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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Effects of MnS Inclusions on the Banded Microstructure in Non-quenched and Tempered Steel

The effects of MnS inclusions in a non-quenched and tempered steel on banded ferrite/pearlite (F/P) microstructure have been studied in this investigation. The results show that the banded microstructure is mainly caused by fluctuations in the concentration of alloying elements such as Mn and Cr, which were determined by energy dispersive spectroscopy. As a manganese-rich precipitate, MnS inclusions might produce extra effects on the banded microstructure and diffusion behavior of alloying elements depending on their size and distribution. Large-sized MnS inclusions distributed within pearlite bands retard the diffusion process of alloying elements, and accordingly, aggregate the degree of banding. On the contrary, small-sized MnS inclusions are much smaller than average grain size, which have little effects on the diffusion of alloying elements on a large scale, and they can promote the nucleation of ferrite and lead to a uniform distribution of ferrite and pearlite. An extended homogenization treatment at high temperatures can convert large-sized MnS inclusions into evenly dispersed smaller inclusions, and accordingly reduce the effect of MnS inclusions on the final microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Mg-Bearing Oxide(+TiN) Inclusion on Microstructure of Fe-16 Mass Pct Cr Ferritic Alloy and Its Evolution During Heating at 1573 K (1300 °C)

Both the effects of Mg-bearing oxide and Mg-bearing oxide +TiN inclusions on the microstructures of Fe-16 mass pct Cr alloy should be clarified. In this paper, the effects of Mg-bearing oxide(+TiN) inclusions on the microstructures of Fe-16 mass pct Cr ferritic alloy and changes due to the inclusions during heating at 1573 K (1300 °C) were studied by manual and automatic SEM-EDS analyses. Three alloys were used as specimens. The inclusions were Al{sub 2}TiO{sub 4} +TiN with a small amount of TiN in alloy #1, Al{sub 2}(Mg, Ti)O{sub 4} in alloy #2 and Al{sub 2}(Mg, Ti)O{sub 4} +TiN in alloy #3. The average grain size was smaller, and the ratio of columnar grains was lower in the as-cast alloy #2 and as-cast alloy #3 than that in the as-cast alloy #1. This is attributed to the heterogeneous nucleation of delta ferrite on Al{sub 2}(Mg, Ti)O{sub 4} during solidification. Refinement of the microstructures of ferritic steel by Mg-bearing oxide + multi-TiN inclusions is proposed. Changes in composition, aspect ratio, and size distribution of inclusions in each alloy during heating were investigated systematically. Mg-bearing oxide(+TiN) was dispersed in both the as-cast alloys and heated alloys, which contributed to microstructural refinement of the heated alloys through the pinning effect.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure Stability During Creep of Friction Stir Welded AA2024-T3 Alloy

The poor weldability of the AA2024 aluminum alloy limits its use in industrial applications. Because friction stir welding (FSW) is a non-fusion welding process, it seems to be a promising solution for welding this alloy. In the current study, FSW was applied to butt weld AA2024-T3 aluminum alloy plates. Creep tests were conducted at 250 and at 315 °C on both the parent material and the friction stir welded specimens. The microstructures of the welded and non-welded AA2024-T3 specimens before and after the creep tests were studied and compared. A comprehensive transmission electron microscopy study together with a high-resolution scanning electron microscopy study and energy-dispersive x-ray spectroscopy analysis was conducted to investigate the microstructure stability. The parent material seems to contain two kinds of Cu-rich precipitates—coarse precipitates of a few microns each and uniformly dispersed fine nanosized precipitates. Unlike the parent material, the crept specimens were found to contain the two kinds of precipitates mentioned above together with platelet-like precipitates. In addition, extensive decoration of the grain boundaries with precipitates was clearly observed in the crept specimens. Controlled aging experiments for up to 280 h at the relevant temperatures were conducted on both the parent material and the welded specimens in order to isolate the contribution of exposure to high temperatures to the microstructure changes. TEM study showed the development of dislocation networks into a cellular dislocation structure in the case of the parent metal. Changes in the dislocation structure as a function of the creep strain and the FSW process were recorded. A detailed creep data analysis was conducted, taking into account the instability of the microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure Evolution and Mechanical Property of Low-Alloy Steel Used for Armor Layer of Flexible Pipe During Thermomechanical Process and Hot Rolling Process

