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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Boundary characterization using 3D mapping of geometrically necessary dislocations in AM Ta microstructure

Additive manufacturing (AM) of high strength metallic materials produces microstructures and defects that deviate substantially from those created through conventional manufacturing methods. It has recently been demonstrated that with application of extreme energy densities, a high-temperature refractory metal, tantalum (Ta), can be printed to a fully dense state with exceptionally low porosity. Here we employ a combination of three-dimensional electron backscattered diffraction (EBSD) TriBeam technology and crystallographic geometrically necessary dislocation (GND) theory to characterize the microstructure and defect boundaries of this unusual AM product. Two-dimensional (2D) EBSD and these three-dimensional (3D) measurements indicate that the microstructure of AM Ta is highly oriented <111> along the build direction, yet at the same time contains large crystallographic orientation gradients that span mm’s across the build. Crystallographic GND density analysis of the 3D microstructure reveals that highly misoriented subboundaries exist within this strongly textured microstructure that have large dislocation densities of 1×10 16 m –2 , just as large as those comprising the high-angle grain boundaries (HAGBs) in the same material. The 3D crystallographic GND density mapping reveals these subboundaries are part of a complex, finely spaced network that extends throughout the entire microstructure. Here, the orientation of these boundaries can be related to the scan strategy used during printing. TEM measurements corroborate an extremely high dislocation density at the microscale and indicate a cell-like dislocation network structure existing in the AM Ta at the sub-μm scale.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Influence of Temperature on the Cyclic Properties of the Transversely Isotropic Nanocomposite System Under Kinematic Harmonic Loading

A micromechanical model is developed to determine the effective inelastic properties of nanocomposites under monoharmonic deformation by taking into account the detailed microstructural geometries and constitutive models of the constituents. By using the correspondence principle in viscoelasticity and the modified Mori–Tanaka method, the effects of interface between the inclusion and the matrix are taken into account. By applying the developed model, we perform the numerical analysis aimed at the determination of complex moduli for a polymeric nanocomposite reinforced with nanofibers composed from carbon nanotubes under the isothermal conditions. The dependences of complex moduli on temperature and the amplitude of strain intensity are analyzed. The composites reinforced with unidirectionally aligned nanofibers are considered. The accumulated results demonstrate a strong dependence of the storage and loss moduli on temperature within a broad temperature range. The storage and loss moduli are found to monotonically increase with the volume fraction of nanofibers. At the same time, they decrease as temperature increases. The obtained results show that the strength of material decreases as temperature increases in the elastic and inelastic regions and the inelastic behavior occurs for lower strain amplitude as temperature increases.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2018

Effect of Deformation Parameters on Microstructure and Properties During DIFT of X70HD Pipeline Steel

Grain refinement is a critical approach to improve the strength of materials without damaging the toughness. The grains of deformation-induced ferrite are considerably smaller than those of proeutectoid ferrite. Grain refinement is crucial to the application of deformation-induced ferrite. The composition of ferrite and bainite or martensite is important in controlling the performance of X70HD pipeline steel, and cooling significantly influences the control of their ratio and grain size. By analyzing the static and dynamic phase-transition points using Gleeble-3800 thermal simulator, thermal simulations were performed through two-stage deformations in the austenite zone. Ferrite transformation rules were studied with thermal simulation tests under different deformation and cooling parameters based on the actual production of cumulative deformation. The influence of deformation parameters on the microstructure transformation was analyzed. Numerous fine-grain deformation-induced ferrites were obtained by regulating various parameters, including deformation temperature, strain rate, cooling rate, final cooling temperature and other parameters. Results of metallographic observation and microtensile testing revealed that the selection of appropriate parameters can refine the grains and improve the performance of the X70HD pipeline steel.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Microstructural evolution and intermetallic formation in Zn-3Mg (wt%) powder mixture processed by high-pressure torsion

Severe plastic deformation (SPD) techniques have been used extensively over the past 40 years for producing strong metals and alloys. High-pressure torsion (HPT) is one of the most promising SPD techniques for achieving high strength through nanoscale grain refinement and phase transformation. In this research, a mixture of pure zinc (Zn) and magnesium (Mg) powders, Zn-3Mg (wt%), was HPT-processed under a pressure of 6 GPa for 1, 5, 10, 20, and 30 turns at room temperature to achieve a high strength biodegradable material. In order to understand the effects of pre-consolidation on the resulting microstructure and hardness, HPT processing was performed on loose powders placed in the die and also on a pre-compacted powder mixture and the resulting HPT disks were characterized by X-ray diffraction, scanning electron microscopy, atom probe tomography, and Vickers microhardness. In both cases, the HPT disk microstructures contained nanoscale grains, and stable and metastable strain-induced intermetallics, but an unusual softening appeared at large shear strains. Grain size, grain morphology, and the formation of different intermetallics were analyzed to explain the unusual hardness distribution, and it was found that an inverse Hall-Petch relationship between hardness and grain size exists. It is suggested that thermally-activated phenomena such as grain boundary sliding contributed to the strain-induced softening of this nano-structured biomaterial due to its low melting point. Finally, the current results are compared with those for HPT-processed cast alloys and hybrids of the same composition.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Assessment of diffuse-interface methods for compressible multiphase fluid flows and elastic-plastic deformation in solids

