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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Superior High-Temperature Strength in a Supersaturated Refractory High-Entropy Alloy

Refractory high-entropy alloys (RHEA) show promising applications at high temperatures. However, achieving high strengths at elevated temperatures above 1,173K is still challenging due to heat softening. Using intrinsic material characteristics as the alloy-design principles, a single-phase body-centered-cubic (BCC) CrMoNbV RHEA with high-temperature strengths (beyond 1,000 MPa at 1,273 K) is designed, superior to other reported RHEAs as well as conventional superalloys. The origin of the high-temperature strength is revealed by in-situ neutron scattering, transmission-electron microscopy, and first-principles calculations. The CrMoNbV’s elevated-temperature strength retention up to 1,273 K arises from its large atomic-size and elastic-modulus mismatches, the insensitive temperature dependence of elastic constants, and the dominance of non-screw character dislocations caused by the strong solute pinning, which makes the solid-solution strengthening pronounced. The alloy-design principles and the insights in this study pave the way to design RHEAs with outstanding high-temperature strength.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Deformation heterogeneity and intragrain lattice misorientation in high strength contrast, dual-phase bridgmanite/periclase

A bridgmanite/periclase aggregate is investigated due to its prevalence in the Earth’s lower mantle and its importance for understanding geodynamic processes. In dual-phase polycrystalline aggregates, both strength contrast between phases and single crystal elastic and plastic anisotropy are known to influence the development of intragrain misorientation, and the evolution of crystallographic texture. In this study, full-field crystal plasticity simulations are performed with a finite element solution method, and applied to an aggregate of a mechanically strong orthorhombic phase with perovskite structure (bridgmanite, MgSiO 3 ), and a relatively weaker cubic phase (periclase, MgO). The relative strengths of the phases are parameterized to elucidate the effect that strength contrast has on texture evolution and single-phase simulations are performed for comparison. Altogether, results indicate that the relative strength between the two phases influences the development of plasticity, and the overall texture evolution. Results are discussed in light of trends related to the evolution of plasticity and misorientation in the aggregate, and their dependence on both the strength contrast between phases as well as the spatial distribution of grains and phases.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Developing a robust strength model using physically-informed genetic programming

The strength of materials is influenced by a range of external conditions, such as temperature and deformation rate. Consequently, materials that demonstrate substantial variations in their mechanical behavior due to fluctuations in temperature and strain rate require complex strength models to accurately predict material performance in real-world applications. To predict such complex behavior, a robust and flexible strength model is necessary. In this work, we utilize genetic programming-based symbolic regression (GPSR) to develop data-driven strength models that accurately represent the measured stress–strain responses of tin across a wide range of strain, strain rate and temperature regimes. The GPSR models are constrained by physically-informed conditions, which leads to significant improvement in extrapolation. The best model is integrated into a multi-physics code to perform Taylor impact simulations, validating the model’s accuracy and robustness. In conclusion, the model predictions showed excellent agreement with experimental results, particularly when compared to predictions using traditional strength models.

Genetic programming↗
DOE OSTI2023

Compressive strength improvements from noncircular carbon fibers: A numerical study

The benefits of high-performance unidirectional carbon fiber composites are limited in many cost-driven industries due to the high cost relative to alternative reinforcement fibers. Low-cost carbon fibers have been previously proposed, but the longitudinal compressive strength continues to be a limiting factor or studies are based on simplifications that warrant further analysis. A micromechanical model is used to (1) determine if the longitudinal compressive strength of composites can be improved with noncircular carbon fiber shapes and (2) characterize why some shapes are stronger than others in compression. In comparison to circular fibers, the results suggest that the strength can be increased by 10%–13% by using a specific six-lobe fiber shape and by 6%–9% for a three-lobe fiber shape. A slight increase is predicted in the compressive strength of the study two-lobe fiber but has the highest uncertainty and sensitivity to fiber orientation and misalignment direction. The underlying mechanism governing the compressive failure of the composites was linked to the unique stress fields created by the lobes, particularly the pressure stress in the matrix. Importantly, this work provides mechanics-based evidence of strength improvements from noncircular fiber shapes and insight on how matrix yielding is altered with alternative fiber shapes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Equibiaxial flexural strength determination of UO 2 using a ball-on-ring test

