Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Optical Microscopy”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 595 records · Page 33

Dynamic Uniaxial Compression of HSLA-65 Steel at Elevated Temperatures

Here, the dynamic response of a high-strength, low alloy Grade 65 (HSLA-65) steel, used by the United States Navy for ship hull construction, is investigated under dynamic uniaxial compression at temperatures ranging from room temperature to 1000 °C using a novel elevated temperature split-Hopkinson pressure bar. These experiments are designed to probe the dynamic response of HSLA-65 steel in its single α-ferrite phase, mixed α + γ-austenite phase, and the single γ-austenite phase, as a function of temperature. The investigation is conducted at two different average strain rates—1450 and 2100/s. The experimental results indicate that at test temperatures in the range from room temperature to lower than 600 °C, i.e. prior to the development of the mixed α + γ phase, a net softening in flow strength is observed at all levels of plastic strain with increase in test temperatures. As the test temperatures are increased, the rate of this strain softening with temperature is observed to decrease, and at 600 °C the trend reverses itself resulting in an increase in flow stress at all strains tested. This increase in flow stress is understood be due to dynamic strain aging, where solute atoms play a distinctive role in hindering dislocation motion. At 800 °C, a (sharp) drop in the flow stress, equivalent to one-half of its value at room temperature, is observed. As the test temperature are increased to 900 and 1000 °C, further drop in flow stress are observed at all plastic strain levels. In addition, strain hardening in flow stress is observed at all test temperatures up to 600 °C; beyond 800 °C the rate of strain hardening isobserved to decrease, with strain softening becoming dominant at temperatures of 900 °C and higher. Moreover, comparing the high strain rate stress versus strain data gathered on HSLA 65 in the current investigation with those available in the literature at quasi-static strain rates, strain-rate hardening can be inferred. The flow stress increases from 700 MPa at 8 × 10 -4 /s to 950 MPa at 1450/s and then to 1000 MPa at 2100/s at a strain of 0.1. Finally, optical microscopy is used to understand evolution of microstructure in the posttest samples at the various test temperatures employed in the present study.

36 MATERIALS SCIENCE↗

Location specific solidification microstructure control in electron beam melting of Ti-6Al-4V

Relationships between prior beta grain size in solidified Ti-6Al-4V and melting process parameters in the Electron Beam Melting (EBM) process are investigated. Samples are built by varying a machine-dependent proprietary speed function to cover the process space. Optical microscopy is used to measure prior beta grain widths and assess the number of prior beta grains present in a melt pool in the raster region of the build. Despite the complicated evolution of beta grain sizes, the beta grain width scales with melt pool width. The resulting understanding of the relationship between primary machine variables and prior beta grain widths is a key step toward enabling the location specific control of as-built microstructure in the EBM process. Control of grain width in separate specimens and within a single specimen is demonstrated.

42 ENGINEERING↗

Process-Structure-Property Relations for As-Deposited Solid-State Additively Manufactured High-Strength Aluminum Alloy

Solid-state additive manufacturing methods provide innovative solutions to circumvent problems associated with materials susceptible to hot cracking by avoiding liquid solid phase transformations. In this work, the process parameter influence on microstructural evolution and mechanical response of a fully dense aluminum alloy 7050 (AA7050) component manufactured via a rapid, solid-state additive manufacturing process known as Additive Friction Stir Deposition (AFS-D) was quantified for the first time. Three sections (starting dwell, transient, crossover of roads) of the deposition that exhibit differing thermomechanical processing histories were evaluated for the resulting microstructure and mechanical response. The microstructural characterization was performed on the as-deposited AA7050 via Electron Backscatter Diffraction (EBSD), TEM, optical microscopy, and Scanning Electron Microscopy (SEM). The microstructural characterization revealed refined constituent particles and grains throughout the as-deposited AA7050 microstructure. Furthermore, quasi-static tensile experiments were conducted in both the build and transverse directions, in order to quantify the orientation influence on tensile properties of the as-deposited AA7050 build. Spatially dependent tensile properties were observed in the material due to heat input variation coarsening of secondary phases towards the initial layers of the AFS-D build. Post-mortem analysis revealed that voids nucleated and coalesced from the overgrowth of the strengthening precipitates present in the material, resulting in fracture.

