Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “microstructure”

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.

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

At least 847 records · Page 47
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Beam Current Effect on Microstructure and Properties of Electron-Beam-Melted Ti-6Al-4V Alloy

In this study, a noncommercial 3D printing machine was used to fabricate Ti-6Al-4V alloy by electron-beam melting (EBM). The influence of beam current on the microstructure, phase composition and mechanical properties of electron-beam-melted Ti-6Al-4V alloy was investigated. Numerical simulation is implemented to evaluate thermal fields during electron-beam melting of Ti-6Al-4V powder. The decrease in beam current from 3.5 to 2.5 mA leads to refinement of microstructure: The average width of α plates decreases from 10 down to 6 μm. The formation of finer microstructure is attributed to higher cooling rate at lower beam current confirmed by simulation. The phase composition of EBM Ti-6Al-4V indirectly depends on the beam current. High content of β phase (7%) was achieved at the beam current of 3 mA. The produced Ti-6Al-4V samples are characterized by high microhardness (470-520 HV).

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural Development and Mechanical Properties of Friction Stir Welded Ferritic Stainless Steel AISI 409

This work investigates the effect of friction stir welding process parameters (rotation rate and traverse speed) on the microstructural evolution of friction stir welded (FSWed) ferritic stainless steel (FSS) AISI 409. Optical microscope, scanning electron microscope and electron backscattering diffraction are used to quantitatively assess the development in grain structure and texture. The microstructural development suggested that thermo-mechanical deformation occurs in the stir zone within the austenite/ferrite phase region, ultimately transforming upon cooling into bainitic/ferritic microstructure. The fraction and size of the bainitic/ferritic grains are found to vary through the thickness of the joints. High fractions of coarse ferritic grains are found near the top of the stir zone, and low fraction of fine ferritic grains is found near the bottom of the stir zone. This bainitic/ferritic grain structure resulted in an increase in the hardness of the stir zone by about 74% relative to the base material. The tensile strength of the FSWed FSS joints is almost at the same level of the base material with reduction in the ductility as a result of the increased hardness of the weld zone.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure, Mechanical Properties and Residual Stress of Selective Laser Melted AlSi10Mg

AlSi10Mg processed by selective laser melting (SLM) is common in various industries because of its complex structure and high performance. The microstructure, residual stress and mechanical properties restrict its application, while they are affected by the scanning path type and preheating temperature. In this work, to investigate the properties of selective laser melted AlSi10Mg alloys and gain better performance results, the microstructure and mechanical tests are performed at several preheating temperatures based on the uniformity and chessboard scanning strategy. It is found that the selective laser melted AlSi10Mg parts fabricated in the chessboard scanning path have better mechanical properties than those fabricated in the uniformity scanning path. Furthermore, a higher preheating temperature can induce less residual stress due to the enhanced Al crystal faces. Finally, analyses of the microstructures, mechanical and residual stress provide a valuable suggestion that the combination of the range of preheating temperature and the scanning path can improve the performance of selective laser melted AlSi10Mg.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Single-Point Incremental Force Process Parameters on Forming Characteristics and Microstructure Evolution of AA-6061 Alloy Sheet

Single-point incremental forming (SPIF) process comprises a set of process variables, such as forming tool diameter, vertical pitch, spindle rotation speed, and tool velocity, which may affect the forming behavior of the sheet to be deformed. The objective of this work is to study the effect of SPIF process parameters on forming characteristics and microstructure development for the AA-6061 (T6) aluminum alloy sheet. The SPIF experiments and finite element (FE) simulations were performed at different process parameters to achieve conical shapes from the AA-6061 blanks. The effect of process parameters on forming forces, thickness uniformity in wall region of the cone and surface roughness of the blank was analyzed. A detailed microstructure study was performed to analyze the effect of process variables on microstructure and texture evolution during the SPIF process. This study reveals that the process parameters are likely to influence the texture development especially at high tool diameter and vertical pitch values. Therefore, suitability and consequences of using different combinations of tool diameter and vertical pitch values are discussed for AA-6061 alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and Mechanical Behavior of Friction Stir-Welded Sc-Modified Al-Zn-Mg Alloys Made Using Different Base Metal Tempers