This work describes three diffuse-interface methods for the simulation of immiscible, compressible multiphase fluid flows and elastic-plastic deformation in solids. The first method is the localized-artificial-diffusivity approach of Cook, Subramaniam et al., and Adler and Lele, in which artificial diffusion terms are added to the individual phase mass fraction transport equations and are coupled with the other conservation equations. The second method is the gradient-form approach that is based on the quasi-conservative method of Shukla et al., in which the diffusion and sharpening terms (together called regularization terms) are added to the individual phase volume fraction transport equations and are coupled with the other conservation equations. The third approach is the divergence-form approach that is based on the fully conservative method of Jain et al., in which the regularization terms are added to the individual phase volume fraction transport equations and are coupled with the other conservation equations. In the present study, all three diffuse-interface methods are used in conjunction with a four-equation, multicomponent mixture model, in which pressure and temperature equilibria are assumed among the various phases. The primary objective of this work is to compare these three methods in terms of their ability to: maintain constant interface thickness throughout the simulation; conserve mass, momentum, and energy; and maintain accurate interface shape for long-time integration. The second objective of this work is to consistently extend these methods to model interfaces between solid materials with strength. To assess and compare the methods, they are used to simulate a wide variety of problems, including (1) advection of an air bubble in water, (2) shock interaction with a helium bubble in air, (3) shock interaction and the collapse of an air bubble in water, and (4) Richtmyer–Meshkov instability of a copper–aluminum interface. The current work focuses on comparing these methods in the limit of relatively coarse grid resolution, which illustrates the true performance of these methods. In conclusion, this is because it is rarely practical to use hundreds of grid points to resolve a single bubble or drop in large-scale simulations of engineering interest.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

Intergranular fracture in irradiated Inconel X-750 containing very high concentrations of helium and hydrogen

In recent years, it has been determined that Inconel X-750 CANDU spacers have lost strength and material ductility following irradiation in reactor. The irradiated fracture behaviour of ex-service material was also found to be entirely intergranular. The heavily thermalized flux spectrum in a CANDU reactor results in transmutation of 58 Ni to 59 Ni. The 59 Ni itself has unusually high thermal neutron reaction cross-sections of the type: (n, γ), (n, p), and (n,α). The latter two reactions, in particular, contribute to a significant enhancement of the atomic displacements in addition to creating high concentrations of hydrogen and helium within the material. Metallographic examinations by transmission electron microscopy (TEM) have confirmed the presence of helium bubbles in the matrix and aligned along grain boundaries and matrix-precipitate interfaces. He bubble size and density are found to be highly dependent on the irradiation temperature and material microstructure; the bubbles are larger within grain boundary precipitates. TEM specimens extracted from fracture surfaces and crack tips give direct evidence linking crack propagation with grain boundary He bubbles.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Systematic Catalyst Variation for Improved Stereoselective Epoxide Polymerization: Subtle Modifications Resulting in Superior Efficiency

Isotactic poly(propylene oxide) (iPPO) is a semicrystalline polyether that has emerged as a high-strength, photodegradable material for marine applications. To improve the accessibility of i PPO, catalysts with higher activity and selectivity are required. Using rational catalyst design informed by computational insights, we developed a flexibly tethered, bimetallic chromium catalyst exhibiting high enantioselectivity ( k rel ∼ 100) and unprecedented activity (TOF ∼ 50,000 h −1 ) for propylene oxide (PO) polymerization. Mechanistic studies reveal that high enantioselectivity originates from increased steric bulk at the ortho position of the salicylimine moiety, which increases steric repulsion between the alkoxide chain end and the ligand in the disfavored transition state. Furthermore, introducing geminal dimethyl groups that rigidify the flexible tether between the two ligand moieties significantly enhances catalyst activity by destabilizing the resting state during polymerization. The catalyst remains active at loadings as low as 0.5 ppm, enabling the synthesis of colorless, tough i PPO.

