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At least 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Role of Cyclic Phase Transitions in Additive Manufacturing of Metals and Alloys - Lessons Learned from Welding Science

Additive manufacturing (also known as 3D printing) of metals is considered to be a disruptive technology, able to produce limited number of high value components with topologically optimized geometries and functionalities. Realization of the above potential for real-world applications is stifled by lack of standard computational design tools; component certifications, varied starting powder feed stock compositions, methods to probe thermomechanical processes, microstructural homogeneity, residual stress, as well as, anisotropic static- and dynamic-material properties. Detailed research of direct energy deposition, laser- and electron-powder bed additive manufacturing demonstrates that the underlying physics of these processes are very similar to welding, except for complex boundary conditions. This paper will review published literature and on-going research with reference to fundamental aspects of heat and mass transfer, solidification under large (103 to 105 K/m) thermal gradients and (10-3 to 100 m/s) liquid solid-interface velocities, as well as, solid->solid transformation under repeated thermal excursions. Case studies on model based qualification of Ni- and Ti- alloy builds made by additive manufacturing (AM), based on the above fundamental knowledge will be discussed.

Babu, Sudarsanam Suresh↗
DOE OSTI2016

Thermal Desorption of Tritium from Fluoride Salt-Cooled Reactor Materials

The fluoride-salt-cooled high-temperature reactor (FHR) is a high-temperature fission reactor concept involving a liquid fluoride salt coolant, coated particle fuel, and enhanced passive safety mechanisms. Utilizing a low-pressure coolant and high temperature fuel allows for smaller reactor buildings and use of gas Brayton power cycles for higher efficiency in electricity production. One of the fluoride salts being considered for the FHR coolant is 2LiF - BeF{sub 2} (flibe). Tritium is generated frequently in flibe from thermal neutron transmutation of Li-6 and Be-9. Tritium retention in irradiated structural materials presents a challenge to the design of the FHR; high neutron fluence can induce significant material damage and alteration of microstructures to trap tritium in the structure, particularly in carbon-based materials (such as steels). Investigation of tritium transport in flibe salt and structural materials is also critical to evaluating mass balance of tritium in a system for quantifying leakage of tritium to the environment. It is important to understand the uptake of tritium in these proposed core materials since the transport of tritium within an FHR is of critical concern for operational safety due to corrosion, and to prevent tritium release into the environment. The presence of TF corrodes stainless steel by oxidizing chromium. Tritium gas (T{sub 2}) easily diffuses through reactor materials and can be released into the environment through the primary piping and heat exchangers. There is great interest in identifying materials that are compatible with the FHR environment that can be used to getter tritium from the salt, or to inhibit the diffusion of tritium to prevent its release into the environment. As part of the FHR Integrated Research Project (IRP), capsules containing proposed core materials immersed in flibe salt were irradiated at 700 deg. C for 1000 hours (FS-1) and 300 hours (FS-2) in the MIT Research Reactor (MITR). During irradiation, tritium is produced in the salt, and then interacts with the other materials in the capsule. Measurements of the effluent gas during the FHR IRP irradiation experiments indicated that less than 1% of the tritium generated in the salt escaped in the gas phase. It is assumed that most of the tritium was captured, either via diffusion or surface adsorption, on the materials inside the capsule. Tritium frequently adsorbs to sample surfaces in the form of HTO, which requires relatively low temperatures to release (on the order of 100 deg. C). In certain cases, tritium can be bound in the bulk of materials from diffusion or neutron transmutation of lithium and beryllium in the structural materials. Accurate measurement of very small concentrations of hydrogen is difficult; by taking advantage of the radioactive decay of tritium (which emits low-energy beta radiation), several methods become available to detect and quantitatively measure the tritium. The most sensitive method is liquid scintillation counting (LSC), which requires the tritium to be suspended in optically-transparent liquid media that is compatible with scintillating solution, such as water. This measurement technique requires the tritium to be extracted from the material, which can be achieved through leaching into water, thermal desorption, or complete destruction of the sample by acid digestion or pyrolysis. A less destructive method is preferred in order to preserve the specimens, reduce the generation of radioactive mixed wastes, and minimize the carryover of other activation products. For total thermal desorption of tritium from the materials, the tritiated materials must be heated to temperatures in excess of 300 deg. C. Heating the specimens above the irradiation temperature will re-mobilize the tritium and allow it to be captured from the gas stream directly into LSC media. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Design of high-pressure iron Rayleigh–Taylor strength experiments for the National Ignition Facility

