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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.

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At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Influence of CdTe Deposition Temperature and Window Thickness on CdTe Grain Size and Lifetime After CdCl 2 Recrystallization

Grain structure influences both transport and recombination in CdTe solar cells. Larger grains generally are obtained with higher deposition temperatures, but commercially it is important to avoid softening soda-lime glass. Furthermore, depositing at lower temperatures can enable different substrates and reduced cost in the future. We examine how initial deposition temperatures and morphology influence grain size and lifetime after CdCl 2 recrystallization. Techniques are developed to estimate grain distribution quickly with low-cost optical microscopy, which compares well with electron backscatter diffraction data providing corroborative assessments of exposed CdTe grain structures. Average grain size increases as a function of CdCl 2 temperature. For lower temperature close-spaced sublimation CdTe depositions, there can be more stress and grain segregation during recrystallization. However, the resulting lifetimes and grain sizes are similar to high-temperature CdTe depositions. The grain structures and lifetimes are largely independent of the presence and/or interdiffusion of Se at the interface, before and after the CdCl 2 treatment.

14 SOLAR ENERGY↗
DOE OSTI2018

Carrier-Transport Imaging of Cadmium Telluride Intra- and Inter-Grains

Inhomogeneous local minority-carrier transport in thin-film solar cells is a critical aspect for the device operation. In this work, we applied a transport imaging (TI) technique to the intra- and inter-grain carrier-transport properties of cadmium telluride (CdTe) solar cell materials. We compared the TI results with cathodoluminescence and electron backscatter diffraction (EBSD) on the same CdTe thin film. The diffusion lengths of two distinct grain interiors were measured directly, and the values are significantly different. Three types of grain boundaries (GBs) determined by EBSD were studied by TI, and they have different decays, suggesting that different GB structure can be responsible for carrier-transport properties. Further, we did a 2D analytical simulation of carrier diffusion across GBs with varying GB lifetimes. The results suggest that GB lifetimes affect the carrier transport. Comparison of multiple technique results, together with numerical simulation, provides a deeper understanding of carrier-transport properties.

14 SOLAR ENERGY↗
DOE OSTI2017

Net shape processing of alnico magnets by additive manufacturing

Alternatives to rare earth permanent magnets, such as alnico, will reduce supply instability, increase sustainability, and could decrease the cost of permanent magnets, especially for high temperature applications, such as traction drive motors. Alnico magnets with moderate coercivity, high remanence, and relatively high energy product are conventionally processed by directional solidification and (significant) final machining, contributing to increased costs and additional material waste. Additive manufacturing (AM) is developing as a cost effective method to build net-shape three-dimensional parts with minimal final machining and properties comparable to wrought parts. This work describes initial studies of net-shape fabrication of alnico magnets by AM using a laser engineered net shaping (LENS) system. High pressure gas atomized (HPGA) pre-alloyed powders of two different modified alnico “8” compositions, with high purity and sphericity, were built into cylinders using the LENS process, followed by heat treatment. The magnetic properties showed improvement over their cast and sintered counterparts. The resulting alnico permanent magnets were characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), electron backscatter diffraction (EBSD), and hysteresisgraph measurements. Furthermore, these results display the potential for net-shape processing of alnico permanent magnets for use in next generation traction drive motors and other applications requiring high temperatures and/or complex engineered part geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Distribution of Tritium in the Near Surface of Candidate Structural Materials for Fusion Reactors. Type 304L Stainless Steel, Inconel, Hastelloy, Eurofer-97, Oxide Dispersion-Strengthened Alloy 14YWT

Five different candidate structural materials for fusion have undergone pure tritium gas soaking at room temperature and at 310-mbar(a) pressure. The tritium uptake on the surface and in the bulk of the alloys has been analyzed using surface leaching, chemical etching, and thermal desorption. The nickel-based alloys: Inconel-X-750 and Hastelloy-X, absorbed the least amount of total tritium compared with austenitic stainless steel AISI 304L, reduced activation ferritic-martensitic (RAFM) Eurofer-97, and advanced nanoferritic alloy 14YWT. Microstructural analyses using electron backscatter diffraction (EBSD) indicate that the number of grains and mean grain size is not a dominant factor in near surface tritium uptake. The quantity of iron dissolved in the surface oxide appears to be the major factor in encouraging tritium absorption.

