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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Mechanical Properties and Corrosion Behavior of As-Cast Mg-Zn-Zr-(La) Magnesium Alloys

The effects of La content on the mechanical properties and corrosion behavior of as-cast Mg-Zn-Zr (ZK) magnesium alloys were investigated. The results showed that La addition to ZK60 alloy resulted in a considerable grain refinement and an increase in the volume fraction of second phases by formation of Mg-Zn-La ternary phase. The tensile tests were performed at both room and elevated temperatures. At room temperature, the yield and tensile strengths and elongation-to-fracture significantly increased with 0.2 wt.% La addition, then deteriorated slightly with increasing La additions above 0.2 wt.%. At 200 °C, the yield and tensile strengths continually improved and elongation-to-fracture decreased with increasing La content due to the presence of thermally stable Mg-Zn-La phase. Immersion and electrochemical corrosion tests revealed that the formation of Mg-Zn-La phases led to a higher amount of cathodic sites and preferential corrosion propagation, and thus a decrease in the corrosion resistance of ZK60 alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure, Tensile Properties, and Corrosion Behavior of Die-Cast Mg-7Al-1Ca-xSn Alloys

The microstructure, tensile properties, and corrosion behavior of die-cast Mg-7Al-1Ca-xSn (x = 0, 0.5, 1.0, and 2.0 wt.%) alloys were studied using OM, SEM/EDS, tensile test, weight loss test, and electrochemical test. The experimental results showed that Sn addition effectively refined grains and intermetallic phases and increased the amount of intermetallic phases. Meanwhile, Sn addition to the alloys suppressed the formation of the (Mg,Al){sub 2}Ca phase and resulted in the formation of the ternary CaMgSn phase and the binary Mg{sub 2}Sn phase. The Mg-7Al-1Ca-0.5Sn alloy exhibited best tensile properties at room temperature, while Mg-7Al-1Ca-1.0Sn alloy exhibited best tensile properties at elevated temperature. The corrosion resistance of studied alloys was improved by the Sn addition, and the Mg-7Al-1Ca-0.5Sn alloy presented the best corrosion resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Hot Roll Bonding of Aluminum to Twin-Roll Cast (TRC) Magnesium and Its Subsequent Deformation Behavior

In an experiment in which twin-roll cast AZ31 magnesium alloy and commercial purity aluminum (AA 1050) sheets were bonded by hot rolling as Al/Mg/Al laminate composites, it was found that increasing the preheating temperatures up to 400 °C enhances the bonding strength of composites. Further increases in the preheating temperatures accelerate the magnesium oxide growth and thus reduce the bonding strength. The influence of the reduction ratio on the bonding properties was also studied, whereby it was observed that increasing the rolling reduction led to an increase in the bonding strength. The experimental results show that the optimum bonding strength can be obtained at rolling temperatures of 375-400 °C with a 50-60% reduction in thickness. On the other hand, the subsequent deformation behavior of composite was assessed using plane strain compression and deep drawing tests. We demonstrate that the composites produced using the optimum roll bonding conditions exhibited sufficient bonding during subsequent deformation and did not reveal any debonding at the bonding interface.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effects of In Situ Intermetallics on the Microstructural Array and Saline Corrosion Performance of Cast Al/WCp Composites

Al-matrix composites, ex situ reinforced with WC nanoparticles and in situ reinforced with Al{sub 3}(Ti,W), Al{sub 12}W, Al{sub 5}W and Al{sub 4}W, have been fabricated by casting assisted by K{sub 2}TiF{sub 6} wetting agent addition and mechanical stirring. A satisfactory particle incorporation and distribution accompanied by a high reactivity have been attained. The presence, topography, chemical composition of all included phases and their occurrence as clusters or single particles are clarified and justified. Al{sub 12}W is the predominant aluminide phase at WC ≤ 1.5 vol.%. Al{sub 4}W (primarily) and Al{sub 5}W (secondarily) are the predominant aluminide phases at WC ≥ 2.0 vol.%. WC nanoparticles have acted as heterogeneous nucleation sites to Al{sub 3}Ti particles. Reverse polarization tests in 3.5 wt.% NaCl show that the governing form of corrosion is intergranular corrosion of Al around Al{sub 3}FeSi{sub 2} eutectic, fine plates. The corrosion steps/mechanisms are identified. Clusters of aluminides and carbide nanoparticles, as well as intergranular WC nano-dispersoids and their Al-matrix have remained corrosion-free. The role of the aluminides combined with WC remaining nano-cores as inhibitors of the eutectic Al{sub 3}FeSi{sub 2} cathodic activity is highlighted.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Influence of Thermal History on the Hot Ductility of a Continuously Cast Low Alloyed Cr-Mo Steel

