P(MTFSI)Li) of varying molar ratios to develop a mechanistic understanding of ionic conductivity in a miscible polyzwitterion/polyanion system. Polyanions can act as single-ion conductors, but conductivity is often prohibitively low due to the decreased segmental mobility and ion aggregation. Here, it is hypothesized that the introduction of a polyzwitterion would competitively interact with the polyanion charge groups to realize improvements in the conductivity. Attractive interactions between the polyanions and polyzwitterions are confirmed by the blend’s increased glass transition temperature using the Gordon–Taylor equation. Notably, an ordered local nanostructure (∼24 Å) emerged in the P2VPPS/P(MTFSI)Li system at certain compositions, as characterized by small-angle X-ray and neutron scattering (SAXS/SANS). Concurrent with the emergence of this structure, broadband dielectric spectroscopy confirmed improvements in ionic conductivity. The highest conductivity is observed at a specific blend ratio P2VPPS:P(MTFSI)Li = 0.2:1 in the glassy state and 0.3:1 in the rubbery state, corresponding to the lowest effective activation energy (E*). Coarse-grained molecular dynamics simulations further emphasize the role of complexation between polyzwitterion and polyanion chains, correlating with the emergence of a new peak in SAXS and SANS for the blends. This work provides a fresh perspective on the role of local structural design in developing SPEs and offers insights into the morphological effects on ionic conductivity.

chemical structure↗

NASA NTRS1987

Thermal stability of the nickel-base superalloy B-1900 + Hf with tantalum variations

The microstructure of the solutionized and aged nickel-base superalloy B-1900 + Hf was examined after additional aging at 982 C for 72, 250, and 1000 hours. Alloy compositions that were examined contained the normal 1.34 at. pct (4.3 wt pct) Ta as well as 0.67 at. pct and zero Ta levels. The gamma-prime phase agglomerated, became platelike in morphology, and decreased in volume fraction for all three alloys throughout the aging treatments. Changes which occurred in the gamma and gamma-prime phase compositions were nearly complete after 72 hours of aging while changes in the MC carbide composition continued throughout the aging. Blocky M6C carbides precipitated along the grain boundaries of all three alloys in the first 72 hours of aging. In addition, an acicular form of this Mo/Cr/Ni-rich carbide developed in the intragranular regions of the Ta-containing alloys.

Harmon, B. S.↗

NASA NTRS1992

The seeding of life by comets

The chemical and morphological structures of comets and interstellar dust are reviewed to demonstrate the feasibility of comets providing the necessary prebiotic molecules for the formation of life on the early earth. The chemical evolution of interstellar dust is shown to be the source of organics in comets, and the molecules observed in the grains are listed as are the products resulting from grain photolysis. It is emphasized that comets could only transfer prebiotic molecules to the earth if they are fluffy aggregates that break up into fine fragments. The contributions to the early earth are considered in terms of the competition between the evolution of the living organisms and the destructive effects of impacts. It is considered that life began as the bombardment during the first 5 x 10 exp 8 years began to tail off.

Greenberg, J. M.↗

NASA NTRSDate not supplied

Ryugu-Like Phyllosilicate Clast from A Giant Cluster IDP of Probable Cometary Origin: Evidence for Material Exchange Between Asteroidal and Cometary Regions

The presence of hydrous minerals in comets is currently an open question. They were commonly produced inside primitive meteorite parent bodies but apparently not inside the active comets that never contained liquid water. Despite examination of hundreds of particles returned from the Jupiter Family comet Wild 2 by the Stardust(SD) spacecraft, no phyllosilicates have yet been found. Near IR spectra obtained by the Rosetta spacecraft of short-period comet 67P Churyumov-Gerasimenko (67P CG) similarly did not reveal the presence of phyllosilicate minerals. IR spectral features in ejecta from comet Temple 1were interpreted as hydrated minerals but this match is controversial. Studies of a giant cluster interplanetary dust particle (IDP) have demonstrated that the IDP has a large number of chemical and physical properties consistent with its derivation from a comet including 1) its porous aggregate morphology similar to fragile aggregate particles imaged from comet 67P CG, 2) an unequilibrated mineral assemblage, 3) mineral isotopic compositions similar to like minerals in comet Wild 2, 4) uncorrelated Fe-Mn ratios of olivines that mimic those from Wild 2, 5) high presolar silicate abundance [8] and 6) Kool grains which are observed in comet Wild 2 but not in chondrites. Our examination of 70+>5 μm fragments from the IDP have shown that it is overwhelmingly composed of anhydrous silicates. We have observed, however, a 5 x 15 μm porous aggregate fragment (LT10), which contains a rare phyllosilicate clast encased in anhydrous mineral and rock fragments. We conducted detailed TEM and O isotopic analyses of this particle to constrain its origin.