Iron is an important metal, scientifically and technologically. It is a common metal on Earth, forming the main constituent of the planet's inner core, where it is believed to be in solid state at high pressure and high temperature. It is also the main component of many important structural materials used in quasistatic and dynamic conditions. Laser-driven Rayleigh–Taylor instability provides a means of probing material strength at high pressure and high temperature. The unavoidable phase transition in iron at relatively low pressure induces microstructural changes that ultimately affect its strength in this extreme regime. This inevitable progression can make it difficult to design experiments and understand their results. Here, we address this challenge with the introduction of a new approach: a direct-drive design for Rayleigh–Taylor strength experiments capable of reaching up to 400 GPa over a broad range of temperatures. We use 1D and 2D hydrodynamic simulations to optimize target components and laser pulse shape to induce the phase transition and compress the iron to high pressure and high temperature. At the simulated pressure–temperature state of 350 GPa and 4000 K, we predict a ripple growth factor of 3–10 depending on the strength with minimal sensitivity to the equation of state model used. The growth factor is the primary observable, and the measured value will be compared to simulations to enable the extraction of the strength under these conditions. These experiments conducted at high-energy laser facilities will provide a unique way to study an important metal.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

3D Printed Ceramic Reinforced Polymer Composites Microstructure and Mechanical Properties

In Fused Filament Fabrication (FFF) 3D printing a part is made by extruding material layer by layer. Benefits of FFF are the ability to print complex shapes quickly and at a lower cost compared to other manufacturing methods. In this work, filaments composed of either silicon carbide (SiC) or zirconium silicate ceramic particulates in a polylactic-acid (PLA) matrix were used to print specimens for microstructural analysis and mechanical testing. Pure PLA samples were also printed and tested as a baseline for comparison. A Design of Experiments approach was used to test the interactions between three different parameters and their effect on ultimate strength, Young’s modulus, and yield strength. For compression test specimens, these parameters were infill percentage, number of shells, and print orientation angle. For tensile test specimens, the parameters were layer height, number of shells, and infill orientation angle. Pre- and post-compression test samples were evaluated by scanning electron microscopy for microstructural analysis. Infill percentage had the greatest effect on mechanical properties while number of shells and print orientation angle had minor effects. When changing the layer lines from perpendicular to parallel, relative to the loading direction, SiC-PLA had higher mechanical properties while pure PLA properties had decreased, and zirconium silicate-PLA had mix results.

Fused filament fabrication↗
DOE OSTI2016

Predicting Stress vs. Strain Behaviors of Thin-Walled High Pressure Die Cast Magnesium Alloy with Actual Pore Distribution

In this paper, a three-dimensional (3D) microstructure-based finite element modeling method (i.e., extrinsic modeling method) is developed, which can be used in examining the effects of porosity on the ductility/fracture of Mg castings. For this purpose, AM60 Mg tensile samples were generated under high-pressure die-casting in a specially-designed mold. Before the tensile test, the samples were CT-scanned to obtain the pore distributions within the samples. 3D microstructure-based finite element models were then developed based on the obtained actual pore distributions of the gauge area. The input properties for the matrix material were determined by fitting the simulation result to the experimental result of a selected sample, and then used for all the other samples’ simulation. The results show that the ductility and fracture locations predicted from simulations agree well with the experimental results. This indicates that the developed 3D extrinsic modeling method may be used to examine the influence of various aspects of pore sizes/distributions as well as intrinsic properties (i.e., matrix properties) on the ductility/fracture of Mg castings.