O'Callaghan, James↗
DOE OSTI2022

Identifying the microstructural features associated with void nucleation during elevated–temperature deformation of copper

The microstructural-scale mechanisms that produce cracks in metals during deformation at elevated temperatures are relevant to applications that involve thermal exposure. Prior studies of cavitation during high-temperature deformation, for example, creep, suffered from an inability to directly observe the microstructural evolution that occurs during deformation and leads to void nucleation. Here the current study takes advantage of modern high-speed electron backscatter diffraction (EBSD) detectors to observe cavitation in oxygen-free, high-conductivity copper in situ during deformation at 300°C. Most voids formed at the triple junction between a twin boundary and a high-angle grain boundary (HAGB). This finding does not contradict previous studies that suggested that twins are resistant to cracking—it reveals that cracks in HAGBs originate at twin/HAGB triple junctions and that cracks preferentially grow along HAGBs rather than the accompanying twins. Atomistic simulations explored the origins of this observation and suggest that twin/HAGB triple junctions are microstructural weak points.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Vitreous silica formation within shear bands in a dynamically compacted granular crystalline α‐quartz

A shear band is a heterogeneous, narrow seam within a solid material whose formation is caused by intense localized shearing when a sufficiently large amount of deformation occurs. If that deformation occurs at a sufficiently rapid rate, with operative friction, then co‐located ephemeral heating will occur in the shear band. In this study, shear bands were produced from dynamic shear‐induced compaction of a granular form of crystalline α‐quartz (SiO 2 ). The produced shear bands were approximately 25‐µm thick and were examined with scanning electron microscopy/electron backscatter diffraction, transmission electron microscopy, Raman spectroscopy, and nanoindentation. Further, they were found to contain a mixture of vitreous silica and small‐sized crystallites. This finding is significant because the presence of the vitreous silica within the shear band is a postmortem indicator that the localized temperature had reached or exceeded the melting temperature (∼1723°C) of crystalline SiO 2 during the rapid shear and compaction and then sufficiently rapid cooling quenched in that vitreous state.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The strain-dependent spatial evolution of garnet in a high- P ductile shear zone from the Western Gneiss Region (Norway): a synchrotron X-ray microtomography study

Reaction and deformation microfabrics provide key information to understand the thermodynamic and kinetic controls of tectono-metamorphic processes, however they are usually analysed in two dimensions, omitting important information regarding the third spatial dimension. We applied synchrotron-based X-ray microtomography to document the evolution of a pristine olivine gabbro into a deformed omphacite-garnet eclogite in four dimensions, where the 4th dimension is represented by the degree of strain. In the investigated samples, which cover a strain gradient into a shear zone from the Western Gneiss Region (Norway), we focused on the spatial transformation of garnet coronas into elongated clusters of garnets with increasing strain. Our microtomographic data allowed quantification of garnet volume, shape and spatial arrangement evolution with increasing strain. We combined microtomographic observations with light microscope- and backscatter electron images as well as electron microprobe- (EMPA) and electron backscatter diffraction (EBSD) analysis to correlate mineral composition and orientation data with the X-ray absorption signal of the same mineral grains. With increasing deformation, the garnet volume almost triples. In the low strain domain, garnets form a well interconnected large garnet aggregate that develops throughout the entire Page 1 of 52 sample. We also observed that garnet coronas in the gabbros never completely encapsulate olivine grains. In the most highly deformed eclogites, the oblate shapes of garnet clusters reflect a deformational origin of the microfabrics. We interpret the aligned garnet aggregates to direct synkinematic fluid flow and consequently influence the transport of dissolved chemical components. EBSD analyses reveal that garnet show a near-random crystal preferred orientation that testifies no evidence for crystal plasticity. There is, however evidence for minor fracturing, neo-nucleation and overgrowth. Microprobe chemical analysis revealed that garnet compositions progressively equilibrate to eclogite facies, becoming more almandine-rich. We interpret these observations as pointing to a mechanical disintegration of the garnet coronas during strain localisation, and their rearrangement into individual garnet clusters through a combination of garnet coalescence and overgrowth while the rock was deforming.

garnet↗
DOE OSTI2026

Tailoring Thermal and Mechanical Performance Through Multimaterial Laser Powder Directed Energy Deposition of Copper and 17-4PH Stainless Steel

