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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 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Microstructure and crystallographic texture of high frequency electric resistance welded X65 pipeline steel

Here, microstructure and crystallographic texture and their correlation with impact toughness of high-frequency electric resistance welded (HF-ERW) X65 Grade pipeline steel have been investigated. X65 base metal after HF-ERW has formed a typical hourglass-shaped weld joint with four different regions, including the thermomechanical-affected zone (TMAZ), fine-grained heat affected zone (FGHAZ), coarse-grained heat affected zone (CGHAZ), and bondline (Weld Zone). X65 base metal shows prominent (113) [110] and (112) [110] texture components due to thermomechanical-controlled processing. TMAZ depicted random texture with a minor intensity of Cube component (001)[110] due to the partial recrystallization during welding. In the FGHAZ and CGHAZ, near the bondline, the base metal texture has been converted to rotated Goss (110) [110], Goss (110) [001], and rotated cube (001) [110] due to the recrystallization of the austenite and the shear deformation in the austenite temperature range. A high density of {100} and {110} cleavage planes is observed in the CGHAZ, which is often found to be the fracture location for the impact toughness testing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Clarifying the formation of equiaxed grains and microstructural refinement in the additive manufacturing of Ti-Cu

Controlling microstructural evolution in metallic additive manufacturing (AM) is difficult, especially in producing refined as-built grains instead of coarse, directional grains. Traditional solutions involve adding inoculants to AM feedstocks, but titanium (Ti) alloys cannot employ this approach without producing detrimental secondary phases. Ti-Cu (Ti-copper) alloys offer a solution through constitutional supercooling and/or solid state thermal cycling under AM conditions. This work analyzes a compositionally graded directed energy deposition (DED) Ti-Cu build, single-melt laser tracks, and dilatometric heat treatments to evaluate if, when, and by what mechanism(s) microstructural refinement occurs. Refinement by inoculation of unmelted powder particles was also considered. Constitutional supercooling produced no net microstructural refinement as any equiaxed dendrites which form are remelted with new deposition. This finding agreed with solidification modeling of powder bed fusion-laser beam (PBF-LB) and DED builds. Solid state thermal cycling refined microstructures only during ex-situ dilatometric heat treatments, suggesting build parameter optimization is needed to achieve refinement in-situ. Accidental heterogeneous nucleation on unmelted Ti powder, originating from the different thermophysical properties of Ti and Cu, provided the most significant microstructural refinement. This work systematically assesses the microstructural refinement mechanisms of Ti-Cu in AM builds and offers insights into microstructural control in eutectoid alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Enhanced toughness and tear resistance of thin-walled High-Pressure Die-Cast aluminum alloys through Friction stir processing

In this study, we investigate the toughness and resistance to tear of thin-wall high-pressure die-cast (HPDC) aluminum alloys in two different orientations following the implementation of friction stir processing (FSP). The FSP technique was applied to two different HPDC Al-Si alloys: the recyclable-grade, high iron, A380 alloy and the premium-quality, low iron, Aural-5 alloy. Our findings reveal significant tear resistance and strength enhancements for both alloys after FSP modification. Specifically, FSPed A380 alloy requires 126% higher energy to tear, and it has 49% higher tear strength than the HPDC counterpart. Similarly, the tear energy and tear strength of the Aural-5 alloy witness enhancements of 69% and 21%, respectively. In conclusion, these results highlight the potential of FSP as a viable method for augmenting the mechanical properties of HPDC aluminum alloys, thereby opening up new avenues for their utilization in diverse engineering applications for crack obstruction.

36 MATERIALS SCIENCE↗
DOE OSTI2022

NaroNet: Discovery of tumor microenvironment elements from highly multiplexed images