In this paper, the thermomechanical process and hot rolling process were carried out to study the microstructure evolution and mechanical property of low-alloy steel used for armor layer of flexible pipes by analyzing continuous cooling transformation curve, microstructure morphology, grain characteristics, and strength. The experimental results indicate that deformation process promotes phase transformation process of both ferrite and bainite and induces the formation of fine grain. The density of low-angle grain boundary rises with increasing cooling rate. The dislocation concentration in grain becomes larger with the extended cooling rate. The microstructure of hot-rolled specimen consists of polygonal ferrite and granular bainite, which is consistent with one of the deformed specimens with similar cooling rate in dilatometer. The microstructure evolution provides effective data fundament for hot rolling process.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural Properties of Heat-Treated LENS In Situ Additively Manufactured Titanium Aluminide

This study reports on the microstructure, phase identification and hardness property of the LENS-manufactured binary Ti-Al alloy which was achieved via laser in situ alloying. The in situ alloying method, using laser beam as an energy source, indicated that it is possible to achieve a binary gamma phase microstructure from elemental powders of Ti and Al. The as-produced sample, however, was characterized of having different microstructure at the top, middle and bottom regions. The middle and top layers had similar hardness which was lower than that of the bottom region. The as heat-treated sample was characterized of lamellar grain microstructure at the top and just grains at the bottom and the middle. The observed grains were different in size, phase and hardness. This study indicated that in addition to the pores and the precipitation of α{sub 2} phase or aluminum segregation on the grain boundary veins intermetallics lead to severe cracking. Overall, the hardness values of the as-produced and heat-treated samples were similar, and due to extensive cracking, it was inferred that both samples will lack ductility.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Electron Beam Welding of Nimonic 80A Superalloy: Microstructure Evolution and EBSD Study After Aging Heat Treatment

The purpose of this research was to evaluate integrity and microstructure changes of the electron beam-welded Nimonic 80A and the base metal after aging heat treatment process, i.e., 700 °C/72 h/air cooling. Here, microstructure, microhardness and tensile were investigated by various tools, i.e., scanning electron microscope with energy-dispersive spectroscopy and electron backscatter diffraction, x-ray diffraction analysis and Vickers hardness. Evaluation of microstructure shows that the weld zone mainly consists of columnar dendrites. The effect of aging heat treatment on the microstructure morphology and phase structure is very limited. Also, it was observed that there are obvious segregation and precipitates in intracrystalline and along the grain boundaries after aging heat treatment. Electron backscatter diffraction results show that the weld zone and base metal have a clear difference in the grain boundary characterization and kernel average misorientation at room temperature and after aging heat treatment, which leads to a difference in microhardness of the weld zone. In addition, the relationship between microhardness and tensile strength is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Heating Rate during Continuous Annealing on Microstructure and Mechanical Properties of High-Strength Dual-Phase Steel

The study concerns the influence of heating rate during continuous annealing on microstructure and mechanical properties of high-strength ferrite–martensite dual-phase (DP) steel. The study suggests that the superheat (ΔT), carbon diffusion and distribution were strongly influenced by increasing the heating rate, leading to different microstructure and mechanical properties of DP steel. The morphology of martensite was observed to shift from network along ferrite grain boundaries to banded structure to uniformly dispersed, and the average ferrite grain size was refined from 5.3 to 2.0 µm. When the heating rate was 300 °C/s, the steel exhibited excellent mechanical properties with tensile strength (UTS) of 982 MPa, total elongation (TEL) of 17.5%, strength–elongation balance (UTS × TEL) of 17.2 GPa%, because of finer microstructure, uniform martensite distribution and low carbon content of martensite. Moreover, the precipitation strengthening effect of NbC is an important reason for the high-strength DP steels. In addition, the variation in strain-hardening behavior and fracture mechanism of steel subjected to different heating rates is discussed in relation to the microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Microstructural Changes in Inconel ® 740 After Long-Term Aging in the Presence and Absence of Stress

The Ni-based alloy, Inconel ® 740, is being extensively examined for use in advanced ultrasupercritical steam boilers because its precipitation-strengthened microstructure appears to offer the necessary creep strength under the high temperatures and pressures (up to 760°C and 35 MPa) needed for high efficiency power generation. However, because this application requires extremely long lifetimes under these conditions (up to 30 years), long-term microstructure stability is a major concern. In this study, results from microstructural analyses of Inconel 740 specimens aged at 700 and 750°C in the presence and absence of creep loading for times up to ~31,000 h are presented. The primary focus was on the development of the eta η (Ni 3 Ti) phase and coarsening of coherent γ'-Ni 3 (Al,Ti) precipitates and its depletion near eta/matrix interfaces. Finally, however, despite these processes, Inconel 740 showed adequate long-term microstructural stability to assure adequate creep strength for the intended application.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructure Development in Electron Beam-Melted Inconel 718 and Associated Tensile Properties