Ren, Bai-Hao [Cornell Univ., Ithaca, NY (United St↗
DOE OSTI2023

Ultra-strong tungsten refractory high-entropy alloy via stepwise controllable coherent nanoprecipitations

High-performance refractory alloys with ultrahigh strength and ductility are in demand for a wide range of critical applications, such as plasma-facing components. However, it remains challenging to increase the strength of these alloys without seriously compromising their tensile ductility. Here, we put forward a strategy to “defeat” this trade-off in tungsten refractory high-entropy alloys by stepwise controllable coherent nanoprecipitations (SCCPs). The coherent interfaces of SCCPs facilitate the dislocation transmission and relieve the stress concentrations that can lead to premature crack initiation. As a consequence, our alloy displays an ultrahigh strength of 2.15 GPa with a tensile ductility of 15% at ambient temperature, with a high yield strength of 1.05 GPa at 800 °C. The SCCPs design concept may afford a means to develop a wide range of ultrahigh-strength metallic materials by providing a pathway for alloy design.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Intrinsic shape of free carrier absorption spectra in 4H-SiC

Free carrier absorption spectra are measured along the different polarization directions with respect to the c-axis of 4H-SiC using ultrafast differential transmission spectroscopy. Probing of excited carrier spectra in an undoped material reveals intrinsic resonances within the conduction band. Widths of the detected resonance peaks are shown to be wider than their theoretical estimates and more comparable to the ones observed in a low doped material. Relative strength of the peaks, on the other hand, is shown to be nearly excitation independent in contrast to the doping induced absorption weakening for the same transitions in n-type samples. Finally, free carrier cross sections are extracted from the excitation dependency of the detected spectra and linked to the individual electron and hole contributions in the near infrared range.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Fast strength model characterization using Bayesian statistics

A variety of flow stress models exist with new models constantly being developed. These models aim to approximate the strength of materials in a variety of regimes from quasistatic loading through shock scenarios. All models contain an array of parameters which need to be tuned to the material under study. Some models perform well under limited conditions, requiring adjustment of the parameters when venturing outside of those predefined ranges. Other models perform well over a wide range of conditions with a set of parameters, but may be outperformed by other models optimized on a tighter range of conditions. Recent research by Los Alamos demonstrated the ability to optimize the Johnson Cook (JC) model using a set of 3 plate-impact experiments on Aluminum. They utilized Bayesian statistics and emulation to determine optimal parameters for the model with a quantification of parameter uncertainty. We present an extension of this capability to incorporate velocimetry from plate-impact tests, stress-strain data from split Hopkinson pressure bar and quasistatic compression tests, plus profiles from Taylor cylinders in a unified fashion. Statistically robust comparisons of the performance and uncertainty of different realizations of the JC flow stress model were carried out based on calibration to several possible combinations of these three different experiment types.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Analysis of a Length Extensional Piezoelectric Transformer for Compact and Efficient Particle Acceleration

To produce a compact and efficient particle accelerator, several different piezoelectric transformer configurations are evaluated for their applicability in this demanding application area. Using a derived 1-D model for three different electroding and mounting schemes, accelerator efficiency and gradient are optimized. In conclusion, it is shown that with some advancements in material yield strength and advanced bonding techniques, reaching 4 MeV/m with over 40% efficiency is possible.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Fatigue performance of the Deeply Embedded Ring Anchor

Existing anchor solutions are limited in their applicability to the floating offshore wind industry, which demands prolonged load endurance in extreme weather conditions and varied seabed soils. This limitation restricts project feasibility and increases costs. In order to address these challenges, the Deeply Embedded Ring Anchor (DERA) is proposed to achieve substantial reductions in anchor costs through efficiency enhancements. Ensuring the long-term safety and reliability of the DERA, especially considering a minimum operational period of 25 years, necessitates a comprehensive understanding of fatigue damage. Induced by repetitive loading below material yield strength, fatigue poses a significant threat to structures exposed to waves and currents. Anchors, vital for station keeping, are susceptible to fatigue damage, particularly in the padeye area. This paper conducts a fatigue analysis, focusing on factors such as the wall thickness of the ring anchor, inner stiffeners, and stiffener thickness, to evaluate the performance of DERA in this context. The results showed that the stiffener significantly affects the elongation of the total life of the anchor. In conclusion, this paper focuses on advancing innovations like DERA, enabling the efficient utilization of offshore wind resources, and addressing safety concerns through meticulous fatigue analysis.