Ductility↗
DOE OSTI2022

Cantor-derived medium-entropy alloys: bridging the gap between traditional metallic and high-entropy alloys

The year 2004 marked the beginning of a new era in the design of metallic materials, as the concept of multiple principal component alloys, commonly known as High-Entropy Alloys (HEAs), was proposed by Cantor and Yeh. The unexpected single-phase microstructure, instead of the expected brittle intermetallic compounds, was attributed to the large entropy of mixing and immediately caught the attention of the scientific community. Today, HEAs are considered important advanced materials and a broad range of alloys using nominally the same design principle have been investigated. Despite that, the CrMnFeCoNi (Cantor) alloy stands out as the most successful HEA due to its outstanding mechanical properties and microstructure. In this scenario, variants of the Cantor alloy, named medium-entropy alloys (MEAs), are gaining significant interest as they display a better industrial potential than both HEAs and traditional alloys. These variants of the Cantor alloy with only three or four main elements result in 15 possible combinations. The microstructure of these alloys is discussed in terms of advanced characterization as well as thermodynamic parameters and computational simulation. Their phase stability is addressed over a wide range of temperatures and strain rates. The mechanical properties, especially the fracture toughness, of the CrFeCoNi and CrCoNi alloys have been reported to be even superior to those of the Cantor alloy and most modern engineering alloys. This is associated with the formation of a continuous sequence of strengthening mechanisms, including hierarchical twin networks, which serve to prolong the strain hardening. The present article reviews and critically assesses, for the first time, recent advances in these Cantor-derived MEAs.

36 MATERIALS SCIENCE↗
DOE OSTI2026

High temperature stabilization of ultrafine grain tungsten alloys through synergistic compositional complexities

Thermally-stabilized fine-grained microstructures in tungsten provide a pathway to harnessing enhanced properties such as a reduced ductile-to-brittle transition temperature and improved strength while mitigating the adverse effects of grain growth and recrystallization. Here, in this study, we employ a material design strategy that relies on grain boundary segregation in the nanocrystalline state driven by alloy thermodynamics balanced with impurity scavenging through in situ formation of kinetically-stabilizing metal carbides. A W-Ti-Cr alloy is designed through lattice Monte Carlo methods and subsequently synthesized in a single-phase nanocrystalline state, which upon annealing, evolves into an ultrafine grained microstructure containing chromium grain boundary segregation collectively with a dispersed TiX (X=C,O) phase through the reaction of titanium with carbon and oxygen impurities. In situ synchrotron X-ray diffraction experiments demonstrate that increased Ti promotes stabilization across a larger temperature range but with diminishing returns above 10 at.% Ti. Long-term stability was confirmed through the retention of the ultrafine grained microstructure for a total of 8 days (192 h) at 1300 °C without grain/carbide growth and/or recrystallization. Our results demonstrate that, through strategic tailoring of composition and microstructure, one can harness the benefits of both thermodynamic and kinetic stabilization mechanisms, opening pathways for future alloy formulations that expand the window of stability.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and Mechanical Properties of Low-Activation Fe-Cr-V Multicomponent Single-Phase Alloys

A ternary equiatomic and nearly equiatomic alloy composed of the low-activation elements Fe, Cr, and V was designed for potential application as low-activation structural materials for the first wall of fusion reactors. The optimal composition of the multicomponent alloy was determined by minimizing the Gibbs free energy for solid-solution formation. The microstructure, phase stability, and mechanical properties of the equiatomic and optimized Fe-Cr-V alloys were studied. The equiatomic alloy consisted of a body-centered-cubic (BCC) solid-solution phase with a small amount of a face-centered-cubic (FCC) solid-solution phase, whereas the optimized alloy consisted of a single BCC solid-solution phase in the as-cast state. The crystal grains of both alloys were equiaxial. No phase transition was observed in the optimized alloy after homogenization; however, for the equiatomic alloy, the FCC solid-solution phase disappeared and surface relief was observed. The Vickers microhardness and yield strength of the Fe-Cr-V alloys increased after homogenization compared with those of the as-cast alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Status Report on Design of In-situ Thermomechanical Testing at LANSCE