To increase nuclear fuel performance and reliability, their mechanical properties require an accurate and statistically relevant assessment. Biaxial flexural strength tests provide an alternative to bend bar techniques for assessing mechanical behavior; namely, the transverse rupture strength (TRS) of ceramic samples. Biaxial test samples require simple geometries and minimal surface preparation, reducing fabrication costs and handling hazards. This study investigated the TRS of polycrystalline UO 2 fuel forms at room temperature using a ball-on-ring test fixture. Here, pellets were fabricated from UO 2 powder using conventional powder processing and sintering techniques. The TRS and Weibull parameters were obtained through Weibull statistics on over 60 UO 2 samples tested under equibiaxial flexure. The larger sample size in this study enabled a more robust Weibull statistical analysis than alternative test methods, which may not capture the stochastic failure of typical ceramics. Furthermore, two different loading ball diameters were employed to assess the impact of contact damage on fracture strength. While Hertzian contact damage was observed with the smaller loading ball, the fracture strength remained unaffected. A fracture analysis of the tested UO 2 samples indicated a mixture of intergranular and transgranular fracture that transitions to transgranular fracture with increasing distance from the fracture origin. The characteristic strength of the combined data sets was determined to be 148 MPa, and the Weibull modulus was determined to be 9.1. The TRS values and Weibull parameters were close to values found in the literature for alternative testing techniques using samples with similar microstructure and density. The findings in this study validate the ball-on-ring method used to obtain the TRS of UO 2 with a sample geometry more representative of nuclear fuels. Additionally, experimental TRS results from this study can be implemented in modeling codes to predict fuel performance, which is critical to fuel burnup extension and advanced nuclear fuel technologies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

A lightweight Fe–Mn–Al–C austenitic steel with ultra-high strength and ductility fabricated via laser powder bed fusion

Lightweight Fe–Mn–Al–C steels have become a topic of significant interest for the defense and automotive industries. These alloys can maintain high strength and ductility while also reducing weight in structural applications. Conventionally processed Fe–Mn–Al–C austenitic steels with high Al content (~9 wt%) demonstrate greater than 1.5 GPa strength with 35% elongation. Several recent studies have demonstrated success in fabricating steel parts using laser powder bed fusion (L-PBF) additive manufacturing (AM), which can generate near-net-shape components with complex geometries and is capable of local microstructural control. However, studies on L-PBF processing of Fe–Mn–Al–C alloys have focused on low Al content (<5 wt%) compositional regimes representing alloys that undergo transformation-induced plasticity (TRIP) and twinning-induced plasticity (TWIP). Here, in this study, we present the effects of L-PBF processing on the microstructure and mechanical properties of an Fe–30Mn–9Al–1Si-0.5Mo-0.9C austenitic steel. A process optimization framework is employed to determine an ideal L-PBF processing space that will result in >99% density parts. Implementing this framework resulted in near-fully dense specimens fabricated over a broad range of process parameters. Additionally, two bi-directional scan rotation strategies (90° and 67°) were applied to understand their effects on texture and anisotropy in this material. As-printed specimens displayed considerable work-hardening characteristics with average strengths of up to 1.3 GPa and 36% elongation in the build direction. However, solidification microcracks oriented in the build direction resulted in anisotropy in tensile strength and ductility resulting in average strengths of 1.1 GPa and 20% elongation perpendicular to the build direction. The successful L-PBF fabrication of Fe–30Mn–9Al–1Si-0.5Mo-0.9C presented here is expected to open new avenues for weight reduction in structural applications with a high degree of control over part topology.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High-strength, lightweight nano-architected silica

Continuous nanolattices are an emerging class of mechanical metamaterials that are highly attractive due to their superior strength-to-weight ratios, which originate from their spatial architectures and nanoscale-sized elements possessing near-theoretical strength. Rational design of frameworks remains challenging below 50 nm because of limited methods to arrange small elements into complex architectures. Here, we fabricate silica frameworks with ~4- to 20-nm-thick elements using self-assembly and silica templating of DNA origami nanolattices and perform in situ micro-compression testing to examine the mechanical properties. We observe strong effects of lattice dimensions on yield strength (σ $\mathcal{y}$ ) and failure mode. Silica nanolattices are found to exhibit yield strengths higher than those of any known engineering materials with similar mass density. The robust coordination of the nanothin and strong silica elements leads to the combination of lightweight and high-strength framework materials offering an effective strategy for the fabrication of nanoarchitected materials with superior mechanical properties.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2020