36 MATERIALS SCIENCE↗

Fallout melt debris and aerodynamically-shaped glasses in beach sands of Hiroshima Bay, Japan

An intricate association of millimeter-sized, aerodynamically-shaped debris, including glass spherules, glass filaments, and composite-fused melt particles was recovered from beach sands on the shores of the Motoujina Peninsula in Hiroshima Bay, Japan. Based on optical microscopy, this debris comprises six morphological groups ranging from clear glasses to rubber-like constituents. Scanning electron microscopy and synchrotron X-ray microdiffraction revealed dominant aluminum, silicon and calcium (Al-Si-Ca) elemental composition with some iron, mainly in glass, associated with precipitates of mullite and anorthite microcrystals, hematite dendrites and iron-chromium globules, indicative of original temperature conditions >1800 °C. Aerodynamically-shaped fallout debris, including glass spherules described in this study, are generally produced by single high-energy catastrophic events, such as an extraterrestrial body impacting Earth or a nuclear explosion. Our work interprets the large volumes of fallout debris generated under extreme temperature conditions as products of the Hiroshima August 6th, 1945 atomic bomb aerial detonation. The chemical composition of the melt debris provides clues to their origin, particularly with regard to city building materials. This study is the first published record and description of fallout resulting from the destruction of an urban environment by atomic bombing.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Friction stir processing of dual certified 304/304L austenitic stainless steel for improved cavitation erosion resistance

Cavitation phenomenon is known to be prevalent in equipment in hydraulic environments. Understanding cavitation and improving the cavitation resistance of commonly used materials is of interest for both scientific and economic reasons. In this study, friction stir processing was employed to modify commercial dual certified AISI 304/304L austenitic stainless steel plates. The cavitation erosion resistance of the processed plates was evaluated and compared to that of the unprocessed steel. A temperature control algorithm was employed to maintain a target tool temperature during the processing. The cross sections of the processed nuggets were evaluated using optical microscopy, scanning electron microscopy and Vickers hardness testing. Cavitation testing was performed conforming to ASTM G134 on specimens cut out of the nuggets of the commercially unprocessed and the processed 304/304L steel. The tool temperature was found to affect the microstructure and the cavitation performance. Friction stir processed steel showed 3 times better cavitation resistance than the unprocessed 304/304L. Surface cavitation patterns and cavitation rates were characterized and the mechanisms of material removal were discussed.

Jiang, Xiujuan↗

Probing labeling-induced lysosome alterations in living cells by imaging-derived mean squared displacement analysis

Lysosomes are not merely degradative organelles but play a central role in nutrient sensing, metabolism and cell-growth regulation. Our ability to study their function in living cells strictly relies on the use of lysosome-specific fluorescent probes tailored to optical microscopy applications. Still, no report thus far quantitatively analyzed the effect of labeling strategies/procedures on lysosome properties in live cells. We tackle this issue by a recently developed spatiotemporal fluctuation spectroscopy strategy that extracts structural (size) and dynamic (diffusion) properties directly from imaging, with no a-priori knowledge of the system. We highlight hitherto neglected alterations of lysosome properties upon labeling. In particular, we demonstrate that Lipofectamine reagents, used to transiently express lysosome markers fused to fluorescent proteins (FPs) (e.g. LAMP1-FP or CD63-FP), irreversibly alter the organelle structural identity, inducing a ∼2-fold increase of lysosome average size. The organelle structural identity is preserved, instead, if electroporation or Effectene are used as transfection strategies, provided that the expression levels of the recombinant protein marker are kept low. This latter condition can be achieved also by generating cell lines stably expressing the desired FP-tagged marker. Reported results call into question the interpretation of a massive amount of data collected so far using fluorescent protein markers and suggest useful guidelines for future studies.

60 APPLIED LIFE SCIENCES↗

Investigation of B 4 C for inhibiting crystallization in silica at high temperatures

Amorphous silica has numerous high temperature applications due to its inherent thermal shock resistance and low coefficient of thermal expansion (CTE). However, at the high temperatures required for processing (>1200 °C), the metastable β-cristobalite phase preferentially forms and is accompanied by a volume change, and potential cracking, upon conversion to the low temperature α-cristobalite phase. The CTE of the final crystalline phase is an order of magnitude higher than its amorphous counterpart. Here experimental results demonstrate that small additions of B 4 C (3.5 wt%) effectively inhibit silica crystallization in powder and sintered gel-cast forms up to 22h at temperatures as high as 1500°C as confirmed via x-ray diffraction. Further, the oxidation of B 4 C to B 2 O 3 and its subsequent melt and evaporation disrupts the nucleation and growth of the cristobalite phase. The mechanism for crystallization inhibition is further explored through optical microscopy to probe changes in surface morphology.