Nuclear fuel encounters severe thermomechanical environments in which its mechanical response is determined by its microstructure, temperature and stress level histories. Simulating the response of such microstructures is crucial for predicting both performance and transient fuel mechanical responses and experimental verification of such predictions is therefore of great interest. While most of the deformation in a nuclear fuel rod occurs in the cladding, deformation of the fuel itself is still of interest with deformation mechanisms at operating temperature and above including creep, swelling, cracking as well as pellet-clad interaction. Characterization of these properties and understanding of the underlying deformation phenomena at operating or excursion temperatures is therefore of great importance for development and ultimately licensing of improved and novel nuclear fuel forms. Diffraction techniques offer unique insight on the atomistic (e.g. crystal structure) and microstructure (e.g. phase transformations, texture, defects) length scales and have a long history of providing unique data to inform relevant deformation models that enable the required predictive capabilities. For example, dislocations lead to diffraction peak broadening that can be characterized to estimate the dislocation density and study the role of dislocations on the deformation while measuring lattice strains allows to studie load sharing in two phase materials. In this report the requirements for a sample environment for high temperature deformation of nuclear fuels are defined. The HIPPO neutron time-of-flight diffractometer at LANSCE will host this sample environment and is also described. This instrument covers diffraction angles from 140° to 40° and is also equipped with an event-mode neutron imaging detector system, enabling energy-resolved neutron imaging in parallel with the diffraction that could measure sample temperature from Doppler broadening of neutron absorption resonances or measure pore densities from changes in the attenuation. Designs of devices to characterize thermomechanical properties of nuclear fuel without diffraction are also considered to guide the design. While this report is focused on applications for nuclear fuels, the device can also characterize cladding, moderator or structural materials and therefore contribute to other fields of research and development for advanced reactors. The temperatures planned to be reached are above 2000℃, thus enabling characterization of LWR reactor fuels under accident scenarios but also reaching temperatures of fuels developed for nuclear thermal propulsion and providing opportunities to characterize those. In conjunction with the energy-resolved neutron imaging detector, this setup would allow to measure neutron cross-sections at high temperatures, filling a gap towards development of reactors operating at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2009

Alloy Design Challenge: Development of Low Density Superalloys for Turbine Blade Applications

New low density single crystal (LDS) alloys have been developed for turbine blade applications, which have the potential for significant improvements in the thrust to weight ratio over current production alloys. An innovative alloying strategy was identified to achieve high temperature creep resistance, alloy density reductions, microstructural stability, and cyclic oxidation resistance. The approach relies on the use of molybdenum (Mo) as a potent solid solution strengthener for the nickel (Ni)-base superalloy; Mo has a density much closer to Ni than other refractory elements, such as rhenium (Re) or tungsten (W). A host of testing and microstructural examinations was conducted on the superalloy single crystals, including creep rupture testing, microstructural stability, cyclic oxidation, and hot corrosion. The paper will provide an overview of the single crystal properties that were generated in this new superalloy design space. The paper will also demonstrate the feasibility of this innovative approach of low density single crystal superalloy design. It will be shown that the best LDS alloy possesses the best attributes of three generations of single crystal alloys: the low density of first-generation single crystal alloys, the excellent oxidation resistance of second-generation single crystal alloys, and a creep strength which exceeds that of second and third generation alloys.

