SEARCH · Engineering Papers

Results for “ZONES”

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.

SourceResearch connectionFrom yearThrough year

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

At least 739 records · Page 41

All sources NASA NTRS DOE OSTI

DOE OSTI2017

Use of Friction Stir Processing for Improving Heat-Affected Zone Liquation Cracking Resistance of a Cast Magnesium Alloy AZ91D

In this work, a cast magnesium alloy AZ91D was friction stir processed. Detailed microstructural studies and Gleeble hot ductility tests were conducted on the as-cast and the FSPed samples to comparatively assess their heat-affected zone liquation cracking behavior. The results show that the use of FSP as a pretreatment to fusion welding can strikingly improve the heat-affected zone liquation cracking resistance of alloy AZ91D by reducing the amount and size of the low-melting eutectic β (Mg{sub 17}Al{sub 12}) as well as by refining the matrix grain size.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Modeling of the Heat-Affected and Thermomechanically Affected Zones in a Ti-6Al-4V Inertia Friction Weld

Inertia friction welding has been used across the aerospace, automotive, and power-generation industries for the fabrication of complex axisymmetric components for over forty years. The process involves one axisymmetric piece being held stationary and another piece being brought into contact set to rotate about its axis of symmetry by a flywheel with the system under an applied load across the joint. Plasticization at the joint interface through the frictional heating sees the two pieces bond together. The titanium alloy Ti-6Al-4V has been widely studied for inertia welding applications. A successful selection of processing parameters (flywheel energy and mass, applied load) allows an inertia welding process which produces a very high-integrity weld, with a minimal heat-affected zone (HAZ) and thermomechanically affected zone (TMAZ), formed as a narrow band at the interface and extending further into the material. The width of this narrow band of heated material is dependent upon the process parameters used. A series of experimental inertia friction welds were performed using Ti-6Al-4V, and a finite element (FE) modeling framework was developed using the FE code Deform in order to predict the widths of the HAZ and TMAZ at the weld interface. The experimentally observed HAZ boundaries were correlated with the thermal fields from the FE model, while TMAZ boundaries were correlated with the Von Mises plastic strain fields.

42 ENGINEERING↗

DOE OSTI2019

Effect of Heat Input on M-A Constituent and Toughness of Coarse Grain Heat-Affected Zone in an X100 Pipeline Steel

The joining of 14.8 mm thick pipeline steels was achieved with developments in high-power fiber laser by laser welding or hybrid laser arc welding. However, there were few studies on the effects of single-pass welding heat input on the M-A component and impact toughness of the heat-affected zone. In this study, single-pass welding thermal cycle was performed on Gleeble 3800 thermal simulation tester; the effect of heat input on microstructure, M-A constituent, hardness, toughness and corrosion resistance of coarse-grained heat-affected zone of X100 pipeline steel was studied. The results showed: The microstructure was lath martensite with a heat input of less than 8 kJ/cm. When the heat input was 26-36 kJ/cm, the microstructure was granular bainite. The heat input had not obvious effect on hardness (only 16% hardness reduction in this heat input arrange). However, the impact toughness was strongly influenced by heat input, with an 88% hardness reduction compared to base metal, due to M-A constituent and prior austenite grain size. Few finer M-A constituent dispersing in austenite was obtained instead of necklace-like M-A constituent at the prior austenite grain boundary when the welding heat input was less than 15 kJ/cm, which was beneficial to improve the impact toughness and corrosion resistance of welded joints of X100 pipeline steels.

36 MATERIALS SCIENCE↗

DOE OSTI2016

A new predictive multi-zone model for HCCI engine combustion

Here, this work introduces a new predictive multi-zone model for the description of combustion in Homogeneous Charge Compression Ignition (HCCI) engines. The model exploits the existing OpenSMOKE++ computational suite to handle detailed kinetic mechanisms, providing reliable predictions of the in-cylinder auto-ignition processes. All the elements with a significant impact on the combustion performances and emissions, like turbulence, heat and mass exchanges, crevices, residual burned gases, thermal and feed stratification are taken into account. Compared to other computational approaches, this model improves the description of mixture stratification phenomena by coupling a wall heat transfer model derived from CFD application with a proper turbulence model. Furthermore, the calibration of this multi-zone model requires only three parameters, which can be derived from a non-reactive CFD simulation: these adaptive variables depend only on the engine geometry and remain fixed across a wide range of operating conditions, allowing the prediction of auto-ignition, pressure traces and pollutants. This computational framework enables the use of detail kinetic mechanisms, as well as Rate of Production Analysis (RoPA) and Sensitivity Analysis (SA) to investigate the complex chemistry involved in the auto-ignition and the pollutants formation processes. In the final sections of the paper, these capabilities are demonstrated through the comparison with experimental data.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Air quality and comfort constrained energy efficient operation of multi-zone buildings