17 WIND ENERGY↗
DOE OSTI2012

A Preliminary Analysis of Dose Rates Associated with ITER CVCS Equipment/Area Location

A preliminary analysis of the ITER Chemical and Volume Control System (CVCS) Area was performed to assess dose rates outside the walls and ceiling of the facility after 1.5 years of operation at shutdown, 2 days, and 10 days after shutdown. For this purpose a simplified Monte Carlo computer model was developed using the MCNP (MCNP5 Ver. 1.51) code. Two components are included: the smaller filter tank and the larger ion exchanger. These pieces of equipment are associated with the Integrated Blanket ELM Divertor Primary Heat Transfer System, which will have the largest dose rates associated with activated corrosion products during operation in comparison with other systems. The ion exchanger contained two source regions, a 1.2-m-thick resin bed above a 0.55 m-thick skirt, and a 0.8-m-thick water region. The filter constituted an additional source. Thus the model consisted of three sources (filter, resin, water), homogeneously distributed within the appropriate source regions. However, much of the results (that address individual isotopes) are presented with the two sources in the ion exchanger combined. In these cases the sources are referred to as the 'ion exchanger source' and the 'filter source.' Dimensions for the facility and components, as well as source isotopes and strengths, and material densities, were supplied by US ITER. Because of its simplification, the model does not contain pipes. Consequently, radiation streaming through pipe penetrations, radiation emanating from the pipes, and shielding from the pipes were not considered in this analysis. Dose rates on the outside of two walls and the ceiling were calculated. The two walls are labeled as the 'long' wall (aligned with the X-axis) and the 'short' wall (aligned with the Y-axis). These walls and ceiling were nominally set to 30-cm-thick concrete. In the original analysis, standard concrete (2.3 g/cc density) was used. In addition to the shielding walls/ceiling, a floor and an additional wall opposite the long wall were added for photon scattering contributions. These were both 10-cm-thick, standard concrete structures. Other components (tanks, pipes, etc.), that were not included in the model, would potentially add additional scattering and shielding. Possibly these additional effects will be addressed in a later, more detailed analysis. The room was 29.6 m in length (X-axis), but was limited to 15 m in the model. The inside width (Y axis) and height (Z axis) were 4 m and 3.4 m, respectively. The origin for the model was located inside the room at the corner opposite the long wall and adjacent to the short wall at the floor level. The room was filled with air at standard temperature and pressure. The stainless steel (SS304) wall thicknesses for the ion exchanger and filter were 2.2 cm and 0.8 cm, respectively. The axial center of the filter was located 140 cm from the short wall and 100 cm from the long wall (outer surface). The axial center of the ion exchanger was located 440 cm from the short wall and 250 cm from the long wall (inner surface). The resin was assumed to be a homogeneous mixture of equal atom density fractions of hydrogen and carbon* at a specified density of 1.136 g/cc. The filter material was assumed to be homogeneous carbon at a specified density of 1.8 g/cc. If the filter media were stainless steel and the accumulated activity were the same, the dose rate outside the filter would be lower, provided the density of the stainless steel sintered filter material is significantly higher than 1.8g/cc. The densities of the water and air were assumed to be 1.0 g/cc and 1.096E-3 g/cc, respectively. The model included 10 small volumes placed outside the model adjacent to the wall at locations where the dose rates were expected to be highest and which showed to a degree the fall-off of the dose rate with distance along a particular wall or ceiling. These 'tally cells' are shown in Fig. 2 and are described in Table 1. Each cell had dimensions of 50 cm x 50 cm x 1 cm and was oriented so that the 1-cm-thick dimension was perpendicular to the wall against which the cell was located. Also, smaller tally volumes were placed at 5 cm (updated model), 30 cm, 50 cm, and 100 cm from each source, both radially from the outside of each component at the height of each source mid-plane, and vertically, along the axial centerline, above the ion-exchanger and below the filter. (For the ion exchanger, the vertical distance was limited to 75 cm because of interference from the ceiling.) These tally regions can be seen in Fig. 3. Each cell had dimensions of 5 cm x 5 cm x 1 cm, oriented so that the 1-cm-thick dimension was perpendicular to the X, Y or Z axis.

08 HYDROGEN↗
DOE OSTI2012

The fundamentals of plastic deformation: several case studies of plasticity in confined volumes

Plasticity in small volumes is significantly different than in large, bulk-like specimens. The strength of materials in the micron and sub-micron regime depends not only on the microstructure but also on the size of the material. Given that a number of important mechanical processes occur at these length scales, it is important to build a comprehensive understanding of these materials and processes. This work examines several different processes in small volumes. The motion of dislocations in the drag regime are examined as a function of material volume which exhibits higher drag than in the bulk. The stability of single arm sources are also investigated using molecular dynamics. Finally, dislocation nucleation from the free surface is investigated using both atomistic as well as continuum models. These results provide a better understanding of plastic processes in confined volumes.