MacKay, Rebecca A.↗
DOE OSTI2025

Influence of temperature, oxygen partial pressure, and microstructure on the high-temperature oxidation behavior of the SiC Layer of TRISO particles

Tristructural isotropic (TRISO)-coated fuel particles are designed for use in high-temperature gas-cooled nuclear reactors, featuring a structural SiC layer that may be exposed to oxygen-rich environments over 1000 °C. Surrogate TRISO particles were tested in 0.2–20 kPa O 2 atmospheres to observe the differences in oxidation behavior. Oxide growth mechanisms remained consistent from 1200–1600 °C for each P O$_2$ , with activation energies of 228 ± 7 kJ/mol for 20 kPa O 2 and 188 ± 8 kJ/mol for 0.2 kPa O 2 . At 1600 °C, kinetic analysis revealed a change in oxide growth mechanisms between 0.2 and 6 kPa O2. In 0.2 kPa O 2 , oxidation produced raised oxide nodules on pockets with nanocrystalline SiC. Oxidation mechanisms were determined using Atom probe tomography. Active SiC oxidation occurred in C-rich grain boundaries with low P O$_2$ , leading to SiO 2 buildup in porous nodules. Here, this phenomenon was not observed at any temperature in 20 kPa O 2 environments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1989

Identification of a cast iron alloy containing nonstrategic elements

A program was performed to address the mechanical and environmental needs of Stirling engine heater head and regenerator housing components, while reducing the dependence on strategic materials. An alloy was developed which contained no strategic elemental additions per se. The base is iron with additions of manganese, molybdenum, carbon, silicon, niobium, and ferro-chromium. Such an alloy should be producible on a large scale at very low cost. The resulting alloy, designated as NASAUT 4G-Al, contained 15 Mn, 15 Cr, 2 Mo, 1.5 C, 1.0 Si, 1.0 Nb (in weight percent) with a balance of Fe. This alloy was optimized for chemistry, based upon tensile strength, creep-rupture strength, fracture behavior, and fatigue resistance up to 800 C. Alloys were also tested for environmental compatibility. The microstructure and mechanic properties (including hardness) were assessed in the as-cast condition and following several heat treatments, including one designed to simulate a required braze cycle. The alloy was fabricated and characterized in the form of both equiaxed and columnar-grained castings. The columnar grains were produced by directional solidification, and the properties were characterized in both the longitudinal and transverse orientations. The NASAUT 4G-Al alloy was found to be good in cyclic-oxidation resistance and excellent in both hydrogen and hot-corrosion resistance, especially in comparison to the baseline XF-818 alloy. The mechanical properties of yield strength, stress-rupture life, high-cycle-fatigue resistance, and low-cycle-fatigue resistance were good to excellent in comparison to the current alloy for this application, HS-31 (X-40), with precise results depending in a complex manner on grain orientation and temperature. If required, the ductility could be improved by lowering the carbon content.

Cooper, C. V.↗
DOE OSTI2018

Thermo-structural design of the European DEMO water-cooled blanket with a multiscale-multiphysics framework

The Water-Cooled Lithium-Lead (WCLL) blanket concept is one of four possible embodiments under consideration for the European Demonstration Power Plant DEMO, beyond ITER. It is based on a water-cooled first wall and blanket structure with the RAFMS (Reduced Activation Ferritic/Martensitic Steel, Eurofer 97) as structural material and PbLi as neutron multiplier and tritium breeder. We first develop a multiphysics modeling framework in order to optimize the design and achieve long blanket lifetime, maintainability, and high reliability. The approach is demonstrated by coupling Computational Fluid Dynamics (CFD), heat transfer and solid mechanics. The multiphysics framework is then utilized to provide the loading conditions for a multiscale design approach particularly focused on modeling the effects of both steady-state and operational transients on the structural integrity of the First Wall (FW). The methodology builds on the ITER Structural Design Criteria for In-Vessel Components (ISDC-IC), then extending the criteria to progressively incorporate continuum plasticity models and microstructure-based representation of deformation and fracture. We finally introduce advanced fracture mechanics concepts based on a Materials-Specific Failure Assessment Diagram (MS-FAD), in which precise calculations of the J-integral of an elasto-plastic material is required. This is especially important for the water-cooled design because of the limited fracture toughness of Eurofer 97 below 300 °C. The methodology has been applied to screen the FW/Blanket performance of a range of steady state heat flux assumed to be applied during the plasma pulse flat top, and up to 0.8 MW/m 2 . It has become clear that the radiation steady state load will be lower than the values screened here, while the local heat flux due to particle loads will lead to global higher values than the values investigated here. The methodology will be further fine-tuned to specific loading conditions in order to assess actual performance limits of the DEMO WCLL BB.