Maintaining indoor air quality (IAQ) through effective ventilation is essential for the well-being and productivity of building occupants. Control strategies aimed at improving the efficiency of heating, ventilation and air conditioning (HVAC) systems must jointly determine ventilation and heating and cooling processes. Here, in this paper, we study the problem of minimizing the energy consumption of the HVAC system in a multi-zone building, while meeting thermal comfort and IAQ requirements. We first perform a steady state analysis of the zonal carbon dioxide (CO 2 ) concentration and the temperature dynamics. The resulting expressions are convex in the zonal mass flow rates and zonal temperatures. Guided by the steady state solutions for meeting the thermal comfort constraints, we develop two control policies for improving the energy efficiency of building HVAC systems while jointly satisfying indoor temperature and IAQ constraints. We compare the performance of our proposed approaches with those of multiple baseline approaches which implement separate regimes for controlling zonal temperature and IAQ for a typical work-day in a multi-zone campus building. We have evaluated the performance of our proposed approaches under varying levels of flexibility in zonal temperatures. We have shown that zonal temperature flexibility can result in energy savings up to 32% (for the same control strategies) as compared to the case where no such flexibility is permitted. Our proposed approaches were seen to offer potential savings of nearly 29% compared to the baseline.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Energy performance of a bedroom task/ambient air conditioning (TAC) system applied in different climate zones of China

Here, task/ambient air conditioning (TAC) system applied to bedrooms has been investigated and its energy efficient performance reported. To promote the application of bedroom TAC to a larger region, a numerical study was carried out on a bedroom TAC system applied in five different climate zones. To simplify the numerical study, response surface methodology (RSM) was used to predict operating power of TAC based on CFD results. It's found that the daily energy consumption in the typical day was from 0 kWh in Kunming to 1.27 kWh in Shanghai, the averaged daily energy consumption varied from 0.47 kWh in June to 0.56 kWh in August for Guangzhou, and the total energy consumption in summer ranged from 0 kWh in Kunming to 58.33 kWh in Guangzhou. Meanwhile, the operating time of the TAC were also different between these five cities. In order to save energy, different set points of t oz (average air temperature in the occupied zone) were investigated. Additionally, it's found that increasing the t oz from 24 to 25 °C can reduce energy consumption by about 23.42% in Shanghai to 36.23% in Beijing. Besides, the energy saving potential using two operating modes were compared: variable air flow rate and variable air temperature.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2014

A Unified Cohesive Zone Approach to Model Ductile Brittle Transition in Reactor Pressure Vessel Steels

In this study, a unified cohesive zone model has been proposed to predict, Ductile to Brittle Transition, DBT, in Reactor Pressure Vessel, RPV, steels. A general procedure is described to obtain the Cohesive Zone Model, CZM, parameters for the different temperatures and fracture probabilities. In order to establish the full master-curve, the procedure requires three calibration points with one at the upper-shelf for ductile fracture and two for the fracture probabilities, Pf, of 5% and 95% at the lower-shelf. In the current study, these calibrations were carried out by utilizing the experimental fracture toughness values and flow curves. After the calibration procedure, the simulations of fracture behavior (ranging from completely unstable to stable crack extension behavior) in one inch thick compact tension specimens at different temperatures yielded values that were comparable to the experimental fracture toughness values, indicating the viability of such unified modeling approach.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Pressure falloff testing to characterize CO 2 plume and dry-out zone during CO 2 injection in saline aquifers

The fluid mobilities and the lateral extent of the CO 2 plume and the dry-out zone are among important unknowns required to effectively manage CO 2 storage in saline aquifers projects. These unknowns can be derived from pressure falloff testing which has been widely used to characterize the subsurface. This paper provides a three-region analytical solution for falloff pressure during the infinite-acting period of CO 2 injection in saline aquifers. The solution is derived using Laplace transformation technique of the governing diffusivity equations and the accompanying initial and boundary conditions. The exact solution is validated against numerical results obtained from a black-oil reservoir simulator for two cases. The solution is approximated into simple forms in real-time domain considering different time periods. Then, a graphical semi-log analysis technique based on the approximate solutions is provided as an interpretation tool of falloff tests where the fluid mobilities and the extents of dry-out zone and CO 2 plume can be inferred. The interpretation technique is applied to synthetic falloff test data to investigate its potential and reliability.