The hot ductility of a low alloyed Cr-Mo steel has been investigated to evaluate the surface cracking sensitivity within the straightening or unbending regime during the continuous casting process. Tensile samples were subjected to various thermal treatments, including melting and solidification, and were tested at deforming temperatures ranging between 600 and 1100 °C using a strain rate of 10{sup −3} s{sup −1}. Hot ductility was evaluated based on reduction in area measurement and metallographic investigations. The investigated steel exhibits a drop in ductility at around 800 °C due to intergranular cracking. Microstructural examinations and supplementary thermokinetic computer simulations were carried out to describe the evolution of the microstructure during solidification and cooling.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Very High Cycle Fatigue of a Cast Aluminum Alloy: Size Effect and Crack Initiation

Fatigue properties of an Al-Si-Cu cast alloy were investigated with life up to very high cycle fatigue regime. Particular attention was given to specimen size effect and fatigue crack initiation mechanism. Uniaxial fatigue tests with constant amplitudes were carried out by using ultrasonic fatigue testing machine operating at 20 kHz, compared to the results obtained by using conventional hydraulic fatigue machine at 35 Hz. In order to evaluate the size effect, two sets of specimens with different dimensions were used. The results show that the fatigue strength of the studied alloy decreases with the increase in specimen size. Scanning electron microscopy observation of fracture surfaces revealed that most fatigue cracks initiated from microstructural defects such as porosity located on specimen surface or in subsurface. Weibull statistical analysis of fatigue data accounting for size effect was performed to predict the fatigue life of the Al-Si-Cu alloy in the very high cycle regime. Good agreement was found between the fatigue life prediction and the experimental data.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A Two-Stage Physical-Based Model for Predicting Flow Stress of As-cast TiAl Alloy Under Hot Deformation Conditions

The hot deformation behavior of Ti-30Al-4.2Mn-4.5Nb-0.2B alloy was investigated using the isothermal compression experiment at temperatures of 1020-1200 °C and strain rates of 0.001-1 s{sup −1}. The flow stress was sensitive to the deformation parameters like temperature and strain rate, which decreases with the increase in temperature and decrease in strain rates. Based on the true stress-true strain data, a two-stage physical-based model was proposed to describe the flow stress curve of as-cast TiAl alloy during hot deformation process. For establishing the model, at first, the flow curves of dynamic recovery (DRV) were modeled by employing stress-dislocation relation and adjusting dislocation annihilation coefficient Ω. Then, the flow curves of dynamic recrystallization (DRX) were modeled by considering the dynamic softening behavior into Avrami equation. Finally, the flow curves in the entire deformation stages could be described by embedding the predicted data of DRV model (i.e., flow stress before the critical strain) into the predicted data by DRX model (i.e., flow stress after the critical strain). The critical strain for initiation of DRX was determined by the double-differentiation method. To evaluate the applicability and effectiveness of DRX kinetics equation, the DRX curves were calculated and were consistent with the microstructure observation. Comparison between the experimental and predicted data shows that the proposed physical-based model can well forecast the flow stress under a wide working domain.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Workability Characteristics and Deformation Mechanisms of Die-Cast AM60 and AZ91 Magnesium Alloys: Correlation with Processing Maps

Thermo-mechanical deformation behavior of the die-cast AM60 and AZ91 alloys was assessed by performing uniaxial compression tests on Gleeble 3800 simulator under different temperatures and strain rate conditions. Low-temperature deformation behavior of both alloys was accessed at 25, 100, and 150 °C, at the strain rates of 0.1 and 1 s{sup −1}. Processing maps at a true strain of 0.5 were generated to study the intrinsic hot workability of AM60 and AZ91 alloys. Optimum processing windows were identified, and the evolution of microstructures and textures was correlated with the imposed deformation conditions. The processing map for the AM60 alloy exhibited three dynamic recrystallization (DRX) domains in the ranges: (1) 320-400 °C and 0.2-1.5 s{sup −1}, (1A) 300-325 °C and 0.1-0.2 s{sup −1}, and (2) 360-400 °C and 3-5 s{sup −1}. In Domain 1, DRX occurred predominantly by pyramidal slip and recovery mechanisms by cross-slip as confirmed by the randomized textures. Deformation in Domain 1A is by the combination of basal and prismatic slip. In Domain 2, dynamic recovery was a softening mechanism controlled by the climb. The processing map for AZ91 alloy exhibited two DRX domains in the ranges: (1) 260-310 °C and 0.1-0.5 s{sup −1} and (2) 325-350 °C and 0.8-3 s{sup −1}. The rate-controlling mechanism was climb by lattice self-diffusion in Domain 1 and by grain boundary self-diffusion in Domain 2. Both alloys exhibited flow instability at 200 and 250 °C, and therefore, they were unsuitable for processing at these temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Eutectic Characteristics on Hot Tearing of Cast Superalloys