The microstructure and property of friction stir weld joints of a Sc-modified Al-Zn-Mg alloy developed using base metal in hot-rolled (HR) and T6 temper were studied and compared in this work. The results showed that the microstructure and property exhibited significant difference between the two friction stir weld joints. The weld efficiency of the FSW joint developed using base metal in HR condition is over 90%, while that of the FSW joint developed using base metal in T6 condition is only 70%. The hardness of the weld nugget of HR joint is obviously higher than that of the weld nugget of T6 joint, due to the different changes in the original precipitates during the friction stir welding process. The strengthening mechanism in different zones of the two FSW joints was discussed to examine the microstructure–properties relationship, and the main difference of the strengthening mechanism between the two FSW joints was revealed.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Predicting mesoscale microstructural evolution in electron beam welding

Using the kinetic Monte Carlo simulator, Stochastic Parallel PARticle Kinetic Simulator, from Sandia National Laboratories, a user routine has been developed to simulate mesoscale predictions of a grain structure near a moving heat source. Here, we demonstrate the use of this user routine to produce voxelized, synthetic, three-dimensional microstructures for electron-beam welding by comparing them with experimentally produced microstructures. When simulation input parameters are matched to experimental process parameters, qualitative and quantitative agreement for both grain size and grain morphology are achieved. The method is capable of simulating both single- and multipass welds. As a result, the simulations provide an opportunity for not only accelerated design but also the integration of simulation and experiments in design such that simulations can receive parameter bounds from experiments and, in turn, provide predictions of a resultant microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

An Algorithm to Generate Synthetic 3D Microstructures from 2D Exemplars

The inverse problem of constructing 3D microstructures from 2D data is an area of active research within the materials science community. This paper presents the implementation of a robust, computationally efficient algorithm, Hierarchical Algorithm for the Reconstruction of Exemplars (HARE), written in Python to reconstruct 3D features in a given microstructure from up to three orthogonal 2D exemplars using nearest neighbor matching to reproduce feature qualities, such as shape, size, and distribution. HARE’s feature sampling implements histogram reweighting to avoid both over- and undersampling. A neighborhood voting scheme allows each pixel to provisionally affect its neighbors according to its weight. Finally, the algorithm is presently configured for two-phase materials and is being extended to accommodate multiple phases. HARE is a convenient and robust base from which to generate statistically representative synthetic microstructures for use in multi-scale modeling or machine learning applications to support advanced manufacturing and materials discovery.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Microstructure-Based Modeling of Laser Beam Shaping During Additive Manufacturing

Recent experimental studies suggest the use of spatially extended laser beam profiles as a strategy to control the melt pool during laser powder bed fusion (LPBF) additive manufacturing. However, linkages connecting laser beam profiles to thermal fields and resultant microstructures have not been established. Herein, we employ a coupled thermal transport-Monte Carlo model to predict the evolution of temperature fields and grain microstructures during LPBF using Gaussian, ring, and Bessel beam profiles. In addition, simulation results reveal that the ring-shaped beam yields lower temperatures compared with the Gaussian beam. Owing to the small melt pool size when using the Bessel beam, the grains are smaller in size and more equiaxed compared to those using the Gaussian and ring beams. Our approach provides future avenues to predict the impact of laser beam shaping on microstructure development during LPBF.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Hot Isostatic Pressing and Powder Feedstock on Porosity, Microstructure, and Mechanical Properties of Selective Laser Melted AlSi10Mg

AlSi10Mg tensile bars were additively manufactured using the powder-bed selective laser melting process. Samples were subjected to stress relief annealing and hot isostatic pressing. Tensile samples built using fresh, stored, and reused powder feedstock were characterized for microstructure, porosity, and mechanical properties. Fresh powder exhibited the best mechanical properties and lowest porosity while stored and reused powder exhibited inferior mechanical properties and higher porosity. The microstructure of stress relieved samples was fine and exhibited (001) texture in the z-build direction. Microstructure for hot isostatic pressed samples was coarsened with fainter (001) texture. To investigate surface and interior defects, scanning electron microscopy, optical fractography, and laser scanning microscopy techniques were employed. Hot isostatic pressing eliminated internal pores and reduced the size of surface porosity associated with the selective laser melting process. Hot isostatic pressing tended to increase ductility at the expense of decreasing strength. Furthermore, scatter in ductility of hot isostatic pressed parts suggests that the presence of unclosed surface porosity facilitated fracture with crack propagation inward from the surface of the part.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Transmission electron microscopy of the rapid solidification microstructure evolution and solidification interface velocity determination in hypereutectic Al-20at.%Cu after laser melting