02 PETROLEUM↗

DOE OSTI2019

In-situ observation of an unusual phase transformation pathway with Guinier-Preston zone-like precipitates in Zr-based bulk metallic glasses

The pathway of amorphous-to-crystalline phase transformation in Zr 52.5 Cu 17.9 Ni 14.6 Al 10 Ti 5 bulk metallic glasses was studied using a suite of in-situ techniques. Multi-scale structure evidence reveals a five-stage pathway, analogous to the non-equilibrium transformation process with Guinier-Preston zones during aging in precipitation-hardened alloys, by the following sequence upon isothermal annealing the alloy in the supercooled liquid region: polyamorphous phase transition, chemical phase separation, the formation of a poorly-ordered metastable phase, and the formation of a final crystalline product. The changeable incubation periods at different annealing temperatures, and the abrupt multi-scale structure changes, as well as a latent heat release in the calorimetric measurements, support the first-order nature of the phase transformation at early stages. The structure evolution in real-space indicates that the enhancement of cluster connectivity on the medium-range scale plays essential roles in the early stages of the phase transformation, while the interface-limited ordering dominates the later stages. The experimental results suggest the phase transformation pathway with "Guinier-Preston zone-like" precipitates accompanied by the kinematic development of core-shell structures of diffuse interfaces with order parameters gradients, enabling the step-by-step decrease of free energy of the alloy system during phase transformation, which might be a universal behavior for alloys with excellent glass-forming ability.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Growth of CuFeO 2 single crystals by the optical floating-zone technique

CuFeO 2 single crystals up to 50 mm in length and up to 10 mm in diameter were grown by the optical floating-zone method. Stoichiometric polycrystalline rods with a diameter of 6–12 mm were used as feed materials to produce crystals of sufficient size to be used as substrates for the growth of thin films of delafossites. For stable growth along the c-axis, low growth rates of 0.4 mm/h are necessary. Due to the incongruent melting behavior of CuFeO 2 , a stable melt zone requires adjustment of the lamp power during growth. The melting of CuFeO 2 is not simply incongruent because the thermodynamic equilibrium includes more than two solid phases and the melt; the gas phase is also involved. Finaly, the crystals were characterized by X-ray diffraction and X-ray fluorescence measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2012

Extended reaction zone of La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3 cathode for solid oxide fuel cell

The oxygen reduction reaction at the cathode of solid oxide fuel cell (SOFC) is a complicated process which involves the interaction of oxygen molecules, electrons, and oxygen ions. Therefore, it can only proceed at locations where gas, electronic conductor, and an oxygen ion conductor meet. Although the extension of the reaction zone beyond the traditional so-called triple-phase-boundary (TPB) is widely accepted for a mixed ionically and electronically conductive cathode, work in this area has yet to reach a consensus on how far the reaction zone can be extended. In this study, anode-supported fuel cells with a variety of LSCF cathode thicknesses were fabricated and tested in two cathode environments, flowing oxygen and flowing air. In flowing oxygen, the cell performance increased with LSCF cathode thickness over the entire range investigated (from 5 to 33 μm). In flowing air, the cell performance also increased with the LSCF cathode thickness from 5 to 13 μm, but then remained almost constant with further increase in cathode thickness. In flowing oxygen, since there was no concentration polarization related to oxygen diffusion, the polarization resistance of oxygen reduction decreased with the LSCF cathode thickness because of the increased number of reaction sites. A linear relationship was established between the reciprocal of the polarization resistance and the cathode thickness, which was explained by a model developed for aqueous gas diffusion electrodes.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2016

Ghost microstructure evolution and identification in the coarse grain heat affected zone of 2.25Cr-1Mo-V-Ti steel using tint etching

Microstructural characteristics of the CGHAZ (coarse grained heat affected zone) made of the 2.25Cr-1Mo-V-Ti material for the thermal power plant boiler tube were discussed using the technique of tint etching. To conduct the micro structural characterization, the sample on which CGHAZ was produced by using a high temperature thermal cycle simulator, Gleeble 3500 equipment was used for comparative analyses using the existing Nital etching (ASTM E407-74) and the alkaline etching (ASTM E40785). The latter was used to observe a specific phase. For the microstructure on which the alkaline etching was experimented, the shape of a black strip (Ghost microstructure) in a few microns was observed, which was not observed from the Nital etching. It was found from the phase identifications based EPMA, EBSD and TEM experiments that the image of the black strip in a few microns represented the alpha phase in which C, Cr and Mo became segregated. In addition, it was verified that austenite and M{sub 23}C{sub 6} phase were present around the segregated zone. Based on such results, the mechanism by which the image of the black strip in a few microns was formed at the CGHAZ. In this study, we have investigated the mechanism of the appeared black strip in the CGHAZ. - Highlights: •Ghost microstructure was observed which was not observed from the nital etching. •Ghost microstructure has high concentrations of carbon and molybdenum than matrix. •Schematic illustration proposed of why Ghost microstructure was generated. •Ghost microstructure caused by partial dissolution of M{sub 23}C{sub 6} precipitation.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Characterization of martensite-austenite constituents and micro-hardness in intercritical reheated and coarse-grained heat affected zones of API X70 HSLA steel