D J Joswiak↗

NASA NTRS2020

Exploratory Experiments to Probe the Effect of Bulk Density and Porosity on The Morphology and Ejecta Kinematics of Impact Craters

The morphometry of relatively small impact craters are influenced by the physical properties of the target. To investigate the control of bulk density and porosity on the crater-formation processing the gravity regime, we conducted a series of impact experiments, varying each these target parameters while holding the other constant. Three different sands were used to construct cohesionless targets: quartz (0.4-0.8 mm), garnet (0.425-1.0 mm), and alumina (0.297-0.71mm), representing a range of intrinsic grain densities from 2.65 to 4.02 g cm-3. High-porosity targets were constructed by carefully pouring the sand into the center of a cylindrical PVC target bucket (inner diameter 26.2 cm, height 12 cm) and allowing it to fill the bucket at the angle of repose before being leveled flat at the top of the bucket. Low-porosity targets were obtained by pluviation of the granular material through a 1 mm sieve that was set directly above the target bucket. With the disparate intrinsic densities of the sand in combination with the variations of the packing technique, we attained differences in the bulk-target density of up to 32%while keeping porosity constant. The impact experiments were conducted with the vertical gun in the Experimental Impact Laboratory at NASA Johnson Space Center; using 3/16” (4.76 mm) diameter aluminum projectiles launched at1.55 ± 0.03 km s-1. The ejecta were observed using the laser-based Ejection Velocity Measurement System, providing data on launch positions and velocities of ejected particles. Submillimeter topographic data of the resulting craters were collected after each experiment with a NextEngine 3D scanner. Regardless of target material or density, all craters exhibited a simple bowl shape, but a trend of increasing depth-diameter ratio with increasing target porosity is observed across the entire experimental suite. Despite these morphometric differences, ejecta launch angles and speeds remain remarkably similar amongst all of the target configurations.

impact cratering↗

DOE OSTI2024

The Beneficial Effect of Iron in Aluminum-Cerium-Based Cast Alloys

Iron (Fe) has been considered a major impurity since it is detrimental to the mechanical properties of many cast aluminum alloys due to the formation of Fe-containing brittle intermetallic phases. Fe is found naturally as an impurity in bauxite ore, resulting in Fe contamination of aluminum alloys with increasing contamination from current recycling practices. The Al–Ce–Fe system was investigated using CALPHAD (CALculation of PHAse Diagrams) modeling and experimental casting techniques. It was found that additions of Fe to the Al–Ce system are beneficial to the strength (slightly) and ductility (significantly) of the ternary alloys, which is attributed to the formation of fine metastable Al 8 CeFe 2 phase with aggregate morphology and equilibrium Al 10 CeFe 2 phase, suppressing coarse proeutectic Al 11 Ce 3 phase in near-eutectic Al–Ce alloys. Heat treatment study showed that the metastable Al 8 CeFe 2 phase transforms to predicted equilibrium Al 10 CeFe 2 phase at 500 °C, with essentially no intermetallic or grain coarsening; thus, the alloy displayed excellent property retention. The Al–Ce–Fe alloy system offers opportunities for sustainable, recyclable alloy development using low-cost Fe and low-cost cerium (a byproduct of rare-earth extraction).

42 ENGINEERING↗

DOE OSTI2021

Unveiling the mechanism of phase and morphology selections during the devitrification of Al-Sm amorphous ribbon