The evolution of rapid solidification (RS) microstructure and solidification interface velocity has been studied experimentally by in-situ transmission electron microscopy and postmortem characterization for hypereutectic Al-20at.%Cu (37 wt.%Cu) after laser melting. Four morphologically distinct regions formed via growth modes changing from θ-Al 2 Cu phase dendrites to eutectic cell growth, possibly α-Al dendrite growth (α-cell), banded growth, and α-Al plane front growth. Tendency for faceting and low capacity for solute trapping limited the θ-phase dendrite growth to solidification interface velocity v < 0.07 m/s. Consequently, formation of pro-eutectic micro-constituent was suppressed, and RS microstructure formation was dominated by eutectic, α-cell, and banded morphology grains for the Al-20at.%Cu alloy. Eutectic growth operated for interface velocity of 0.1 m/s ≤ v < 0.3 m/s, with a transition from regular lamellar, 2-λ and 1-λ mode to a dense irregular morphology dominated by α-phase at v = 0.3 m/s. Interface temperature calculations indicated feasibility of α-cell growth mode for 0.3 m/s ≤ v < 0.7 m/s. Banded growth occurred for 0.7 m/s ≤ v < 1.3 m/s. Plane front α-phase growth was evident for interface velocities v ≥ 1.3 m/s. Previous work on rapid solidification microstructure development in hypereutectic Al-Cu alloys reported a regime of α-cell growth subsequently to eutectic and prior to transition to banded growth for Al-19at.%Cu (36 wt.%Cu), while for Al-22at.%Cu (40 wt.%Cu) eutectic growth transitioned directly to α-plane front growth without emergence of a banded regime. Finally, based on the current study the disappearance of the banded growth regime occurs for a composition larger than 20at.%Cu.

36 MATERIALS SCIENCE↗
DOE OSTI2025

GrainPaint: A multi-scale diffusion-based generative model for microstructure reconstruction of large-scale objects

Simulation-based approaches to microstructure generation can suffer from a variety of limitations, such as high memory usage, long computational times, and difficulties in generating complex geometries. Generative machine learning models present a way around these issues, but they have previously been limited by the fixed size of their generation area. Here, we present a new microstructure generation methodology leveraging advances in inpainting using denoising diffusion models to overcome this generation area limitation. We show that microstructures generated with the presented methodology are statistically similar to grain structures generated with a kinetic Monte Carlo simulator, SPPARKS.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructure-sensitive mechanical behavior of an additively manufactured psuedoelastic shape memory alloy

The additive manufacturing of shape memory alloys into complex geometries enables fabrication of advanced functional systems across a variety of fields and domains. This work presents results focused on the mechanical behavior of additively manufactured shape memory pseudoelastic NiTi. The deformation induced solid state phase transformation from austenite to martensite allows this system to accommodate large recoverable strains. This deformation behavior is fundamentally driven by crystal-scale transformation physics. Laser powder bed fusion processing reveals that the resulting microstructure, both grain morphology and crystallographic texture, is strongly dependent on the manufacturing processing history. Exhaustive mechanical testing demonstrates that these microstructural factors strongly impact both tensile and cyclic stress–strain behavior. Cyclic dissipative behavior, however, is similar across all tested microstructures following an initial transient period. Remarkably, analysis of spatial strain fields during tensile loading reveals two distinctly different localization “modes”. The first is initiation of localized deformation bands which continuously propagate through the tensile bar during loading. In the second mode localization is observed but lacks propagation; instead additional localization cites nucleate during subsequent loading. The latter phenomena is suspected to be driven by grain-scale deformation physics as the localized band morphologies coincide with grain morphologies. These phenomena strongly impact the resulting aggregate stress–strain behavior. Hence, manufacturers and designers of psuedoelastic functional components must at the very least consider the potential variability in properties when considering additive manufacturing processing. More ideally the process–structure–property relations can be used to further tailor and optimize final functional performance.