Highlights: • The influence of cold wire addition to the tandem submerged arc welding process on the ICRCGHAZ is investigated. • Comprehensive characterization of the microstructure and micro-hardness in the ICRCGHAZ of a HSLA steel is performed. • A lower fraction of finely distributed M-A formed in the ICRCGHAZ of TSAW + cold wire steel, leading to lower micro-hardness. • The aspect ratio and inter-particle spacing of M-A constituents decreased in the ICRCGHAZ through cold wire addition. - Abstract: The thermal cycles that high strength low alloy (HSLA) low carbon steels experience during welding inevitably affect the microstructure and mechanical properties of the weld joints. It is generally agreed that the coarse-grained heat affected zone (CGHAZ) and the intercritical reheated coarse-grained heat affected zone (ICRCGHAZ) in one-pass and multi-pass welding, respectively, have the poorest microstructure and mechanical properties relative to the rest of the steel joint. The martensite-austenite (M-A) constituents formed in the HAZ regions predominantly govern property deterioration in the CGHAZ and the ICRCGHAZ by promoting the initiation and propagation of micro-cracks. However, the characteristics of the M-A constituents, i.e., fraction, size, shape and aspect ratio, are strongly affected by the welding heat input. Accordingly, in this study, the aim was to evaluate the influence of a cold wire addition in conventional tandem submerged arc welding (TSAW + cold-wire) on the microstructure and micro-hardness in the CGHAZ and ICRCGHAZ. Microstructural characterization showed that a lower fraction of finely distributed M-A constituents associated with smaller prior austenite grains (PAGs) formed in the CGHAZ of the steel welded by the TSAW + cold-wire process (CW-OD weld) relative to that welded by the conventional TSAW process (TW-OD weld). Furthermore, the fraction of M-A constituents in the ICRCGHAZ of the CW-OD weld was decreased. A higher fraction of slender shaped M-A constituents in the ICRCGHAZ of the TW-OD weld resulted in an increase in the micro-hardness. The microstructure and micro-hardness changes associated with cold wire addition were attributed to the lower welding heat input and, consequently, the faster cooling rate with a corresponding reduction in the retention time in the austenitic region and ferrite/austenite region in the CGHAZ and ICRCGHAZ regions, respectively.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Toughening mechanism of inter-critical heat-affected zone in a 690 MPa grade rack plate steel

Highlights: • Relationship between toughness and microstructure was confirmed. • The toughness of ICHAZ is higher than that of FGHAZ. • Fine bainitic microstructure in ICHAZ plays an important role on improving toughness. • The homogeneous distribution of dislocation and local strain facilitate the plastic deformation prior fracture. - Abstract: The inter-critical heat-affected zone (ICHAZ) and fine grain heat-affected zone (FGHAZ) of a 690 MPa grade rack plate steel were simulated by Gleeble3500 simulator. The toughening mechanism of ICHAZ was clarified by analyzing microstructural characteristics and instrumental Charpy impact tests. The study showed that the ICHAZ had higher toughness than FGHAZ. And the microstructure in FGHAZ was martensite, while bainitic microstructure was obtained in ICHAZ. Both the prior austenite grain size and effective grain size of ICHAZ were smaller than that of FGHAZ, which played an important role in improving the toughness of ICHAZ. It was found that the extensive plastic deformation prior fracture in ICHAZ could consume large energy during crack initiation and propagation. The large plastic deformation capacity of ICHAZ was related to the large fraction of large-angle boundaries and low dislocation density, as well as the homogeneous distribution of local strain and geometrically necessary dislocations.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Optical and scintillation properties of ScAlMgO{sub 4} crystal grown by the floating zone method