Superior strength-ductility synergy by hetero-structuring high manganese steel

Lacking of forest hardening makes low ductility in steels long challenge particularly at high yield strength. Here, we report to make good use of hetero-structuring for superior strength-ductility synergy in high manganese steel. The point is to retain original deformed structure of large quantity, along with recrystallized ultrafine-grains and fine grains, jointly for most effective heterogeneous deformation-induced (HDI) hardening especially at high strength. The residual plastic strain of larger than 0.2% and large proportion of HDI stress over 60% indicate the crucial role in ductility by HDI hardening. This renders a significantly upgraded strength-ductility combination within high strength scope.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Nuclear level density and γ -decay strength of Sr 93

This work presents the first experimentally determined nuclear level density and γ-ray strength function of the short-lived fission product 93 Sr, accomplished using the β-Oslo method. Direct measurement of the 92 Sr(n, γ) 93 Sr cross section is not currently possible, as the half-life of 2.66 hours is too short; instead, 93 Sr was formed through β decay of 93 Rb to excitation energies around the neutron separation energy. The γ-ray spectra were measured using a total absorption spectrometer at the National Superconducting Cyclotron Laboratory (NSCL) at Michigan State University (MSU). The statistical properties of the 93 Sr nucleus were experimentally determined, including the γ-ray strength function and nuclear level density. At low energies, the γ-ray strength function exhibits a constant γ-decay strength, rather than a slightly increasing strength with decreasing γ-ray energy as had been previously observed for several nuclei in this mid-mass region. Finally, these statistical properties were then implemented in the reaction code TALYS1.95 to calculate the 92 Sr(n, γ) 93 Sr cross section.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

The ASSIST trial: Acute effects of manipulating strength exercise volume on insulin sensitivity in obese adults: A protocol for a randomized controlled, crossover, clinical trial

Type 2 diabetes mellitus is a disease in which insulin action is impaired, and an acute bout of strength exercise can improve insulin sensitivity. Current guidelines for strength exercise prescription suggest that 8 to 30 sets could be performed, although it is not known how variations in exercise volume impact insulin sensitivity. Additionally, this means an almost 4-fold difference in time commitment, which might directly impact an individual’s motivation and perceived capacity to exercise. This study will assess the acute effects of high- and low-volume strength exercise sessions on insulin sensitivity. After being thoroughly familiarized, 14 obese individuals of both sexes (>40 year old) will undergo 3 random experimental sessions, with a minimum 4-day washout period between them: a high-volume session (7 exercises, 3 sets per exercise, 21 total sets); a low-volume session (7 exercises, 1 set per exercise, 7 total sets); and a control session, where no exercise will be performed. Psychological assessments (feeling, enjoyment, and self-efficacy) will be performed after the sessions. All sessions will be held at night, and the next morning, an oral glucose tolerance test will be performed in a local laboratory, from which indexes of insulin sensitivity will be derived. We believe this study will aid in strength exercise prescription for individuals who claim not to have time to exercise or who perceive high-volume strength exercise intimidating to adhere to. This trial was prospectively registered.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Homogenization of Dendritic Structures and the High-Temperature Strength of the Refractory High-Entropy Alloy MoNbTaVW

MoNbTaVW, a pioneering refractory high-entropy alloy (RHEA), is renowned for its exceptional strength at elevated temperatures. Like most RHEAs, it solidifies into a dendritic microstructure with steep concentration gradients, necessitating heat treatment for equilibration. Steep concentration gradients typically complicate mechanical property analysis and modeling, key challenges for high-throughput alloy discovery. This study examines the effects of high-temperature homogenization (1800 °C for 8 hours) on the microstructure and mechanical properties of MoNbTaVW across temperatures up to 1200 °C. Postmortem microstructural analysis, coupled with chemical, crystallographic, and mechanical assessments, revealed that yield strength was surprisingly insensitive to homogenization, with less than a 3 pct difference between as-cast and heat-treated materials. Nanoindentation confirmed minimal nanohardness changes across the dendritic structure at room temperature. However, homogenization significantly enhanced high-temperature work hardening, producing higher peak compressive strength. Both as-cast and homogenized MoNbTaVW exhibited room-temperature strengths of 1400 MPa, exceeding previously reported values. These findings demonstrate that high-temperature treatment enables microstructural homogenization without compromising strength, a unique behavior among RHEAs. In conclusion, while not universally applicable, this insight highlights the importance of understanding microstructural development in experimental alloys and offers a pathway to design alloys that achieve homogeneous-like properties without heat treatment.