Additive manufacturing↗
DOE OSTI2020

Build Orientation Dependent Microstructure in Polymer Laser Sintering: Relationship to Part Performance and Evolution with Aging

Laser sintering (LS) is widely used to produce functional polymeric parts; however, the resulting parts are often limited by their porous structure, and performance of the part may be strongly anisotropic. Relating the structural features of parts to build process conditions or powder feedstock has been explored previously. In contrast, little is known regarding how the unique internal structures of LS parts evolve and relate to their performance later in their life cycle, for example, after use in a real-world operating environment. In this study, a tightly controlled LS build process and measurement campaign by standard X-ray computed tomography (XCT), supported by high-resolution synchrotron XCT, was used to benchmark the internal microstructure (e.g. porosity) as a function of four different build orientations in printed polyamide-12 (PA-12) parts. The initial performance of the parts after printing was characterized by tensile testing and dynamic mechanical analysis (DMA). Arrays of PA-12 parts in different build orientations were exposed to steam (under pressure) and air across multiple temperature and time points for the purposes of accelerated aging through oxidative and hydrolytic breakdown. Exposing parts to steam dramatically altered the internal microstructure and functional properties such as the glass transition temperature, tensile properties, and damping behavior. Notably, post-aging XCT revealed large microstructural changes after only 40 h of steam treatment relative to the as-printed specimens. Furthermore, pore reorganization and changes in crystallinity occurred regardless of whether the steam temperature was aggressive enough to induce a significant loss in mechanical properties. The build orientation dependence on the aging rate was minimal with the relative trend in performance persisting across most metrics among the different orientations even after aging.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Part-scale microstructure prediction for laser powder bed fusion Ti-6Al-4V using a hybrid mechanistic and machine learning model

Laser powder bed fusion (LPBF) Ti-6Al-4V is widely studied for use in structural applications in aerospace and medical industries, but mechanical anisotropy and microstructural inhomogeneity prohibits its wider adoption. Although successful microstructure prediction models have been developed, a remaining challenge is their limited integration across length/time scales and validation by experimental studies. Here, this work proposes a physics-augmented machine learning surrogate model to unite predictions of LPBF temperature, β phase morphology and texture, and α/α’ formation into a single framework that is calibrated and validated with experiments. First, a phase field (PF) model of the martensitic β→α’ transformation is developed and calibrated using data from in-situ synchrotron cyclic heating/cooling studies quantifying the variation of α phase fraction with time. In parallel, an established finite difference-Monte Carlo (FDMC) model predicts the part-scale temperature profile and β grain formation during solidification. A dataset is developed using LPBF cyclic temperature descriptors from the FDMC model as inputs and corresponding α/α’ phase fraction and width from the PF model as outputs. Five machine learning (ML) regression models are tested and optimized, having mean absolute error in testing ≤ 4 %, and the k-nearest neighbors (KNN) model is selected as the best performing. The KNN model is called at the nodal level during post-processing of the FDMC model to replace and downscale the response of the PF model. The combined agility and accuracy of the hybrid FDMC-ML model enables part-scale microstructure predictions that can be further used for property predictions to accelerate AM process optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effect of laser melt schedule on the microstructure of additively manufactured IN718 Superalloy

Laser powder bed fusion (L-PBF) has enabled the fabrication of geometrically complex metallic structures and components that are challenging to producing using conventional manufacturing approaches. The site-specific and far from equilibrium thermal conditions of L-PBF offer the potential to facilitate multi-length scale design of structure and properties across the atomic-through macro-levels. However, L-PBF systems face scalability challenges due to throughput constraints. Laser rotary powder bed fusion (L-RPBF) systems are being investigated as a solution to enhance the deposition rates compared to conventional L-PBF. Rotary systems also offer additional flexibility for controlling the time structure of melting through laser interleaving on alternating layers. Here, in this study, IN718 test samples were printed using single-laser or interleaved dual-laser configuration in a L-RPBF system to investigates the effect of process settings and melt-interleaving on as-fabricated microstructure. The microstructural evolution, such as grain size and crystallographic texture, was assessed by determining variations in the melt-pool shapes. Laser interleaving leads to a reduction in average grain size compared to single laser by ∼ 40 % at high power (400 W) and by ∼36 % at medium power (370 W). Results presented here identify key challenge for obtaining uniform microstructures and barriers for the broader adoption of high-deposition rate L-RPBF.