36 MATERIALS SCIENCE↗

Surface evolution of synthetic bilgewater emulsion

Bilgewater is oil-in-water emulsion emitted from shipboard and it is a source of pollution to the ocean. Wastewater treatment needs fundamental knowledge of the bilgewater surface changes; however, limited information is available. We have reported the first surface characterization of synthetic bilgewater emulsion using time-of-flight secondary ion mass spectrometry (ToF-SIMS) coupled with optical microscopy. A NAVY synthetic bilgewater emulsion consisting of three oils and a detergent mixture is used as the synthetic bilgewater model. Both fresh and aged emulsion samples are analyzed to determine their droplet size distributions (DSDs) and surface chemical compositions. Our results show that fresh emulsions are largely mono-modal with hydrocarbon fragments as the main surface composition. Aged emulsions are also monomodal with slightly larger size. Both SIMS spectral comparison and Principal Component Analysis (PCA) show that some surfactant components appear on the fresh emulsion surface immediately while larger molecular weight components appear at the aged bilge droplet surface. Our results indicate that the oil-water interface evolves after emulsion droplet forms. More importantly, surface evolution not only changes the bilgewater DSD but also surface chemical composition and reactivity.

bilgewater, droplet size distribution, ToF-SIMS, s↗

Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys

Friction-stir-welding (FSW) has gained importance as an effective way to join dissimilar materials due to its solid-state nature. However, FSW produces substantial residual stresses in aluminum welding, often deteriorating the component's structural performance and reliability. In the current study, the d-spacing (inter-atomic distance) of several locations on a battery tray and stress-free reference samples are measured with neutron diffraction to calculate the residual stresses in a lap 6061 to A365 dissimilar friction-stir-weld. Furthermore, the present study connects the measured residual stress to microstructure properties through electron backscatter diffraction (EBSD) and optical microscopy analyses. The EBSD results indicate that the FSW operation affects the grains’ orientation, thereby producing location-specific directionally varying elasticity across the weldment. Further, this varied elasticity creates unique d-spacing profiles even in the stress-free material. Additionally, the resulting stressed and stress-free d-spacing profiles show dependencies on the FSW tool geometry, traverse direction, and rotational direction. Lastly, this study suggests that the final component residual stress can be influenced by the sequence of multi-pass welds contributing to a rise in temperature in the presence of a completed weld relaxing its residual stress.

36 MATERIALS SCIENCE↗

Failure mechanisms of cross-ply carbon fiber reinforced polymer laminates under longitudinal compression with experimental and computational analyses

Here, this study investigates the failure mechanisms of cross-ply laminates subjected to longitudinal compressive loading. A sequence of failure initiation and propagation process is observed based on optical microscopy images of failed specimens. Specifically, the failure process in the cross-ply laminates involves a combination of four failure mechanisms: fiber kinking, delamination, matrix cracking, and fiber/matrix splitting. We find that the kink-bands in the middle 0° plies of the cross-ply laminates most often show a wedge shape and the angle of matrix cracks in the 90° plies is slightly larger than that of pure 90° plies. The reason has been attributed to the constraining effects by the adjacent plies. The next focus of this study is to propose hybrid micro-macro models to more systematically study the failure mechanisms of the cross-ply laminates. We show that these models accurately predict the combined failure modes of the cross-ply laminates and enable us to closely investigate the interactions of different failure mechanisms. More importantly, the hybrid models achieve great computational efficiency compared to full-scale microstructural models. Finally, the combined experimental and computational analyses presented here provide a new level of understanding of the kink-band morphology and damage mechanisms in the cross-ply laminates.