Understanding the spatial interactions between the elements of the tumor microenvironment -i.e. tumor cells. fibroblasts, immune cells- and how these interactions relate to the diagnosis or prognosis of a tumor is one of the goals of computational pathology. We present NaroNet, a deep learning framework that models the multi-scale tumor microenvironment from multiplex-stained cancer tissue images and provides patient-level interpretable predictions using a seamless end-to-end learning pipeline. Trained only with multiplex-stained tissue images and their corresponding patient-level clinical labels, NaroNet unsupervisedly learns which cell phenotypes, cell neighborhoods, and neighborhood interactions have the highest influence to predict the correct label. To this end, NaroNet incorporates several novel and state-of-the-art deep learning techniques, such as patch-level contrastive learning, multi-level graph embeddings, a novel max-sum pooling operation, or a metric that quantifies the relevance that each microenvironment element has in the individual predictions. We validate NaroNet using synthetic data simulating multiplex-immunostained images where a patient label is artificially associated to the -adjustable- probabilistic incidence of different microenvironment elements. We then apply our model to two sets of images of human cancer tissues: 336 seven-color multiplex-immunostained images from 12 high-grade endometrial cancer patients; and 382 35-plex mass cytometry images from 215 breast cancer patients. In both synthetic and real datasets, NaroNet provides outstanding predictions of relevant clinical information while associating those predictions to the presence of specific microenvironment elements.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Ammonium sulfate leaching of NaOH-treated monazite

Rare earth elements (REEs) can be extracted from monazite under aggressive decomposition and leaching conditions. Much of the waste rocks are removed prior to the extraction process to minimize the costs and waste generation, which is difficult with coal byproducts. The possibility of extracting REEs from low-grade monazite concentrates under relatively mild conditions has been explored to simulate the extraction of REEs from coal byproducts. It has been found that monazite can be decomposed in 10 to 50 % NaOH solutions at 80 °C, with the resulting hydrous oxide being subjected to the ammonium sulfate leaching at pH 4. Further, the ς-potential measurements conducted in the presence of the lixiviant suggest that the NH 4+ ions displace the hydrated Ln 3+ ions from the surface of Ln(OH) 3 (s) by an ion-exchange mechanism, which may be driven by the large differences in the hydration enthalpies between the charged species involved. This approach may be advantageous over acid leaching, including the regeneration of spent lixiviant, lower chemical consumption, and leaching at higher pH.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Effects of low-temperature neutron irradiation on the microstructure and tensile properties of duplex 2304 stainless steel and its electron-beam welds

A lean duplex stainless steel material (2304-grade) in its base metal and electron beam (e-beam) welded conditions were studied microstructurally and mechanically as a function of irradiation conditions to evaluate its use as a structural material at low temperatures (60–100 °C). Neutron irradiation up to a fluence of 1.40 × 10 19 n/cm 2 (E > 0.1 MeV) or ~0.011 dpa decreased the total elongation of both base metal and e-beam welded samples. Overall, radiation hardening was observed in all the samples. The transversely cut irradiated samples showed some nonuniform quasi-cleavage and shearing in their fracture surfaces, indicating the variance of ductile nature of the two-phased (deformable austenite and harder ferrite) duplex structure. The e-beam welded samples also showed quasi-cleavage fracture, which is a characteristic of radiation-induced embrittlement. Furthermore, these observations of the e-beam welded samples were attributed to the formation of coarse ferrites, grain boundary and intragranular phases such as γ 2 and γ 3 , and minor impurity phases such as CrN and Cr 2 N in the weld pool and/or heat-affected zone of the samples. Radiation-induced elemental segregation was also identified in the post-irradiated base metal.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Laser powder bed fusion of oxide dispersion-strengthened IN718 alloys: A complementary study on microstructure and mechanical properties

In this study, two new grades of oxide dispersion strengthened (ODS) Inconel 718 (IN718) alloys were designed by the thermochemical CALPHAD method and produced by laser powder bed fusion (LPBF) technique. Alloys designated as IN718-YF and IN718-YFH, that consist Y 2 O 3 –FeO and Y 2 O 3 –FeO–Hf, respectively, were fabricated with >99.9 % densification using optimized process parameters. CALPHAD calculations were highly consistent with experimental findings, highlighting the formation of Al-containing Y–Ti–O and Y–Hf–O nano-oxides in both alloy types. Texture analyzes revealed no significant texture development in as-built (AB) or heat-treated (HT) alloys. Heat treatment was applied at 1050 °C for 1 h to enhance nano-oxide density. Further, the nano-oxide number density remained similar in IN718-YF while it decreased in IN718-YFH alloy as a result of carbide formation after the heat treatment. Besides, formation of secondary γ' particles was observed in the IN718-YFH/HT alloy. Even though the yield strengths of IN718-YF and IN718-YFH alloys in both AB and HT conditions were similar, the ductility of IN718-YFH was ~50 % less in almost all conditions compared to the ductility of IN718-YF. This has been shown to be as a result of irregular shaped micron-sized Y-Hf-O oxides, martensite formation in AB condition, increased amount of carbides and existence of secondary γ' particles in HT condition in IN718-YFH. High density of stacking faults (SF) forming at the interface of the nano-oxides have been detected in IN718-YF alloys. Besides dislocation/nanoparticle interactions, SFs which are responsible for the delocalization of the deformation improve the ductility of IN718-YF alloys. Overall, high temperature mechanical tests exhibit that both alloys have higher strength with improved ductility compared to the standard IN718 alloys, indicating the contribution of the nano-oxides.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Electric field enhanced diffusion welding of alloy 617: Microstructural characteristics and mechanical properties