The complex interplay between energetic and kinetic factors that governs the phase and morphology selections can originate at the earliest stage of crystallization in the amorphous parent phases. Because of the extreme difficulties in capturing the microscopic nucleation process, a detailed picture of how initial disordered structures affect the transformation pathway remains unclear. Here, we report the experimental observation of widely varying phase selection and grain size evolution during the devitrification of a homogeneous melt-spun glassy ribbon. Two different crystalline phases, θ-Al 5 Sm and ε-Al 60 Sm 11 , are found to form in the different regions of the same metallic glass ribbon during the devitrification. The grain size of ε-Al 60 Sm 11 phase shows a strong spatial heterogeneity. Coarse-grained ε-Al 60 Sm 11 phase coupled with the small volume fraction of θ-Al 5 Sm phase is preferably formed close to wheel side of the melt-spun ribbon. Combining experimental characterization and computational simulations, we show that phase selection and microstructure evolution can be traced back to different types and populations of atomic clusters that serve as precursors for the nucleation of different crystalline phases. Inhomogeneous cooling rates cause different structure orders across the glass sample during the quenching process. Our findings provide direct insight into the effect of structural order on the crystallization pathways during the devitrification of metallic glass. It also opens an avenue to study the detailed nucleation process at the atomic level using the metallic glass as a platform and suggests the opportunity of microstructure and property design via controlling the cooling process.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1981

The fracture morphology of nickel-base superalloys tested in fatigue and creep-fatigue at 650 C

The fracture surfaces of compact tension specimens from seven nickel-base superalloys fatigue tested at 650 C were studied by scanning electron microscopy and optical metallography to determine the nature and morphology of the crack surface in the region of stable growth. Crack propagation testing was performed as part of an earlier study at 650 C in air using a 0.33 Hz fatigue cycle and a creep-fatigue cycle incorporating a 900 second dwell at maximum load. In fatigue, alloys with a grain size greater than 20 micrometers, HIP Astroloy, Waspaloy, and MERL 76, exhibited transgranular fracture. MERL 76 also displayed numerous fracture sites which were associated with boundaries of prior powder particles. The two high strength, fine grain alloys, IN 100 and NASA IIB-7, exhibited intergranular fracture. Rene 95 and HIP plus forged Astroloy displayed a mixed failure mode that was transgranular in the coarse grains and intergranular in the fine grains. Under creep-fatigue conditions, fracture was found to be predominantly intergranular in all seven alloys.

Gayda, J.↗

NASA NTRS2002

Morphological Evolution and Weak Interface Development within CVD-Zirconia Coating Deposited on Hi-Nicalon Fiber

The phase contents and morphology of a ZrO2 fiber coating deposited at 1050 C on Hi-Nicalon(Tm) by chemical vapor deposition were examined as a function of deposition time from 5 to 120 min. The morphological evolution in the ZrO2 coating was correlated to the development of delamination within the ZrO2 coating. The delamination appears to occur as a result of: (1) continuous formation of tetragonal ZrO2 nuclei on the deposition surface; (2) martensitic transformation of the tetragonal phase to a monoclinic phase upon reaching a critical grain size; and (3) development of significant compressive hoop stresses due to the volume dilation associated with the transformation. Our observations suggest that it will be of critical importance to further understand and eventually control the nucleation and grain growth behavior of CVD ZrO2 and its phase transformation behavior for its potential applications for composites.

Li, Hao↗

NASA NTRS2006

SIMS Studies of Allende Projectiles Fired into Stardust-type Aluminum Foils at 6 km/s

We have explored the feasibility of C-, N-, and O-isotopic measurements by NanoSIMS and of elemental abundance determinations by TOF-SIMS on residues of Allende projectiles that impacted Stardust-type aluminum foils in the laboratory at 6 km/s. These investigations are part of a consortium study aimed at providing the foundation for the characterization of matter associated with micro-craters that were produced during the encounter of the Stardust space probe with comet 81P/Wild 2. Eleven experimental impact craters were studied by NanoSIMS and eighteen by TOF-SIMS. Crater sizes were between 3 and 190 microns. The NanoSIMS measurements have shown that the crater morphology has only a minor effect on spatial resolution and on instrumental mass fractionation. The achievable spatial resolution is always better than 200 nm, and C- and O-isotopic ratios can be measured with a precision of several percent at a scale of several 100 nm, the typical size of presolar grains. This clearly demonstrates that presolar matter, provided it survives the impact into the aluminum foil partly intact, is recognizable even if embedded in material of Solar System origin. TOF-SIMS studies are restricted to materials from the crater rim. The element ratios of the major rockforming elements in the Allende projectiles are well characterized by the TOF-SIMS measurements, indicating that fractionation of those elements during impact can be expected to be negligible. This permits information on the type of impactor material to be obtained. For any more detailed assignments to specific chondrite groups, however, information on the abundances of the light elements, especially C, is crucial.

Hoppe, Peter↗