42 ENGINEERING↗

Polyester-based epoxy vitrimer integrating spent coffee ground as a natural filler

Coffee is a widely consumed beverage, but approximately 80% mass of coffee cherry is discarded as waste. Here, in this study, spent coffee grounds (SCG) were recycled and used as a natural filler in a polyester-based epoxy matrix made from reactions of diglycidyl ethers of Bisphenol A and polyethylene glycol with methyl nadic anhydride. The properties of SCG/epoxy composites with various SCG contents up to 40% w/w were evaluated using various techniques such as FT-IR spectroscopy, tensile testing, optical microscopy, differential scanning calorimetry, and rheology. The SCG filled polyester-based epoxy matrix demonstrated excellent dimensional stability and retained a permanently crosslinked network, but re-shaping was possible at ~150 °C through transesterification, which occurred due to a dynamic chain exchange reaction between the ester group of the epoxy matrix and the hydroxyl group of the SCG fillers. The transesterification also improved the interfacial adhesion between the matrix and SCG fillers, resulting in tensile strength of over 20 MPa and a modulus of around 2.5 GPa, even with high SCG contents up to 40% w/w. While neat, cured epoxy shows thermoset behavior, filling the matrix with SCG enables reforming and origami-inspired spontaneous change in shape.

42 ENGINEERING↗

Understanding interfacial crystallization dynamics on carbon fiber reinforced polypropylene composite manufacturing

Reinforcing polymers with discontinuous fibers improves mechanical properties, such as strength and stiffness, and in some cases achieve isotropic properties, rendering them suitable for various engineering applications. Matrix materials are generally highly engineered thermosets (e.g. crosslinked epoxies), bonded to the fiber periphery by proprietary surface and sizing chemistries. Semicrystalline thermoplastic matrices are less utilized due to poor fiber-matrix bonding resulting in inefficient interfacial load-transfer in reinforced composites. However, flexibility with melt-processing or molding conditions can be leveraged to promote non-covalent interfacial bonding between matrix and fiber via crystallization of the matrix onto fiber surface. In the present study, we utilize a co-mingle chopped carbon and isotactic polypropylene fibers to form isotropic composites, tailoring interfacial immobilized matrix or interphase morphology to optimize performance through precise control of thermal processing/molding windows. Calorimetry and optical microscopy were employed to investigate the impact of carbon fiber at various volume fractions (10, 20, and 30 %) on isotactic polypropylene crystallization and mechanical performance. Variations in mechanical properties correspond to the structural evolution of the interfacial region and are correlated to underlying microstructural attributes using wide-angle X-ray scattering, thermal analysis, and low-field nuclear magnetic resonance spectroscopy. These results provide a practical framework for the manufacturing of thermoplastic matrix composites. In conclusion, the results presented provide a guide for the strategic optimization of interphase design, showcasing tailorable tensile strengths which outperform any isotactic polypropylene carbon fiber composites previously reported in literature.

36 MATERIALS SCIENCE↗

Experimental and computational analysis of failure mechanisms in unidirectional carbon fiber reinforced polymer laminates under longitudinal compression loading

Here, his study investigates the failure mechanisms of notched unidirectional (UD) carbon fiber reinforced polymer (CFRP) laminates subjected to longitudinal compressive loading. A sequence of failure initiation and propagation is observed based on optical microscopy images of specimens during failure. The micrographs reveal that the main failure mechanism in UD laminates is fiber kinking failure. The influence of manufacturing defects and voids on fiber kinking mechanisms is also analyzed. The results show that the voids in the resin-rich area lead to kink-band splitting, while in some cases the voids cause the kink-band to deflect in a new direction depending on the location of the voids. The next focus of this study is to propose a computational micromechanics model considering local fiber waviness to study the fiber kinking failure mechanism. The computational results on kink-band formation and stress-strain response show good consistency with our experimental analysis. Lastly, the failure envelopes of σ 11 -σ 22 and σ 11 -τ 12 subjected to combined loading conditions are obtained from the computational model, which provide essential inputs for future theoretical failure criteria.