This study investigated the microstructural characteristics and mechanical behavior of diffusion welded nickel-based Alloy 617 obtained by electric field-assisted sintering (EFAS) using various parameters. The interfacial microstructure exhibited different characteristics including good grain boundary (GB) migration across the interface in the samples diffusion-welded at 1100 °C and a flat interface in the samples joined at 1000 °C and 1050 °C. The interface consisted of fine Al 2 O 3 oxides, while precipitation of interfacial M 23 C 6 carbides was not observed. Grain boundaries migrated across the Al 2 O 3 oxides, leaving these oxides within the grains. Graded grain size was observed, with grain coarsening being more significant near the sample surface due to the temperature gradient induced by EFAS. Tensile testing revealed that the specimens fractured in the matrix away from the interface, indicting strong diffusion-welded joints. Further, the peak tensile strength of 807 MPa was obtained in the samples welded at 1000 °C due to minimal grain growth. The materials obtained at 1100 °C exhibited reduced tensile strength but improved ductility. Strain maps revealed by digital image correlation showed alternating high and low strain segments in the samples produced at 1000 °C and 1050 °C, indicating that the flat interfaces with no GB migration were less ductile compared to the matrix. A greater strain uniformity was observed along the bond interfaces with improved GB migration. The hardness reduced near the sample surfaces due to enlarged grains induced by temperature gradient. This study demonstrates that GB migration and enhanced mechanical strength can be achieved in diffusion-welded Alloy 617.

36 MATERIALS SCIENCE↗
DOE OSTI2022

An overview of cobalt-free, nickel-containing cathodes for Li-ion batteries

The need for high-energy, low-cost batteries is projected to grow dramatically in the next decade due to electrification of the transportation market. Such demands are straining Li-ion supply chains for critical materials including lithium, nickel, and cobalt. Price instability, environment toxicity, and limits in the absolute supply lead to great concern for the continued use of cobalt. Similar to cobalt, the required grade of nickel for batteries, known as Class 1 nickel, has also been declining due to geological scarcity and low incentive prices. Herein, this review summarizes alternative cathode chemistries with no cobalt and reduced nickel content for high-energy Li-ion batteries targeting sustainable growth in the electric vehicle market. Further, the primary challenges associated with each material system are generally classified as being related to four common categories: (1) ion instability during charging, (2) poor electronic conductivity, (3) poor ionic conductivity, and (4) poor thermal stability.

25 ENERGY STORAGE↗
DOE OSTI2024

Effect of impurities on phase transformation and precipitation in a low-carbon steel

Impurity elements have been added to a commercial low carbon steel grade to simulate the levels that could arise as a result of increased scrap recycling during steel production. In this study, continuous cooling transformation (CCT) diagrams were constructed for the steels with varying levels of impurities, and it is shown that impurities suppress the phase transformation across a wide range of cooling rates. It was found that a step was formed in the start temperature curve, separating the reconstructive and displacive transformations. The influence of impurities on both the reconstructive transformation and displacive transformation are discussed. Additionally, Cu precipitates were observed using scanning transmission electron microscopy (STEM) in the highest impurity-containing steel after slow cooling (0.05°C/s), fast cooling (5°C/s) and interrupted cooling. It was found that the precipitation kinetics is in the following order: cementite within the secondary phase and cementite at secondary phase-ferrite interface> ferrite grain boundaries> ferrite grain matrix. Atom-probe tomography (APT) revealed Cu precipitates formed on the surface of cementite lamellae, but not within it. This work offers insights for the phase transformation control and precipitation regulation during the thermomechanical processing of low carbon steels containing impurity elements due to scrap recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Rossi-alpha measurements of fast plutonium metal assemblies using organic scintillators