The occurrence of hot cracks in the blades of Ni-based superalloy turbocharger wheels is thought to be closely related to eutectic characteristics. Different alloys that are susceptible to hot tearing, namely K418, K419 and K424, were studied. SEM was used to obtain the microstructure of the alloys. DSC, isothermal solidification quenching process and EPMA were conducted to determine the relationship between the eutectic characteristics and solidification process, segregation behavior and dendrite coalescence. The results show that a large volume fraction of γ/γ′ eutectic indicates a wide-temperature solidification range and severe segregation. A large γ/γ′ eutectic size is a result of element segregation and poor dendrite coalescence. Ti is thought to promote the formation of a large isolated residual liquid pool and lead to a large eutectic size, leading to the poor coalescence behavior of the dendrites. The volume fraction and size of the γ/γ′ eutectic were considered, and a eutectic influence factor (E) was defined to evaluate the effect of eutectic characteristics on hot tearing in cast superalloys. It was found that a high E corresponds to high hot-tearing susceptibility.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of Sintering Temperature on the Porosity and Mechanical Behavior of Porous Titanium Scaffolds Prepared by Freeze-Casting

The purpose of this study was to investigate the effects of sintering temperature on the microstructure, and associated mechanical properties of porous titanium scaffolds prepared by freeze-casting. Sintering temperature significantly influenced the porosity and the mechanical properties of the titanium scaffolds. The porosity decreased from 60 to 20% as the sintering temperatures increased from 800 to 1100 °C. The scaffolds were of an open pore structure with pore sizes ranging from 2 to 20 μm. The average wall thickness of the porous titanium was measured, using a micro-computed tomography, to be in the range from 9.2 to 26.2 μm. Elastic modulus was between 2 to 7 GPa, depending on vacuum annealing conditions. The compression strength of the scaffolds may exceed 1000 MPa as the sintering temperature higher than 1000 °C. The increase in titanium strength and stuffiness could be mainly attributed to the decrease in porosity as well as the increase in wall thickness.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Cerium-based, intermetallic-strengthened aluminum casting alloy: High-volume co-product development

Here, several rare earth elements are considered by-products to rare earth mining efforts. By using one of these by-product elements in a high-volume application such as aluminum casting alloys, the supply of more valuable rare earths can be globally stabilized. Stabilizing the global rare earth market will decrease the long-term criticality of other rare earth elements. The low demand for Ce, the most abundant rare earth, contributes to the instability of rare earth extraction. In this article, we discuss a series of intermetallic-strengthened Al alloys that exhibit the potential for new high-volume use of Ce. The castability, structure, and mechanical properties of binary, ternary, and quaternary Al-Ce based alloys are discussed. We have determined Al-Ce based alloys to be highly castable across a broad range of compositions. Nanoscale intermetallics dominate the microstructure and are the theorized source of the high ductility. In addition, room-temperature physical properties appear to be competitive with existing aluminum alloys with extended high-temperature stability of the nanostructured intermetallic.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Manufacturing Processes for Permanent Magnets: Part I—Sintering and Casting

Abstract Permanent magnets (PMs) produce magnetic fields and maintain the field even in the presence of an opposing magnetic field. Electrical machines using permanent magnets are more efficient than those without. Currently, all known strong magnets contain rare earth (RE) elements, and they are core components of a wide range of applications including electric vehicles and wind turbines. RE elements such as Nd and Dy have become critical materials due to the growing demand and constrained supply. Improving the manufacturing process is effective in mitigating the RE criticality issue by reducing waste and improving parts consistency. In this article, the state of the industry for PM is reviewed in detail considering both the technical and economic drivers. The importance of RE elements is discussed along with their economic importance to green energy. The conventional sintering and casting manufacturing processes for commercial magnets, including Nd-Fe-B, Sm-Co, Alnico, and ferrite, are described in detail.