Highlights: • ScAlMgO4 single crystal is synthesized by the floating zone method. • Optical and scintillation properties of the crystal are studied. • The band gap is observed around 200 nm which is consistent with the theoretical work. • The emission appears around 400 nm in photoluminescence and scintillation. - Abstract: The undoped ScAlMgO{sub 4} crystal was synthesized by the Floating Zone (FZ) method, and we evaluated the optical and scintillation properties. The transmittance spectrum showed the absorption edge around 200 nm. VUV-excited emission/excitation spectrum was characterized at a synchrotron facility (UVSOR). Our experiment revealed that the emission was around 400 nm by 200 nm excitation, and the excitation band was 170–210 nm for the latter emission peak. The decay time characterized by 280 nm excitation was 8.3 and 43 ns. Under X-ray irradiation, an emission was observed around 400 nm as for VUV excitation, and the latter decay time constants were 0.23 and 2.2 μs. In addition, the afterglow level at 20 ms after X-ray irradiation was around 0.1% of the intensity during irradiation.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Magnetic studies on Sm0.55Sr0.45Mn0.4Fe0.6O3 single crystals grown by optical floating zone technique

Highlights: • Single crystals of Sm0.55Sr0.45Mn0.4Fe0.6O3 were grown by optical floating zone technique. • Replacement of Mn by iron has suppressed the double exchange interactions and ferromagnetism. • Crystal exhibited spin glass behavior below 35 K due to the competition between the Mn{sup 3+}-O-Mn{sup 4+} double exchange and the Mn{sup 3+}-O-Fe{sup 3+} super exchange interactions. - Abstract: Single crystals of high concentration iron substituted Sm{sub 0.55}Sr{sub 0.45}Mn{sub 0.4}Fe{sub 0.6}O{sub 3} were grown by optical floating zone technique in oxygen atmosphere. Analysis of powder X-ray diffraction and Laue patterns revealed single-phase formation and crystal quality respectively. Replacement of Mn by iron has reduced the ratio of trivalent to tetravalent Mn ions thus suppressing the double exchange interactions and ferromagnetism. The grown crystal exhibits spin glass behavior below 35 K due to the competition between the Mn{sup 3+}-O-Mn{sup 4+} double exchange and the Mn{sup 3+}-O-Fe{sup 3+} super exchange interactions.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2025

Low embodied energy and carbon, high lifetime silicon boules via a combined chemical vapor deposition/float zone process

This work evaluates a new process route to making float zone (Fz)-quality silicon wafers using a combination of computational fluid dynamics (CFD) modeling and technoeconomic analysis. Our analysis finds that the new process competes with Czochralski (Cz)-grown wafers on a levelized cost of energy system level. The new process also decreases embodied energy and carbon of silicon photovoltaics (PV) by ~6x circumventing the energy-costly Siemens process used in polycrystalline silicon (poly-Si) production plants to generate feedstock for Fz and Cz boules. Instead of using poly-Si from the Siemens process to feed crystallization, the new process uses the high-purity, trichlorosilane (TCS) precursor gas to grow a poly-Si feed rod in-situ during a modified Fz1,2 boule growth process. The gas-to-boule float zone process enables opportunity to produce high-purity (low metals and oxygen content), uniformly doped single crystal silicon boules and wafers with high bulk lifetimes (τ bulk > 15 ms) to enable higher efficiency cells (>27 %) with fewer known degradation mechanisms than Czochralski (Cz)-grown wafers. These benefits reduce the levelized cost of electricity (LCOE) of PV-produced electricity. Here we show the results of our CFD and chemical modeling of the process to prove feasibility and economic viability.

14 SOLAR ENERGY↗

DOE OSTI2022

Ambient Noise Attenuation Tomography Reveals an Asymmetric Damage Zone Across San Jacinto Fault Near Anza, California

Here, we perform seismic attenuation tomography of the shallow structure for the San Jacinto Fault in the Ramona Reservation of southern California. The study uses ambient seismic noise recorded by a linear array of 65 3-C sensors across the fault. We extract amplitude decay information, with uncertainty, from noise interferometry functions. To account for strong heterogeneities in the complex shallow fault zone structure, we apply a frequency-dependent amplitude correction for focusing/defocusing effects using inverted phase velocity maps obtained by solving the transport equation. We then estimate the attenuation structure based on the linear station-triplet method for both Love and Rayleigh waves. The attenuation tomography indicates strong attenuation correlated with known San Jacinto Fault surface traces. The Love wave attenuation tomography reveals an asymmetric damage zone that exists primarily on the fault side with faster seismic velocity, consistent with earthquake ruptures on a fault bimaterial interface with preferred propagation direction to the northwest.

58 GEOSCIENCES↗