Dual-laser↗
DOE OSTI2020

The microstructure of a selective laser melting (SLM)-fabricated NiTi shape memory alloy with superior tensile property and shape memory recoverability

A selective laser melting (SLM)-fabricated NiTi with superior tensile property and shape memory recoverability was obtained by using a unique stripe rotation scanning strategy. Here, the alloy characteristics, formation mechanisms and evolution in terms of twins, dislocations and precipitations of the alloy were systematically studied. Compared to the conventional smelting-followed-by-machining, the SLM fabrication process involves rapid solidification and repeated heating, which confer distinctive characteristics to the microstructures of SLM-fabricated NiTi alloys. Rapid solidification promotes the formation of a supersaturation solid solution matrix containing a high concentration vacancies, which in turn aggregate to generate a high density of dislocations. During subsequent repeated heating stages, these dislocations occur thermal motion along three directions of <001 > , <111> and <110 >, leading to the formation of thermal kinks, helical dislocations and wave morphology. Simultaneously, precipitated particles Ti 3 Ni 4 repeatedly nucleate and heterogeneous grow with the movement of dislocation. Such precipitation behavior, termed repeated precipitation, has not been previously reported in the conventional NiTi alloys, suggesting that it could be a unique characteristic of such alloy. After martensitic transformation, only two twins, {1 1¯ 1} type I twin and compound twin, are detected. The twinning lamellae of these two twins, where precipitation and dislocation pile-ups exist, often have uneven thickness and chaotic arrangement. Besides, the unique self-accommodated microstructures, such as secondary {1 1¯ 1} type I twin and compound twin with “herring-bone’’ lamellae, which often appear in the deformed or nanocrystalline NiTi, can also be observed. These unique microstructures may confer the distinctive properties to the SLM-fabricated NiTi.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of microstructure and temperature on nuclear graphite oxidation using the 3D Random Pore Model

This work compared the 3D Random Pore Model (3D-RPM) with experimental and characterization data to systematically study the effect of nuclear graphite microstructure and air oxidation temperature. It is well known that oxidation-induced weight loss at elevated temperatures degrades graphite structure and properties; however, a fundamental understanding of the role of graphite microstructure is still unclear. In this work, three diverse grades of nuclear graphite—IG-110, NBG-18, and PCEA—were examined and tested at air oxidation temperatures of 600, 650, 700, and 750 °C following ASTM D7542. Here, the 3D-RPM reproduced the microstructure and temperature dependence of mass loss curves for these grades. For the first time, measurements and modeling were combined to show how bulk density and the amount and spatial distribution of open and closed porosity affects oxidation. IG-110 was less dense and had an open pore network that is finer and more uniformly spread, and showed fastest oxidation. PCEA porosity was less uniform and showed less oxidation, while NBG-18 was more dense, had the least fine and uniform porosity, and showed the slowest oxidation. In general, oxidation proceeds faster if open porosity is more uniformly distributed and can incrementally access closed pore surface area with more ease.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Microstructural and strength improvements through the use of Na{sub 2}CO{sub 3} in a cementless Ca(OH){sub 2}-activated Class F fly ash system

This study explores the beneficial effects of Na{sub 2}CO{sub 3} as an additive for microstructural and strength improvements in a Ca(OH){sub 2}-activated fly ash system. NaOH-activated fly ash samples were also tested to compare the effect of Na{sub 2}CO{sub 3}. Compressive strength testing, XRD, SEM/BSE/EDS, {sup 29}Si/{sup 27}Al MAS-NMR, MIP and TGA were performed. The testing results indicate that the use of Na{sub 2}CO{sub 3} for Ca(OH){sub 2}-activation led to a noticeable improvement in strength and microstructure, primarily due to (1) more dissolution of raw fly ash at an early age, (2) more formation of C–S–H [or C–S–H(I)], (3) porosity reduction, and (4) pore-size refinement. We also found that (1) an early high alkalinity from the NaOH formation was not a major cause of strength, (2) geopolymer was not formed despite the early NaOH formation, and (3) no visible pore-filling action of CaCO{sub 3} was observed. However, Na{sub 2}CO{sub 3} did not produce any improvement in strength for NaOH-activated fly ash. -- Highlights: •The use of Na{sub 2}CO{sub 3} significantly improved strength and microstructure. •The use of Na{sub 2}CO{sub 3} induced more dissolution of raw fly ash at early ages. •The use of Na{sub 2}CO{sub 3} promoted more C–S–H [or C–S–H(I)] formation. •The use of Na{sub 2}CO{sub 3} reduced total porosity and refined pore-size distribution. •The use of Na{sub 2}CO{sub 3} produced neither geopolymer formations nor pore-filling actions from CaCO{sub 3}.

36 MATERIALS SCIENCE↗