This study investigates the additive manufacturing (AM) processing, microstructural evolution, and resulting mechanical and thermal properties of multimaterial components combining 17-4PH stainless steel and pure copper (Cu) fabricated via laser powder directed energy deposition (LP-DED). Conventional tooling steels exhibit limited thermal conductivity, significantly constraining production throughput in high-volume processes. Incorporating Cu, with its superior thermal conductivity, could significantly enhance tool performance, though Cu and steel present metallurgical incompatibilities when processed via AM. A systematic investigation was conducted across compositions ranging from 0 to 100 wt% Cu, revealing critical thresholds influencing solidification behavior, defect formation, microstructure, hardness, and thermal transport. Optical microscopy, electron backscatter diffraction (EBSD), hardness testing, and thermal conductivity measurements provided comprehensive process–structure–property correlations. Severe hot cracking occurred at low-Cu contents (6–25 wt%), aligning generally well with crack susceptibility modeling, with an unexpected discrepancy at 25 wt%. Porosity remained low (≥99% dense) throughout the compositional spectrum. EBSD analysis revealed a transformation from columnar martensitic structures at low-Cu contents to equiaxed FCC Cu-dominated structures at higher Cu concentrations, highlighting the complex microstructural transitions driven by Cu-induced changes in solidification and phase stability. Hardness decreased from 330 HV (pure 17-4PH) to 62 HV (pure Cu), consistent with microstructural changes. Concurrently, thermal conductivity improved substantially from 13.5 W/m K to 367.9 W/m K, emphasizing Cu’s dominant role in thermal transport. The findings highlight the feasibility of leveraging compositional gradients between 17-4PH and Cu to achieve tailored tooling with optimized thermal and mechanical performance.

17-4PH↗
DOE OSTI2017

Polarization effects associated with thermal processing of HY-80 structural steel using high-power laser diode array

Localized heating of roughened steel surfaces using disperse laser light emitted from high power laser diode arrays was experimentally demonstrated and compared with theoretical predictions. The Fresnel equations were used to analyze the optical absorptivity in terms of the angle of incidence and polarization state to understand the laser-induced temperature rise of HY-80 steel plates under 383-612 W laser irradiation. Laser-induced, transient temperature distributions were directly measured using bulk thermocouple probes and thermal imaging. Finite element analysis yielded quantitative assessment of energy deposition and heat transport in HY-80 steel using absorptivity as a tuning parameter. The extracted absorptivity values ranged from 0.62 to 0.75 for S-polarized and 0.63 to 0.85 for P-polarized light, in agreement with partially oxidized iron surfaces. Microstructural analysis using electron backscatter diffraction revealed a heat affected zone for the highest temperature conditions (612 W, P-polarized) as evidence of rapid quenching and an austenite to martensite transformation. In conclusion, the efficient use of diode arrays for laser-assisted advanced manufacturing technologies such as hybrid friction stir welding is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Gradient nanostructured steel with superior tensile plasticity

Nanostructured metallic materials with abundant high-angle grain boundaries exhibit high strength and good radiation resistance. While the nanoscale grains induce high strength, they also degrade tensile ductility. We show that a gradient nanostructured ferritic steel exhibits simultaneous improvement in yield strength by 36% and uniform elongation by 50% compared to the homogenously structured counterpart. In situ tension studies coupled with electron backscattered diffraction analyses reveal intricate coordinated deformation mechanisms in the gradient structures. The outermost nanolaminate grains sustain a substantial plastic strain via a profound deformation mechanism involving prominent grain reorientation. This synergistic plastic co-deformation process alters the rupture mode in the post-necking regime, thus delaying the onset of fracture. The present discovery highlights the intrinsic plasticity of nanolaminate grains and their significance in simultaneous improvement of strength and tensile ductility of structural metallic materials.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Creep cavitation bands control porosity and fluid flow in lower crustal shear zones