During the electron beam melting (EBM) process, builds occur at temperatures in excess of 800°C for nickel-base superalloys such as Inconel 718. When coupled with the temporal differences between the start and end of a build, a top-to-bottom microstructure gradient forms. Characterized in this study is the microstructure gradient and associated tensile property gradient that are common to all EBM Inconel 718 builds. From the characteristic microstructure elements observed in EBM Inconel 718 material, the microstructure gradient can be classified into three distinct regions. Region 1 (top of a build) and is comprised of a cored dendritic structure that includes carbides and Laves phase within the interdendritic regions. Region 2 is an intermediate transition zone characterized by a diffuse dendritic structure, dissolution of the Laves phase, and precipitation of δ needle networks within the interdendritic regions. The bulk structure (Region 3) is comprised of a columnar grain structure lacking dendritic characteristics with δ networks having precipitated within the grain interiors. Mechanically at both 20°C and 650° C, the yield strength, ultimate tensile strength, and elongation at failure exhibit the general trend of increasing with increasing build height.

36 MATERIALS SCIENCE↗
DOE OSTI2026

MoNbTi-based Refractory Multi-principal Element Alloy System: A Review of the Thermodynamic Phase Predictions, Formed Microstructures, and Mechanical Properties as a Function of the Fabrication Methods (AM versus SPS versus VAM)

Abstract Multi-principal element alloys, particularly of refractory compositions, are an increasingly popular candidate for extreme-environment applications, including for next-generation nuclear reactors and in other industries, such as biomedical and aerospace, due to their high strength. The ability to achieve solid-solution microstructures provides these alloys with improved mechanical properties; however, these microstructures are heavily composition- and processing-dependent. In this review, the multi-principal element alloy MoNbTi-based system (with Zr, V, and Cr additions) was selected to compare the effects of elemental composition and processing route on the resulting microstructures and mechanical properties. The review provides insight into identifying the optimal alloy composition and processing route for a balance of desired microstructure and mechanical properties.

Krogh, Kara↗
DOE OSTI2013

Investigation of Magnetic Signatures and Microstructures for Heat-Treated Ferritic/Martensitic HT-9 Alloy

There is increased interest in improved methods for in-situ nondestructive interrogation of materials for nuclear reactors in order to ensure reactor safety and quantify material degradation (particularly embrittlement) prior to failure. Therefore, a prototypical ferritic/martensitic alloy, HT-9, of interest to the nuclear materials community was investigated to assess microstructure effects on micromagnetics measurements – Barkhausen noise emission, magnetic hysteresis measurements, and first-order reversal curve analysis – for samples with three different heat-treatments. Microstructural and physical measurements consisted of high-precision density, resonant ultrasound elastic constant determination, Vickers microhardness, grain size, and texture. These were varied in the HT-9 alloy samples and related to various magnetic signatures. In parallel, a meso-scale microstructure model was created for alpha iron and effects of polycrystallinity and demagnetization factor were explored. It was observed that Barkhausen noise emission decreased with increasing hardness and decreasing grain size (lath spacing) while coercivity increased. The results are discussed in terms of the use of magnetic signatures for nondestructive interrogation of radiation damage and other microstructural changes in ferritic/martensitic alloys.

Environmental Molecular Sciences Laboratory↗
DOE OSTI2022

Impact of the plastic deformation microstructure in metals on the kinetics of recrystallization: A phase-field study

The sensitivity of recrystallization kinetics in metals to the heterogeneity of microstructure and deformation history is a widely accepted experimental fact. However, most of the available recrystallization models employ either a mean field approach or use grain-averaged parameters, and thus neglecting the mesoscopic heterogeneity induced by prior deformation. Here in the present study, we investigate the impact of deformation-induced dislocation (subgrain) structure on the kinetics of recrystallization in metals using the phase-field approach. The primary focus here is upon the role of dislocation cell boundaries. The free energy formulation of the phase-field model accounts for the heterogeneity of the microstructure by assigning localized energy to the resulting dislocation microstructure realizations generated from experimental data. These microstructure realizations are created using the universal scaling laws for the spacing and the misorientation angles of both the geometrically necessary and incidental dislocation boundaries. The resulting free energy is used into an Allen-Cahn based model of recrystallization kinetics, which are solved using the finite element method. The solutions thus obtained shed light on the critical role of the spatial heterogeneity of deformation in the non-smooth growth of recrystallization nuclei and on the final grain structure. The results showed that, in agreement with experiment, the morphology of recrystallization front exhibits protrusions and retrusions. By resolving the subgrain structure, the presented algorithm paves the way for developing predictive kinetic models that fully account for the deformed state of recrystallizing metals.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Microstructure effects on high velocity microparticle impacts of copper