36 MATERIALS SCIENCE↗
DOE OSTI2021

From casting to 3D printing geopolymers: A proof of concept

The objective of this paper is to define a mix design strategy allowing the implementation of geopolymer in powder bed 3D printing. In a selective binder approach, an aluminosilicate powder bed is activated through the deposit of an alkaline silicate solution. We first show that, in comparison to casting, this technology requires mastering the spreading of the liquid into the powder bed to ensure that the reaction takes place where it is needed. A series of experiments at the drop level, mimicking the 3D printing process, were performed to determine the printing solution composition for a given powder bed packing. We then highlight the relationship between the compressive strength of the printed geopolymer and the powder bed saturation, controlled by the printing parameters. Finally, SEM/EDX analysis confirm the formation of geopolymer with desired Si/Al and Na/Al ratios in the resulting printed material.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Sulfate performance of blended cements (limestone and illite calcined clay) exposed to aggressive environment after casting

This paper evaluates how early aggressive exposure affects the sulfate resistance of blended cements containing limestone filler and/or calcined clay. Mortar and cement paste specimens were elaborated with different combinations of limestone filler and two different illitic calcined clays and exposed to a sodium sulfate solution shortly after casting. Assessment of sulfate resistance was based on expansion, mass variation, and compressive strength. Microscale evolution and distribution were examined by mercury intrusion porosimetry, X-ray diffraction, and scanning electron microscopy with energy-dispersive spectrometry measurements. Results prove superior sulfate resistance of compositions with high calcined clay content over limestone filler addition. Furthermore, the results reported suggest that the pozzolanic reaction progresses enough to reduce the sulfate ingress even at early exposure conditions. Therefore, calcined clay replacement can still provide effective pore refinement to limit sulfate penetration, increase strength, and reduce available CH to limit expansive phase formation.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Alkali-silica reaction expansion model for confined concrete with stress-dependency and casting direction anisotropy

Alkali-silica reaction (ASR) is a deleterious chemical reaction between alkali hydroxyl ions and types of silica found in some aggregates of concrete. Owners and regulators of nuclear power plants aim to ensure the safety of the concrete structures with optimal maintenance strategies. A new model was developed for predicting the expansion of concrete structures affected by alkali-silica reaction. The model includes a novel combination of existing models as an alkali-silica reaction advancement model, a casting direction anisotropic expansion model, a stress-dependent anisotropic expansion model, and a material property evolution model dependent on the degree of ASR expansion. The model parameters were calibrated based on existing literature data and data generated by previous efforts of this study. The calibrated model was then validated with the experiments carried out in previous efforts of this study. The model was shown to accurately predict the ASR-expansion of large-scale reinforced concrete specimens with confinement.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Influence of casting porosity on the corrosion behaviour of Mg0.1Si

We investigated the influence of casting porosity on the corrosion behaviour of Mg0.1Si for immersion in 3.5% NaCl solution saturated with Mg(OH) 2 . The corrosion behaviour was characterised using (i) hydrogen evolution, (ii) weight loss, (iii) cathodic polarisation curves, (iv) electrochemical impedance spectroscopy (EIS), and (v) an examination of the corroded surfaces. Specimens with porosity had higher corrosion rates attributed to the corrosion associated with the pores activating significant corrosion over the whole specimen surface, wherein important aspects were (i) the breakdown of a partly protective surface film, and (ii) micro-galvanic acceleration of the corrosion by Fe-rich particles.

36 MATERIALS SCIENCE↗
DOE OSTI2018

3D microstructure reconstruction of casting aluminum alloy based on serial block-face scanning electron microscopy

In this work, the inner microstructure of aluminum-silicon casting alloy was experimentally investigated to reveal the spatial morphology and phase distribution. Its industrial use is as a light-weight structural material. As a powerful three-dimensional (3D) imaging tool at the nano-scale, the serial block-face scanning electron microscopy (SBFSEM) was employed to investigate the specimens. After being 3D reconstructed, the images were visualized to identify preference for several specific intermetallics by quantitative analysis. It was found that these phases have certain relationships in spatial distribution and differences in spatial shapes. In conclusion, the spatial distribution of cracks was studied to understand their propagation and growth.

3D microstructure reconstruction↗
DOE OSTI2025

Laser-induced slip casting as an additive manufacturing approach for silicon carbide

Here, this work presents processing silicon carbide (SiC) with the laser-induced slip casting (LIS) additive manufacturing (AM). SiC was stabilized in water with polyethyleneimine (PEI) dispersant, and SiC slurries were made with rheology for LIS printing. High-density ceramic parts were printed, followed by single-step binder burnout and sintering. The printed parts achieved 93–95 % of theoretical density. X-ray computed tomography (XCT) revealed a small distribution of flaws exceeding 100 microns. The mechanical properties were measured in both parallel and perpendicular to the printing layers, and the orientation with layers perpendicular to the bending moment resulted in higher strength compared to the parallel direction. Porosity resulting from processing and large inclusions of boron carbide (B4C) were the root cause of failure in the measured samples. Despite these defects through this effort, this new approach demonstrates promise for green forming of SiC with densities greater than 95 % theoretical and tensile strengths above 250 MPa.

Additive Manufacturing↗