Rietema, C. J. [Lawrence Livermore National Labora↗
DOE OSTI2020

Assessing the sensitivity of land-atmosphere coupling strength to boundary and surface layer parameters in the WRF model over Amazon

Modeling tools can be used to diagnose regional land-atmosphere (L-A) coupling strength in the absence of sufficient observations, but subject to uncertainties associated with parameters in model physical parameterizations. Different sensitivity analysis (SA) approaches may lead to different conclusions about the underlying sensitivities. In this study, we quantify simulation uncertainties related to parameter perturbations, and use different approaches to conduct parameter SA on the WRF model pertaining to L-A coupling strength for simulations over the Amazon region. A total of twenty parameters from the Yonsei University (YSU) planetary boundary layer (PBL) and the revised MM5 surface layer (SL) schemes were selected in this analysis. Three different SA methods, the Morris One-at-A-Time (MOAT) method, the Multivariate Adaptive Regression Splines (MARS) method, and the Sobol’ method, were employed to analyze seven WRF-simulated variables and five L-A coupling metrics. Results show that 1) parameter perturbations cause large simulation uncertainties which are comparable to those in the observations; 2) three different SA methods give consistent L-A coupling strength outcomes; 3) six out of the twenty parameters contribute 80%–95% of the total variance in the metrics analyzed, and first-order effects dominate over interaction effects; 4) the twelve variables/metrics of interest show similar sensitivity patterns to the selected parameters, which is consistent across all the methods used. Physical mechanisms for how the sensitive parameters act in determining the L-A coupling strength and associated variables also are illustrated. Our results will help quantifying L-A coupling strength and establishing a basis for parameter calibration over the Amazon region.

Wang, Chen↗
DOE OSTI2023

A comparative investigation of the effect of gas type on foam strength and flow behavior in tight carbonates

Foam generation technique has been practically applied to overcome gas mobility issue during enhanced oil recovery (EOR) processes. Incorporated with the utilized gas, the capability of foaming agent to generate persistent foam determines the flow performance under reservoir conditions. Here, in this study, we first identified the surfactants with excellent phase behavior and foaming properties and, second, evaluated their bulk foam performance with different gases, including N 2 , CO 2 , and hydrocarbon gas (CH 4 ) under high-pressure and high-temperature conditions. In bulk, the foam generated with the high-density gas, i.e., CO 2 , exhibited the greatest foamability but the lowest foam stability. With amidoamine oxide-based surfactant, CH 4 -foam was found to be more stable than N 2 -foam, while the opposite was observed for sulfobetaine-based surfactant. The most effective surfactant was later used to perform flow experiments on two tight carbonate rocks, including Minnesota Norther Cream Buff and Edwards limestone, with permeabilities of ~0.8 and 16 mD, respectively. The core-flooding experiments showed that the optimum quality of CO 2 -foam was lower than that of N 2 - and CH 4 -foams. For a given flow rate and fixed foam quality, the steady-state strength followed the descending order of CH 4 -, N 2 -, and CO 2 -foam. However, in general, the difference in foam strength between N 2 - and CH 4 -foams was insignificant when the total flow rate was varied. We also found that the variation in rock permeability had a greater effect on the strength of the CO 2 -foam compared to those generated with N 2 and CH 4 . In the presence of oil, the shear-thinning behavior of all foams was found more prominent. The increase in oil saturation had a more adverse effect on the strength of N 2 - and CH 4 -foams, particularly in the higher permeability rock. The results indicated that the foam strength, which is key in the effectiveness of foam EOR applications, is greatly influenced by several factors such as gas density, gas solubility in water, the presence of oil, and rock permeability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

The role of specimen size and grain boundary characteristics in the yield strength of tungsten in microtensile tests

To effectively use the measured properties from small-scale tensile tests for bulk material performance predictions, it is essential to understand the threshold of specimen size-effect strengthening and the interaction between dislocations and microstructures within miniaturized specimens. This study uses pure tungsten to investigate the size effect in terms of specimen size, grain size, and grain boundary characteristics relative to the yield strength of tungsten at room temperature. We evaluate the transition from miniaturized specimen properties to bulk properties and the deformation behavior through small-scale tensile tests of three specimen sizes (large: 80 × 100 × 233 µm³; medium: 7 × 7 × 18 µm³; and small: 2 × 2 × 5 µm³). The testing results reveal that the small and medium specimens exhibit high yield strength with ductile behavior, while the large specimens exhibit brittle failure, consistent with the room temperature strength of tungsten, indicating bulk behavior. We further explore the specimen size-effect sensitivity to yield stress and the scaling relationship between yield strength and the number of grains involved in the deformation. A power-law relationship with the exponent value of approximately -0.5 was found in the yield strength–grain number scaling, implying the Hall-Petch like behavior. A minimum of 7–17 effective grain boundaries across the tensile gauge dimension is required to accurately measure bulk properties.