Constitutive models can fail to predict high-rate deformation behavior due to their inability to account for microstructural effects. In part, this is because of a dearth of experimental benchmarking data in the high strain-rate, low pressure regime, since many high-rate experiments also probe a region of strong shockwaves, at which point microstructure effects no longer play a primary role. This work uses laser-induced particle impact testing to quantitatively study high velocity impacts of small, rigid alumina microspheres on flat copper substrates with varying amounts of initial cold work in the weak shock regime, but at very high strain rates up to ~10 7 s –1 . Through paired experiments and numerical simulations, this work shows that the initial microstructure condition can have significant influence on dynamical mechanical properties in this range. Specifically, prior work hardening of the copper substrate leads to increased rebounding of the microparticles (i.e., less plastic dissipation in the impact) as well as smaller craters. Each of these experimental measurables can be converted into a strength measure, i.e., the dynamic yield strength or dynamic hardness, respectively, neither of which is well predicted consistently by existing constitutive laws. The general trend of hardening can be captured by such models by incorporating an existing “pre-strain,” suggesting that future calibration of the materials parameters may yield a good fit over a broader range of conditions. Our results emphasize the importance of reporting the microstructural condition in dynamic studies, as well as the necessity of accounting for these factors when formulating and optimizing constitutive models.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Microstructural modification of additively manufactured metals by electropulsing

Additive manufacturing (AM) promises rapid development cycles and fabrication of ready-to-use, geometrically-complex parts. The metallic parts produced by AM often contain highly non-equilibrium microstructures, e.g. chemical microsegregation and residual dislocation networks. While such microstructures can enhance some material properties, they are often undesirable. Many AM parts are thus heat-treated after fabrication, a process that significantly slows production. This study investigated if electropulsing, the process of sending high-current-density electrical pulses through a metallic part, could be used to modify the microstructures of AM 316 L stainless steel (SS) and AlSi10Mg parts fabricated by selective laser melting (SLM) more rapidly than thermal annealing. Electropulsing has shown promise as a rapid postprocessing method for materials fabricated using conventional methods, e.g. casting and rolling, but has never been applied to AM materials. For both the materials used in this study, as-fabricated SLM parts contained significant chemical heterogeneity, either chemical microsegregation (316 L SS) or a cellular interdendritic phase (AlSi10Mg). In both cases, annealing times on the order of hours at high homologous temperatures are necessary for homogenization. Using electropulsing, chemical microsegregation was eliminated in 316 L SS samples after 10, 16 ms electrical pulses. In AlSi10Mg parts, electropulsing produced spheroidized Si-rich particles after as few as 15, 16 ms electrical pulses with a corresponding increase in ductility. Finally, this study demonstrated that electropulsing can be used to modify the microstructures of AM metals.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Effect of heat treatment on microstructural evolution and hardness homogeneity in laser powder bed fusion of alloy 718

The thermal history developed in laser powder bed fusion (LPBF) processes has been shown to be complex resulting in equally complex microstructures and mechanical properties. Microscopic observations and Vickers micro-hardness mapping measurements were carried out on diff ;erent section planes of LPBF alloy 718 cuboids. Three-dimensional finite element analysis was used to simulate thermal history and to predict the residual stress distribution in the as-built material. Computational thermodynamics was used to predict the micro-segregation and nucleation driving force of various phases in the bulk and in segregated regions. Varied heat-treatments such as simulated hot isostatic pressing, and double aging were applied. Their influence on the microstructure, microsegregation, precipitate formation, and micro-hardness variations of LPBF alloy 718 were investigated. Hardness map results showed heterogeneous micro-hardness on the xy- and xz-planes of the as-built parts where the bottom plane and center regions had larger hardness of ~315 HV 0.5 while the top plane and contours showed hardness of ~300 HV 0.5 . It was found that the aging treatment increased the overall hardness of the as-built condition from ~310 HV 0.5 to 470 HV 0.5 but also increased the hardness gradient throughout the coupon. After simulated hot isostatic pressing process (i.e., without applied pressure) at 1020 °C for 4 h followed by water quench (HIPWQ), the hardness gradient and hardness was minimized (~210 HV 0.5 ) as the microstructure transitioned from heterogeneous columnar grains in the as-built condition to more uniform recrystallized grains. A double aging treatment was applied to enhance hardness from ~210 HV 0.5 to ~440 HV 0.5 . Finally, HIPWQ followed by double aging produced a homogeneous microstructure and more uniform hardness map with enhanced mechanical properties in LPBF alloy 718 coupons.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Generation and characterization of carbon fiber microstructure in atomistic simulations