The reactivity and the k-effective multiplication factor (k eff ) of a fissionable assembly are quantities of widespread interest. These values can be inferred from Rossi-alpha measurements of the prompt neutron decay constant (or the inverse:α -1 ). It has been shown that 3 He-gas proportional counter-based detection systems are insensitive to α -1 of fast assemblies (much faster than tens of microseconds). Therefore, it is of interest to investigate fast detection systems such as those based on organic scintillation detectors. In this work, an array of 12 cylindrical, 5.08 cm x 5.08 cm diameter trans-stilbene organic scintillators was used to measure five subcritical assemblies. One assembly was a sphere of approximately 4.5 kg of alpha-phase, weapons-grade plutonium (k eff = 0.773, α -1 = 11.84 ns) known as the BeRP ball encased in a thin stainless-steel clad. The other assemblies used the same encased sphere and 7.62 cm of iron, nickel, copper, or tungsten reflectors (k eff = 0.884, 0.916, 0.924, 0.939, respectively and α -1 = 36.60, 41.56, 49.60, 70.32 ns, respectively). Finally, this work (1) validates Rossi-alpha measurements with organic scintillators by demonstrating good agreement between measurements and simulations; and (2), demonstrates that organic scintillator-based systems are sensitive to α -1 on the order of 10–100 ns.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

The CLAS12 Silicon Vertex Tracker

Silicon Vertex Tracker (SVT) has been designed for the CLAS12 spectrometer using single-sided microstrip sensors fabricated by Hamamatsu Photonics. The sensors have a graded angle design to minimize dead areas and a readout pitch of 156 um, with intermediate strips. Each double-sided SVT module hosts three daisy-chained sensors on each side with a full strip length of 33 cm. There are 512 channels per module, read out by four Fermilab Silicon Strip Readout (FSSR2) chips, featuring data-driven architecture, mounted on a rigid–flex hybrid board. The modules are assembled in a barrel configuration using a unique cantilevered geometry to minimize the amount of material in the tracking volume. This paper is focused on the design, qualification of the performance, and experience in operating and commissioning the tracker during the first year of the data taking.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Validation of the two-region Rossi-alpha model for reflected assemblies

Nuclear criticality safety, nonproliferation and safeguards, emergency response, and stockpile stewardship utilize estimates of the k eff multiplication factor. The value of k eff cannot be directly measured, but it can be inferred from the prompt neutron period. One modality of measuring the prompt neutron period is the Rossi-alpha method, which is predicated on fitting a histogram of detection time differences due to the nonrandom temporal distribution of same-fission-chain neutrons. Recent works have developed the motivation and theory to expand traditional one-region point kinetic models resulting in one-exponential histogram fits to two-region models that result in two-exponential fits. This paper validates the new two-region model using organic scintillator measurements of copper-reflected weapons-grade plutonium (0:83 ≤ k eff ≤ 0:94) and high-density- polyethylene-reflected highly enriched uranium (0:73 ≤ k eff ≤ 0:95). Furthermore, the results show that more thermal systems have shorter prompt neutron periods in the core region due to increased induced-fission probabilities for moderated neutrons. Here, a new parameter introduced by the two- region model is also shown to be correlated to the amount of reflection, and may be used to infer assembly properties such as type and amount of reflector.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Initial tests of large format sensors for the ATLAS ITk strip tracker

For the construction of the Inner Tracker (ITk) as part of the phase-II upgrade programme of the ATLAS detector for the High-Luminosity (HL) LHC, batches of Long Strip (LS) and Short Strip (SS) n + -in-p type micro-strip sensors have been produced by Hamamatsu Photonics and Infineon. The full size sensors measure approximately 98 × 98 mm 2 and are designed and engineered for tolerance against the 9.7 × 10 14 1 MeV n eq /cm 2 fluence expected at the HL-LHC, including a safety factor of 1.5. Each sensor has 2 or 4 columns of 1280 individual channels arranged at 75.5 μ m horizontal pitch. To ensure the sensors comply with their specifications, a Quality Control (QC) procedure has been implemented, comprising measurements on every individual sensor as well as on a sample basis. Every sensor is subjected to an initial visual inspection, after which the full surface of the sensor is captured with very high resolution by an automated camera setup. Non-contact metrology is performed to obtain the sensor surface profile. Electrical measurements establishing the reverse bias leakage current and depletion voltage are then conducted automatically. Sample sensors from every batch are subjected to 40 h of leakage stability checks in controlled atmosphere, and tests on every channel measuring leakage current, coupling capacitance and bias resistance are done. The recorded results are uploaded to a production database following data quality checks. In this paper, QC test validation data and the compiled results for the first batches of production grade sensors are presented. The QC protocol was validated, and the first production sensors were confirmed to be within specification. The results are compared to those from the previous generation of prototype sensors.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Surface processing and discharge-conditioning of high voltage electrodes for the Ra EDM experiment