36 - MATERIALS SCIENCE↗
DOE OSTI2023

Determining the tensile strength of fuel surrogate TRISO-coated particle buffer, IPyC, and buffer-IPyC interlayer regions

A novel micro tensile sample fabrication technique for determining the tensile strength of the buffer, IPyC, and buffer -IPyC interlayer regions of surrogate (ZrO2) TRISO fuel particle layers was refined and implemented. Copper micro tensile samples served as baseline materials to verify the methods used. Tensile tests performed in this study, while limited in number, were analyzed using standard and Weibull statistics. As expected, the buffer layer was weakest, with an average ultimate tensile strength of 138.70 MPa, and the IPyC layer samples, were strongest, with an average ultimate tensile strength of 189.74 MPa. In the buffer -IPyC interface samples, all breaks occurred in the buffer region, though the average ultimate tensile strength of the samples, 159.80 MPa, was between the pure buffer and IPyC samples. These results suggest the interlayer region has unique properties, perhaps associated with pyrocarbon infiltration into the buffer layer during particle coating. All interlayer samples fractured within the buffer side; however, the stress strain behavior of some of these samples resembled the behavior of the IPyC layer samples. Here, the buffer and IPyC layer strengths had a normal distribution under Weibull analysis, while the interlayer region had a Rayleigh distribution. Further testing is needed to clarify both the standard and Weibull statistical results

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Microstructure-based prediction of thermal aging strength reduction factors for grade 91 ferritic-martensitic steel

This study aimed to develop a microstructure-based mechanistic approach to address the long-term thermal aging effect on yield stress and ultimate tensile strength and to provide a physical basis for developing thermal aging factors for G91 for a design life of 60 years. Several heats of G91 steel were examined. Controlled aging experiments were conducted on two heats at temperatures of 550, 600, and 650 °C for times up to ~64,000 h. Specimens were also taken from archived creep-tested specimens of G91 and from a tube removed from the Kingston coal-fired power plant to obtain data that cover a wide range of temperatures and for aging times up to 155,000 h. Thermal aging caused significant subgrain recovery, coarsening of M 23 C 6 carbides at subgrain boundaries and MX carbonitrides within subgrains. The intermetallic Laves phase forms during aging and grows rapidly. The growth rate of the subgrain width and MX mean size during thermal aging were described by kinetic models. Thermal aging results in the reductions in the yield stress and the ultimate tensile strength of G91. The effects of thermal aging on the reductions in yield stress and ultimate tensile strength were well described by the microstructure-strength model that considers three superimposed strengthening mechanisms, namely, sub-boundary strengthening, MX precipitation hardening, and Mo solid solution strengthening. Furthermore, the model was independently validated by the ASME Code values and is being used by the ASME to develop the aging-induced strength reduction factors for G91 steel for a design life of 60 years.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Simultaneous improvement in strength and ductility in 7xxx Al through a combination of natural aging and deformation

Room temperature processing methods of reaching near-T6 yield and ultimate tensile strength in Al–Zn–Mg–Cu alloys provide a potentially lower cost alternative to high temperature forming and post-forming artificial aging methods. Here, this study demonstrates a method, where a combination of pre-deformation and natural aging matched T6 strength along with ductility and strain hardening greater than the T6 values. Tensile deformation of 5% and 10% was applied to naturally aged samples at 144 h (6 days) and the samples were further naturally aged up to 220 days. The pre-deformed samples showed strong type A Portevin-Le Chatelier (PLC) banding with limited ductility and strain hardenability. Further natural aging increased both strength and ductility simultaneously and converted PLC to type B. This resulted in the same yield strength as T6 temper in the 10% deformed sample but with almost 77% greater total ductility (including the 10% pre-deformation). The simultaneous increase in strength and ductility was attributed to the small, shearable clusters/precipitates and solutes present in the microstructure as suggested by the changes in the PLC behavior.

36 MATERIALS SCIENCE↗