Shear zones channelize fluid flow in Earth’s crust. However, little is known about deep crustal fluid migration and how fluids are channelized and distributed in a deforming lower crustal shear zone. This study investigates the deformation mechanisms, fluid-rock interaction, and development of porosity in a monzonite ultramylonite from Lofoten, northern Norway. The rock was deformed and transformed into an ultramylonite under lower crustal conditions (temperature = 700–730 °C, pressure = 0.65–0.8 GPa). The ultramylonite consists of feldspathic layers and domains of amphibole + quartz + calcite, which result from hydration reactions of magmatic clinopyroxene. The average grain size in both domains is <25 mm. Microstructural observations and electron backscatter diffraction analysis are consistent with diffusion creep as the dominant deformation mechanism in both domains. Festoons of isolated quartz grains define C'-type bands in feldspathic layers. These quartz grains do not show a crystallographic preferred orientation. The alignment of quartz grains is parallel to the preferred elongation of pores in the ultramylonites, as evidenced from synchrotron X-ray microtomography. Such C'-type bands are interpreted as creep cavitation bands resulting from diffusion creep deformation associated with grain boundary sliding. Mass-balance calculation indicates a 2% volume increase during the protolith-ultramylonite transformation, which is consistent with synkinematic formation of creep cavities producing dilatancy. Thus, this study presents evidence that creep cavitation bands may control deep crustal porosity and fluid flow. Nucleation of new phases in creep cavitation bands inhibits grain growth and enhances the activity of grain size–sensitive creep, thereby stabilizing strain localization in the polymineralic ultramylonites.

CENTRAL ALPS↗
DOE OSTI2016

Quartz c-axis orientation patterns in fracture cement as a measure of fracture opening rate and a validation tool for fracture pattern models

Here, we evaluate a published model for crystal growth patterns in quartz cement in sandstone fractures by comparing crystal fracture-spanning predictions to quartz c-axis orientation distributions measured by electron backscatter diffraction (EBSD) of spanning quartz deposits. Samples from eight subvertical opening-mode fractures in four sandstone formations, the Jurassic– Cretaceous Nikanassin Formation, northwestern Alberta Foothills (Canada), Cretaceous Mesaverde Group (USA; Cozzette Sandstone Member of the Iles Formation), Piceance Basin, Colorado (USA), and upper Jurassic–lower Cretaceous Cotton Valley Group (Taylor sandstone) and overlying Travis Peak Formation, east Texas, have similar quartzose composition and grain size but contain fractures with different temperature histories and opening rates based on fluid inclusion assemblages and burial history. Spherical statistical analysis shows that, in agreement with model predictions, bridging crystals have a preferred orientation with c-axis orientations at a high angle to fracture walls. The second form of validation is for spanning potential that depends on the size of cut substrate grains. Using measured cut substrate grain sizes and c-axis orientations of spanning bridges, we calculated the required orientation for the smallest cut grain to span the maximum gap size and the required orientation of the crystal with the least spanning potential to form overgrowths that span across maximum measured gap sizes. We find that within a 10° error all spanning crystals conform to model predictions. Using crystals with the lowest spanning potential based on crystallographic orientation (c-axis parallel to fracture wall) and a temperature range for fracture opening measured from fluid inclusion assemblages, we calculate maximum fracture opening rates that allow crystals to span. These rates are comparable to those derived independently from fracture temperature histories based on burial history and multiple sequential fluid inclusion assemblages. Results support the R. Lander and S. Laubach model, which predicts that for quartz deposited synchronously with fracture opening, spanning potential, or likelihood of quartz deposits that are thick enough to span between fracture walls, depends on temperature history, fracture opening rate, size of opening increments, and size, mineralogy, and crystallographic orientation of substrates in the fracture wall (transected grains). Results suggest that EBSD maps, which can be more rapidly acquired than measurement of tens to hundreds of fluid inclusion assemblages, can provide a useful measure of relative opening rates within populations of quartz-filled fractures formed under sedimentary basin conditions. Such data are useful for evaluating fracture pattern development models.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Characterizing Corrosion Mechanisms Of Structural Alloys In Actinide-based Molten Chloride Salt

This is a dataset consisting of 33 GB of .png image files, each featuring a two-dimensional distribution of different element species captured an individual slice of the specimen, and .ang files that capture microstructural information captured from each respective slice using a technique called electron backscatter diffraction. The .ang files can be processed to visualize alloy grains captured in a respective slice.

Copeland, Trishelle M.↗
DOE OSTI2025

Improving high temperature resilience of fiber sensor embedded smart components through laser shock peening

This study explores the use of laser shock peening (LSP) to enhance material properties and high-temperature performance of fiber-sensor-fused smart parts fabricated by additive manufacturing (AM) methods. Using embedded fiber sensors as distributed strain gauges, the study demonstrates that LSP can induce compressive strains of up to 130 µε on fiber embedded 1-mm below metal surfaces. The electron backscatter diffraction (EBSD) analysis shows that, with optimized LSP parameters, the metallic matrix undergoes substantial microstructural refinement, resulting in denser structures. Thermal cycling tests showed that the LSP process can increase fiber slippage temperatures by more than 50 °C. This work shows that the LSP process is an effective room-temperature process for enhancing both surface quality and increasing fiber slippage threshold under both thermal and mechanical stress.