The Ra EDM experiment uses a pair of high voltage electrodes to search for the atomic electric dipole moment of 225 Ra. We use identical, plane–parallel electrodes with a primary high gradient surface of 200 mm 2 to generate reversible DC electric fields. Our statistical sensitivity is linearly proportional to the electric field strength in the electrode gap. We adapted surface decontamination and processing techniques from accelerator physics literature to chemical polish and clean a suite of newly fabricated large-grain niobium and grade-2 titanium electrodes. Three pairs of niobium electrodes and one pair of titanium electrodes were discharge-conditioned with a custom high voltage test station at electric field strengths as high as +52.5 kV/mm and –51.5 kV/mm over electrode gap sizes ranging from 0.4 mm to 2.5 mm. One pair of large-grain niobium electrodes was discharge-conditioned and validated to operate at ±20 kV/mm with steady-state leakage current ≤ 25 pA (1σ) and a polarity-averaged 98 ± 19 discharges per hour. These electrodes were installed in the Ra EDM experimental apparatus, replacing a copper electrode pair, and were revalidated to ±20 kV/mm. Here, the niobium electrodes perform at an electric field strength 3.1 times larger than the legacy copper electrodes and are ultimately limited by the maximum output of our 30 kV bipolar power supply.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Neutron capture of UO 2 targets prepared by spin-coating assisted combustion synthesis

Two uranium dioxide (UO 2 ) targets of (414 ± 23) nm and (1092 ± 93) nm thicknesses were prepared on 6061 aluminum alloy and puratronic grade aluminum backing materials. The targets were deposited with a novel method combining spin coating and solution combustion synthesis (SCS). The target layers consisted of small (3–7 nm) UO 2 grains and uniformly distributed ultra-small (1–3 nm) pores. The prepared targets were tested at the Los Alamos National Laboratory’s LANSCE facility for neutron irradiation damage and suitability for neutron capture experiments. The samples showed no signs of target material loss after the irradiation. However, irradiation caused a significant increase in the grain size (4–10 nm), as well as upward mass diffusion and coalescence of the pores due to the thermal spikes. The magnesium in the aluminum 6061 alloy backing also diffused into the UO 2 layer during neutron irradiation. The structural changes in the target after the irradiation do not affect the data from neutron capture. As a result, the new method can be used more broadly to prepare other actinide targets for nuclear physics experiments.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Survey of tungsten gross erosion from main plasma facing components in WEST during a L-mode high fluence campaign

An initial high fluence campaign was performed in WEST, in 2023, on the newly installed actively cooled tungsten divertor composed of ITER-grade monoblocks. The campaign consisted in the repetition of a 60 s long Deuterium L-mode pulse in attached divertor conditions, cumulating over 10000s of plasma exposure. A maximum deuterium fluence of approximately 5⋅1⁢026 m−2 was reached in the outer strike point region, representative of a few high performance ITER pulses. Gross tungsten erosion inferred from visible spectroscopy shows that the most eroded plasma facing component is the inner divertor target with rates ten times larger than on the outer divertor target. The outer midplane tungsten bumpers, located a few centimeters from the plasma, show gross erosion rates two times lower than at the outer divertor. We conclude that the outer midplane bumpers have a negligible contribution to the long range tungsten migration and deposition onto the lower divertor. The cumulated gross erosion rate on the inner divertor translates in an effective gross erosion thickness of about 20μ⁢m, while it is about 2μ⁢m for the outer divertor. Strikingly, these orderings coincide with the thickness of deposits found locally on the divertor: the exposed surfaces of high field side monoblocks are covered with several tens of μ⁢m tungsten deposits, while on the lower field side, few μ⁢m thin tungsten deposits are only found on the magnetically shadowed parts of monoblocks. The strong impact of those deposits on WEST operation, namely perturbation of surface temperature measurement with infra-red thermography, and the emission of flakes causing radiative perturbation of the confined plasma, calls for anticipating similar issues in ITER. In particular, the start of research operation shall consider the definition of a divertor erosion budget in order to anticipate the formation of deleterious deposits.

Fedorczak, N.↗