A clear understanding of carbon fiber (CF) microstructure is necessary for the development of high strength CFs. Here, we present an atomistic approach for generating and characterizing realistic mi- crostructures of CFs. Large-scale reactive molecular dynamics simulations are used to generate a set of distinct CF microstructures. Comprehensive characterization of the simulated microstructures is enabled by the development of a suite of computational structural analysis tools capable of evaluation of hy- bridization states of carbon atoms, populations and orientations of individual carbon rings, degree of graphitization, and pore size distribution. The calculation of X-ray diffraction profiles provides a direct link between the structural features of simulated samples and experimental data available for CFs. The CF generation algorithm is shown to produce microstructures with experimental densities and with structural characteristics matching those of PAN-based CFs. The key structural features affecting the properties of CFs, such as the relative fractions of graphitic, turbostratic and amorphous micro- constituents, degree of alignment, pore size distributions, and chemical cross-linking can be effectively controlled in simulations, thus enabling efficient exploration of structureeproperties relationships in CFs. The capabilities of the developed approach are illustrated by performing computational analysis of the mechanical deformation and fracture of CFs under axial tensile loading.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Equivariant graph convolutional neural networks for the representation of homogenized anisotropic microstructural mechanical response

Composite materials with different microstructural material symmetries are common in engineering applications where grain structure, alloying and particle/fiber packing are optimized via controlled manufacturing. In fact these microstructural tunings can be done throughout a part to achieve functional gradation and optimization at a structural level. To predict the performance of particular microstructural configuration and thereby overall performance, constitutive models of materials with microstructure are needed. In this work we provide neural network architectures that provide effective homogenization models of materials with anisotropic components. These models satisfy equivariance and material symmetry principles inherently through a combination of equivariant and tensor basis operations. We demonstrate them on datasets of stochastic volume elements with different textures and phases where the material undergoes elastic and plastic deformation, and show that the these network architectures provide significant performance improvements.

anisotropy↗
DOE OSTI2017

Relating microstructure, temperature, and chemistry to explosive ignition and shock sensitivity

An analysis is put forth that relates explosive properties including microstructure, temperature, and chemistry to explosive ignition and sensitivity. Unlike approaches that focus only on elucidating mesoscopic mechanisms important to ignition, the present analysis seeks a methodology directly applicable to continuum explosive burn models. Because the Scaled Uniform Reactive Front (SURF) burn model has a microstructural basis, it is chosen as the starting point of the present analysis. To build upon the SURF framework, a literal translation is performed of the high-level conceptual notions for which SURF is based, to concrete ignition–combustion parameters, a statistical description of the microstructure, and other thermo-chemical data acquired by non-shock experiments. The analysis requires a void volume fraction distribution acquired from ultra-small angle neutron scattering (USANS). The shock response of PBX 9502 is used to illustrate the theory. While the analysis requires calibration to a shock experiment (the pop plot, for example), the results are a self-consistent set of realistic physical quantities that contribute to the shock initiation process including, initial temperature, chemical kinetics, a statistical description of the microstructure, and the hot spot size, spacing, and temperature. The utility of having a mesoscale based theory is that once the critical hot spot temperature, as a function of shock pressure, is known for a given explosive and initial porosity distribution, the entire set of meso- and macro-scale results, including the pop plot can be calculated for any other porosity. Thus, one can understand changes in sensitivity at different densities (void size distributions), relying only on the assumption that the hot spot temperature curve would not differ significantly if the morphology of the hots spots were similar. Another important utility of the present analysis is to address the question of the role of initial temperature on the observed shock sensitivity of PBX 9502 and other explosives.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