Zhong, Shuda [University of Pittsburgh, PA (United↗
DOE OSTI2016

Texture development during rolling of α+β dual-phase ZrNb alloys - 2016-0070

The texture evolution during high-temperature rolling (800 deg. C) of two model zirconium-niobium alloys was studied using electron backscatter diffraction. The aim was to decouple the relative importance of deformation and phase transformation on the final texture in an effort to elucidate the origin of the strong α-transverse basal texture commonly found in the hot-rolled product. The analysis uses a reconstruction software based on the Burgers relation to reconstruct the high-temperature β orientations, with the indexed α as input. In the low niobium content alloy, the texture evolution of the {11 2-bar 0}<10 1-bar 0> component was consistent with deformation in both α and β phases, along with a variant selection mechanism that occurred during the β → α phase transformation. Variant selection was observed to depend on the orientation of the deformed prior β grains. In the high niobium content alloy, a lower α volume fraction during hot rolling gave rise to different β textures and promoted the formation of a Goss component. This contributed to the {11 2-bar 0} <10 1-bar 0> component upon cooling, with variant selection enhanced by anisotropic grain breakup. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2021

Deformation and fracture characteristics of zirconium plate produced via ultrasonic additive manufacturing

Abstract The microstructural evolution, deformation modes, and fracture mechanisms of zirconium plate produced using ultrasonic additive manufacturing (UAM) are presented. In addition to conventional tensile testing techniques, digital image correlation captured highly variable strain accumulation in specimens loaded perpendicular or parallel to the build height (Z). When tested in parallel to Z, delamination at prior foil/foil interfaces creates strain localization noticeable in strain rate maps, whereas specimens loaded perpendicular to Z illustrate conventional strain hardening until necking accelerates delamination. Although bond strengths are statistically and spatially variable, in situ electron backscattering diffraction tests illustrate the ability for grains near interfaces to accommodate strain with twinning and slip modes consistent with conventionally produced zirconium alloys. Finally, mixtures of ductile and delamination-induced fracture highlight the interface-driven failure modes of UAM zirconium plate in the as-built condition. Graphic abstract

36 MATERIALS SCIENCE↗
DOE OSTI2013

Improving 6061-Al Grain Growth and Penetration across HIP-Bonded Clad Interfaces in Monolithic Fuel Plates: Initial Studies

Grain penetration across aluminum-aluminum cladding interfaces in research reactor fuel plates is desirable and was obtained by a legacy roll-bonding process, which attained 20-80% grain penetration. Significant grain penetration in monolithic fuel plates produced by Hot Isostatic Press (HIP) fabrication processing is equally desirable but has yet to be attained. The goal of this study was to modify the 6061-Al in such a way as to promote a much greater extent of crossinterface grain penetration in monolithic fuel plates fabricated by the HIP process. This study documents the outcomes of several strategies attempted to attain this goal. The grain response was characterized using light optical microscopy (LOM) electron backscatter diffraction (EBSD) as a function of these prospective process modifications done to the aluminum prior to the HIP cycle. The strategies included (1) adding macroscopic gaps in the sandwiches to enhance Al flow, (2) adding engineering asperities to enhance Al flow, (3) adding stored energy (cold work), and (4) alternative cleaning and coating. Additionally, two aqueous cleaning methods were compared as baseline control conditions. The results of the preliminary scoping studies in all the categories are presented. In general, none of these approaches were able to obtain >10% grain penetration. Recommended future work includes further development of macroscopic grooving, transferred-arc cleaning, and combinations of these with one another and with other processes.

36 MATERIALS SCIENCE↗
DOE OSTI2013

EBSD Characterization of Tubular Cladding Plasticity after Bend Testing: A Feasibility Study

The Light Water Reactor Sustainability (LWRS) Program developed a bend test method for tubular samples during FY12. The purpose of this report is to provide details of the Electron Backscattered Diffraction (EBSD) measurements performed on the various sample sets to provide a comparative baseline of the impact that the silicon carbide ceramic matrix composites (SiC-CMC) sleeves had on the deformation and plasticity properties of the Zircaloy-4 (Zr-4) cladding tube.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