European DEMO↗
DOE OSTI2017

Design of Novel Precipitate-Strengthened Al-Co-Cr-Fe-Nb-Ni High-Entropy Superalloys

Here, a series of non-equiatomic Al-Co-Cr-Fe-Nb-Ni high-entropy alloys, with varying levels of Co, Nb and Fe, were investigated in an effort to obtain microstructures similar to conventional Ni-based superalloys. Elevated levels of Co were observed to significantly decrease the solvus temperature of the γ' precipitates. Both Nb and Co in excessive concentrations promoted the formation of Laves and NiAl phases that formed either during solidification and remained undissolved during homogenization or upon high-temperature aging. Lowering the content of Nb, Co, or Fe prevented the formation of the eutectic type Laves. In addition, lowering the Co content resulted in a higher number density and volume fraction of the γ' precipitates, while increasing the Fe content led to the destabilization of the γ' precipitates. Various aging treatments were performed which led to different size distributions of the strengthening phase. Results from the microstructural characterization and hardness property assessments of these high-entropy alloys were compared to a commercial, high-strength Ni-based superalloy RR1000. Potentially, precipitation-strengthened high-entropy alloys could find applications replacing Ni-based superalloys as structural materials in power generation applications.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Effect of processing conditions on microstructural features in Mn–Si sintered steels

Sintering of steels containing oxidation sensitive elements is possible if such elements are alloyed with others which present lower affinity for oxygen. In this work, a master alloy powder containing Fe–Mn–Si–C, specifically designed to create a liquid phase during sintering, has been used for such purpose. The effect of processing conditions such as sintering temperature and atmosphere was studied with the aim of describing the microstructural evolution as well as the morphology and distribution of oxides in the sintered material, evaluating the potential detrimental effect of such oxides on mechanical properties. Chemical analyses, metallography and fractography studies combined with X-ray photoelectron spectroscopy analyses on the fracture surfaces were used to reveal the main mechanism of fracture and their correlation with the chemical composition of the different fracture surfaces. The results indicate that the main mechanism of failure in these steels is brittle fracture in the surrounding of the original master alloy particles due to degradation of grain boundaries by the presence of oxide inclusions. Mn–Si oxide inclusions were observed on intergranular decohesive facets. The use of reducing atmospheres and high sintering temperatures reduces the amount and size of such oxide inclusions. Besides, high heating and cooling rates reduce significantly the final oxygen content in the sintered material. A model for microstructure development and oxide evolution during different stages of sintering is proposed, considering the fact that when the master alloy melts, the liquid formed can dissolve some of the oxides as well as the surface of the surrounding iron base particles. - Highlights: • Oxide distribution in steels containing oxidation-sensitive elements • Mn, Si introduced in a master alloy powder, mixed with a base iron powder • Selective oxidation of Mn and Si on iron grain boundaries • Decohesive fracture caused by degradation of grain boundaries by oxide inclusions • Reducing agents efficient at low temperatures critical for avoiding oxide inclusions.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fine grained fully lamellar structure acquisition and microstructure characteristics of Ti-44Al-4Nb-4V-0.3Mo-Y alloy