Weinberger, Christopher Robert↗
DOE OSTI2023

Hybrid Electrochemical Hydrogen/Metal Hydride Compressor (Final Technical Report)

Various alternatives to traditional mechanical compressor systems have been considered, including MHC and EHC. Both MHCs and EHCs are solid-state systems that have no moving parts other than valves. Both are quiet and have low maintenance requirements. However, strength and material issues as well as water and heat management issues have challenged EHCs, especially, when operated at very high pressures. Similarly, low efficiency, especially, when staging is required to attain high, pressure ratios, has challenged MHCs and has made them too complex and expensive. Material degradation, due to hydrogen impurity effects, has also created issues for MHCs. One novel alternative evaluated here is to combine EHC and MHC technologies in a way to maximize their advantages and to minimize each of their challenges to improve the overall systems performance on a path to meet or exceed current DOE targets. A hybrid EH/MH compressor takes advantage of lower maintenance and operating costs as well as increased reliability associated with both the MHC and EHC technologies over traditional mechanical compressors. Neither the MHC nor the EHC have any moving parts other than valves. The hybrid system also takes advantage of the higher efficiency and lower cost of the EHC by operating at lower delivery pressures combined with the robust and simple operation of a single-stage, MH compressor at higher pressures. Both MHC and EHC technologies are scalable and can be used for a variety of hydrogen compression and delivery applications.

08 HYDROGEN↗
DOE OSTI2024

Electromagnetic Design Optimization Integrated with Mechanical Stress Analysis of PM-Assisted Synchronous Reluctance Machine Topologies Enabled with a Blend of Magnets

Permanent Magnet-Assisted Synchronous Reluctance Machines (PMASynRM) provide a low-cost alternative to Surface PM Machines due to the use of relatively lower grades of rare-earth (RE) or RE-free magnets, as the performance degradation due to weaker magnets is compensated by the presence of reluctance torque. However, the weaker magnets suffer from a high risk of demagnetization, leading to unreliable motor operation. Using a blend of RE and RE-free magnets has the potential to overcome this issue. This paper proposes to blend different grades of various rare-earth (RE) and rare-earth-free (RE-free) magnets in six different combinations and utilizes them in two-layer and three-layer U-shaped PMASynRM topologies with both eight-pole and six-pole variations. The rotor of the various designs is then optimized using a differential evolution (DE) based optimization algorithm to obtain low-cost designs with reduced RE magnet volume and minimum demagnetization risk. The optimization of each design is also integrated with the evaluation of mechanical stresses in the rotor laminations so as to maintain the stresses below the material yield strength. Furthermore, the various performance metrics, such as toque–speed/power–speed characteristics, demagnetization, and efficiency maps, are evaluated for each of the optimized and mechanically feasible designs. A quantitative comparison of the various optimized designs is also obtained to highlight the various trade-offs. The results indicate the feasibility of meeting the baseline torque requirement across the entire speed range, even with a 100% reduction in RE magnet volume and less than 5% demagnetization risk, while achieving a cost reduction exceeding 50%. Moreover, the two-layer, eight-pole designs exhibit relatively higher performance, whereas the three-layer, eight-pole designs are found to be the most economical option.

design optimization↗
DOE OSTI2022

Miniature Beryllium Split-Hopkinson Pressure Bars for Extending the Range of Achievable Strain-Rates

Conventional Split Hopkinson Pressure Bars (SHPB) or “Kolsky” bars are often used for determining the high-rate compressive yield and failure strength of materials. However, for experiments generating very high strain-rates (>10 3 /s) miniaturization of the setup is often required for minimizing the effects of elastic wave dispersion in order to enable the inference of decreasingly short loading events from the data. Miniature aluminum and steel bars are often sufficient for meeting these requirements. However, for high enough strain-rates, miniaturization of steel or aluminum Kolsky bars may require prohibitively small diameter bars and test specimens that could become inappropriate for inferring representative properties of materials with large grain size relative to the test specimen size. The use of a beryllium Kolsky bar setup is expected to enable high rates to be accessible with larger diameter bars/specimen combinations due to the inherent physical properties of beryllium, which are expected to minimize the effects of elastic wave dispersion. For this reason, a series of beryllium Kolsky bars have been developed, and, in this paper, the dispersion characteristics of these bars are measured and compare the data with those of similarly sized 7075-T6 aluminum and C350 maraging steel. The results, which agree well with the theory, show no appreciable frequency dependence of the elastic wavespeed in the data from the beryllium bars, demonstrating its advantage over aluminum and steel in application to Kolsky bars.

36 MATERIALS SCIENCE↗