36 MATERIALS SCIENCE↗

Stirring and peristaltic pumping alter flow electrode particle size and morphology

Flowable carbon-based electrodes are widely studied in electrochemical systems for energy storage and water treatment. Most laboratory- and pilot-scale studies employ active mixing for slurry preparation and handling and use peristaltic pumps for slurry circulation. Magnetic stirring is the most prevalent mixing method at the laboratory scale, and the combination of magnetic mixing and peristaltic pumping is favored for convenience and compatibility with particulate suspensions. However, these methods can strongly affect particle size and morphology (and therefore cell performance). In this study, we evaluate how mixing and pumping influence particle degradation in two commonly used carbon materials: spherical carbon black (CB) beads and powdered activated carbon (AC). We performed 24 h stirring-only experiments using magnetic, orbital, and overhead stirring. Separately, we conducted 32 h circulation experiments using a commercial peristaltic pump. Particle morphology and size were analyzed using optical microscopy and laser diffraction. The initially spherical CB beads (~580 μm, 1.5 wt%) exhibit rapid and extensive breakdown under both peristaltic pumping and magnetic stirring. By comparison, AC particles (initially ~31 μm) tested at 1.5 and 15 wt% showed measurable size reductions of up to ~25 % under either stirring or pumping. In conclusion, these findings highlight the need to account for and quantify morphological changes caused by both stirring and pumping in the design and associated evaluation of flowable electrode systems.

Chemistry↗

Crack nucleation and growth during dynamic indentation of chemically-strengthened glass

Dynamic point impact loading is a primary cause of fracture of glass screens on mobile devices. An improved understanding of crack initiation and evolution under high-speed indentation could contribute to the development of materials with better performance, but experimental observations are challenging due to the short timescales and limited depth-of-field of optical microscopy. To address this need, we have observed fracture of a chemically-strengthened glass during dynamic indentation using in situ x-ray phase-contrast imaging (XPCI). Median cracks initiate below the surface of the glass, at a depth approximately corresponding to the depth at which the surface residual compressive stress diminishes to zero. These cracks initially propagate at ~10ms –1 , rapidly accelerating to > 100ms –1 . We also observe some evidence for rate-dependent behavior, in that indentation at the lowest rates studied here (below about ~0.15ms –1 ) fails to initiate cracks regardless of the depth of the indentation (up to 18μm), while indentation at higher rates produces median cracks that either arrest or cause complete fracture, depending on the depth of indentation.

36 MATERIALS SCIENCE↗

Highly resolved Eulerian simulations of fuel spray transients in single and multi-hole injectors: Nozzle flow and near-exit dynamics

In high pressure fuel injectors, needle opening and closing transients cause complex off-design fluid dynamics behaviors that profoundly impact the spray and mixture formation processes. These dynamics are completely different from what is known to occur in steady state conditions. In this study, diesel spray transients have been investigated in single-hole and 3-hole nozzles, encompassing internal and external nozzle flow and including needle motion, performing highly resolved (2.5 μm) computational fluid dynamics (CFD) simulations. We focused on end-of-injection (EOI) and start-of-injection (SOI) processes, in order to provide insights in to the physics. The liquid fuel, vapor and gas species are modeled with a single-fluid multiphase mixture approach, with diffuse interface, and with large eddy simulations (LES) of the turbulence. Occurrence of phase change due to cavitation is accounted for, and the spray dispersion is described with a turbulent dispersion model. Detailed needle motion data and orifice internal surface are available from xray synchrotron source measurements carried out at Argonne National Laboratory, and shared through the Engine Combustion Network (ECN) community. Simulations are compared against x-ray phase contrast imaging and radiography of the internal and near-exit flow, in addition to optical microscopy data of the near-exit sprays. Simulation results are found to agree well with available experimental data, and are able to realistically capture local and global features. The simulations allow to gain insight into the physics of gas ingestion and dribbles at EOI, for different hole diameters, operating conditions and number of holes. At SOI, timing of liquid appearance out of the injector and spray tip penetration are adequately predicted, by using the EOI flow field as in-nozzle initialization, and by prescribing the measured tip needle displacement with an informed effective valve opening point inferred from the x-ray observations. Lastly, the variation of spreading angle over time is also discussed in detail for the multi-hole case, including hole-to-hole variations. Due to real geometry features and asymmetric needle motion with eccentric components, it is found that the three holes exhibit swirling flows of increasing intensity as the lift decreases, causing the near cone angle to open and spread, in a quasi-hollow cone structure. These features are not observed in axial single-hole injectors because of their relative simplicity and intrinsic symmetry.

42 ENGINEERING↗