Highlights: • Cellular structure is the component of the microstructure of hot forging in α + β two-phase-field. • Inhomogeneous lamellar structure could be eliminated by hot forging in β+γ binary phase field. • After hot forging and annealing at β+γ two-phase-region, fine grained fully-lamellar microstructure is obtained. - Abstract: In this paper, the microstructure characteristic of a β solidifying TiAl alloy Ti-44Al-4Nb-4V-0.3Mo-Y (at. %) was investigated systematically. Cylindrical blanks were isothermal forged at 1250 °C within (α + β) two-phase-field and 1200 °C within (β + γ) two-phase-field under the strain rate of 0.02 s{sup −1} and 0.03 s{sup −1}, with a total reduction of 75%. The microstructure of the alloy forged in α + β two-phase-field consists of lamellar colonies (only represents α{sub 2}/γ lamellar colonies), mixture structure of β/B2 phase and γ phase as well as β/γ lamellae resulted from cellular reaction. However, a large amount of equiaxed γ grains appear with no β/γ lamellae available under forging in β + γ two-phase-field, and the average size of γ grain is about 10 μm. By further annealed at 900 °C for about 0.5 h, the structure of hot forging at 1250 °C is composed of β/B2 phase and equiaxed γ grains with the mean size about 5 μm. After heat treated at 1200 °C for 2 h, the microstructure of this annealed samples is characterized by fine grained fully lamellar (FFL) structure with size of 20 μm. A specially designed hot forging process is proposed, which prevents the existence of inhomogeneous lamellar structure.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Rapid Design and Manufacturing of High-Performance Materials for Turbine Blades

This research demonstrated the concept of carbide precipitation-strengthened refractory high entropy alloys (RHEA). The advantage of a precipitation strengthened alloy is all phases are in thermodynamic equilibrium promoting microstructural stability, and consequently retention of properties at elevated temperatures. Additionally, as with any precipitation strengthened – or age hardened - alloy, components can be heat-treated after manufacturing to manipulate the microstructure and optimize properties for performance. This is an advantage of the precipitation strengthened alloys over composites and ceramics materials, where the microstructure and properties are essentially fixed upon the initial materials manufacturing stage. High throughput (HT), multi-scale computer modeling was used to identifying novel RHEA compositions with desired characteristics needed for precipitation strengthening. Designs were validated by producing small ingots via are melting. The results showed that carbides precipitated and consequently, the strength of the alloys (measured in compression) increased after heat-treatment, which is the desired effect. The project also demonstrated the feasibility of producing articles from RHEA by additive manufacturing (AM). Electron beam melting (EBM) and laser direct energy deposition (L-DED) additive manufacturing methods, were explored with various processing parameters were interrogated for both methods. Sound (crack-free and dense) precipitation strengthened RHEA samples were produced via EDM AM, demonstrating the feasibility of the concept.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Effects of Constituent Properties on Performance Improvement of a Quenching and Partitioning Steel

In this paper, a two-dimensional microstructure-based finite element modeling method is adopted to investigate the effects of material parameters of the constituent phases on the macroscopic tensile behavior of Q&P steel and then to do a computational materials design approach for its performance improvement. For this purpose, a model Q&P steel is first produced and various experiments are then performed to characterize the steel. Actual microstructure-based model is generated based on the information from EBSD, SEM and nano-indentation test, and the material properties for the constituent phases are determined based on the initial constituents’ properties from HEXRD test and the subsequent calibration of model prediction to tensile test results. Influence of various material parameters of the constituents on the macroscopic behaviors is then investigated by separately adjusting them by small amount. Based on the observation on the respective influence of constituents’ material parameters, a new set of material parameters are devised, which results in better performance in ductility. The results indicate that various material parameters may need to be concurrently adjusted in a cohesive way in order to improve the performance of Q&P steel. In summary, higher austenite stability, less strength difference between the phases, higher hardening exponents of the phases are generally beneficial for the performance improvement. The information from this study can be used to devise new Q&P heat-treating parameters to produce the Q&P steels with better performance.

Advanced high strength steel↗